Subaru Forester 2001 Service Manual

2001 FORESTER SERVICE MANUAL GENERAL INFORMATION SECTION
QUICK REFERENCE INDEX
This service manual has been prepared to provide SUBARU service personnel with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. This manual includes the procedures for maintenance, disassembling, reassembling, inspection and adjustment of components and diagnostics for guidance of experienced mechanics. Please peruse and utilize this manual fully to ensure complete repair work for satisfying our customers by keeping their vehicle in optimum condition. When replacement of parts during repair work is needed, be sure to use SUBARU genuine parts.
All information, illustration and specifications contained in this manual are based on the latest product information available at the time of publication approval.
FUJI HEAVY INDUSTRIES LTD. G8050GE1
2001 FORESTER SERVICE MANUAL ENGINE1 SECTION
2001 FORESTER SERVICE MANUAL TRANSMISSION SECTION
2001 FORESTER SERVICE MANUAL CHASSIS SECTION
2001 FORESTER SERVICE MANUAL BODY SECTION
G8050GE6
2001 FORESTER SERVICE MANUAL WIRING SYSTEM SECTION
FOREWORD
FW
1. Page Foreword .....................................................................................................2
Foreword
FOREWORD
SA01674
1. Foreword
A: FOREWORD
SA01674G21
These manuals are used when performing maintenance, repair, or diagnosis of the Subaru Forester. Applied model: SF***** from 2001MY. The additional manuals below are also available: AUTOMATIC TRANSMISSION SERVICE MANUAL (Pub. No. G0853ZE) The manuals contain the latest information at the time of publication. Changes in specifications, methods, etc. may be made without notice.
FW-2
HOW TO USE THIS MANUALS
HU
1. Page How to Use This Manuals...........................................................................2
How to Use This Manuals
HOW TO USE THIS MANUALS

SA02675
1. How to Use This Manuals

SA02675F69
A: HOW TO USE THIS MANUALS

1. STRUCTURE
SA02675F6901
Each section consists of SCT that are broken down into SC that are divided into sections for each component. The specification, maintenance and other information for the components are included, and diagnosis information has also been added where necessary.
2. INDEX
SA02675F6902
The first page has an index with tabs. And at the end of each section is an alphabetical index.
3. COMPONENTS
SA02675F6903
For each component, a composition drawing is included.
4. SPECIFICATIONS 5. INSPECTION
SA02675F6904
If necessary, specifications are also included

SA02675F6905
Inspections are included to be carried out before and after maintenance.
6. MAINTENANCE
SA02675F6906
Maintenance instructions are provided for each component. When multiple components comprise one process, refer to the instructions for that process for each component.
7. DIAGNOSIS
SA02675F6907
Tables showing a step-by-step process make it easy to conduct diagnosis.
8. SI UNITS
SA02675F6909
Measurements in these manuals are according to the SI units. Metric and yard/pound measurements are also included.
HU-2
SPECIFICATIONS
SPC
1. Page Forester .......................................................................................................2
Specifications
FORESTER
SA08758
1. Forester
A: DIMENSIONS
Model Overall length Overall width Overall height (at CW) Compartment Length Width Height Wheelbase Tread Front Rear Minimum road clearance *1: With bushing bar *2: With fender flare *3: With sunroof *4: Australia spec. vehicles
SA08758G28
mm mm mm mm mm mm mm mm mm mm
(in) (in) (in) (in) (in) (in) (in) (in) (in) (in)
2.0 L Non-TURBO 2.0 L TURBO 4,460 (175.6), 4,530 (178.3)*1 1,735 (68.3), 1,765 (69.5)*2 1,595 (62.8) 1,585 (62.4) 1,745 (68.7) 1,435 (56.5) 1,245 (49.0), 1,220 (48.0)*3 2,525 (99.4) 1,475 (58.1) 1,465 (57.7) 190 (7.5), 200 (7.9)*4
B: ENGINE
Model Engine type Valve arrangement Bore Stroke Displacement Compression ratio Firing order Idle speed at Park/ Neutral position Maximum output Maximum torque
SA08758G29
mm (in) cm (cu in)

3
rpm kW (HP)/rpm Nm (kgf-m, ft-lb)/rpm
2.0 L Non-TURBO 2.0 L TURBO Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine Overhead camshaft type 92 75 (3.62 2.95) 1,994 (121.67) 10.0 8.0 1324 700100 101 (137)/5,600 186 (19.0, 137.0)/3,600 130 (174)/5,600 245 (25, 181)/3,200
C: ELECTRICAL
SA08758G30
Model Ignition timing at idling speed Spark plug Type and manufacturer Generator Battery
2.0 L Non-TURBO BTDC/rpm 1210/700 NGK: BK5E-11 (without catalyst) CHAMPION: RC10YC4 (with catalyst) 12 V 75 A 5MT: 12 V 48AH 4AT: 12 V 52AH 12 V 40AH 12 V 40AH
2.0 L TURBO NGK: PFR6B
Type and capacity (5HR)
For Europe For Australia Others
SPC-2
FORESTER D: TRANSMISSION
Model Transmission type Clutch type Gear ratio
SA08758G31
Specifications
2.0 L Non-TURBO AWD 5MT*1 DSPD 3.454 2.062 1.448 1.088 0.871 3.333 1.000 1.447 Hypoid 4.111 Hypoid 1.000 Hypoid 4.111 4AT*2 TCC 2.785 1.545 1.000 0.694 2.272 Helical 1.000 Hypoid 4.444 Hypoid 4.444
2.0 L TURBO 5MT*1 DSPD 3.454 1.947 1.366 0.972 0.738 3.333 Hypoid 4.444 Hypoid 1.081*4, 1.000*5 Hypoid 4.111*4, 4.444*5 4AT*2 TCC 2.785 1.545 1.000 0.694 2.272 Helical 1.000 Hypoid 4.111 Hypoid 4.111
Auxiliary transmission gear ratio Reduction gear 1st reduction (Front drive) Final reduction Reduction gear Transfer reduc(Rear drive) tion Final reduction
1st 2nd 3rd 4th 5th Reverse High Low Type of gear Gear ratio Type of gear Gear ratio Type of gear Gear ratio Type of gear Gear ratio
5MT*1: 5 2 forward speeds with synchromesh and 1-reverse with center differential and viscous coupling 4AT*2: Electronically controlled fully-automatic, 4-forward speeds and 1-reverse with hydraulically controlled transfer clutch 5MT*3: 5-forward speeds with synchromesh and 1-reverse with center differential and viscous coupling DSPD: Dry Single Plate Diaphragm TCC: Torque Converter Clutch *4: For Europe *5: Others
E: STEERING
Model Type Turns, lock to lock Minimum turning circle
SA08758G32
LHD Rack and Pinion 3.4 m (ft) Curb to curb: 10.8 (35.4)
RHD 3.0
F: SUSPENSION
Front Rear
SA08758G33
MacPherson strut type, Independent, Coil spring Dual link strut type, Independent, Coil spring
SPC-3
Specifications
FORESTER
SA08758G34
G: BRAKE
Model
Service brake system Front Rear Parking brake
Australia spec. vehicles and 2000 Others TURBO Dual circuit hydraulic with vacuum suspended power unit Ventilated disc brake Disc brake Drum brake Mechanical on rear brakes
H: TIRE
Rim size Tire size Type
SA08758G35
15 6J 205/70R15 Steel belted radial, Tubeless
16 61/2JJ 215/60R16
I: CAPACITY
Model
SA08758G36
Fuel tank Engine oil
Upper level Lower level Transmission gear oil Automatic transmission fluid AT differential gear oil AWD rear differential gear oil Power steering fluid Engine coolant
(US gal, Imp gal) (US qt, Imp qt) (US qt, Imp qt) (US qt, Imp qt) (US qt, Imp qt) (US qt, Imp qt) (US qt, Imp qt) (US qt, Imp qt) (US qt, Imp qt)
2.0 L Non-TURBO AWD 5MT 4AT 60 (15.9, 13.2) 4.5 (4.8, 4.0) 3.5 (3.7, 3.1) 4.0 (4.2, 3.5) 8.4 (8.9, 7.4) 1.2 (1.3, 1.1) 0.8 (0.8, 0.6) 0.7 (0.7, 0.6) 6.4 (6.8, 5.6) 6.3 (6.7, 5.5)
2.0 L TURBO AWD 5MT 4AT 60 (15.9, 13.2) 5.0 (5.3, 4.4) 4.0 (4.2, 3.5) 3.5 (3.7, 3.1) 9.3 (9.8, 8.2) 1.2 (1.3, 1.1) 0.8 (0.8, 0.6) 0.7 (0.7, 0.6) 6.4 (6.8, 5.6) 6.3 (6.7, 5.5)
SPC-4
FORESTER J: WEIGHT
Model LHD Curb weight (CW) Front Rear Total Front Rear Total kg kg kg kg kg kg (lb) (lb) (lb) (lb) (lb) (lb) 5MT 730 (1,610) 615 (1,356) 1,345 (2,966) 920 (2,029) 990 (2,183) 1,875 (4,134) 4AT 745 (1,643) 615 (1,356) 1,360 (2,999) 930 (2,051) 990 (2,183) 1,890 (4,163) 5MT 745 (1,643) 620 (1,367) 1,365 (3,010) 920 (2,029) 990 (2,183) 1,875 (4,134)
SA08758G37
Specifications
1. EXCEPT AUSTRALIA SPEC. VEHICLE
SA08758G3706
2.0 L Non-TURBO AWD RHD 4AT 760 (1,676) 620 (1,367) 1,380 (3,043) 930 (2,051) 990 (2,183) 1,890 (4,167)
Maximum permissible axle weight (MPAW) Maximum permissible weight (MPW) Model
2.0 L TURBO AWD LHD RHD 4AT 815 (1,797) 630 (1,389) 1,445 (3,186) 995 (2,195) 1,010 (2,225) 1,970 (4,344) 5MT 790 (1,742) 630 (1,389) 1,420 (3,131) 975 (2,150) 1,010 (2,225) 1,950 (4,300) 4AT 810 (1,786) 630 (1,389) 1,440 (3,185) 975 (2,150) 1,010 (2,225) 1,970 (4,344) 5MT 795 (1,753) 635 (1,400) 1,430 (3,153) 975 (2,150) 1,010 (2,225) 1,950 (4,300)
Curb weight (CW)
Maximum permissible axle weight (MPAW) Maximum permissible weight (MPW)
Front Rear Total Front Rear Total
kg kg kg kg kg kg
(lb) (lb) (lb) (lb) (lb) (lb)
NOTE: When any of the following optional parts are installed, add the weight to the curb weight.
Weight of optional parts ABS (Turbo model) ABS (NonTurbo model) 11 (24) 1 (2) 10 (22) Cruise control Selflevelizer Fog lamp Air conditioner Sunroof SRS airbag (Driver & Passenger) 3 (7) 2 (4) 5 (11) SRS airbag (Side) Cold weather pack Cold weather pack (Leather seat) 2.6 (5.7) 4.4 (9.7) 7.0 (15.4)
Front kg (lb) Rear kg (lb) Total kg (lb)
10 (22) 1 (2) 9 (20)
2 (4) 0 (0) 2 (4)
1 (2) 2 (4) 1 (2)
3.6 (7.9) 1 (2) 2.6 (5.7)
17 (38) 3 (7) 14 (31)
9 (20) 14 (31) 23 (51)
2 (4.4) 2 (4.4) 4 (8.8)
2 (4) 1 (2) 1 (2)
SPC-5
Specifications
FORESTER
SA08758G3704
2. AUSTRALIA SPEC. VEHICLE

Model
Unladen mass (UM)
Gross vehicle mass (GVM )
Front Rear Total Front Rear Total
kg kg kg kg kg kg
(lb) (lb) (lb) (lb) (lb) (lb)
2.0 L Non-TURBO AWD RHD 5MT 4AT 740 (1,632) 755 (1,665) 625 (1,378) 625 (1,378) 1,365 (3,010) 1,380 (3,043) 885 (1,951) 910 (2,007) 990 (2,183) 980 (2,161) 1,875 (4,134) 1,890 (4,167)
2.0 L TURBO AWD RHD 5MT 810 (1,786) 630 (1,389) 1,440 (3,175) 960 (2,117) 990 (2,183) 1,950 (4,300) 4AT 835 (1,841) 625 (1,378) 1,460 (3,219) 980 (2,161) 990 (2,183) 1,970 (4,344)
NOTE: When any of the following optional parts are installed, add the weight to the unladen mass.
Weight of optional parts Front kg (lb) Rear kg (lb) Total kg (lb) ABS Cruise control 2 (4) 0 (0) 2 (4) Selflevelizer 1 (2) 2 (4) 1 (2) Fog lamp Air conditioner 17 (38) 3 (7) 14 (31) Sunroof Cold SRS airbag SRS airbag (Side) weather (Driver & pack Passenger) 3 (7) 2 (4.4) 2.6 (5.7) 2 (4) 2 (4.4) 4.4 (9.7) 5 (11) 4 (8.8) 7.0 ( 15.4)
10 (22) 1 (2) 9 (20)
3.6 (7.9) 1 (2) 2.6 (5.7)
9 (20) 14 (31) 23 (51)
SPC-6
PRECAUTION
PC
1. Page Precaution ...................................................................................................2
Precaution
PRECAUTION
SA04677
1. Precaution
7. AIRBAG MODULE
SA04677F5907
A: PRECAUTION
SA04677F59
Please clearly understand and adhere to the following general precautions. They must be strictly followed to avoid minor or serious injury to the person doing the work or people in the area.
1. ABS
SA04677F5901
Handle the ABS as a total system. Do not disassemble or attempt to repair individual parts. Doing so could prevent the ABS system from operating when needed or cause it to operate incorrectly and result in injury.
Adhere to the following when handing and storing the airbag module to prevent bodily injury from unexpected deployment: Do not hold harnesses or connectors to carry the module. Do not face the bag in the direction that it opens towards yourself or other people. Do not face the bag in the direction that it opens towards the floor or walls.
8. AIRBAG SPECIAL TOOLS
SA04677F5908
To prevent unexpected deployment, only use special tools.
2. BRAKE FLUID
SA04677F5902
9. WINDOW
SA04677F5909
If brake fluid gets in your eyes or on your skin, do the following: Wash out your eyes and seek immediate medical attention. Wash your skin with soap and then rinse thoroughly with water.
Always wear safety glasses when working around any glass to prevent glass fragments from damaging your eyes.
10. WINDOW ADHESIVE
SA04677F5910
3. ELECTRIC FAN
SA04677F5903
Always use the specified urethane adhesive when attaching glass to prevent it from coming loose and falling, resulting in accidents and injury.
The electric fan may rotate without warning, even when the engine is not on. Do not place your hand, cloth, tools, or other items near the fan at any time.
4. ROAD TESTS
SA04677F5904
Always conduct road tests in accordance with traffic rules and regulations to avoid bodily injury and interrupting traffic.
5. AIRBAG
SA04677F5905
To prevent bodily injury from unexpected deployment of airbags and unnecessary maintenance, follow the instructions in this manual when performing maintenance on airbag components or nearby, and airbag wiring harnesses or nearby. To prevent unexpected deployment, perform one of the steps below and then wait at least 20 seconds to discharge electricity before beginning work. Step 1: Turn the ignition switch OFF. Step 2: Remove the negative battery terminal.
6. AIRBAG DISPOSAL
SA04677F5906
To prevent bodily injury from unexpected airbag deployment, do not dispose airbag modules in the same way as other refuse. Follow the special instructions for disposal in this manual. Follow all government regulations concerning disposal of refuse.
PC-2
NOTE
NT
1. Page Note .............................................................................................................2
Note
NOTE
SA03676
1. Note
A: NOTE
SA03676A15
This is information that can improve efficiency of maintenance and assure sound work.
1. FASTENER NOTICE
SA03676A1501
Fasteners are used to prevent parts from damage and dislocation due to looseness. Fasteners must be tightened to the specified torque. Do not apply paint, lubricant, rust retardant, or other substances to the surface around bolts, fasteners, etc. Doing so will make it difficult to obtain the correct torque and result in looseness and other problems.
2. STATIC ELECTRICITY DAMAGE
SA03676A1502
Do not touch the ECM, connectors, logic boards, and other such parts when there is a risk of static electricity. Always use a static electricity prevention cord or touch grounded metal before conducting work.
3. IGNITION OFF BATTERY
SA03676A1503
When removing the battery cables, always be sure to turn the ignition off to prevent electrical damage to the ECM from rush current.
4. SERVICE PARTS
SA03676A1504
Use authentic service parts for maximum performance and maintenance, when conducting repairs. Subaru/FHI will not be responsible for poor performance resulting from the use of parts not specified by a genuine dealer.
NT-2
NOTE
5. LIFTS AND JACKS
SA03676A1505
Note
When using a lift or jack-ridged rack to raise a vehicle, always follow instructions concerning jack-up points and weight limits to prevent the vehicle from falling, which could result in injury. Be especially careful to make sure the vehicle is balanced before raising it.
S1M0137A
NT-3
Note
NOTE
S1M0138A
S1M0139A
NT-4
NOTE
6. TIE DOWNS
SA03676A1506
Note
Tie downs are used when transporting vehicles and when using the chassis dynamo. Attach tie downs only to the specified points on the vehicle.
S1M0142A
7. TOWING
S1M0140A
SA03676A1507
Avoid towing vehicles except when the vehicle cannot be driven. For vehicles with AWD, AT, or VTD, use a loader instead of towing. When towing other vehicles, to prevent excessive weight from damaging the hook or vehicle: Do not tow other vehicles with a front towing hook. Make sure the vehicle towing is heavier that the vehicle being towed.
8. TRAINING
SA03676A1508
For information about training, contact a dealer or agent.

S1M0141A
9. GENERAL SCAN TOOL
SA03676A1509
Using general scan tools will greatly improve efficiency of repairing engine electronic controls. The Subaru Select Monitor can be used to diagnose the engine and also the ABS, and other parts.
GI0103
NT-5
Note
NOTE
MEMO:
NT-6
IDENTIFICATION
ID
1. Page Identification ................................................................................................2
Identification
IDENTIFICATION
SA06679
1. Identification
A: IDENTIFICATION
SA06679F70
1. IDENTIFICATION NUMBER AND LABEL LOCATIONS
SA06679F7001
The VIN (Vehicle Identification Numbers) is used to classify the vehicle. Positioning of the plate label for identification
S1M0148A
GI0007A
GI0009A
ID-2
IDENTIFICATION
Identification
GI0008A
S1M0149A
GI0011A
ID-3
Identification
IDENTIFICATION
SA06679F7002
2. MEANING OF V.I.N.
The meaning of the VIN is as follows:
Europe, Australia and General (Except GCC)

]JF1SF5LJ31G002001[ The starting and ending brackets ( ][ ) are stop marks.
Digits 1 to 3 4 5 6 7 8 JF1 S F 5 L J Code Meaning Manufacturer body area Car line Body type Displacement Steering position Engine & transmission Details JF1: Passenger car, FHI made JF2: MPV, FHI made Forester F: Wagon 5: 2.0 L AWD K: RHD (Right-hand drive) L: LHD (Left-hand drive) J: SOHC MPI Full-time AWD 5-speed MT R: SOHC MPI 4-speed AT D: DOHC Turbo Full-time AWD 5-speed MT P: DOHC Turbo 4-speed AT 3: Full-time AWD 5-speed MT single range 4: Full-time AWD 5-speed MT dual range 5: Full-time AWD 4-speed AT 1: 2001MY 2: 2002MY G: FHI (Gunma)
Drive type
10 11 12 to 17
1 G 002001
Model year Factory location Serial number
GCC countries (Saudi Arabia, etc.)

]JF1SF53MX1J002001[ The starting and ending brackets ( ][ ) are stop marks.
Digits 1 to 3 4 5 6 7 8 9 10 11 12 to 17 JF1 S F 5 3 M X 1 J 002001 Code Meaning Manufacturer body area Car line Body type Displacement Grade Restraint Check digit Model year Transmission type Serial number Details JF1: Passenger car, FHI made Forester E: Wagon 5: 2.0 L AWD 3: BASE 5: NA SPRT M: Manual belts, dual airbag 1: 2001MY 2: 2002MY H: Full-time AWD 4-speed AT J: Full-time AWD 5-speed MT dual range
ID-4
IDENTIFICATION
3. MODEL NUMBER PLATE
SA06679F7003
Identification
The model number plate indicates: the applied model, the option code, the trim code, the engine type, the transmission type, and the exterior color code. This information is helpful when placing orders for parts. SF9CL7R
Digits 1 2 3 S F 9 Code Meaning Series Body style Engine displacement Drive system Suspension system Minor change Destination Details Forester F: Wagon 5: 2.0 L AWD 9: 2.5 L AWD 2001MY K: Right-hand drive for general market L: Left-hand drive for general market Y: For United States, Canada 2: BASE 3: HUNTER Ver. 4: NA SPORT 5: TYPES E: DOHC MPI 4-speed AT P: DOHC MPI Turbo 4-speed AT D: DOHC MPI Turbo center differential AWD J: SOHC MPI center differential AWD R: SOHC MPI 4-speed AT
4 5
C L
Grade
Transmission, fuel feed system
The engine and transmission type are as follows:
Engine
EJ20DAXBBB
Digits 1 and 2 3 and 4 5 Code EJ 20 D Meaning Engine type Displacement Fuel feed system Details EJ: 4 cylinders 20: 2.0 L 25: 2.5 L 1: D-MPI SOHC-A 2: D-MPI SOHC-B 4: MPI DOHC 5: MPI Turbo Used when ordering parts. See the parts catalog for details. W: AWD MT X: AWD AT Used when ordering parts. See the parts catalog for details.
6 7 8 to 10
A X BBB
Detailed specifications Transmission Detailed specifications
ID-5
Identification
IDENTIFICATION
Transmission
TZ1A3ZS3AA
Digits 1 2 3 and 4 5 6 T Z 1A 3 Z Code Meaning Transmission Transmission type Classification Series Transmission specifications Details T: Transmission Y: Full-time AWD MT center differential Z: Full-time AWD AT MPT 75: MT 1A: New AT 3: AT 5: MT V: Full-time AWD 5-speed MT with viscous coupling center differential single range X: Full-time AWD 5-speed MT with viscous coupling center differential dual range Z: Full-time AWD 4-speed AT with MPT Used when ordering parts. See the parts catalog for details.
7 to 10
AAA
Detailed specifications
Rear differential 1
VA1RFF
Digits 1 2 3 4 5 6 V A 1 R F F Code Meaning For AWD Type Hypoid gear diameter Details
V: AWD A: A type 1: 152 dia. 2: 160 dia. Installation position R: Rear Reduction gear ratio F: 4.444 Specification differences F: Case A
Rear differential 2
T1
Code T1 T2 TP BK BP BL VB Reduction gear ratio 3.900 4.111 4.444 4.111 4.111 4.444 3.700 LSD No No No No Strengthened type Strengthened type No
ID-6
RECOMMENDED MATERIALS
RM
1. Page Recommended Materials ............................................................................2
Recommended Materials
SA05678
1. Recommended Materials
SA05678G22
A: RECOMMENDED MATERIALS
1. GENERAL
SA05678G2201
To insure the best performance, always use the specified oil, gasoline, adhesive, sealant, etc. or that of equivalent quality.
2. FUEL
SA05678G2202
Always use a gasoline of the same or higher octane value than specified in the owner s manual. Ignoring the specifications below will result in damage or poor operation of the engine and fuel injection system. Use the specified gasoline to correct performance.
Unleaded gasoline
Use unleaded gasoline and not leaded gasoline on vehicles with catalytic converter installed to reduce air pollution. Using leaded gasoline will damage the catalytic converter.
Leaded gasoline
On vehicles without catalytic converter, use gasoline with an octane value of 90 RON or higher.
RM-2
3. LUBRICANTS
SA05678G2203
Use either the lubricants in the table below or equivalent lubricants. See the table below to choose the correct SAE viscosity.
Lubricant Engine oil Recommended API Spec. CCMC Spec. SJ Grade Energy conserving G4 or G5 Alternative ACEA Spec. A1, A2 or A3 API: SH or SG
GI0001
GI0002
Manual transmission oil Front differential Rear differential SAE viscosity Engine oil
GL-5 GL-5 GL-5
SAE viscosity No. and applicable temperature SAE J300
GI0003A
RM-3
SAE viscosity Manual transmission oil
SAE viscosity No. and applicable temperature SAE J300
Rear differential
GI0004A
Front differential
GI0005A
4. FLUID
SA05678G2204
Use the fluids specified in the table below. Do not mix two different kinds or makes of fluid.
Fluid Automatic transmission fluid Power steering fluid Brake fluid Clutch fluid Recommended DEXRON III DEXRON III FMVSS No. 116 DOT3 FMVSS No. 116 DOT3 Alternative FMVSS No. 116 DOT4 FMVSS No. 116 DOT4 Remarks
5. COOLANT
Coolant Coolant Water for dilution
SA05678G2205
Use genuine coolant to protect the engine.

Recommended SUBARU coolant Distilled water Item number 000016218 Alternative None Tap water
RM-4
The table below shows the ratio of coolant to distilled water.
Coolant Specifications Lowest anticipated atmospheric temperature Above 30C (22F) Above 15C (5F) SUBARU coolant-to*water ratio (Volume) % 50 50 30 70 Specification gravity at 10C (50F) 1.084 1.050 at 20C (68F) 1.079 1.049 at 30C (86F) 1.074 1.042 at 40C (104F) 1.068 1.037
at 50C (122F) 1.062 1.032
Freezing point
36C (33F) 16C (3F)
*: It is recommended that distilled water be used.
6. REFRIGERANT
SA05678G2206
Standard air conditioners on Subaru vehicles use HFC134a refrigerant. Do not mix it with other refrigerants. Also, do not use any air compressor oil except for ZXL200PG and DENSO OIL 9.
Air conditioner Refrigerant Compressor oil Recommended HFC134a ZXL200PG Item number Alternative None None
7. GREASE
SA05678G2207
Use the grease and supplementary lubricants shown in the table below.
Grease Supplementary lubricants Grease Application point O2 sensor Bolts, etc. MT main shaft Clutch master cylinder push rod Steering shaft bearing Gear shift bush Steering gear box Disc brake Drum brake Brake pad Brake shoe Front axle SFJ Front BJ Rear axle BJ Rear axle EBJ (Turbomodel) Rear axle DOJ Control cable Throttle linkage Water pump Door latch Door striker Recommended SUBARU CRC FX clutch grease Slicolube G-40M SUNLIGHT2 Item number 004301003 000040901 004404003 003602010 Alternative
Valiant grease M-2 Niglube RX-2 Molykote No. 7439 Molykote AS-880N SSG-6003 NTG 2218 Molykote No. 2 NTG 2218 VU-3A702 Slicolube G-30M
003608001 003606000 or 725191040 72519460 26298AC000 28093TA000 28093AA000 723223010 28093AA000 23223GA050 004404002
RM-5
8. ADHESIVES
Adhesive Adhesive
SA05678G2210
Use the adhesives shown in the table below, or equivalent.

Application point Windshield and body Weatherstrip, rubber parts Soft vinyl Momentary sealant Recommended Essex Chemical Crops Urethane E Cemedine 5430L Cemedine 540 Cemedine 3000 RS-300 Item number Alternative Sunstar 580 3Ms EC-1770 EC-1368 3Ms EC-776 EC-847 or EC-1022 (Spray type) Armstrongs Eastman 910
9. SEAL MATERIAL
Seal material
SA05678G2209
Use seal material shown in the table below, or equivalent.

Application point Engine case Transmission Rear differential Rear differential Weatherstrip Steering adjusting screw SOHC cam cap Recommended Three Bond 1215B Three Bond 1217B Three Bond 1324 Three Bond 1105 Starcalking B-33A Three Bond 1102 Three Bond 1280B Item number 004403007 K0877YA020 004403042 004403010 000018901 004403006 K0877YA018 Alternative Dow Cornings No. 7038 Dow Cornings No. 7038 Butyl Rubber sealant
RM-6
PRE-DELIVERY INSPECTION
PI
1. Page Pre-delivery Inspection................................................................................2
Pre-delivery Inspection
SA09719
1. Pre-delivery Inspection
A: GENERAL
SA09719G23
The purposes of the pre-delivery inspection (PDI) are as follows. Remove the additional parts used for ensuring the vehicle quality during transportation and restore the vehicle to its normal state. Check if the vehicle before delivery is in a normal state. Check for any damage or missing parts that may have taken place during transportation or storage. Make sure to provide a complete vehicle to the customer. Because of the above reasons, all dealerships must always carry out the PDIs before delivering a vehicle. In addition, all franchised shops and PDI centers must check the status of every vehicle received to identify who is responsible for any possible defects.
PI-2
PRE-DELIVERY INSPECTION B: PDI PROCEDURE

SA09719G50
Follow the procedures shown in the table below. Static Checks Just After Vehicle Receipt
Check point (1) If the vehicle is covered with protective coating, visually check the vehicle body for damage and dents. If the protective coating has been removed, visually check the body paints for small areas of damage or stains. (2) Visually check the glass and light lenses for any damage and cracks or excessive gaps to the body sheet metal. (3) Visually check the plated parts for any damage. 2. Tire check (1) Check the tires for damage, abnormal conditions, and dents on the wheels. (2) Check the tire air pressure. 3. Fuse installation (1) If the vehicle is about to be delivered to the customer, attach a room lamp fuse. 4. Check the doors for lock/unlock and open/ (1) Using the key, check if the door can be locked and unlocked normally. close operations. (2) Open and close the all doors to see that there are no abnormal conditions. 5. Operation check of trunk lock release lever (1) Operate the trunk lock release lever to check that the trunk opens normally. 6. Check the rear gate for lock/unlock and open/ (1) Using the key, check if the door can be locked and unlocked normally. close operations. (2) Open and close the doors to see that there are no abnormal conditions. 7. Operation check of fuel lid opener lock release (1) Operate the fuel lid opener to check that the fuel lid is unlocked norlever mally. 8. Operation check of child lock system. (1) Check that the child lock operates normally. 9. Accessory check Check the following accessories are provided: Owner s manual Warranty booklet Service booklet Spare key Jack Tool set Spare tire 10. Operation check of hood lock release system (1) Operate the hood lock release lever to check that the hood opens normally. 11. Connection of air conditioner harness (1) If the vehicle is about to be delivered to the customer, connect the air conditioner harness. 12. Battery (1) Check the battery for any abnormal conditions such as rust and trace of battery fluid leaks. 13. Brake fluid (1) Check the fluid amount. 14. Engine oil (1) Check the oil amount. 15. Transmission fluid (1) Check the fluid amount. (2) For AT, check the front differential oil. 16. AT front differential oil (1) Check the AT front differential oil amount. 17. Coolant (1) Check the coolant amount. 18. Clutch fluid (1) Check the clutch fluid amount. 19. Window washer fluid (1) Check the window washer fluid amount. 20. Hood latch check (1) Check that the hood is closed and latched securely. 21. Keyless entry system (1) Check that the keyless entry system operates normally. 22. Seat (1) Check the seat surfaces for smears or dirt. (2) Check the seat installation conditions and functionality. 23. Seat belt (1) Check the seat belt installation conditions and functionality. 24. Wheel alignment (1) Check that the wheel alignments are properly adjusted. 1. Appearance check Step
PI-3
Checks with the Engine Running

Step 1. Read memory and test mode connectors 2. Starting condition 3. Exhaust system 4. Indicator light 5. Clock 6. Radio 7. Cigarette lighter 8. Lighting system 9. Window washer 10. Wiper 11. Power window operation check Check point Read memory and test mode connectors Start the engine and check that the engine starts smoothly. Check that the exhaust noise is normal and no leaks are found. Check that all the indicator lights operate normally. Check that the clock operate normally. Check that the radio system operates normally. Check that the cigarette lighter operates normally. Check that the lighting systems operate normally. Check that the window washer system operates normally. Check that the wiper system operates normally. Check the power window for correct operations.
(1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1)
Dynamic Test with the Vehicle Running

Step 1. Brake test 2. Parking brake 3. AT shift control 4. Heater & ventilation 5. Air conditioner 6. Cruise control (1) (1) (1) (1) (1) (1) Check Check Check Check Check Check Check point that the foot brake operates normally. that the parking brake operates normally. the AT shift patterns are correct. that the heater & ventilation system operates normally. that the air conditioner operates normally. that the cruise control system operates normally.
Checks after Dynamic Test

Step 1. ATF level 2. Power steering fluid level 3. Fluid leak check 4. Water leak check 5. Appearance check 2 Check point Check that the ATF level is normal. Check that the power steering fluid level is normal. Check for fluid/oil leaks. Spray the vehicle with water and check for water leaks. Remove the protective coating (if any). Check the body paints for damage and smears. Check the plated parts for damage and rust.
(1) (1) (1) (1) (1) (2) (3)
PI-4
1. APPEARANCE CHECK
SA09719G5001
If the vehicle is covered with protective coating, visually check the vehicle body for damage and dents. If there is no protective coating, check the body paints for small areas of damage or stains and repair as necessary. Check the window glass, door glass, and lights for any cracks or damage and repair or replace the parts as necessary. Check the plated parts, such as the grilles and door knobs, for damage or loss of gloss and repair or replace the parts as necessary.
4. CHECK THE DOOR OPERATIONS, LOCK/UNLOCK AND OPEN/CLOSE, AS FOLLOWS. SA09719G5003

Using the key, lock and unlock the door several times to check for normal operation. Open and close the door several times for smooth movement.
2. TIRE CHECK
SA09719G5002
Check the tire outer faces for any damage. Check the tire air pressure by referring to the following table.
Tire size Light load Full load Light P215/60R16 94H* load 215/60R16 95V TURBO 215/60R16 95Q Full (SNOW) load P205/70R15 95S* Non205/70R15 95H TURBO 205/70R15 95Q (SNOW) *: Australia model Tire inflation pressure kPa (kg/cm2 , psi) Front Rear 200 190 (2.0, 29) (1.9, 28) 200 250 (2.0, 29) (2.5, 36) 200 190 (2.0, 29) (1.9, 28) 200 250 (2.0, 29) (2.5, 36)
GI0078A
Vehicles with manual door locks:

Sit in the driver seat, close the door completely, and move the lock lever to the lock position. Then, pull the inside door handle to ensure the door will not open.
Vehicles with power door locks:

Sit in the driver seat, close the driver s door completely, and place the door lock knob (A) to the lock position. Then pull the all inside door handles (B) to ensure that the all doors will not open. For other doors, place the lock levers to the lock positions and then pull the inside door handles to ensure that the doors will not open.
NOTE: After inspecting and adjusting the tire pressure, be sure to put the valve cap back. When towing, adjust the tire inflation pressures as follows: Front: 200 kPa (2.0 kg/cm2, 29 psi) Rear: 280 kPa (2.8 kg/cm2, 41 psi)
3. FUSE INSTALLATION
SA09719G5010
A vehicle just delivered has no fuses for the room lamp circuit to prevent battery discharge. Attach a 15 A fuse as shown in the figure.
S1M0145A
5. OPERATION CHECK OF TRUNK LOCK RELEASE LEVER SA09719G5005

Operate the trunk lock release lever and verify that the trunk lid opens.
GI0084A
PI-5
9. ACCESSORY CHECK
SA09719G5008
6. OPERATION CHECK OF REAR GATE LOCK RELEASE LEVER SA09719G5006

Operate the rear gate lock release lever and verify that the rear gate is unlocked and opened smoothly. Using the key, lock and unlock the door several times to check for normal operation. Open and close the door several times for smooth movement.
7. OPERATION CHECK OF FUEL LID OPENER LOCK RELEASE LEVER SA09719G5007

Operate the fuel lid opener and verify that the fuel lid opens normally. Check that the filler cap is securely closed.
Check that the following accessories are provided in the luggage compartment or cargo area. Owner s manual Warranty booklet Service booklet Spare key Jack Tool set Spare tire
8. CHECK THE OPERATION OF CHILD SAFETY LOCKS SA09719G5052

1) Set the child safety lock on both rear doors to the lock positions. 2) Close the rear doors completely. 3) Check that the lock levers of the rear doors are in the unlock positions. Then, pull the inside door handles of the rear doors to ensure that the doors will not open. 4) Next, pull the outside door handles of the rear doors to ensure that the doors will open. 5) Repeat the above steps two or three times.
S1M0143A
10. OPERATION CHECK OF HOOD LOCK RELEASE SYSTEM SA09719G5009

Unlatch and open the hood while checking that no abnormal conditions are found. Then, support the hood with the hood stay.
GI0082A S1M0157A
S1M0144A
PI-6
11. CONNECTION OF AIR CONDITIONER HARNESS SA09719G5011
A vehicle just delivered has its air conditioner harness disconnected to protect the air conditioner compressor. Connect the harness as shown in the figure.
SA09719G5014
14. ENGINE OIL
Check the engine oil amount. If the amount is insufficient, check that no leaks are found. Then, add the necessary amount of the specified engine oil.
GI0087A GI0085
15. TRANSMISSION FLUID 12. BATTERY

SA09719G5012
SA09719G5015
Check the battery terminals to make sure that no rust or corrosions due to fluid leaks are found. Check that the battery tent is securely tightened.
Check the transmission fluid amount. If the amount is insufficient, check that no leaks are found. Then, add the necessary amount of the specified fluid.
GI0088A GI0086A
16. AT FRONT DIFFERENTIAL OIL 13. BRAKE FLUID

SA09719G5013
SA09719G5016
Check the brake fluid amount. If the amount is insufficient, carry out a brake line test to identify brake fluid leaks and check the brake operation. After that, refill the brake fluid tank with the specified type of fluid.
Check the AT front differential oil amount. If the amount is insufficient, check that no leaks are found. Then, add the necessary amount of the specified AT front differential oil.
GI0089A
PI-7
21. KEYLESS ENTRY SYSTEM
SA09719G5021
17. COOLANT
SA09719G5017
Check the coolant amount on the reservoir. If the amount is insufficient, check that no leaks are found. Then, add the necessary amount of coolant with the specified concentration.
18. CLUTCH FLUID
SA09719G5018
Check the clutch fluid amount. If the amount is insufficient, check that no leaks are found. Then, add the necessary amount of the specified fluid.
Check the keyless entry system operations as follows. Remove the key from the ignition switch and close all the doors including rear gate (wagon). Press the LOCK button on the transmitter momentarily once and check if all the doors are locked and the hazard light flashes ones.
B5M1182 GI0090A
19. WINDOW WASHER FLUID
SA09719G5019
Check the window washer fluid amount. If the amount is insufficient, check that no leaks are found. Then, add the necessary amount of washer fluid commercially available.
20. HOOD LATCH CHECK
SA09719G5020
Press the OPEN button on the transmitter momentarily once and check if the driver s door is unlocked, the hazard light flashes twice and the dome light illuminates. Close all doors and rear gate, press the LOCK button of the transmitter. Press the OPEN button of the transmitter and wait for 30 seconds. Check that all doors and the rear gate are automatically locked again.
Retract the hood stay and close the hood. Check that the hood is securely latched.
22. SEAT
SA09719G5023
Check that each seat provides full functionality in sliding and reclining. Check all available functions of the rear seat such as a trunk-through center arm rest.
23. SEAT BELT
SA09719G5024
Pull out the seat belt and then release it. Check that the belt webbing retracts smoothly.
24. WHEEL ALIGNMENT
SA09719G5026
Check the wheel alignments. <Ref. to FS-6 Wheel Alignment.> and <Ref. to RS-7 Wheel Alignment.>
PI-8
25. READ MEMORY AND TEST MODE CONNECTORS SA09719G5050
Turn the ignition switch to ON and check that the check-engine light starts blinking. If the light blinks, return the ignition key to LOCK and disconnect the test mode connector. Then, turn the ignition key to ON again. If the check-engine light blinks at that time in spite of the disconnected test mode connector, carry out an engine diagnosis. With OBD model
30. RADIO
SA09719G5033
Check the radio for full functionality and normal noise level. Also check the CD unit operations.
31. CIGARETTE LIGHTER 32. LIGHTING SYSTEM
SA09719G5034
Check that the cigarette lighter operations.

SA09719G5035
Check the headlight operations. Check the brake light operations. Check the other lights for normal operations.
33. WINDOW WASHER
SA09719G5036
Check that the window washer system injects washer fluid to the specified area of the windshield shown in the figure.
GI0095A
Without OBD model
S1M0146A
GI0119A
26. STARTING CONDITION
SA09719G5029
Start the engine and check that the engine starts smoothly. If any battery voltage problems are found, recharge or replace the battery. If any abnormal noises are observed, immediately stop the engine and check and repair the necessary components.
S1M0147A
34. WIPER
SA09719G5037
Check the front and rear wipers for normal operations.
27. EXHAUST SYSTEM
SA09719G5030
Listen to the exhaust noise to see if no abnormal noises are observed.
35. POWER WINDOW OPERATION CHECK SA09719G5004

Manipulate the power window switches one by one to check that each of the power windows goes up and down with no abnormal noises.
28. INDICATOR LIGHT 29. CLOCK
SA09719G5031
Check that all the indicator lights are off.

SA09719G5032
36. BRAKE TEST
SA09719G5038
Check the foot brake for normal operations.
Check the clock for normal operations and enough accuracy.
37. PARKING BRAKE
SA09719G5039
Check the parking brake for normal operations.
PI-9
SA09719G5041
38. AT SHIFT CONTROL
43. POWER STEERING FLUID LEVEL

SA09719G5046
Set the AT select lever to each gear position while checking that the demanded gear position is correctly attained.
GI0113A
Selector Position D 3 2 1
1st Yes Yes Yes Yes
Gear Position 2nd 3rd Yes Yes Yes Yes Yes
4th Yes
1) Check power steering fluid for deterioration or contamination. If the fluid is highly deteriorated or contaminated, drain it and refill with new fluid. 2) Check joints and units for oil leakage. If any oil leaks are found, repair or replace the applicable part. 3) Inspect fluid level on flat and level surface with engine OFF by indicator of reservoir tank. If the level is at lower point or below, add fluid to keep the level in the specified range of the indicator. If at upper point or above, drain fluid by using a syringe or the like. (1) Check at temperature 20C (68F) on reservoir surface of oil pump; read the fluid level on the COLD side. (2) Check at temperature 80C (176F) on reservoir surface of oil pump; read the fluid level on the HOT side. Non-turbo model
39. HEATER & VENTILATION
SA09719G5042
Operate the heater and ventilation system to check for normal airflow and heating capacity.
40. AIR CONDITIONER
SA09719G5043
Operate the air conditioner. Check that the A/C compressor operates normally and enough cooling is provided.
H4M1007
41. CRUISE CONTROL
SA09719G5044
Turbo model
Operate the cruise control system. Check that the system is activated and deactivated correctly.
42. ATF LEVEL
SA09719G5045
Check that the ATF level is normal. If insufficient, check that no leaks are found. Then add the necessary amount of the specified ATF.
B4M1674A
44. FLUID LEAK CHECK
SA09719G5047
Check the entire areas of the vehicle for any trace of coolant/oil/fluid leaks.
GI0098A
PI-10
45. WATER LEAK TEST
SA09719G5048
Spray the vehicle with water and check that no water enters the passenger compartment. Before performing the water leakage test, remove anything that may obstruct the operation or which must be kept dry. Close all of the windows completely, and then close all of the doors tightly. Close the hood and trunk lid before starting the test. Connect a hose to a tap, and spray water on the vehicle. The rate of water discharge must be approx. 20 to 25 liters (5.3 to 6.6 US gal, 4.4 to 5.5 Imp gal) per minute. When spraying water on areas adjacent to the floor and wheel house, increase the pressure. When directing water on areas other than the floor portion and wheel house, decrease the pressure. But the force of water must be made strong occasionally by pressing the end of the hose. NOTE: Be sure to keep the hose at least 10 cm (3.9 in) from the vehicle. Check the following areas: Front window and body framework mating portion Door mating portions Glass mating portions Rear quarter window mating portions Rear window and body framework mating portion Around roof drips If any dampness in the compartments is discovered after the water has been applied, carefully check all areas that may have possibly contributed to the leak.
46. APPEARANCE CHECK 2
SA09719G5049
Check the vehicle body paints, plated faces, glass, and lenses for any dirt or damage.
PI-11
MEMO:
PI-12
PERIODIC MAINTENANCE SERVICES
PM
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. Page General Description.....................................................................................2 Schedule......................................................................................................3 Engine Oil....................................................................................................6 Engine Oil Filter...........................................................................................8 Spark Plugs .................................................................................................9 Drive Belt(s)...............................................................................................10 Camshaft Drive Belt ..................................................................................12 Valve Clearance ........................................................................................14 Fuel Line....................................................................................................15 Fuel Filter ..................................................................................................16 Air Cleaner Element ..................................................................................17 Cooling System .........................................................................................18 Coolant ......................................................................................................19 Idle Mixture................................................................................................21 Clutch System ...........................................................................................22 Hill-holder System .....................................................................................24 Transmission Oil........................................................................................25 ATF ............................................................................................................26 Front & Rear Differential Oil......................................................................27 Brake Line .................................................................................................29 Brake Fluid ................................................................................................31 Disc Brake Pads and Discs ......................................................................32 Brake Linings and Drums..........................................................................33 Suspension................................................................................................35 Wheel Bearing...........................................................................................37 Axle Boots & Joints ...................................................................................38 Steering System (Power Steering)............................................................39 Supplemental Restraint System................................................................42
Periodic Maintenance Services
GENERAL DESCRIPTION
SA07001
1. General Description
A: GENERAL
SA07001G23
Be sure to perform periodic maintenance in order to maintain vehicle performance and find problems before they become serious.
PM-2
SCHEDULE
2. Schedule
SA07682
A: MAINTENANCE SCHEDULE 1
1. MAINTENANCE SCHEDULE 1 (1)
SA07682G24
SA07682G2401
For periodic maintenance of over 50,000 km (30,000 miles) or 48 months, carry out inspections by referring to the following tables. For a maintenance period gone beyond these tables, apply them repeatedly as a set of 50,000 km (30,000 miles) or 48 months.
Maintenance Interval [Number of months or km (miles), whichever occurs first] 12 24 36 48 Remarks 5 12.5 25 37.5 50 3 7.5 15 22.5 30 R R R R R R R R
SA07682G2402
1 2
Months 1,000 km 1,000 miles Engine oil Engine oil filter
2. MAINTENANCE SCHEDULE 1 (2)
For periodic maintenance of over 100,000 km (60,000 miles) or 48 months, carry out inspections by referring to the following tables. For a maintenance period gone beyond these tables, apply them repeatedly as a set of 100,000 km (60,000 miles) or 48 months.
Maintenance Interval [Number of months or km (miles), whichever occurs first] 12 24 36 48 Remarks 1.6 25 50 75 100 1 15 30 45 60 R R I I I I R Use in Europe counInspect every 100,000 km (60,000 tries miles) Use in others Inspect every 160,000 km (100,000 miles) I I R I R I R I I R R I I I I I For models without catalyst converter I I I I I I I I I R R R R R R I R I I I I I I I I I R I I I I
3 4 5 6
Months 1,000 km 1,000 miles Spark plugs Drive belt(s) Camshaft drive belt Valve clearance
7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
Fuel line Fuel filter Air cleaner element Cooling system Coolant Idle mixture Clutch system Hill-holder system Transmission oil ATF Front & rear differential oil Brake line Brake fluid Disc brake pads & discs Brake linings and drums Parking brake Suspension
PM-3
SCHEDULE
Maintenance Interval [Number of months or km (miles), whichever occurs first] 12 24 36 48 Remarks 1.6 25 50 75 100 1 15 30 45 60 I I I I I I I I I I
24 25 26
Months 1,000 km 1,000 miles Wheel bearing Axle boots & joints Steering system (Power steering)
Symbols used: R: Replace I: Inspection (R) or (I): Recommended service for safe vehicle operation. NOTE: (1) When the vehicle is used in extremely dusty conditions, the air cleaner element should be replaced more often. (2) ATF filter is maintenance free part. ATF filter needs replacement, when it has physically damaged or ATF leaked.
PM-4
SCHEDULE B: MAINTENANCE SCHEDULE 2

Item Every
SA07682G25
Repeat short Repeat distance drive rough/muddy road drive Replace more frequently Replace more frequently
Extremely cold weather area Replace more frequently Replace more frequently
Salt or other corrosive used or coastal area
High humidity Repeat towing trailer or mountain area Replace more frequently Replace more frequently
Engine oil Engine oil filter Fuel line 6 months 12,500 km 7,500 miles
Transmission oil ATF Front & rear differential oil Brake line
Brake fluid
Brake pads
Brake linings and drums Parking brake
Suspension
Axle boots & joints Steering system (Power steering)
6 months 12,500 km 7,500 miles 12 months 25,000 km 15,000 miles 6 months 12,500 km 7,500 miles 6 months 12,500 km 7,500 miles 6 months 12,500 km 7,500 miles 6 months 12,500 km 7,500 miles 6 months 12,500 km 7,500 miles 6 months 12,500 km 7,500 miles
Replace more frequently Replace more frequently Replace more frequently I
PM-5
ENGINE OIL
NOTE: When replenishing oil, it does not matter if the oil to be added is a different brand from that in the engine; however, use oil having the API classification and SAE viscosity No. designated by SUBARU. If vehicle is used in desert areas with very high temperatures or for other heavy duty applications, the following viscosity oils may be used: API classification: SJ or SH SAE Viscosity No.: 30, 40, 10W-50, 20W-40, 20W-50 6) Close engine oil filler cap. 7) Start engine and warm it up for a time. 8) After engine stops, recheck the oil level. If necessary, add engine oil up to upper level on level gauge.
3. Engine Oil
SA07077
A: REPLACEMENT
SA07077A20
1) Drain engine oil by loosening engine oil drain plug.
GI0012A
2) Open engine oil filler cap for quick draining of the engine oil. 3) Replace drain plug gasket. 4) Tighten engine oil drain plug after draining engine oil. Tightening torque: 44 Nm (4.5 kgf-m, 33 ft-lb) 5) Fill engine oil through filler pipe up to upper point on level gauge. Make sure that vehicle is placed level when checking oil level. Use engine oil of proper quality and viscosity, selected in accordance with the table in figure. Engine oil capacity (Non-TURBO model): Upper level 4.5 (4.8 US qt, 4.0 Imp qt) Lower level 3.5 (3.7 US qt, 3.1 Imp qt) Engine oil capacity (TURBO model): Upper level 5.0 (5.3 US qt, 4.4 Imp qt) Lower level 4.0 (4.2 US qt, 3.5 Imp qt)
GI0016A
GI0015A
The proper viscosity helps vehicle get good cold and hot starting by reducing viscous friction and thus increasing cranking speed.
PM-6
ENGINE OIL B: INSPECTION

SA07077A10
1) Park vehicle on a level surface. 2) Remove oil level gauge and wipe it clean. 3) Reinsert the level gauge all the way. Be sure that the level gauge is correctly inserted and in the proper orientation. 4) Remove it again and note the reading. If the engine oil level is below the L line, add oil to bring the level up to the F line.
GI0013A
5) After turning off the engine, wait a few minutes for the oil to drain back into the oil pan before checking the level. 6) Just after driving or while the engine is warm, engine oil level may show in the range between the F line and the notch mark. This is caused by thermal expansion of the engine oil. 7) To prevent overfilling the engine oil, do not add oil above the F line when the engine is cold.
PM-7
ENGINE OIL FILTER

SA07585
4. Engine Oil Filter

A: REPLACEMENT
SA07585A20
1) Remove oil filter with ST. ST 498547000 OIL FILTER WRENCH
GI0012A
2) Get a new oil filter and apply a thin coat of engine oil to the seal rubber. 3) Install oil filter by turning it by hand, being careful not to damage seal rubber. 4) Tighten more (approximately 2/3 to 3/4 turn) after the seal rubber contacts the oil pump case. 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. NOTE: The filter element and filter case are permanently joined; therefore, interior cleaning is not necessary. 6) Check the engine oil level. <Ref. to PI-7, ENGINE OIL, PDI PROCEDURE, Pre-delivery Inspection.>
PM-8
SPARK PLUGS
5. Spark Plugs
SA07683
tighten further 1/4 to 1/2 turns.
A: REPLACEMENT
2. TURBO MODEL
SA07683A20 SA07683A2003
SA07683A2004
1. NON-TURBO MODEL
NOTE: For spark plug replacement procedure details, refer to IG section. <Ref. to IG(SOHC)-4, Spark Plug.> and <Ref. to IG(SOHCw/oOBD)-5, Spark Plug.> 1) 2) 3) 4) 5) 6) Disconnect battery ground cable. Remove air intake duct as a unit. Remove resonator chamber. Remove washer tank and put it aside. Disconnect spark plug cord. Remove spark plug with a plug-wrench.
NOTE: For spark plug replacement procedure details, refer to IG section. <Ref. to IG(DOHC TURBO)-4, Spark Plug.> 1) Disconnect battery ground cable, and then remove battery and battery carrier. 2) Remove air cleaner lower case. <Ref. to IN(DOHC TURBO)-7, Air Cleaner.> 3) Remove washer tank and put it aside. 4) Disconnect connector from ignition coil. 5) Remove ignition coil. 6) Remove spark plug with a plug-wrench.
EN0859 GI0018
7) Set new spark plug. Recommended spark plug: NGK: PFR6B 8) Tighten spark plug lightly with hand, and then secure with a plug-wrench to the specified torque. Tightening torque: Spark plug 21 Nm (2.1 kgf-m, 15 ft-lb) Ignition coil 16 Nm (1.63 kgf-m, 11.8 ft-lb) NOTE: Be sure to place the gasket between the cylinder head and spark plug. If torque wrench is not available, tighten spark plug until gasket contacts cylinder head; then tighten further 1/4 to 1/2 turns.
7) Set new spark plug. Recommended spark plug: With OBD CHAMPION RC10YC4 CHAMPION RC8YC4 NGK BKR6E-11 NIPPONDENSO K20PR-U11 Spark plug gap 1.0 1.1 mm (0.039 0.043 in) Without OBD NGK BKR6E (Without catalytic converter) CHAMPION RC10YC4 (With catalytic converter) NGK BKR5E-11 (With catalytic converter) Spark plug gap 0.7 0.8 mm (0.028 0.031 in) (Without catalytic converter) 1.0 1.1 mm (0.039 0.043 in) (With catalytic converter) 8) Tighten spark plug lightly with hand, and then secure with a plug-wrench to the specified torque. Tightening torque: 20.6 Nm (2.10 kgf-m, 15.19 ft-lb) NOTE: Be sure to place the gasket between the cylinder head and spark plug. If torque wrench is not available, tighten spark plug until gasket contacts cylinder head; then
PM-9
DRIVE BELT(S) B: REPLACEMENT

SA07684A20
6. Drive Belt(s)
A: INSPECTION
SA07684
SA07684A10
1) Replace belts, if cracks, fraying or wear is found. 2) Check drive belt tension and adjust it if necessary by changing generator installing position and/or idler pulley installing position. Belt tension (A) replaced: 7 9 mm (0.276 0.354 in) reused: 9.0 10.0 mm (0.354 0.394 in) (B)* replaced: 7.5 8.5 mm (0.295 0.335 in) reused: 9.0 10.0 mm (0.354 0.394 in) *: There is no belt (B) on models without an air conditioner.
NOTE: Wipe off any oil or water on the belt and pulley. 1) Loosen the lock bolt (A). 2) Loosen the slider bolt (B). 3) Remove the front side belt (C).
GI0021A
4) Loosen the lock nut (A). 5) Loosen the slider bolt (B). 6) Remove the rear side belt.
GI0019A
C/P Crankshaft pulley GEN Generator P/S Power steering oil pump pulley A/C Air conditioning compressor pulley I/P Idler pulley
GI0022A
7) as 8) 9)
Install a new belt, and tighten the slider bolt so to obtain the specified belt tension. Tighten the slider bolt (B). Tighten the lock nut (A).
Tightening torque: 22.6 Nm (2.3 kgf-m, 16.6 ft-lb)
GI0022A
10) Install a new belt, and tighten the slider bolt so as to obtain the specified belt tension. 11) Tighten the slider bolt (B). 12) Tighten the lock bolt (A).
PM-10
DRIVE BELT(S)
Tightening torque: Lock bolt, through bolt: 25 Nm (2.5 kgf-m, 18 ft-lb) Slider bolt: 8 Nm (0.8 kgf-m, 5.8 ft-lb)
GI0021A
PM-11
CAMSHAFT DRIVE BELT

SA07685
7. Camshaft Drive Belt

A: REPLACEMENT
1. SOHC MODEL
SA07685A20 SA07685A2001
2. DOHC MODEL
SA07685A2002
NOTE: For camshaft drive belt replacement procedure details, refer to ME(SOHC) section. <Ref. to ME(SOHC)-46, Timing Belt Assembly.> 1) Remove radiator fan <Ref. to CO-32, Radiator Main Fan and Fan Motor.> and air conditioner fan <Ref. to CO-34, Radiator Sub Fan and Fan Motor.>. 2) Remove V-belt cover. 3) Remove V-belts. <Ref. to ME(SOHC)-42, V-belt.> 4) Remove air conditioning compressor drive belt tensioner. 5) Remove pulley bolt. ST 499977100 CRANKSHAFT PULLEY WRENCH 6) Remove crankshaft pulley. 7) Remove left side belt cover. 8) Remove front belt cover. 9) Remove timing belt guide. (MT vehicle only) 10) Turn crankshaft and align alignment marks on crankshaft, and left and right camshaft sprockets with notches of belt cover and cylinder block: ST 499987500 CRANKSHAFT SOCKET
NOTE: For camshaft drive belt replacement procedure details, refer to ME(DOHC) section. <Ref. to ME(SOHC)-46, Timing Belt Assembly.> 1) Remove radiator fan and air conditioning fan. <Ref. to CO-32, Radiator Main Fan and Fan Motor.> and <Ref. to CO-34, Radiator Sub Fan and Fan Motor.> 2) Remove V-belts. <Ref. to ME(DOHC TURBO)44, V-belt.> 3) Remove air conditioning compressor drive belt tensioner. 4) Remove pulley bolt. ST 499977300 CRANKSHAFT PULLEY WRENCH 5) Remove crankshaft pulley. 6) Remove air conditioning compressor drive belt tensioner. 7) Remove left side belt cover. 8) Remove right side belt cover. 9) Remove front belt cover. 10) Remove timing belt guide. (MT vehicle only) 11) Turn crankshaft and align alignment marks on crankshaft, and left and right camshaft sprockets with notches of belt cover and cylinder block. To turn crankshaft, Use ST: ST 499987500 CRANKSHAFT SOCKET
S1M0150A GI0025A
11) Remove belt idler. 12) Remove belt idler (No. 2). 13) Remove timing belt. 14) Remove automatic belt tension adjuster assembly.
12) Remove belt idler. 13) Remove timing belt. 14) Remove automatic belt tension adjuster assembly.
PM-12
CAMSHAFT DRIVE BELT B: INSTALLATION

1. SOHC MODEL
SA07685A11

SA07685A10
C: INSPECTION
1. SOHC MODEL
SA07685A1101
SA07685A1001
Install in the reverse order of removal. <Ref. to ME(SOHC)-46, Timing Belt Assembly.>
2. DOHC MODEL
SA07685A1102
Install in the reverse order of removal. <Ref. to ME(DOHC TURBO)-48, Timing Belt Assembly.> NOTE: When installing the timing belt, be sure to align all alignment marks on the belt with corresponding marks on the sprockets. If incorrectly installed, interference between pistons and valves may occur.
1) Remove left and right timing belt covers. 2) While cranking engine at least four rotations, check timing belt back surface for cracks or damage. Replace faulty timing belt as needed. 3) Measure timing belt width W. If it is less than 27 mm (1.06 in), check idlers, tensioner, water pump pulley and cam sprocket to determine idler alignment (squareness). Replace worn timing belt.
GI0028A
4) Install left and right timing belt covers.
2. DOHC MODEL
SA07685A1002
1) Remove left and right timing belt covers. 2) While cranking engine at least four rotations, check timing belt back surface for cracks or damage. Replace faulty timing belt as needed. 3) Measure timing belt width W. If it is less than 30 mm (1.18 in), check idlers, tensioner, water pump pulley and cam sprocket to determine idler alignment (squareness). Replace worn timing belt. 4) Install left and right timing belt covers.
S1M0151A
PM-13
VALVE CLEARANCE
SA07083
8. Valve Clearance
A: INSPECTION
SA07083A10
For the inspection procedures of the valve clearance: <Ref. to ME(SOHC)-29, Valve Clearance.> or <Ref. to ME(DOHC TURBO)-28, Valve Clearance.>
PM-14
FUEL LINE
9. Fuel Line
SA07686
A: INSPECTION
SA07686A10
The fuel line is located mostly internally, so check pipes, areas near pipes, and engine compartment piping for rust, hose damage, loose bands, etc. If faulty parts are found, repair or replace them. <Ref. to FU(SOHC)-69, Fuel Delivery, Return and Evaporation Lines.> or <Ref. to FU(SOHCw/ oOBD)-56, Fuel Delivery, Return and Evaporation Lines.> or <Ref. to FU(DOHC TURBO)-67, Fuel Delivery, Return and Evaporation Lines.>
PM-15
FUEL FILTER
10. Fuel Filter
SA07027
A: REPLACEMENT
SA07027A20
For fuel filter replacement procedures, refer to FU section. <Ref. to FU(SOHC)-66, Fuel Filter.> or <Ref. to FU(SOHCw/oOBD)-54 Fuel Filter.> or <Ref. to FU(DOHC TURBO)-64, Fuel Filter.>
PM-16
AIR CLEANER ELEMENT

SA07687A2002
11. Air Cleaner Element

A: REPLACEMENT
SA07687A20
SA07687
2. TURBO MODEL
NOTE: Do not attempt to clean the air cleaner element. The filter paper of the element is wetted with a special inflammable slow-evaporating viscous liquid. It is resistant to cold weather and has a long service life. Dirt adhering to this filter paper forms porous laminations with the viscous liquid, which function as a filtration layer to reduce dust penetration into the filter paper. If this filter paper is cleaned, the filtration layer thus formed will be lost along with the viscous liquid.
GI0126
1) Remove the clip (B) above the air cleaner case.
1. NON-TURBO MODEL
SA07687A2001
GI0127
GI0032
2) Remove air cleaner. 3) Install in the reverse order of removal. CAUTION: Before installing air cleaner upper cover, align holes with protruding portion of air cleaner lower case, then secure upper cover to lower case.
1) Remove bolt (A) which install air cleaner case to stays. 2) Remove the clip (B) above the air cleaner case.
H2M2947A
3) Remove air cleaner. 4) Install in the reverse order of removal. CAUTION: Fasten with a clip after inserting the lower tab of the case.
EN0906
PM-17
COOLING SYSTEM
SA07688
12. Cooling System

A: INSPECTION
SA07688A10
1) Check radiator for leakage, filling it with coolant and attach radiator cap tester (A) to the filler neck. Then apply a pressure of 157 kPa (1.6 kg/cm2 , 23 psi) and check the following points: Each portion of radiator for leakage Hose joints and other connections for leakage CAUTION: When attaching or detaching tester and when operating tester, use special care not to deform radiator filler neck. Non-TURBO model
Raise the pressure until the needle of gauge stops and see if the pressure can be retained for five to six seconds. The radiator cap is normal if a pressure above the service limit value has been maintained for this period. Radiator cap valve open pressure Standard value: 93 123 kPa (0.95 1.25 kg/cm2, 14 18 psi) Service limit: 83 kPa (0.85 kg/cm2 , 12 psi)
GI0034
S1M0152A
TURBO model
GI0035A
S1M0153A
When performing this check, be sure to keep the engine stationary and fill radiator with coolant. Wipe off check points before applying pressure. Use care not to spill coolant when detaching tester from radiator. 2) Check the radiator cap valve open pressure using radiator cap tester. NOTE: Rust or dirt on cap may prevent valve from functioning normally: be sure to clean cap before testing.
3) If the coolant temperature exceeds 76.0 to 80.0C (169 to 176F) while radiator is not so hot, check thermostat. If thermostat does not open at 76.0 to 80.0C (169 to 176F), replace it with a new one. 4) If electric fan does not operate when coolant temperature exceeds 90 to 94C (194 to 201F), check thermoswitch or fan motor.
PM-18
COOLANT
13. Coolant
SA07689
A: REPLACEMENT
SA07689A20
1. REPLACEMENT OF COOLANT
SA07689A2001
WARNING: The radiator is of the pressurized type. Do not attempt to open the radiator cap immediately after the engine has been stopped. 1) Lift up the vehicle. 2) Remove under cover. 3) Fit vinyl tube to drain pipe. 4) Place a container under drain tube. 5) Loosen drain cock to drain engine coolant into container.
S1M0156A
(4) Stop engine and wait until coolant temperature lowers. Then open radiator cap to check coolant level and add coolant up to radiator filler neck. Next, add coolant into reservoir tank up to FULL level. (5) After adding coolant, securely install radiator and reservoir tank caps. 11) TURBO model. (1) Slowly pour prepared coolant from coolant flow tank filler port up to the brim of port, and install cap, then pour coolant into reserve tank up to FULL level. (2) Run engine for about 15 minutes, not exceeding 2,000 rpm. (Run engine until radiator becomes hot in order to purge air trapped in cooling system.) (3) Stop engine and wait until coolant temperature lowers. [below 50C (122F) or 60C (140F)] Open coolant flow tank cap and add coolant up to the brim of the port. (4) Wait until coolant temperature lowers further [below 30C (86F)], then pour into reserve tank up to the FULL level. (5) Run the vehicle until the coolant temperature rises to 80C (176F) and check the level in the coolant flow tank, add coolant up to the FULL level. Coolant capacity (fill up to FULL level) MT model Approx. 6.4 (6.8 US qt, 5.6 Imp qt) AT model Approx. 6.3 (6.7 US qt, 5.5 Imp qt)
6) For quick draining, open radiator cap. CAUTION: Be careful not to spill coolant on the floor. 7) Drain coolant from reservoir tank. 8) Tighten radiator drain screw securely after draining coolant. 9) Install reservoir tank to original position. 10) Non-TURBO model. (1) Slowly pour prepared coolant from radiator filler port to neck of filler, then pour into reservoir tank up to FULL level. Coolant capacity (fill up to FULL level) MT model: Approx. 6.4 (6.8 US qt, 5.6 Imp qt) AT model: Approx. 6.3 (6.7 US qt, 5.5 Imp qt) NOTE: The SUBARU Genuine Coolant containing antifreeze and anti-rust agents is especially made for SUBARU engine, which has an aluminum crankcase. Always use SUBARU Genuine Coolant, since other coolant may cause corrosion. (2) Securely install radiator cap. (3) Run engine for more than five minutes at 2,000 to 3,000 rpm. (Run engine until radiator becomes hot in order to purge air trapped in cooling system.)
PM-19
COOLANT
3. PROCEDURE TO ADJUST THE CONCENTRATION OF THE COOLANT
SA07689A2003
2. RELATIONSHIP OF SUBARU COOLANT CONCENTRATION AND FREEZING TEMPERATURE SA07689A2002

The concentration and safe operating temperature of the SUBARU coolant is shown in the diagram. Measuring the temperature and specific gravity of the coolant will provide this information. [Example] If the coolant temperature is 25C (77F) and its specific gravity is 1.054, the concentration is 35% (point A), the safe operating temperature is 14C (7F) (point B), and the freezing temperature is 20C (4F) (point C).
To adjust the concentration of the coolant according to temperature, find the proper fluid concentration in the above diagram and replace the necessary amount of coolant with an undiluted solution of SUBARU genuine coolant (concentration 50). The amount of coolant that should be replaced can be determined using the diagram. [Example] Assume that the coolant concentration must be increased from 25% to 40%. Find point A, where the 25% line of coolant concentration intersects with the 40% curve of the necessary coolant concentration, and read the scale on the vertical axis of the graph at height A. The quantity of coolant to be drained is 2.1 liters (2.2 US qt, 1.8 Imp qt). Drain 2.1 liters (2.2 US qt, 1.8 Imp qt) of coolant from the cooling system and add 2.1 liters (2.2 US qt, 1.8 Imp qt) of the undiluted solution of SUBARU coolant. If a coolant concentration of 50% is needed, drain all the coolant and refill with the undiluted solution only.
GI0037A
GI0038A
PM-20
IDLE MIXTURE
14. Idle Mixture

SA07734G26
SA07734
A: INSPECTION AND ADJUSTMENT

1. IDLE MIXTURE
SA07734G2601
Before measuring the idle mixture, make sure that the ignition timing and the engine idle speed are within specifications. 1) Set the gear position at Neutral for MT, or N or P for AT. 2) Warm up engine sufficiently until cooling fan starts to operate. 3) Measure the idle mixture with the CO meter.
Engine idle speed 700100 rpm CO 1.00.5%
4) If out of specification, adjust the idle mixture using CO adjusting screw of mass air flow sensor. 5) After adjusting the CO value, check and adjust increment coefficient of CO resistor by using Select Monitor. (1) Select Current data display & Save on the select monitor. (2) If out of specified data, adjust the increment coefficient of CO resistor while rotating CO adjusting screw. Specified data: 0.28 4.22 V
GI0114A
NOTE: If driving the vehicle on out of specified data, the trouble code 49 is indicated in many case.
PM-21
CLUTCH SYSTEM
SA07690
15. Clutch System

SA07690G26

1. MECHANICAL CLUTCH TYPE
SA07690G2601
Standard: 80 mm (3.15 in) or more 3) Pedal height Check that the clutch pedal pad surface is level with or higher than brake pedal pad surface.
1) Inspect free play of clutch pedal by operating pedal by hand. If it is out of the specified value, adjust it by turning wing nut on engine side of clutch cable at release fork. Tightening torque (Adjusting nut on release fork): 4.4 7.4 Nm (0.45 0.75 kgf-m, 3.3 5.4 ft-lb) Standard free play: AT clutch pedal 10 20 mm (0.39 0.79 in)
2. HYDRAULIC CLUTCH TYPE
SA07690G2602
1) Push the release lever to retract the push rod of the operating cylinder and check if the fluid level in the clutch reservoir tank rises or not.
GI0128
GI0144
Fork lever free play allowance: 2 4 mm (0.08 0.16 in)
S1M0159A
GI0145
2) Pedal-to-floor plate gap in disengaged position. (1) With the engine idling, pull parking brake lever completely. (2) Slowly depress clutch pedal while moving shift lever into reverse. (3) Stop depressing clutch pedal when gearshifting is complete. With clutch pedal in this position, measure the distance between the upper side of pedal pad and the lower end of front panel (intersection of front panel with floor). Check that the measured value is within the specified standard.
2) If the fluid level rises, pedal free play is correct. 3) If the fluid level does not rise, or the push rod cannot be retracted, adjust the clutch pedal. <Ref. to CL-37 Clutch Pedal.> 4) Inspect the underside of master cylinder, clutch damper and operating cylinder for clutch system, hoses, piping and their couplings for fluid leaks. If fluid leaks are found, correct them by retightening their fitting bolt and/or replacing their parts. 5) Check the fluid level using the scale on the outside of the clutch master cylinder tank (A). If the level is below MIN (B), add clutch fluid to bring it up to MAX (C). Recommended clutch fluid: FMVSS No. 116, fresh DOT3 or DOT4 brake fluid
PM-22
CLUTCH SYSTEM
NOTE: Avoid mixing different brakes of brake fluid to prevent degradation of the fluid. Be careful not to allow dirt or dust to get into the reservoir tank.
GI0040A
PM-23
HILL-HOLDER SYSTEM
SA07735
16. Hill-holder System

SA07735G26

1) Confirm stopping and starting performance by activating hill-holder on an uphill road of 3 or higher inclination. (1) When vehicle does not stop; Tighten adjusting nut of PHV cable. (2) When vehicle does not start properly; A; When hill-holder is released later than engagement of clutch (engine tends to stall): Loosen adjusting nut gradually until smooth starting is enabled. B; When hill-holder is released earlier than engagement to clutch (vehicle slips down slightly): Tighten adjusting nut so that hill-holder is released later than engagement of clutch (status in A). Then make adjustment the same as in A. NOTE: Whenever turning adjusting nut, hold inner cable with pliers to prevent it from turning. Replace pressure hold valve (PHV), return spring of PHV or PHV cable with new one, if they are defective and/or damaged.
GI0115A
PM-24
TRANSMISSION OIL
17. Transmission Oil

A: REPLACEMENT
SA07691A20
SA07691
1. MANUAL TRANSMISSION
SA07691A2001
1) Drain gear oil by removing drain plug after allowing the engine to cool for 3 to 4 hours. NOTE: Before starting work, cool off the engine well.
GI0041
2) Reinstall drain plug after draining gear oil and tighten it to the specified torque. Tightening torque: 44 Nm (4.5 kgf-m, 32.5 ft-lb) NOTE: Be sure to place a gasket between the transmission case and drain plug. Replace the gasket with a new one. Each oil manufacturer has its base oil and additives. Thus, do not mix two or more brands. 3) Fill transmission gear oil through the oil level gauge hole up to the upper point of level gauge. Gear oil capacity: Single range model 3.5 (3.7 US qt, 3.1 Imp qt) Dual range model 4.0 (4.2 US qt, 3.5 Imp qt)
GI0042A
PM-25
ATF
2. ATF FILTER
SA07692A2002
18. ATF
SA07692
A: REPLACEMENT
SA07692A2001
SA07692A20
1. AUTOMATIC TRANSMISSION FLUID

1) Drain ATF (Automatic Transmission Fluid) by removing drain plug after allowing the engine to cool for 3 to 4 hours. NOTE: Before starting work, cool off the engine well.
NOTE: ATF filter is maintenance free part. ATF filter needs replacement, when it has physically damaged or ATF leaked. For the replacement procedures of the ATF filter: <Ref. to AT-46, ATF Filter.>
GI0043A
2) Reinstall drain plug after draining ATF, and tighten it to the specified torque. Tightening torque: 25.0 Nm (2.55 kgf-m, 18.4 ft-lb) 3) Fill ATF up to the middle of the COLD side on level gauge by using the gauge hole. Recommended fluid: Dexron III type automatic transmission fluid Fluid capacity: Fill the same amount drained from ATF drain plug hole. 4) Run the vehicle until the ATF temperature rises to 60 to 80C (140 to 176F) and check the ATF level.
GI0044A
PM-26
FRONT & REAR DIFFERENTIAL OIL
19. Front & Rear Differential Oil

SA07693
3) Fill differential gear oil through the oil level gauge hole up to the upper point of level gauge. Differential gear oil capacity: 1.1 1.3 (1.2 1.4 US qt, 1.0 1.1 lmp qt)
A: REPLACEMENT
SA07693A20
1. FRONT DIFFERENTIAL (MANUAL TRANSMISSION) SA07693A2001

For M/T vehicle, manual transmission oil works as differential oil to lubricate differential. Refer to Transmission Oil. <Ref. to PM-25 MANUAL TRANSMISSION, REPLACEMENT, Transmission Oil.>
2. FRONT DIFFERENTIAL (AUTOMATIC TRANSMISSION) SA07693A2002

1) Drain differential gear oil by removing drain plug after allowing the engine to cool for 3 to 4 hours. NOTE: Before starting work, cool off the engine well.
GI0046A
3. REAR DIFFERENTIAL
SA07693A2003
1) Drain oil by removing drain plug. 2) Remove filler plug for quick draining oil. 3) Reinstall drain plug after draining oil. NOTE: Apply fluid packing to drain plug threads before installation in T-type. VA-type uses a new aluminum gasket. Fluid packing: Three Bond 1105
GI0045
2) Reinstall drain plug after draining differential gear oil and tighten it to the specified torque. Tightening torque: 44 Nm (4.5 kgf-m, 32.5 ft-lb) NOTE: Be sure to place a gasket between the transmission case and drain plug. Replace the gasket with a new one. Each oil manufacturer has its base oil and additives. Thus, do not mix two or more brands.
Tightening torque: T-type: 49.0 Nm (5.0 kgf-m, 36.2 ft-lb) VA-type: 34 Nm (3.5 kgf-m, 25.3 ft-lb) 4) After installing drain plug onto rear differential gear case firmly, fill oil up fully to the mouth of filler plug.
GI0047A
Oil capacity: 0.8 (0.8 US qt, 0.7 lmp qt) NOTE: Each oil manufacturer has its base oil and additives. Thus, do not mix two or more brands.
PM-27
FRONT & REAR DIFFERENTIAL OIL
5) Install filler plug onto rear differential gear case firmly. NOTE: Apply fluid packing to filler plug before installation in T-type. VA-type uses a new aluminum gasket. Fluid packing: Three Bond 1105 Tightening torque: T-type: 49.0 Nm (5.0 kgf-m, 36.2 ft-lb) VA-type: 34 Nm (3.5 kgf-m, 25.3 ft-lb)
PM-28
BRAKE LINE

SA07694G27
20. Brake Line

A: INSPECTION
1. BRAKE LINE
SA07694
B: CHECKING
SA07694A10
1. SERVICE BRAKE
SA07694G2701
SA07694A1001
1) Check scratches, swelling, corrosion and/or traces of fluid leakage on brake hoses or pipe joints. 2) Check the possibility of adjacent parts interfering with brake pipes/hoses during driving, and loose connections/clamps. 3) Check any trace of fluid leakage, scratches, etc. on master cylinder, wheel cylinder and pressure control valve. NOTE: When the brake fluid level in the reservoir tank is lower than the specified limit, the brake fluid warning light on the combination meter will come on. Visually check brake hose (using a mirror where it is difficult to see) for any damage.
1) Check the free play of brake pedal with a force of less than 10 N (1 kgf, 2 lb). Brake pedal free play: 1 3 mm (0.04 0.12 in)
GI0050A
GI0048A
2) If the free play is out of specifications above, adjust the brake pedal as follows: (1) Be sure engine is off. (No vacuum is applied to brake booster.) (2) There should be play between brake booster clevis and pin at brake pedal installing portion. [Depress brake pedal pad with a force of less than 10 N (1 kgf, 2 lb) to a stroke of 1 to 3 mm (0.04 to 0.12 in).] (3) Depress the surface of brake pad by hand. (4) If there is no free play between clevis pin and clevis, turn brake switch adjusting nut until the clearance between stopper and screw of brake switch becomes 0.3 mm (0.012 in).
S1M0154A
GI0051A
PM-29
BRAKE LINE
4) Check valve is built into vacuum hose. Disconnect vacuum hose to inspect function of check valve. Blow air into vacuum hose from its brake booster side end: Air must flow out of engine side end of hose. Next blow air into hose from engine side: Air should not flow out of hose. Replace both check valve and vacuum hose if check valve is faulty. Engine side of vacuum hose is indicated by marking ENGINE as shown.
3) Check the pedal stroke. While the engine is idling, depress the brake pedal with a 490 N (50 kgf, 110 lb) load and measure the distance between the brake pedal and steering wheel. With the brake pedal released, measure the distance between the pedal and steering wheel again. The difference between the two measurements must be less than 95 mm (3.74 in). If the distance is more than specified, there is a possibility air is in the inside of the hydraulic unit. Brake pedal reserve distance: A more than 95 mm (3.74 in)/ 490 N (50 kgf, 110 lb)
GI0053A
5) Check vacuum hose for cracks or other damage.

GI0052A
4) Check to see if air is in the hydraulic brake line by the feel of pedal operation. If air appears to exist in the line, bleed it from the system. 5) Check for even operation of all brakes, using a brake tester or by driving the vehicle for a short distance on a straight road.
NOTE: When installing the vacuum hose on the engine and brake booster, do not use soapy water or lubricating oil on their connections. 6) Check vacuum hose to make sure it is tight and secure.
2. BRAKE SERVO SYSTEM
SA07694G2702
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 the pedal should move slightly toward the floor. 3) With the brake pedal depressed, stop the engine and keep the pedal depressed for 30 seconds: Make sure the pedal height should not change.
PM-30
BRAKE FLUID
21. Brake Fluid
SA07162
A: REPLACEMENT
SA07162A20
1) Either jack up vehicle and place a safety stand under it, or lift up vehicle. 2) Remove both front and rear wheels. 3) Draw out the brake fluid from master cylinder with syringe. 4) Refill reservoir tank with recommended brake fluid. Recommended brake fluid: FMVSS No. 116, fresh DOT3 or 4 brake fluid NOTE: Avoid mixing different brands of brake fluid to prevent degrading the quality of the fluid. Be careful not to allow dirt or dust to get into the reservoir tank. Bleeding sequence (1) (2) (3) (4)
NOTE: Cover bleeder with waste cloth, when loosening it, to prevent brake fluid from being splashed over surrounding parts. During bleeding operation, keep the brake reserve tank filled with brake fluid to eliminate entry of air. Brake pedal operation must be very slow. For convenience and safety, it is advisable to have two men working. The amount of brake fluid required is approximately 500 m (16.9 US fl oz, 17.6 Imp fl oz) for total brake system. 6) Instruct your co-worker to depress the brake pedal slowly two or three times and then hold it depressed. 7) Loosen bleeder screw approximately 1/4 turn until a small amount of brake fluid drains into container, and then quickly tighten screw. 8) Repeat steps 6) and 7) above until there are no air bubbles in drained brake fluid and new fluid flows through vinyl tube. NOTE: Add brake fluid as necessary while performing the air bleed operation, in order to prevent the tank from running short of brake fluid. 9) After completing the bleeding operation, hold brake pedal depressed and tighten screw and install bleeder cap.
GI0054A
Tightening torque: 8 Nm (0.8 kgf-m, 5.8 ft-lb) 10) Bleed air from each wheel cylinder by following the previous 5 steps. 11) Depress brake pedal with a force of approximately 294 N (30 kgf, 66 lb) and hold it there for approximately 20 seconds. At this time check pedal to see if it makes any unusual movement. Visually inspect bleeder screws and brake pipe joints to make sure that there is no fluid leakage. 12) Install wheels, and drive vehicle for a short distance between 2 to 3 km (1 to 2 miles) to make sure that brakes are operating properly.
(1) (2) (3) (4) (5) (6)
Front right Rear left Front left Rear right Secondary Primary
5) Install one end of a vinyl tube onto the air bleeder and insert the other end of the tube into a container to collect the brake fluid.
GI0055
PM-31
DISC BRAKE PADS AND DISCS

NOTE: When replacing a pad, always replace the pads for both the left and right wheels at the same time. Also replace pad clips if they are twisted or worn.
22. Disc Brake Pads and Discs

SA07695
A: INSPECTION
SA07695A10
1. DISC BRAKE PAD AND DISC
SA07695A1001
1) Jack up vehicle and support with rigid racks. Then remove wheels. 2) Visually check pad thickness through inspection hole of disc brake assembly. Replace pad if necessary.
GI0058
GI0056A
Pad thickness including back metal mm (in) Front Rear Standard 17 (0.67) 14 (0.55) Service limit 7.5 (0.295) 6.5 (0.256) Service limit 1.5 (0.059) 1.5 (0.059) (exclusive back metal)
GI0057A
3) Check the disc rotor, and correct or replace if it is damaged or worn.

Brake disc thickness mm (in) Front Rear 24 (0.94) 10 (0.39) 22 (0.87) 8.5 (0.335)
Standard Wear limit
4) Measure the disc rotor runout at a point less than 5 mm (0.20 in) from the outer periphery of the rotor. Disc rotor runout limit: Front: 0.075 mm (0.0030 in) Rear: 0.075 mm (0.0030 in)
PM-32
BRAKE LININGS AND DRUMS
23. Brake Linings and Drums

SA07696
If deformation or wear of back plate, shoe, etc. is noticeable, replace the affected parts.
A: INSPECTION
SA07696A10
1. REAR DRUM BRAKE
SA07696A1001
1) Remove brake drum, and check that there is no fluid leakage from wheel cylinder. If there is fluid leakage from wheel cylinder, replace it. <Ref. to BR-34, Rear Drum Brake Drum.> 2) Inspect brake shoes for damage or deformities and check brake linings for wear. NOTE: Always replace both leading and trailing brake shoes for the left and right wheels at the same time. When either the left or the right brake assembly is replaced, always replace the leading shoe and trailing shoe of the other. The cotter pin, once removed, cannot be reused. Thickness of lining (except back metal) Standard value: 4.1 mm (0.161 in) Service limit: 1.5 mm (0.059 in)
GI0060A
2. PARKING BRAKE (REAR DISC BRAKE)

SA07696A1002
Inspect brake linings and drums of both sides of the rear brake at the same time by removing brake drums. 1) Inspect brake shoes for damage or deformation and check brake linings for wear. NOTE: Always replace both primary and secondary brake shoes for the left and right wheels at the same time. Brake lining thickness excluding back metal Standard value: 3.2 mm (0.126 in) Wear limit: 1.5 mm (0.059 in)
GI0059A
(1) (2) (3) (4) (5) (6) (7)
Rotational direction of drum (Forward) Wheel cylinder Upper shoe return spring Adjusting lever Trailing shoe Lower shoe return spring Leading shoe
S1M0158A
To replace trailing shoe, remove cotter pin. Clevis pin should also be replaced if worn. 3) Check brake drum for wear, dents or other damage. If the inside surface of brake drum is streaked, correct the surface with emery cloth (#200 or more). If it is unevenly worn, tapered, or the outside surface of brake drum is damaged, correct or replace it. Brake drum inner diameter Standard value: 228.6 mm (9.000 in) Service limit: 230.6 mm (9.079 in)
PM-33
BRAKE LININGS AND DRUMS B: ADJUSTMENT

SA07696A01
2) Check brake drum for wear, dents or other damage. If the inside surface of brake drum is streaked, correct the surface with emery cloth (#200 or more). If it is unevenly worn, tapered, or the outside surface of brake drum is damaged, correct or replace it. Brake drum inside diameter Standard value: 170 mm (6.69 in) Wear limit: 171 mm (6.73 in)
1. REAR DRUM BRAKE
SA07696A0101
The main brake is adjusted automatically, and so there is no need to adjust it.

SA07696A0102
For rear disc brake, adjust parking brake after bleeding the air. 1) Remove rear cover (rubber) installed at back plate. 2) Turn adjuster toward arrow mark (upward) until it is locked slightly, by using slot-type screwdriver as shown in illustration.
GI0062A
3) If the deformation or wear of back plate, shoe, etc. is noticeable, replace them. 4) When the shoe return spring tension is excessively weakened, replace it, taking care to identify upper and lower springs.
GI0063A
3) Turn back (downward) adjuster 3 to 4 notches. 4) Install cover (rubber) at original position correctly.
PM-34
SUSPENSION
24. Suspension
A: INSPECTION
SA07697
SA07697A10
1. SUSPENSION BALL JOINT
SA07697A1001
NOTE: When transverse link ball joint has been removed or replaced, check toe-in of front wheel. If front wheel toe-in is not at specified value, adjust toe-in. <Ref. to FS-6, Wheel Alignment.>
1) Jack up vehicle until front wheels are off ground. 2) Next, grasp bottom of tire and move it in and out. If relative movement is observed between brake disc cover and end of transverse link, ball joint may be excessively worn. 3) Next, grasp end of transverse link and move it up and down. Relative movement between housing and transverse link boss indicates ball joint may be excessively worn. 4) If relative movement is observed in the immediately preceding two steps, remove and inspect ball joint. If free play exceeds standard, replace ball joint. <Ref. to FS-17, Front Ball Joint.>
GI0066A
2. TRANSVERSE LINKS REAR BUSHING

SA07697A1002
Check oil leaks at around liquid-filled bushing. If oil leaks, replace bushing.
GI0064A
GI0067A
3. WHEEL ARCH HEIGHT
SA07697A1003
GI0065A
5) Damage of dust seal Visually inspect ball joint dust seal. If it is damaged, remove transverse link. <Ref. to FS-14, Front Transverse Link.> And measure free play of ball joint. <Ref. to FS-17, Front Ball Joint.> (1) When looseness exceeds standard value, replace ball joint. (2) If the dust seal is damaged, replace with the new ball joint.
1) Unload cargoes and set vehicle in curb weight condition. 2) Then, check wheel arch height of front and rear suspensions to ensure that they are within specified values. 3) When wheel arch height is out of standard, visually inspect following components and replace deformed parts. Suspension components [Front strut assembly and rear strut assembly] Body parts to which suspensions are installed. 4) When no components are deformed, adjust wheel arch height by replacing coil spring in the suspension whose wheel arch height is out of standard. <Ref. to FS-6, Wheel Alignment.> and <Ref. to RS-7, Wheel Alignment.>
PM-35
SUSPENSION
8. DAMAGE TO SUSPENSION PARTS
SA07697A1008
4. WHEEL ALIGNMENT OF FRONT SUSPENSION SA07697A1004

1) Check alignment of front suspension to ensure that following items conform to standard values. Toe-in Camber angle Caster angle Steering angle <Ref. to FS-6, Wheel Alignment.> 2) When caster angle does not conform to standard value, visually inspect following components and replace deformed parts. Suspension components [Strut assembly, crossmember, transverse link, etc.] Body parts to which suspensions are installed. 3) When toe-in and camber are out of standard value, adjust them so that they conform to respective service standard. 4) When right-and-left turning angles of tire are out of standard, adjust to standard value.
5. WHEEL ALIGNMENT OF REAR SUSPENSION SA07697A1005

1) Check alignment of rear suspension to ensure that following items are within standard values. Toe-in Camber angle Thrust angle <Ref. to RS-7, Wheel Alignment.> 2) When camber angle does not conform to standard value, visually inspect parts listed below. If deformation is observed, replace damaged parts. Suspension components [Strut assembly, crossmember, lateral link, etc.] Body parts to which suspensions are installed. 3) When toe-in and thrust angle are out of standard value, adjust them so that they conform to respective service standard.
1) Check the following parts and the fastening portion of the vehicle body for deformation or excessive rusting which impairs the suspension. If necessary, replace damaged parts with new ones. If minor rust formation, pitting, etc. are noted, remove rust and apply remedial anti-corrosion measures. Front suspension Transverse link Crossmember Strut Rear suspension Lateral link Crossmember Strut In the district where salt is sprayed to melt snow on a road in winter, check suspension parts for damage caused by rust every 12 months after lapse of 60 months. Take rust prevention measure as required.
6. OIL LEAKAGE OF STRUT
SA07697A1009
Visually inspect front strut and rear strut for oil leakage as instructed. Replace front strut and rear strut if oil leaks excessively.
7. TIGHTNESS OF BOLTS AND NUTS

SA07697A1007
Check bolts and nuts shown in the figure for looseness. Retighten bolts and nuts to specified torque. If self-lock nuts and bolts are removed, replace them with new ones. Front suspension: <Ref. to FS-2, General Description.> Rear suspension: <Ref. to RS-2, General Description.>
PM-36
WHEEL BEARING
25. Wheel Bearing

A: INSPECTION
SA07698A10
SA07698
1. FRONT WHEEL BEARING
SA07698A1001
6) While supporting rear drive shaft horizontally with one hand, turn hub COMPL with the other to check for noise or binding. If hub COMPL is noisy or binds, disassemble rear axle and check condition of oil seals, bearings, etc.
NOTE: Inspect the condition of front wheel bearing grease. 1) Jack up the front of vehicle. 2) While holding front wheel by hand, swing it in and out to check bearing free play. 3) Loosen wheel nuts and remove front wheel. 4) If bearing free play exists in step 2) above, attach a dial gauge to hub and measure axial displacement in axial direction. Service limit: Straight-ahead position within 0.05 mm (0.0020 in) 5) Remove bolts and self-locking nuts, and extract transverse link from front crossmember. 6) While lightly hammering spring pin which secures S.F.J. to transmission spindle, remove it. 7) Extract S.F.J. from transmission spindle. <Ref. to DS-17, Front Axle.> 8) While supporting front drive shaft horizontally with one hand, turn hub with the other to check for noise or binding. If hub is noisy or binds, disassemble front axle and check condition of oil seals, bearing, etc.
GI0134
GI0133
2. REAR WHEEL BEARING
SA07698A1002
1) Jack up the rear of vehicle. 2) While holding rear wheel by hand, swing it in and out to check bearing free play. 3) Loosen wheel nuts and remove rear wheel. 4) If bearing free play exists in step 2) above, attach a dial gauge to hub COMPL and measure axial displacement in axial direction. Service limit: Straight-ahead position within 0.05 mm (0.0020 in) 5) Remove the DOJ of rear drive shaft from rear differential. <Ref. to DS-38, Rear Drive Shaft.>
PM-37
AXLE BOOTS & JOINTS

SA07699
26. Axle Boots & Joints

A: INSPECTION
SA07699A10
1. FRONT AND REAR AXLE BOOTS
SA07699A1001
Inspect front axle boots (A) and rear axle boots (B) for deformation, damage or failure. If faulty, replace them with new ones. <Ref. to DS-32, Front Drive Shaft.> and <Ref. to DS-38, Rear Drive Shaft.>
GI0070A
GI0135
2. PROPELLER SHAFT
SA07699A1002
Inspect propeller shaft for damage or failure. If faulty, replace with new one. <Ref. to DS-14, Propeller Shaft.>
PM-38
STEERING SYSTEM (POWER STEERING)

SA07701A1002
27. Steering System (Power Steering)

SA07701
2. STEERING SHAFT JOINT
A: INSPECTION
SA07701A10
1. STEERING WHEEL
SA07701A1001
1) Set steering wheel in a straight-ahead position, and check wheel spokes to make sure they are correctly set in their specified positions. 2) Lightly turn steering wheel to the left and right to determine the point where front wheels start to move. Measure the distance of the movement of steering wheel at the outer periphery of wheel. Steering wheel free play: 0 17 mm (0 0.67 in)
1) When steering wheel free play is excessive, disconnect universal joint of steering shaft and check it for any play and yawing torque (at the point of the crossing direction). Also inspect for any damage to sealing or worn serrations. If the joint is loose, retighten the mounting bolts to the specified torque. Tightening torque: 24 Nm (2.4 kgf-m, 17.4 ft-lb)
GI0075A
3. GEARBOX
GI0074A
SA07701A1003
Move steering wheel vertically toward the shaft to ascertain if there is play in the direction. Maximum permissible play: 0.5 mm (0.020 in) 3) Drive vehicle and check the following items during operation. (1) Steering force .............. The effort required for steering should be smooth and even at all points, and should not vary. (2) Pull to one side ............ Steering wheel should not be pulled to either side while driving on a level surface. (3) Wheel runout ................ Steering wheel should not show any sign of runout. (4) Return factor ............... Steering wheel should return to its original position after it has been turned and then released.
1) With wheels placed on a level surface, turn steering wheel 90 in both the left and right directions. While wheel is being rotated, reach under vehicle and check for looseness in gearbox. Tightening torque: 59 Nm (6.0 kgf-m, 43.4 ft-lb)
GI0076A
2) Check boot for damage, cracks or deterioration.
PM-39

3) Check lock nut on the tie-rod end for tightness. If it is loose, retighten it to the specified torque. Tightening torque: 83 Nm (8.5 kgf-m, 61.5 ft-lb)
3) With vehicle on a level surface, quickly turn steering wheel to the left and right. While steering wheel is being rotated, check the gear backlash. If any unusual noise is noticed, adjust the gear backlash in the following manner. (1) Loosen the adjusting screw three to four rotations. (2) Apply liquid packing to at least 1/3 of entire perimeter of adjusting screw thread. (3) Tighten adjusting screw to 7.4 Nm (0.75 kgf-m, 5.4 ft-lb) and then loosen. Repeat this operation twice. (4) Retighten adjusting screw to 7.4 Nm (0.75 kgf-m, 5.4 ft-lb) and back off 25.
5. POWER STEERING FLUID LEVEL

SA07701A1005
GI0077A
(5) Install lock nut. While holding adjusting screw with a wrench, tighten lock nut using ST. ST 926230000 SPANNER Tightening torque (Lock nut): 39 Nm (4.0 kgf-m, 29 ft-lb) Hold the adjusting screw with a wrench to prevent it from turning while tightening the lock nut.
4. TIE-ROD
SA07701A1004
1) Check tie-rod and tie-rod ends for bends, scratches or other damage. Turbo model
H4M1007
GI0105A
2) Check connections of knuckle ball joints for play, inspect for damage on dust seals, and check free play of ball studs. If castle nut is loose, retighten it to the specified torque, then tighten further up to 60 until cotter pin hole is aligned. Tightening torque: 27 Nm (2.75 kgf-m, 19.9 ft-lb)
B4M1674A
NOTE: If fluid level is at MAX level or above, drain fluid to keep the level in the specified range of indicator by using a syringe or the like.
PM-40

Recommended fluid: Dexron IIE or III Fluid capacity: 0.7 (0.7 US qt, 0.6 Imp qt)

SA07701A1009
9. GEARBOX BOOTS
6. POWER STEERING FLUID FOR LEAKS

SA07701A1006
Inspect the underside of oil pump and gearbox for power steering system, hoses, piping and their couplings for fluid leaks. If fluid leaks are found, correct them by retightening their fitting bolts (or nuts) and/or replacing their parts. NOTE: Wipe the leakage fluid off after correcting fluid leaks, or a wrong diagnosis is taken later. Also pay attention to clearances between hoses (or pipings) and other parts when inspecting fluid leaks.
Inspect both sides of gearbox boots as follows, and correct the defects if necessary. 1) (A) and (B) positions of gearbox boot are fitted correspondingly in (A) and (B) grooves of gearbox and the rod. 2) Clips are fitted outside of (A) and (B) positions of boot. 3) Boot does not have crack and hole. NOTE: Rotate (B) position of gearbox boot against twist of it produced by adjustment of toe-in, etc.
7. HOSES OF OIL PUMP FOR DAMAGES

SA07701A1007
Check pressure hose and return hose of oil pump for crack, swell or damage. Replace hose with new one if necessary. NOTE: Prevent hoses from revolving and/or turning when installing hoses.
GI0023A
10. FITTING BOLTS AND NUTS
SA07701A1010
Inspect fitting bolts and nuts of oil pump and bracket for looseness, and retighten them if necessary. Inspect and/or retighten them when engine is cold.
GI0017
8. POWER STEERING PIPES FOR DAMAGE SA07701A1008

Check power steering pipes for corrosion and damage. Replace pipes with new one if necessary.
PM-41
SUPPLEMENTAL RESTRAINT SYSTEM

SA07702
28. Supplemental Restraint System

A: INSPECTION
SA07702A10
Check the airbag system in accordance with the result of the self-diagnosis. <Ref. to AB-2, Basic Diagnostic Procedure.> 1) Ensure that airbag connectors are connected. If not, properly connect (also double lock the connector). When the ignition switch is turned ON with the connector(s) disconnected, the airbag warning light turns on to identify the fault.
S1M0160A
2) Turn the ignition switch ON, and connect the airbag diagnosis terminal of the service connector (located below lower cover) to the ground terminal. 3) The warning light blinks to indicate a trouble code (a fault is identified). When the airbag system is in good order (no trouble codes are stored in the memory), the warning light blinks on and off at 0.6 second intervals (as long as the diagnosis terminal is connected to the ground terminal). 4) When the warning light indicates a trouble code, check the airbag system in accordance with the troubleshooting procedure. <Ref. to AB-2, Basic Diagnostic Procedure.>
PM-42
FUEL INJECTION (FUEL SYSTEMS)
FU(SOHC)
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. Page General Description.....................................................................................2 Throttle Body .............................................................................................14 Intake Manifold ..........................................................................................15 Engine Coolant Temperature Sensor........................................................28 Crankshaft Position Sensor.......................................................................29 Camshaft Position Sensor.........................................................................30 Knock Sensor ............................................................................................31 Throttle Position Sensor............................................................................33 Intake Air Temperature and Pressure Sensor...........................................36 Atmospheric Pressure Sensor ..................................................................37 Idle Air Control Solenoid Valve .................................................................38 Air Assist Injector Solenoid Valve .............................................................39 Fuel Injector...............................................................................................40 Front Oxygen (A/F) Sensor.......................................................................45 Rear Oxygen Sensor.................................................................................47 Engine Control Module..............................................................................49 Main Relay ................................................................................................50 Fuel Pump Relay.......................................................................................51 Fuel............................................................................................................52 Fuel Tank...................................................................................................55 Fuel Filler Pipe ..........................................................................................58 Fuel Pump .................................................................................................62 Fuel Level Sensor .....................................................................................64 Fuel Sub Level Sensor..............................................................................65 Fuel Filter ..................................................................................................66 Fuel Cut Valve...........................................................................................67 Fuel Damper Valve....................................................................................68 Fuel Delivery, Return and Evaporation Lines ...........................................69 Fuel System Trouble in General ...............................................................72
Fuel Injection (Fuel Systems)
GENERAL DESCRIPTION
S155001
A: SPECIFICATIONS
Model Fuel tank
S155001E49
Fuel pump
Capacity Location Type Shutoff discharge pressure Discharge flow
Fuel filter
(15.9 US gal, 13.2 Imp gal) Under rear seat Impeller 373 677 kPa (3.8 6.9 kg/cm2, 54 98 psi) More than 65 (17.2 US gal, 14.3 Imp gal)/h [12 V at 300 kPa (3.06 kg/cm2, 43.5 psi)] Cartridge type
60
FU(SOHC)-2
GENERAL DESCRIPTION
MEMO:
FU(SOHC)-3
GENERAL DESCRIPTION
B: COMPONENT
S155001A05
1. INTAKE MANIFOLD
S155001A0501
S2M2151A
FU(SOHC)-4
GENERAL DESCRIPTION
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) Intake manifold gasket Fuel injector pipe RH Fuel injector O-ring O-ring O-ring Plug (LHD model) PCV valve Purge control solenoid valve Nipple (LHD model) Intake manifold Fuel injector pipe LH Accelerator cable bracket Intake air temperature and pressure sensor (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) O-ring Plug cord holder LH Plug cord holder RH Fuel pipe ASSY Fuel hose Clip Clip Air assist injector solenoid valve Air assist injector solenoid valve bracket Guide pin Atmospheric pressure sensor bracket Atmospheric pressure sensor Nipple (RHD model)

(28) Plug (RHD model)
Tightening torque: Nm (kgf-m, ft-lb) T1: 3.4 (0.35, 2.5) T2: 4.9 (0.50, 3.6) T3: 6.4 (0.65, 4.7) T4: 19 (1.9, 13.7) T5: 16 (1.6, 12) T6: 25 (2.6, 18.8) T7: 7.35 (0.75, 5.421) T8: 17 (1.7, 12) T9: 1.5 (0.15, 1.1)
FU(SOHC)-5
GENERAL DESCRIPTION
S155001A0502
2. AIR INTAKE SYSTEM
B2M3455C
(1) Gasket (2) Throttle position sensor (3) Idle air control solenoid valve
(4) Throttle body
Tightening torque: Nm (kgf-m, ft-lb) T1: 1.6 (0.16, 1.2) T2: 22 (2.2, 16)
FU(SOHC)-6
GENERAL DESCRIPTION

S155001A0503
3. CRANKSHAFT POSITION, CAMSHAFT POSITION AND KNOCK SENSORS
B2M2282B
(1) (2) (3) (4)
Crankshaft position sensor Knock sensor Camshaft position sensor Camshaft position sensor support
Tightening torque: Nm (kgf-m, ft-lb) T1: 6.4 (0.65, 4.7) T2: 24 (2.4, 17.4)
FU(SOHC)-7
GENERAL DESCRIPTION
4. FUEL TANK
S155001A0504
S2M2152A
FU(SOHC)-8
GENERAL DESCRIPTION
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) Heat sealed cover Fuel tank band Protector LH Protector RH Fuel tank Fuel pump gasket Fuel pump ASSY Fuel level sensor Fuel cut valve gasket Fuel cut valve Evaporation hose A Clip (13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) Evaporation hose B Joint pipe Evaporation hose C Evaporation pipe ASSY Evaporation hose D Evaporation hose E Fuel return hose A Retainer Quick connector Evaporation hose F Fuel pipe ASSY Evaporation hose G (25) (26) (27) (28) (29) (30)

Fuel return hose B Fuel sub level sensor gasket Jet pump filter Fuel sub level sensor Evaporation hose H Evaporation hose I
Tightening torque: Nm (kgf-m, ft-lb) T1: 4.4 (0.45, 3.3) T2: 7.4 (0.75, 5.4) T3: 33 (3.4, 25)
FU(SOHC)-9
GENERAL DESCRIPTION
5. FUEL LINE
S155001A0505
S2M2153A
FU(SOHC)-10
GENERAL DESCRIPTION
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) Clip Fuel delivery hose A Fuel filter bracket Fuel filter holder Fuel filter cup Fuel filter Evaporation hose A Fuel damper Fuel delivery hose B Fuel return hose Fuel pipe ASSY Grommet (13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) Canister hose A Canister Canister bracket plate Cushion Canister bracket spacer Rear canister bracket Two-way valve return hose Two-way valve Two-way valve drain hose A Connector Two-way valve drain hose B Clamp (25) (26) (27) (28) (29) (30) (31)

Front canister bracket Evaporation hose B Roll over valve bracket Roll over valve Evaporation hose C Evaporation pipe Canister hose B
Tightening torque: Nm (kgf-m, ft-lb) T: 23 (2.34, 17.0)
FU(SOHC)-11
GENERAL DESCRIPTION
S155001A0506
6. FUEL FILLER PIPE
S2M2245A
(1) (2) (3) (4) (5)
Fuel filler pipe ASSY Evaporation hose holder Clamp Clamp Air vent hose
(6) (7) (8) (9) (10)
Air vent pipe Air vent pipe holder Filler pipe packing Filler ring Filler cap
(11) Fuel filler pipe protector

Tightening torque: Nm (kgf-m, ft-lb) T: 7.5 (0.76, 5.53)
FU(SOHC)-12
GENERAL DESCRIPTION C: CAUTION

S155001A03
Wear working clothing, including a cap, protective goggles, and protective shoes during operation. Remove contamination including dirt and corrosion before removal, installation or disassembly. Keep the disassembled parts in order and protect them from dust or dirt. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly, and replacement.
Be careful not to burn your hands, because each part on the vehicle is hot after running. Be sure to tighten fasteners including bolts and nuts to the specified torque. Place shop jacks or safety stands at the specified points. Before disconnecting electrical connectors of sensors or units, be sure to disconnect negative terminal from battery. Place NO FIRE signs near the working area. Be careful not to spill fuel on the floor.
D: PREPARATION TOOL
ILLUSTRATION
S155001A17
TOOL NUMBER DESCRIPTION 24082AA150 CARTRIDGE (Newly adopted tool)
REMARKS Troubleshooting for electrical system.
B2M3876
22771AA030
SELECT MONITOR KIT
Troubleshooting for electrical systems. English: 22771AA030 (Without printer) German: 22771AA070 (Without printer) French: 22771AA080 (Without printer) Spanish: 22771AA090 (Without printer)
B2M3877
FU(SOHC)-13
THROTTLE BODY
S155010
2. Throttle Body
A: REMOVAL
S155010A18
5) Disconnect connectors from idle air control solenoid valve, throttle position sensor. 6) Disconnect air by-pass hose from throttle body.
1) Disconnect battery ground cable.
B2M3457A G6M0095
2) Remove air cleaner case.
(A) (B) (C)
Throttle position sensor Idle air control solenoid valve Air by-pass hose
7) Disconnect engine coolant hoses from throttle body.
H2M2947
3) Disconnect accelerator cable (A). 4) Disconnect cruise control cable (B). (With cruise control model)
B2M4255
8) Remove bolts which install throttle body to intake manifold.
B: INSTALLATION
NOTE: Always use a new gasket.
S155010A11
Install in the reverse order of removal.
B2M4254A
Tightening torque: Throttle body; 22 Nm (2.2 kgf-m, 15.9 ft-lb) Air cleaner case; 6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
FU(SOHC)-14
INTAKE MANIFOLD
3. Intake Manifold
A: REMOVAL
S155034A18
S155034
NOTE: Do not disconnect power steering hose.
1) Release fuel pressure. <Ref. to FU(SOHC)-52, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.> 2) Open fuel flap lid, and remove fuel filler cap. 3) Disconnect battery ground cable.
S2M1013
(4) Remove bolts which install power steering pump bracket.
G6M0095
4) Remove air intake duct and air cleaner assembly. <Ref. to IN(SOHC)-8, REMOVAL, Air Intake Duct.> and <Ref. to IN(SOHC)-7, REMOVAL , Air Cleaner Case.> 5) Disconnect accelerator cable (A). 6) Disconnect cruise control cable (B). (With cruise control model)
S2M0488
(5) Disconnect connector from power steering pump switch.
B2M4254A
7) Remove power steering pump and tank from brackets. (1) Remove resonator chamber. <Ref. to IN(SOHC)-9, REMOVAL, Resonator Chamber.> (2) Remove front side V-belt. <Ref. to ME(SOHC)-42, REMOVAL, V-belt.> (3) Remove bolts which hold power steering pipes brackets onto intake manifold.
S2M0490
(6) Place power steering pump and tank on the right side wheel apron.
S2M0491
8) Disconnect spark plug cords from spark plugs.
FU(SOHC)-15
INTAKE MANIFOLD
13) Disconnect connectors from engine coolant temperature sensor.
9) Disconnect PCV hose from intake manifold.
B2M4258
10) Disconnect engine coolant hose from throttle body.
B2M4261
14) Disconnect knock sensor connector.
B2M4255
B2M4262
11) Disconnect brake booster hose.
15) Disconnect connector from crankshaft position sensor.
B2M4259
12) Remove air cleaner case stay RH and engine harness bracket, and disconnect engine harness connectors from bulkhead harness connectors.
B2M1252
16) Disconnect switch.
connector
from
oil
pressure
B2M4260
B2M1253
FU(SOHC)-16
INTAKE MANIFOLD
17) Disconnect connector from camshaft position sensor.
20) Remove intake manifold.
B2M0160 B2M4263
18) Disconnect fuel hoses from fuel pipes. WARNING: Do not spill fuel. Catch fuel from hoses in a container or cloth.
B: INSTALLATION
NOTE: Always use new gaskets.
S155034A11
1) Install intake manifold onto cylinder heads.
Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
S2M0500F
(A) (B) (C)
Fuel delivery hose Return hose Evaporation hose
S2M1660
19) Remove bolts which hold intake manifold onto cylinder heads.
2) Connect fuel hoses.
S2M0500F S2M1660
(A) (B) (C)
FU(SOHC)-17
INTAKE MANIFOLD
7) Connect connectors to engine coolant temperature sensor.
3) Connect connector to camshaft position sensor.
B2M4263
4) Connect connector to oil pressure switch.
B2M4261
8) Install air cleaner case stay RH and engine harness bracket, and connect engine harness connectors to bulkhead connectors.
B2M1253
5) Connect connector to crankshaft position sensor. 9) Connect brake booster hose.
B2M4260
B2M1252
6) Connect knock sensor connector.
B2M4259
10) Connect engine coolant hose to throttle body.
B2M4262
B2M4255
FU(SOHC)-18
INTAKE MANIFOLD
11) Connect PCV hose to intake manifold.
(3) Install power steering pipe brackets onto right side intake manifold.
B2M4258
12) Connect spark plug cords to spark plugs. 13) Install power steering pump on brackets. (1) Connect terminal to power steering pump switch.
S2M1013
(4) Install front side V-belt. <Ref. ME(SOHC)-42, INSTALLATION, V-belt.> (5) Install resonator chamber. Tightening torque: 33 Nm (3.4 kgf-m, 24.6 ft-lb)
to
S2M0490
(2) Tighten bolts which install power steering pump on bracket. Tightening torque: 20.1 Nm (2.05 kgf-m, 14.8 ft-lb)
S2M0481A
14) Connect accelerator cable (A). 15) Connect cruise control cable (B). (With cruise control models)
S2M0488 B2M4254A
16) Install air intake duct and air cleaner assembly. <Ref. to IN(SOHC)-8, REMOVAL, Air Intake Duct.> and <Ref. to IN(SOHC)-7, INSTALLATION, Air Cleaner Case.>
FU(SOHC)-19
INTAKE MANIFOLD
3) Remove ignition coil and ignitor assembly.
17) Connect connector to fuel pump relay.
S2M0093
B2M3473
18) Connect battery ground cable.
4) Disconnect connector from intake air temperature and pressure sensor.
G6M0095 B2M3474
C: DISASSEMBLY
S155034A06
1) Disconnect engine ground terminal from intake manifold.
5) Remove intake air temperature and pressure sensor from intake manifold.
B2M3475 B2M4265
2) Disconnect connector from ignition coil and ignitor assembly.
6) Disconnect connectors from throttle position sensor and idle air control solenoid valve.
B2M3479 B2M3472
FU(SOHC)-20
INTAKE MANIFOLD
7) Disconnect air by-pass hose from throttle body.
12) Disconnect pressure regulator vacuum hose from intake manifold.
B2M3480
8) Remove throttle body.
H2M2961
13) Disconnect connectors from fuel injectors.
H2M2951 B2M4270
9) Disconnect connector from air assist injector solenoid valve. 10) Disconnect air by-pass hoses from air assist solenoid valve.
14) Disconnect connector from purge control solenoid valve.
B2M3485 B2M4266
11) Remove air assist injector solenoid valve from intake manifold.
15) Disconnect air by-pass hose from purge control solenoid valve. 16) Remove harness bands (A) and harness bracket (B) which hold engine harness onto intake manifold.
B2M3478 B2M4271A
FU(SOHC)-21
INTAKE MANIFOLD
22) Remove fuel injectors. (1) Remove fuel injector securing clip.
17) Remove engine harness from intake manifold. 18) Remove purge control solenoid valve.
B2M3487
B2M3488
19) Remove bolt which installs injector pipe on intake manifold as shown in figure.
(2) Remove fuel injector while lifting up fuel injector pipe.
S2M2261
H2M2970
20) Remove bolt which installs injector pipe on intake manifold.
23) Disconnect air by-pass hoses from intake manifold.
H2M2966
B2M4149A
21) Remove two bolts which hold fuel pipes on the left side of intake manifold.
24) Loosen clamp which holds front left side fuel hose to injector pipe and remove the pipe from fuel hose.
B2M4272 B2M4273
FU(SOHC)-22
INTAKE MANIFOLD
25) Loosen clamp which holds front right side fuel hose to injector pipe and remove the pipe from fuel hose.
2) Tighten bolt which installs fuel pipes on intake manifold. Tightening torque: 4.9 Nm (0.5 kgf-m, 3.6 ft-lb)
B2M4274
26) Remove fuel injector pipe.
B2M3491
3) Connect right side fuel hose to injector pipe, and tighten clamp screw.
H2M2975
27) Remove bolt which installs fuel pipes on intake manifold. 4) Install fuel injector pipe.
B2M4274
B2M3491
28) Remove fuel pipe assembly and pressure regulator, from intake manifold.
H2M2975
D: ASSEMBLY
5) Connect left side fuel hose to injector pipe, and tighten clamp screw.
S155034A02
1) Install fuel pipe assembly regulator, etc. to intake manifold.
and
pressure
B2M4273
FU(SOHC)-23
INTAKE MANIFOLD
8) Tighten bolt which installs injector pipe on intake manifold. Tightening torque: 4.9 Nm (0.50 kgf-m, 3.6 ft-lb)
6) Connect air assist hoses.
B2M4149A
7) Install fuel injectors. NOTE: Always use new O-rings.

H2M2965
9) Tighten two bolts which install fuel pipes on the left side of intake manifold. Tightening torque: 4.9 Nm (0.50 kgf-m, 3.6 ft-lb)
B2M3492G
(A) (B)
O-ring Fuel injector

B2M4272
NOTE: Do not forget to install the fuel injector securing clip.
10) Tighten bolt which installs injector pipe on intake manifold. Tightening torque: 4.9 Nm (0.50 kgf-m, 3.6 ft-lb)
B2M3488
H2M2966
FU(SOHC)-24
INTAKE MANIFOLD
11) Install purge control solenoid valve. Tightening torque: 16 Nm (1.6 kgf-m, 12 ft-lb)
16) Connect pressure regulator vacuum hose to intake manifold.
H2M2961 B2M3487
12) Connect hoses to purge control solenoid valve. CAUTION: Carefully connect the evaporation hoses.
17) Install air assist injector solenoid valve to bracket. Tightening torque: 4.9 Nm (0.50 kgf-m, 3.6 ft-lb)
B2M3478 B2M1893A
13) Install engine harness onto intake manifold. 14) Connect connectors to fuel injectors and purge control solenoid valve. 15) Hold engine harness by harness band (A) and harness bracket (B). Tightening torque: 16 Nm (1.6 kgf-m, 12 ft-lb)
18) Connect air by-pass hoses to air assist solenoid valve.
B2M4266
19) Connect connector to air assist solenoid valve.
B2M4271B
FU(SOHC)-25
INTAKE MANIFOLD
23) Install intake air temperature and pressure sensor. Tightening torque: 3.4 Nm (0.35 kgf-m, 2.5 ft-lb)
20) Install throttle body to intake manifold. NOTE: Replace gasket with a new one. Tightening torque: 22 Nm (2.2 kgf-m, 15.9 ft-lb)
B2M3475 H2M2951
21) Connect connector to throttle position sensor and idle air control solenoid valve.
NOTE: Replace O-ring with a new one.
H2M2999 B2M3479
22) Connect air by-pass hose to throttle body.
24) Connect connector to intake air temperature and pressure sensor. 25) Install ignition coil and ignitor assembly.
B2M3480 B2M3473
FU(SOHC)-26
INTAKE MANIFOLD
26) Connect connector to ignition coil and ignitor assembly. 27) Install engine ground terminal to intake manifold. Tightening torque: 19 Nm (1.9 kgf-m, 13.7 ft-lb)
B2M2779
E: INSPECTION
S155034A10
Make sure the fuel pipe and fuel hoses are not cracked and that connections are tight.
FU(SOHC)-27
ENGINE COOLANT TEMPERATURE SENSOR
4. Engine Coolant Temperature Sensor

S155047
A: REMOVAL
S155047A18
G6M0095
2) Remove air intake duct and air cleaner assembly. <Ref. to IN(SOHC)-8, REMOVAL, Air Intake Duct.> and <Ref. to IN(SOHC)-7, REMOVAL , Air Cleaner Case.> 3) Disconnect connector from engine coolant temperature sensor.
B2M4261
4) Remove engine coolant temperature sensor.
B: INSTALLATION
S155047A11
Install in the reverse order of removal. Tightening torque: 18 Nm (1.8 kgf-m, 13 ft-lb)
B2M4275
FU(SOHC)-28
CRANKSHAFT POSITION SENSOR

S155043A11
5. Crankshaft Position Sensor

S155043
B: INSTALLATION

S155043A18
A: REMOVAL
Tightening torque: T: 6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
B2M1252B G6M0095
2) Remove bolt which installs crankshaft position sensor to cylinder block.
G2M0408
3) Remove crankshaft position sensor, and disconnect connector from it.
G2M0409
FU(SOHC)-29
CAMSHAFT POSITION SENSOR

4) Remove bolt which installs camshaft position sensor support to camshaft cap LH.
6. Camshaft Position Sensor

S155041
A: REMOVAL
S155041A18
B2M2321
G6M0095
5) Remove camshaft position sensor and camshaft position sensor support as a unit. 6) Remove camshaft position sensor itself.
B2M2322
B2M4263
B: INSTALLATION
S155041A11
3) Remove bolt which installs camshaft position sensor to camshaft position sensor support.
Install in the reverse order of removal. Tightening torque: Camshaft position sensor support; 6.4 Nm (0.65 kgf-m, 4.7 ft-lb) Camshaft position sensor; 6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
B2M2375
FU(SOHC)-30
KNOCK SENSOR

S155042A11
7. Knock Sensor
A: REMOVAL
S155042A18
S155042
B: INSTALLATION
1) Install knock sensor to cylinder block. Tightening torque: 24 Nm (2.4 kgf-m, 17.4 ft-lb) NOTE: The extraction area of the knock sensor cord must be positioned at a 60 angle relative to the engine rear.
1) Disconnect battery ground cable from battery ground terminal.
G6M0095

H2M3511C
H2M2947

B2M4262
3) Install air cleaner case.
B2M4262
4) Remove knock sensor from cylinder block.

H2M2947
S2M1673
FU(SOHC)-31
KNOCK SENSOR
G6M0095
FU(SOHC)-32
THROTTLE POSITION SENSOR

S155039A11
8. Throttle Position Sensor

A: REMOVAL
S155039A18
S155039
B: INSTALLATION
Install in the reverse order of removal. Tightening torque: 1.6 Nm (0.16 kgf-m, 1.2 ft-lb) CAUTION: When installing throttle position sensor, adjust to the specified data.
G6M0095
2) Disconnect connector from throttle position sensor.

H2M2979
B2M3493
3) Remove throttle position screws, and remove it.
sensor
holding
H2M2979
FU(SOHC)-33

(2) Loosen throttle position sensor holding screws.
C: ADJUSTMENT
S155039A01
1) Turn ignition switch to OFF. 2) Loosen throttle position sensor holding screws.
B2M3765 B2M3765
3) When using voltage meter; (1) Take out ECM. (2) Turn ignition switch to ON. (3) Adjust throttle position sensor to the proper position to allow the voltage signal to ECM to be in specification. Connector & terminal / Specified voltage (B136) No. 15 (B136) No. 17 / 0.45 0.55 V [Fully closed.]
NOTE: For detailed operation procedures, refer to the Subaru Select Monitor Operation Manual. (3) Insert the cartridge to Subaru Select Monitor.
S2M0286A
(4) Connect Subaru Select Monitor to the data link connector.
B2M4131A
(4) Tighten throttle position sensor holding screws. Tightening torque: 1.6 Nm (0.16 kgf-m, 1.2 ft-lb)
S2M2157
B2M3765
4) When using Subaru Select Monitor; (1) Turn ignition switch to OFF.
5) Turn ignition switch to ON, and Subaru Select Monitor switch to ON. 6) Select {2. Each System Check} in Main Menu. 7) Select {Engine Control System} in Selection Menu. 8) Select {1. Current Data Display & Save} in Engine Control System Diagnosis. 9) Select {1.12 Data Display} in Data Display Menu. 10) Adjust throttle position sensor to the proper position to match with the following specifications.
FU(SOHC)-34

Condition: Throttle fully closed Throttle opening angle 0.00% Throttle sensor voltage 0.50 V 11) Tighten screws. throttle position sensor holding
B2M3765
FU(SOHC)-35
INTAKE AIR TEMPERATURE AND PRESSURE SENSOR

4) Remove intake air temperature and pressure sensor.
9. Intake Air Temperature and Pressure Sensor

S155044
A: REMOVAL
S155044A18
B2M3497
B: INSTALLATION
G6M0095
S155044A11
Install in the reverse order of removal. Tightening torque: 3.4 Nm (0.35 kgf-m, 2.5 ft-lb)
2) Disconnect spark plug cord from ignition coil and ignitor assembly.
B2M3495
B2M3497
3) Disconnect connector from intake air temperature and pressure sensor.
NOTE: Replace O-ring with a new one.
B2M4276
H2M2999
FU(SOHC)-36
ATMOSPHERIC PRESSURE SENSOR
10. Atmospheric Pressure Sensor

S155045
A: REMOVAL
S155045A18
G6M0095
2) Disconnect connector from atmospheric pressure sensor. 3) Remove atmospheric pressure sensor from bracket.
EN1001
B: INSTALLATION
S155045A11
EN1001
FU(SOHC)-37
IDLE AIR CONTROL SOLENOID VALVE B: INSTALLATION

S155056A11
11. Idle Air Control Solenoid Valve

S155056
A: REMOVAL
S155056A18
B2M3501 G6M0095
2) Disconnect connector from idle air control solenoid valve.
B2M3500
3) Remove idle air control solenoid valve from throttle body.
B2M3501
FU(SOHC)-38
AIR ASSIST INJECTOR SOLENOID VALVE

S155570A11
12. Air Assist Injector Solenoid Valve

S155570
B: INSTALLATION
A: REMOVAL
S155570A18
B2M3503 G6M0095
2) Disconnect connector from air assist injector solenoid valve and disconnect air by-pass hoses.
B2M4266
3) Remove air assist injector solenoid valve from intake manifold.
B2M3503
FU(SOHC)-39
FUEL INJECTOR
S155051
13. Fuel Injector

A: REMOVAL
1. RH SIDE
S155051A18 S155051A1801
S2M0490
G6M0095
4) Remove resonator chamber. <Ref. to IN(SOHC)-9, REMOVAL, Resonator Chamber.> 5) Remove power steering pump and tank from brackets. (1) Remove front side V-belt. <Ref. to ME(SOHC)-42, REMOVAL, V-belt.> (2) Remove bolts which hold power steering pipe bracket onto intake manifold.
S2M0491
6) Remove spark plug cords from spark plugs (#1 and #3 cylinders). 7) Disconnect connector from fuel injector.
S2M1013 B2M4280
(3) Remove bolts which install power steering pump to bracket.
S2M0488
FU(SOHC)-40
FUEL INJECTOR
8) Remove bolt which holds injector pipe to intake manifold.

S155051A1802
2. LH SIDE
B2M4281
G6M0095
4) Remove two bolts which install washer tank on body.
B2M4282
9) Remove fuel injector from intake manifold. (1) Remove fuel injector securing clip.
B2M3139
5) Disconnect connector from front window washer motor. 6) Disconnect connector from rear gate glass washer motor.
B2M4283
B6M0562
B2M3509
FU(SOHC)-41
FUEL INJECTOR
12) Remove bolt which holds fuel pipe on the left side intake manifold.
7) Disconnect rear window glass washer hose from washer motor, then plug connection with a suitable cap. 8) Move washer tank, and secure it away from working area.
H2M2995
B2M3140
13) Remove fuel injector from intake manifold. (1) Remove fuel injector securing clip.
9) Remove spark plug cords from spark plugs (#2 and #4 cylinders). 10) Disconnect connector from fuel injector.
H2M2997

B2M4294
11) Remove bolt which holds injector pipe to intake manifold.
H2M3241
B2M4133
H2M2994
FU(SOHC)-42
FUEL INJECTOR B: INSTALLATION

1. RH SIDE
S155051A1101 S155051A11

S155051A1102
2. LH SIDE
Install in the reverse order of removal. NOTE: Replace O-rings with new ones.
B2M3492G B2M3492G
(A) (B)
(A) (B)
H2M2994 B2M4282
H2M2995 B2M4132
FU(SOHC)-43
FUEL INJECTOR
B2M4133
FU(SOHC)-44
FRONT OXYGEN (A/F) SENSOR

S155642A11
14. Front Oxygen (A/F) Sensor

S155642
B: INSTALLATION
A: REMOVAL
S155642A18
1) Before installing front oxygen (A/F) sensor, apply anti-seize compound only to threaded portion of front oxygen (A/F) sensor to make the next removal easier. Anti-seize compound: SS-30 by JET LUBE CAUTION: Never apply anti-seize compound to protector of front oxygen (A/F) sensor.
G6M0095
2) Disconnect connector from front oxygen (A/F) sensor.
G2M0412
2) Install front oxygen (A/F) sensor. Tightening torque: 21 Nm (2.1 kgf-m, 15.2 ft-lb)
B2M4243
3) Lift-up the vehicle. 4) Apply SUBARU CRC or its equivalent to threaded portion of front oxygen (A/F) sensor, and leave it for one minute or more. SUBARU CRC (Part No. 004301003) 5) Remove front oxygen (A/F) sensor. CAUTION: When removing the oxygen (A/F) sensor, wait until exhaust pipe cools, otherwise it will damage exhaust pipe.
G2M0411
3) Lower the vehicle. 4) Connect connector of front oxygen (A/F) sensor.
B2M4243 G2M0411
FU(SOHC)-45
G6M0095
FU(SOHC)-46
REAR OXYGEN SENSOR

S155657A11
15. Rear Oxygen Sensor

A: REMOVAL
S155657A18
S155657
B: INSTALLATION
1) Before installing rear oxygen sensor, apply antiseize compound only to threaded portion of rear oxygen sensor to make the next removal easier. CAUTION: Never apply anti-seize compound to protector of rear oxygen sensor. Anti-seize compound: SS-30 by JET LUBE
G6M0095
2) Disconnect connector from rear oxygen sensor.
B2M0742A
2) Install rear oxygen sensor. Tightening torque: 21 Nm (2.1 kgf-m, 15.2 ft-lb)
B2M4244
3) Lift-up the vehicle. 4) Apply SUBARU CRC or its equivalent to threaded portion of rear oxygen sensor, and leave it for one minute or more. SUBARU CRC (Part No. 004301003) 5) Remove rear oxygen sensor. CAUTION: When removing the oxygen sensor, wait until exhaust pipe cools, otherwise it will damage exhaust pipe.
B2M0741
3) Lower the vehicle. 4) Connect connector to rear oxygen sensor.
B2M0741
B2M4244
FU(SOHC)-47
REAR OXYGEN SENSOR
G6M0095
FU(SOHC)-48
ENGINE CONTROL MODULE
16. Engine Control Module

A: REMOVAL
S155049A18
S155049
G6M0095
2) Remove lower inner trim of passenger side. <Ref. to EI-38, REMOVAL, Lower Inner Trim.> 3) Detach floor mat of front passenger seat. 4) Remove protect cover.
EN0532
5) Remove nuts (A) which hold ECM to bracket. 6) Remove clip (B) from bracket.
EN0533
7) Disconnect ECM connectors and take out ECM.
B: INSTALLATION
S155049A11
Install in the reverse order of removal. CAUTION: When replacing ECM, be careful not to use the wrong spec. ECM to avoid any damage to the fuel injection system.
FU(SOHC)-49
MAIN RELAY
4) Remove main relay from mounting bracket.
17. Main Relay

A: REMOVAL
S155050
S155050A18
S2M0137
B: INSTALLATION
G6M0095
S155050A11
2) Remove bolt which holds bracket of main relay and fuel pump relay.
S2M0107
3) Disconnect connectors from relays.
S2M0108A
(A) (B) (C)
Blower fan motor relay Main relay Fuel pump relay
FU(SOHC)-50
FUEL PUMP RELAY
18. Fuel Pump Relay

A: REMOVAL
S155048A18
S155048
G6M0095
2) Disconnect connector from fuel pump relay.
S2M0093
3) Remove fuel pump relay from mounting bracket.
S2M0138
B: INSTALLATION
S155048A11
FU(SOHC)-51
FUEL
19. Fuel
S155052
A: OPERATION
S155052A1601
S155052A16
1. RELEASING OF FUEL PRESSURE

WARNING: Place No fire signs near the working area. Disconnect ground terminal from battery. 1) Disconnect connector from fuel pump relay.
G6M0095
4) Remove the floor box located just behind the rear seats. 5) Remove access hole lid.
S2M0093
2) Start the engine, and run it until it stalls. 3) After the engine stalls, crank it for five more seconds. 4) Turn ignition switch OFF.
S2M0246
2. DRAINING OF FUEL
S155052A1603
WARNING: Place No fire signs near the working area. Be careful not to spill fuel on the floor. 1) Release fuel pressure. <Ref. to FU(SOHC)-52, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.> 2) Open fuel flap lid, and remove fuel filler cap.
6) Disconnect connector from fuel pump.
S2M0172
7) Disconnect quick connector, and then disconnect fuel delivery hose (A). <Ref. to FU(SOHC)-69, REMOVAL, Fuel Delivery, Return and Evaporation Lines.>
H2M2535
FU(SOHC)-52
FUEL
8) Move clips, and then disconnect fuel return hose (B) and jet pump hose (C).
12) Remove service hole cover.
G2M0863 S2M0060A
9) Remove nuts which install fuel pump assembly onto fuel tank.
13) Disconnect connector from fuel sub meter. 14) Disconnect fuel jet pump hose.
S2M0151 S2M0061
10) Take off fuel pump from fuel tank.
15) Remove bolts which install fuel sub meter unit on fuel tank.
S2M0062
S2M0152
11) Drain fuel from fuel tank by using a hand pump. WARNING: Do not use a motor pump when draining fuel.
16) Remove fuel sub meter unit.
S2M0153
S2M0163
FU(SOHC)-53
FUEL
17) Drain fuel from there. WARNING: Do not use a motor pump when draining fuel.
S2M0247
FU(SOHC)-54
FUEL TANK
20. Fuel Tank

A: REMOVAL
S155053
S155053A18
8) Disconnect two-way valve hose (A) from twoway valve and disconnect canister hose (B) from canister.
WARNING: Place NO FIRE signs near the working area. Be careful not to spill fuel on the floor. 1) Set vehicle on the lift. 2) Release fuel pressure. <Ref. to FU(SOHC)-52, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.> 3) Drain fuel from fuel tank. <Ref. to FU(SOHC)52, DRAINING FUEL, OPERATION, Fuel.> 4) Remove rear seat. 5) Disconnect connector of fuel tank cord to rear harness.
EN0840
9) Loosen clamp and disconnect fuel filler hose and air vent hose from fuel filler pipe.
S2M0164
EN0539
6) Push grommet which holds fuel tank cord on floor panel into under the body.
10) Move clips, and disconnect quick connector. <Ref. to FU(SOHC)-69, REMOVAL, Fuel Delivery, Return and Evaporation Lines.> 11) Disconnect fuel hoses.
S2M0165
7) Remove rear crossmember. <Ref. to RS-20, REMOVAL, Rear Crossmember.>
EN0540
FU(SOHC)-55
FUEL TANK
4) Connect fuel filler hose and air vent hose.
12) Support fuel tank with transmission jack, remove bolts from bands and dismount fuel tank from the vehicle. WARNING: A helper is required to perform this work.
EN0539
S2M2246
5) Connect fuel hoses, and hold then with clips and quick connector. <Ref. to FU(SOHC)-69, REMOVAL, Fuel Delivery, Return and Evaporation Lines.>
B: INSTALLATION
S155053A11
1) Support fuel tank with transmission jack and push fuel tank harness into access hole with grommet. 2) Set fuel tank and temporarily tighten bolts of fuel tank bands. WARNING: A helper is required to perform this work.
EN0540
6) Tighten band mounting bolts. Tightening torque: 33 Nm (3.4 kgf-m, 25 ft-lb)
S2M2246
3) Connect two-way valve hose (A) to two-way valve and connect canister hose (B) to canister.
S2M2246
7) Install rear crossmember. <Ref. to RS-20, INSTALLATION, Rear Crossmember.>
EN0840
FU(SOHC)-56
FUEL TANK
8) Connect connectors to fuel tank cord and plug service hole with grommet.
S2M0164
9) Set rear seat and floor mat. 10) Connect connector to fuel pump relay.
S2M0093
C: INSPECTION
S155053A10
1) Make sure there are no cracks, holes, or other damage on the fuel tank. 2) Make sure that the fuel hoses and fuel pipes are not cracked and that connections are tight.
FU(SOHC)-57
FUEL FILLER PIPE

S155022
21. Fuel Filler Pipe

A: REMOVAL
S155022A18
8) Remove fuel filler pipe protector.
WARNING: Place NO FIRE signs near the working area. Be careful not to spill fuel on the floor. 1) Release fuel pressure. <Ref. to FU(SOHC)-52, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.> 2) Open fuel filler flap lid and remove filler cap. 3) Disconnect battery ground cable.
B2M1894
9) Separate evaporation hoses from clip of fuel filler pipe.
G6M0095
4) Remove screws holding packing in place.
EN0545
10) Disconnect air vent hose from fuel filler pipe.
EN0542
5) Lift-up the vehicle. 6) Remove rear right side wheel nuts. 7) Remove rear right side wheel.
B2M1896
11) Remove bolts which hold fuel filler pipe bracket on body.
B2M1748 B2M1895
FU(SOHC)-58
FUEL FILLER PIPE

12) Loosen clamp and separate fuel filler hose (A) from fuel filler pipe. 13) Move clip and separate air vent hose (B).
3) Align holes in fuel filler pipe neck and set cup (B), and tighten screws. NOTE: If edges of rubber packing are folded toward the inside, straighten it with a screwdriver.
EN0548
14) Remove fuel filler pipe to under side of the vehicle. 15) Remove air vent pipe together with clip from body.
B2M1196A
4) Install air vent pipe.
EN0549 EN0549
5) Connect air vent hose to fuel filler pipe.
B: INSTALLATION
S155022A11
1) Hold fuel filler flap open. 2) Set fuel saucer (A) with rubber packing (C) and insert fuel filler pipe into hole from the inner side of apron.
B2M1896
B2M1196A
FU(SOHC)-59
FUEL FILLER PIPE

9) Tighten bolts which hold evaporation hoses onto clip of fuel filler pipe.
6) Insert fuel filler hose (A) approximately 35 to 40 mm (1.38 to 1.57 in) over the lower end of fuel filler pipe and tighten clamp. CAUTION: Do not allow clips to touch air vent hose (B) and rear suspension crossmember.
EN0545
10) Install fuel filler pipe protector.

EN0548
7) Insert air vent hose approximately 25 to 30 mm (0.98 to 1.18 in) into the lower end of air vent pipe and hold clip. L = 27.52.5 mm (1.0830.098 in)
B2M1894
11) Install rear right wheel.
B2M1195A
(1) (2) (3)
Hose Clip Pipe

B2M1748
8) Tighten bolt which holds fuel filler pipe bracket on body. Tightening torque: 7.5 Nm (0.75 kgf-m, 5.4 ft-lb)
12) Lower the vehicle. 13) Tighten wheel nuts. 14) Connect connector to fuel pump relay.
B2M1895
S2M0093
FU(SOHC)-60
FUEL FILLER PIPE

15) Connect battery ground terminal.
G6M0095
FU(SOHC)-61
FUEL PUMP
22. Fuel Pump

A: REMOVAL
S155025
S155025A18
WARNING: Place No fire signs near the working area. Be careful not to spill fuel on the floor. 1) Release fuel pressure. <Ref. to FU(SOHC)-52, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.> 2) Open fuel filler flap lid, and remove fuel filler cap.
S2M0172
7) Move clips, and then disconnect fuel delivery hose (A), return hose (B) and jet pump hose (C). 8) Disconnect quick connector, and then disconnect fuel delivery hose (A). <Ref. to FU(SOHC)-69, REMOVAL, Fuel Delivery, Return and Evaporation Lines.>
H2M2535
S2M0060A
G6M0095
S2M0061
S2M0246
S2M0062
FU(SOHC)-62
FUEL PUMP B: INSTALLATION

S155025A11
Install in the reverse order of removal. Do the following: (1) Always use new gaskets. (2) Ensure sealing portion is free from fuel or foreign particles before installation. (3) Tighten nuts in alphabetical sequence shown in the figure to specified torque. Tightening torque: 4.4 Nm (0.45 kgf-m, 3.3 ft-lb)
S2M0063A
C: INSPECTION
S155025A10
Connect lead harness to connector terminal of fuel pump, and apply battery power supply to check whether the pump operate. WARNING: Wipe off the fuel completely. Keep battery as far apart from fuel pump as possible. Be sure to turn the battery supply ON and OFF on the battery side. Do not run fuel pump for a long time under non-load condition.
G2M0366
FU(SOHC)-63
FUEL LEVEL SENSOR

S155026
23. Fuel Level Sensor

A: REMOVAL
S155026A18
WARNING: Place NO FIRE signs near the working area. Be careful not to spill fuel on the floor. NOTE: Fuel level sensor is built in fuel pump assembly. 1) Remove fuel pump assembly. <Ref. to FU(SOHC)-62, REMOVAL , Fuel Pump.> 2) Disconnect connector from fuel pump bracket.
S2M0145
3) Remove bolt which installs fuel level sensor on mounting bracket.
S2M0855
B: INSTALLATION
S155026A11
FU(SOHC)-64
FUEL SUB LEVEL SENSOR
24. Fuel Sub Level Sensor

A: REMOVAL
S155023A18
S155023
WARNING: Place NO FIRE signs near the working area. Be careful not to spill fuel on the floor. 1) Disconnect battery ground cable.
S2M0152
G6M0095
2) Remove the floor box located just behind the rear seats. 3) Remove service hole cover.
S2M0153
B: INSTALLATION
S155023A11
G2M0863
S2M0152
S2M0151
FU(SOHC)-65
FUEL FILTER
25. Fuel Filter

A: REMOVAL
S155027
S155027A18
WARNING: Place NO FIRE signs near the working area. Be careful not to spill fuel on the floor. 1) Release fuel pressure. <Ref. to FU(SOHC)-52, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.> 2) Disconnect fuel delivery hoses from fuel filter.
S2M0195
3) Remove filter from holder.
B: INSTALLATION
S155027A11
CAUTION: If fuel hoses are damaged at the connecting portion, replace it with a new one. If clamps are badly damaged, replace with new ones. 1) Install in the reverse order of removal. 2) Tighten hose clamp screws. Tightening torque: 12.5 Nm (1.27 kgf-m, 9.22 ft-lb)
S2M0195
C: INSPECTION
S155027A10
1) Check the inside of fuel filter for dirt and water sediment. 2) If it is clogged, or if replacement interval has been reached, replace it. 3) If water is found in it, shake and expel the water from inlet port.
FU(SOHC)-66
FUEL CUT VALVE
26. Fuel Cut Valve

A: REMOVAL
S155021A18
S155021
WARNING: Place NO FIRE signs near the working area. Be careful not to spill fuel on the floor. 1) Remove fuel tank. <Ref. to FU(SOHC)-55, REMOVAL, Fuel Tank.> 2) Move clip and disconnect evaporation hose from fuel cut valve.
S2M0176
3) Remove bolts which install fuel cut valve.
B: INSTALLATION
S155021A11
S2M0177
FU(SOHC)-67
FUEL DAMPER VALVE

S155708
27. Fuel Damper Valve

A: REMOVAL
S155708A18
1) Release fuel pressure. <Ref. to FU(SOHC)-52, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.> 2) Remove fuel damper valve from fuel return line.
EN0852
B: INSTALLATION
S155708A11
FU(SOHC)-68
FUEL DELIVERY, RETURN AND EVAPORATION LINES
28. Fuel Delivery, Return and Evaporation Lines

S155019
A: REMOVAL
S155019A18
1) Set vehicle on the lift. 2) Release fuel pressure. <Ref. to FU(SOHC)-52, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.>
3) Open fuel filler flap lid and remove fuel filler cap. 4) Remove floor mat. <Ref. to EI-43, REMOVAL, Floor Mat.> 5) Remove fuel delivery pipes and hoses, fuel return pipes and hoses, evaporation pipes and hoses.
S2M2247
6) In engine compartment, detach fuel delivery hoses, return hoses and evaporation hose.
S2M0500F
(A) (B) (C)
EN0840
7) Lift-up the vehicle.
FU(SOHC)-69
9) Separate quick connector on fuel delivery and return line. (1) Clean pipe and connector, if they are covered with dust. (2) Hold connector (A) and push retainer (B) down. (3) Pull out connector (A) from retainer (B). CAUTION: Replace retainers with new ones.
S2M0230A
(A) (B) (C)
Connector Retainer Pipe
S2M0228A
(A) (B) (C)

S155019A11
CAUTION: Pull the connector to ensure it is connected securely. Ensure the two retainer pawls are engaged in their mating positions in the connector. Be sure to inspect hoses and their connections for any leakage of fuel.
B: INSTALLATION
1) Connect quick connector on fuel delivery line. CAUTION: Always use a new retainer. Make sure that the connected portion is not damaged or has dust. If necessary, clean seal surface of pipe.
(A) (B) (C) Connector Retainer Pipe
S2M0231A
S2M0229A
(1) Set new retainer (B) to connector (A). (2) Push pipe into connector completely. NOTE: At this time, two clicking sounds are heard.
FU(SOHC)-70

2) Connect fuel delivery hose to pipe with an overlap of 20 to 25 mm (0.79 to 0.98 in). Type A: When fitting length is specified. Type B: When fitting length is not specified. : 2.51.5 mm (0.0980.059 in) L: 22.52.5 mm (0.8860.098 in)
B2M1194B
(1) (2) (3)
Fitting Clamp Hose
3) Connect evaporation hose to pipe by approx. 15 mm (0.59 in) from hose end. L = 17.52.5 mm (0.6890.098 in) CAUTION: Be sure to inspect hoses and their connections for any leakage of fuel.
B2M1195A
(1) (2) (3)
Hose Clip Pipe

S155019A10
C: INSPECTION
1) Make sure that there are no cracks on the fuel pipes and fuel hoses. 2) Make sure that the fuel pipe and fuel hose connections are tight.
FU(SOHC)-71
FUEL SYSTEM TROUBLE IN GENERAL

S155571
29. Fuel System Trouble in General

A: INSPECTION
S155571A10
Trouble and possible cause 1. Insufficient fuel supply to the injector 1) Fuel pump will not operate. k k 2) 3) 4) 5) 6) 7) 2. Leakage 1) 2) 3) 4) 5) Defective terminal contact. Trouble in electromagnetic or electronic circuit parts. Lowering of fuel pump function. Clogged dust or water in the fuel filter. Clogged or bent fuel pipe or hose. Air is mixed in the fuel system. Clogged or bent breather tube or pipe. Damaged diaphragm of pressure regulator. or blow out fuel Loosened joints of the fuel pipe. Cracked fuel pipe, hose and fuel tank. Defective welding part on the fuel tank. Defective drain packing of the fuel tank. Clogged or bent air breather tube or air vent tube.
Corrective action
Inspect connections, especially ground, and tighten securely. Replace fuel pump. Replace fuel pump. Replace fuel filter, clean or replace fuel tank. Clean, correct or replace fuel pipe or hose. Inspect or retighten each connection part. Clean, correct or replace air breather tube or pipe. Replace. Retightening. Replace. Replace. Replace. Clean, correct or replace air breather tube or air vent tube.
3. Gasoline smell inside of compartment Loose joints at air breather tube, air vent tube and fuel 1) filler pipe. 2) Defective packing air tightness on the fuel saucer. 3) Cracked fuel separator. 4) Inoperative fuel pump modulator or circuit. 4. Defective fuel meter indicator 1) Defective operation of fuel level sensor. 2) Defective operation of fuel meter. 5. Noise 1) Large operation noise or vibration of fuel pump.
Retightening. Correct or replace packing. Replace separator. Replace. Replace. Replace. Replace.
NOTE: When the vehicle is left unattended for an extended period of time, water may accumulate in the fuel tank. To prevent water condensation: (1) Top off the fuel tank or drain the fuel completely. (2) Drain water condensation from the fuel filter. Refilling the fuel tank. Refill the fuel tank while there is still some fuel left in the tank. Protecting the fuel system against freezing and water condensation. (1) Cold areas In snow-covered areas, mountainous areas, skiing areas, etc. where ambient temperatures drop below 0C (32F) throughout the winter season, use an anti-freeze solution in the cooling system. Refueling will also complement the effect of anti-freeze solution each time the fuel
level drops to about one-half. After the winter season, drain water which may have accumulated in the fuel filter and fuel tank in the manner same as that described under Affected areas below. (2) Affected areas When water condensation is notched in the fuel filter, drain water from both the fuel filter and fuel tank or use a water removing agent (or antifreeze solution) in the fuel tank. Observe the instructions, notes, etc., indicated on the label affixed to the anti-freeze solution (water removing agent) container before use.
FU(SOHC)-72
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)
EC(SOHC)
1. 2. 3. 4. 5. 6. Page General Description.....................................................................................2 Front Catalytic Converter ............................................................................3 Rear Catalytic Converter.............................................................................6 Canister .......................................................................................................7 Purge Control Solenoid Valve .....................................................................8 Two-way Valve ............................................................................................9
Emission Control (Aux. Emission Control Devices)
GENERAL DESCRIPTION
S150001
A: CAUTION
S150001A03
Wear working clothing, including a cap, protective goggles, and protective shoes during operation. Remove contamination including dirt and corrosion before removal, installation or disassembly. Keep the disassembled parts in order and protect them from dust or dirt. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly, and replacement. Be careful not to burn your hands, because each part on the vehicle is hot after running. Be sure to tighten fasteners including bolts and nuts to the specified torque. Place shop jacks or safety stands at the specified points. Before disconnecting electrical connectors of sensors or units, be sure to disconnect negative terminal from battery.
EC(SOHC)-2
FRONT CATALYTIC CONVERTER
2. Front Catalytic Converter

A: REMOVAL
S150017A18
S150017
7) Separate center exhaust pipe from rear exhaust pipe. CAUTION: Be careful, exhaust pipe is hot.
1) Set the vehicle on the lift. 2) Disconnect battery ground cable.
S2M0558 G6M0095
3) Disconnect front oxygen (A/F) sensor connector.
8) Remove bolts which hold front exhaust pipe onto cylinder heads.
B2M3200 B2M4243
4) Disconnect connector from rear oxygen sensor connector.
9) Remove front exhaust pipe and center exhaust pipe from hanger bracket. CAUTION: Be careful not to pull down front exhaust pipe and center exhaust pipe.
B2M4244
5) Lift-up the vehicle. 6) Remove under cover.
B2M3111
EC(SOHC)-3

3) Tighten bolts which hold front exhaust pipe onto cylinder heads. Tightening torque: 30 Nm (3.1 kgf-m, 22.4 ft-lb)
10) Separate front catalytic converter from front exhaust pipe. NOTE: The rear catalytic converter is integrated with front catalytic converter. Therefore, the procedure for removing rear catalytic converter is the same as the description above.
B2M3200
4) Install center exhaust pipe to rear exhaust pipe.

S2M0923
B: INSTALLATION
S150017A11
CAUTION: Replace gaskets with new ones. 1) Install front catalytic converter to front exhaust pipe. Tightening torque: 30 Nm (3.1 kgf-m, 22.4 ft-lb)
S2M0558
5) Tighten bolt which holds center exhaust pipe to hanger bracket. Tightening torque: 35 Nm (3.6 kgf-m, 26.0 ft-lb)
S2M0923
2) Install front exhaust pipe and center exhaust pipe. And temporarily tighten bolt which installs center exhaust pipe to hanger bracket.
B2M3111
6) Install under cover.
B2M3111
EC(SOHC)-4

7) Lower the vehicle. 8) Connect front oxygen (A/F) sensor connector.
B2M4243
9) Connect connector to rear oxygen sensor connector.
B2M4244
G6M0095
NOTE: The rear catalytic converter is integrated with front catalytic converter. Therefore, the procedure for installing rear catalytic converter is the same as the description above.
C: INSPECTION
S150017A10
1) Make sure there are no exhaust leaks from connections and welds. 2) Make sure there are no holes or rusting.
EC(SOHC)-5
REAR CATALYTIC CONVERTER

S150036
3. Rear Catalytic Converter

A: REMOVAL
S150036A18
The front and rear catalytic converter and center exhaust pipe are integrated into one unit. Therefore, the removal and installation procedures are the same as the those for the front catalytic converter. <Ref. to EC(SOHC)-3 REMOVAL, Front Catalytic Converter.>
B2M4164A
(A) (B)
Front catalytic converter Rear catalytic converter

S150036A11
B: INSTALLATION
The front and rear catalytic converter and center exhaust pipe are integrated into one unit. Therefore, the removal and installation procedures are the same as the ones described under front catalytic converter. <Ref. to EC(SOHC)-4 INSTALLATION, Front Catalytic Converter.>
B2M4164A
(A) (B)
Front catalytic converter Rear catalytic converter

S150036A10
C: INSPECTION
EC(SOHC)-6
CANISTER
4. Canister
S150037
A: REMOVAL
S150037A18
1) Lift-up the vehicle. 2) Loosen two clamps which hold two canister hoses, and disconnect evaporation hose from canister.
EN0898
3) Remove canister from body.
B2M4166
B: INSTALLATION
S150037A11
B2M4166
C: INSPECTION
S150037A10
Make sure the canister and canister hoses are not cracked or loose.
EC(SOHC)-7
PURGE CONTROL SOLENOID VALVE B: INSTALLATION

S150035A11
5. Purge Control Solenoid Valve

S150035
Install in the reverse order of removal. Tightening torque: 16 Nm (1.6 kgf-m, 11.6 ft-lb)
A: REMOVAL
S150035A18
H2M2985 G6M0095
2) Remove bolt which installs purge control solenoid valve onto intake manifold.
CAUTION: Carefully connect the evaporation hoses.
H2M2985
B2M1893A
3) Take out purge control solenoid valve through the bottom of the intake manifold. 4) Disconnect connector and hoses from purge control solenoid valve.
C: INSPECTION
S150035A10
Make sure hoses are not cracked or loose.
H2M2986
EC(SOHC)-8
TWO-WAY VALVE
6. Two-way Valve
A: REMOVAL
S150707A18
S150707
1) Lift-up the vehicle. 2) Remove canister from body. <Ref. to EC(SOHC)-7, REMOVAL, Canister.> 3) Remove two-way valve with bracket as a single unit from body.
EN0901
4) Remove two-way valve from bracket.
B: INSTALLATION C: INSPECTION
S150707A11

S150707A10
Make sure that hoses are not cracked or loose.
EC(SOHC)-9
TWO-WAY VALVE
MEMO:
EC(SOHC)-10
INTAKE (INDUCTION)
IN(SOHC)
1. 2. 3. 4. 5. Page General Description.....................................................................................2 Air Cleaner ..................................................................................................6 Air Cleaner Case.........................................................................................7 Air Intake Duct.............................................................................................8 Resonator Chamber ....................................................................................9
Intake (Induction)
GENERAL DESCRIPTION
S154001
A: COMPONENT
S154001A05
1. MODEL WITH OBD
S154001A0501
S2M2236A
IN(SOHC)-2
GENERAL DESCRIPTION
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) Spacer Bushing Resonator chamber Cushion rubber Air intake duct A Air intake duct B Holder Cushion Air cleaner case A Clip (11) Air cleaner element (12) Air cleaner case B (13) Air cleaner case stay LH (MT vehicles) (14) Air cleaner case stay LH (AT vehicles) (15) Air cleaner case stay RH (16) Engine harness bracket (17) Clamp (18) Bushing (19) Spacer
Intake (Induction)
Tightening torque: Nm (kgf-m, ft-lb) T1: 33 (3.4, 24.4) T2: 6.5 (0.66, 4.8) T3: 7.5 (0.76, 5.5) T4: 14 (1.4, 10) T5: 16 (1.6, 11.6) T6: 3 (0.3, 2.2)
IN(SOHC)-3
Intake (Induction)
GENERAL DESCRIPTION
S154001A0502
2. MODEL WITHOUT OBD
S2M2243A
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
Spacer Bushing Resonator chamber Cushion rubber Air intake duct A Air intake duct B Holder Air cleaner case A Clip Air cleaner element
(11) Air cleaner case B (12) Air cleaner case stay LH (MT vehicles) (13) Air cleaner case stay LH (AT vehicles) (14) Air cleaner case stay RH (15) Clamp (16) Intake air temperature sensor (17) Rubber holder (18) Bushing
(19) Spacer
Tightening torque: Nm (kgf-m, ft-lb) T1: 33 (3.4, 25) T2: 6.5 (0.66, 4.8) T3: 7.5 (0.76, 5.5) T4: 14 (1.4, 10.1) T5: 16 (1.6, 11.6)
IN(SOHC)-4
GENERAL DESCRIPTION B: CAUTION

S154001A03
Intake (Induction)
Wear working clothing, including a cap, protective goggles, and protective shoes during operation. Remove contamination including dirt and corrosion before removal, installation or disassembly. Keep the disassembled parts in order and protect them from dust or dirt. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly, and replacement. Be careful not to burn your hands, because each part on the vehicle is hot after running. Be sure to tighten fasteners including bolts and nuts to the specified torque. Place shop jacks or safety stands at the specified points. Before disconnecting electrical connectors of sensor or units, be sure to disconnect negative terminal from battery.
IN(SOHC)-5
Intake (Induction)
AIR CLEANER
S154087
2. Air Cleaner
A: REMOVAL
S154087A18
1) Remove bolts (A) which secure air cleaner case to stays. 2) Remove the clips (B) above the air cleaner case. Model without OBD
S2M1649A
Model with OBD
H2M2947A
3) Remove air cleaner element.
B: INSTALLATION
S154087A11
Install in the reverse order of removal. CAUTION: Fasten with a clip after inserting the lower tab of the case.
C: INSPECTION
S154087A10
Replace if excessively damaged or dirty.
IN(SOHC)-6
AIR CLEANER CASE
Intake (Induction)
3. Air Cleaner Case

A: REMOVAL
S154089A18
S154089
Model with OBD
1) Disconnect battery ground cable. (Model without OBD)
H2M2946
G6M0095
4) Disconnect hoses from air cleaner case. 5) Remove bolts which secure air cleaner case to stays. Model without OBD
2) Disconnect intake air temperature sensor connector. (Model without OBD)
S2M1649
Model with OBD

S2M1647
3) Loosen clamp which connects air cleaner case to throttle body. Model without OBD
H2M2947
B: INSTALLATION
S2M1648
S154089A11
C: INSPECTION
S154089A10
Inspect for cracks and loose connections.
IN(SOHC)-7
Intake (Induction)
AIR INTAKE DUCT

S154566
4. Air Intake Duct

A: REMOVAL
S154566A18
Model with OBD
1) Remove bolts which secure air intake duct on the front side of body. Model without OBD
EN1004
3) Remove air intake ducts as a unit. Model without OBD
H2M2930
Model with OBD
S6M0353
Model with OBD
EN0061
2) Remove bolt which secures air intake duct on body. Model without OBD
EN0063
B2M2284
S154566A11

S154566A10
1) Inspect for cracks and loose connections. 2) Inspect that no foreign objects are mixed in the air intake duct.
IN(SOHC)-8
RESONATOR CHAMBER
Intake (Induction)
S154639A11
5. Resonator Chamber
A: REMOVAL
S154639A18
S154639
B: INSTALLATION
1) Remove air intake duct. <Ref. to IN(SOHC)-8, REMOVAL, Air Intake Duct.> 2) Remove resonator chamber.
B6M1237 B6M1237
C: INSPECTION
S154639A10
Inspect for cracks and loose connections.
IN(SOHC)-9
Intake (Induction)
RESONATOR CHAMBER
MEMO:
IN(SOHC)-10
MECHANICAL
ME(SOHC)
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. Page General Description.....................................................................................2 Compression .............................................................................................23 Idle Speed .................................................................................................24 Ignition Timing ...........................................................................................25 Intake Manifold Vacuum............................................................................26 Engine Oil Pressure ..................................................................................27 Fuel Pressure ............................................................................................28 Valve Clearance ........................................................................................29 Engine Assembly.......................................................................................32 Engine Mounting .......................................................................................40 Preparation for Overhaul...........................................................................41 V-belt .........................................................................................................42 Crankshaft Pulley ......................................................................................44 Belt Cover..................................................................................................45 Timing Belt Assembly ................................................................................46 Camshaft Sprocket....................................................................................51 Crankshaft Sprocket..................................................................................53 Valve Rocker Assembly.............................................................................54 Camshaft ...................................................................................................56 Cylinder Head Assembly ...........................................................................60 Cylinder Block ...........................................................................................67 Engine Trouble in General ........................................................................87 Engine Noise .............................................................................................93
Mechanical
GENERAL DESCRIPTION
S153001
A: SPECIFICATIONS
Type Valve arrangement Bore x Stroke Displacement Compression ratio Compression pressure (at 200 300 rpm) Number of piston rings Opening Intake valve timing Closing Opening Exhaust valve timing Closing Intake Valve clearance Exhaust
S153001E49
Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine Belt driven, single over-head camshaft, 4-valve/cylinder mm (in) 92 x 75 (3.62 x 2.95) 1,994 (121.67) cm3 (cu in) 10.0 kPa (kg/cm2, psi) 1,020 1,275 (10.4 13.0, 148 185) Pressure ring: 2, Oil ring: 1 4 BTDC 48 ABDC 48 BBDC 4 ATDC 0.200.02 (0.00790.0008) 0.250.02 (0.00980.0008) 700100 (No load) With OBD 850100 (A/C switch ON) MT: 650100 (No load) Without OBD AT: 675100 (No load) 800100 (A/C switch ON) 1324 With OBD 1010/700 MT: 1010/650 Without OBD AT: 1010/675
Engine
mm (in) mm (in)
Idling speed [At neutral position on MT, or P or N position on AT] Firing order Ignition timing
rpm
BTDC/rpm
NOTE: STD: Standard I.D.: Inner Diameter O.D.: Outer Diameter US: Undersize OS: Oversize
Belt tensioner adjuster Protrusion of adjuster rod Spacer O.D. Tensioner bush I.D. Belt tensioner Clearance between spacer and bush Side clearance of spacer Valve rocker Clearance between shaft and arm arm STD Limit STD Limit STD Limit 5.2 6.2 mm (0.205 0.244 in) 17.955 17.975 mm (0.7069 0.7077 in) 18.00 18.08 mm (0.7087 0.7118 in) 0.025 0.125 mm (0.0010 0.0049 in) 0.175 mm (0.0069 in) 0.20 0.55 mm (0.0079 0.0217 in) 0.81 mm (0.0319 in) 0.020 0.054 mm (0.0008 0.0021 in) 0.10 mm (0.0039 in)
ME(SOHC)-2
GENERAL DESCRIPTION
Bend limit Thrust clearance Intake Camshaft Cam lobe height Exhaust Camshaft journal O.D. Camshaft journal hole I.D. Oil clearance Cylinder head Surface warpage limit Surface grinding limit Standard height Refacing angle Intake Contacting width Exhaust Inner diameter Valve guide Protrusion above head Intake Head edge thickness Exhaust Stem diameter STD Limit Overall length Free length Squareness Valve spring Tension/spring height Surface warpage limit (mating with cylinder head) Surface grinding limit A Cylinder bore STD B STD Taper Limit STD Out-of-roundness Limit STD Piston clearance Limit Enlarging (boring) limit Intake Exhaust STD Limit STD Limit Intake Exhaust Intake Exhaust Intake Exhaust STD Limit STD Limit STD Limit STD Limit STD Limit STD Limit
Mechanical
Valve set
Valve
Stem oil clearance
Cylinder block
0.020 mm (0.0008 in) 0.030 0.090 mm (0.0012 0.0035 in) 0.11 mm (0.0043 in) 38.732 38.832 mm (1.5249 1.5288 in) 38.632 mm (1.5209 in) 39.257 39.357 mm (1.5455 1.5495 in) 39.157 mm (1.5416 in) 31.928 31.945 mm (1.2570 1.2577 in) 32.000 32.018 mm (1.2598 1.2605 in) 0.055 0.090 mm (0.0022 0.0035 in) 0.10 mm (0.0039 in) 0.05 mm (0.0020 in) 0.1 mm (0.004 in) 97.5 mm (3.84 in) 90 1.0 mm (0.039 in) 1.7 mm (0.067 in) 1.4 mm (0.055 in) 2.1 mm (0.083 in) 6.000 6.012 mm (0.2362 0.2367 in) 20.0 20.5 mm (0.787 0.807 in) 16.5 17.0 mm (0.650 0.669 in) 1.0 mm (0.039 in) 0.6 mm (0.024 in) 1.2 mm (0.047 in) 0.6 mm (0.024 in) 5.950 5.965 mm (0.2343 0.2348 in) 5.945 5.960 mm(0.2341 0.2346 in) 0.035 0.062 mm (0.0014 0.0024 in) 0.040 0.067 mm (0.0016 0.0026 in) 0.15 mm (0.0059 in) 120.6 mm (4.75 in) 121.7 mm (4.79 in) 54.30 mm (2.1378 in) 2.5, 2.4 mm (0.094 in) 218.7 242.5 N (22.3 24.7 kgf, 49.2 54.5 lb)/ 45.0 mm (1.772 in) 526.6 581.6 N (53.7 59.3 kgf, 118.4 130.8 lb)/34.7 mm (1.366 in) 0.05 mm (0.0020 in) 0.1 mm (0.004 in) 92.005 92.015 mm (3.6222 3.6226 in) 91.995 92.005 mm (3.6218 3.6222 in) 0.015 mm (0.0006 in) 0.050 mm (0.0020 in) 0.010 mm (0.0004 in) 0.050 mm (0.0020 in) 0.010 0.030 mm (0.0004 0.0012 in) 0.050 mm (0.0020 in) 0.5 mm (0.020 in)
ME(SOHC)-3
Mechanical
GENERAL DESCRIPTION
A B Outer diameter 0.25 mm (0.0098 in) OS 0.50 mm (0.0197 in) OS Standard inner diameter of piston pin hole Outer diameter Standard clearance between piston pin and hole in piston STD Degree of fit Top ring Piston ring gap Second ring Oil ring Clearance between piston ring and piston ring groove Top ring Second ring STD Limit STD Limit STD Limit STD Limit STD Limit Limit 91.985 91.995 mm (3.6214 3.6218 in) 91.975 91.985 mm (3.6211 3.6214 in) 92.225 92.235 mm (3.6309 3.6313 in) 92.475 92.485 mm (3.6407 3.6411 in) 23.000 23.006 mm (0.9055 0.9057 in) 22.994 23.000 mm (0.9053 0.9055 in) 0.004 0.008 mm (0.0002 0.0003 in) Piston pin must be fitted into position with thumb at 20C (68F). 0.20 0.35 mm (0.0079 0.0138 in) 1.0 mm (0.039 in) 0.35 0.50 mm (0.0138 0.0197 in) 1.0 mm (0.039 in) 0.20 0.70 mm (0.0079 0.0276 in) 1.5 mm (0.059 in) 0.040 0.080 mm (0.0016 0.0031 in) 0.15 mm (0.0059 in) 0.030 0.070 mm (0.0012 0.0028 in) 0.15 mm (0.0059 in) 0.10 mm (0.0039 in) 0.070 0.330 mm (0.0028 0.0130 in) 0.4 mm (0.016 in) 0.010 0.038 mm (0.0004 0.0015 in) 0.05 mm (0.0020 in) 1.492 1.501 mm (0.0587 0.0591 in) 1.510 1.513 mm (0.0594 0.0596 in) 1.520 1.523 mm (0.0598 0.0600 in) 1.620 1.623 mm (0.0638 0.0639 in) 0 0.022 mm (0 0.0009 in) 0.030 mm (0.0012 in) 0.035 mm (0.0014 in) 0.020 mm (0.0008 in) or less 0.250 mm (0.0098 in) 51.984 52.000 mm (2.0466 2.0472 in) 51.954 51.970 mm (2.0454 2.0461 in) 51.934 51.950 mm (2.0446 2.0453 in) 51.734 51.750 mm (2.0368 2.0374 in) 59.992 60.008 mm (2.3619 2.3625 in) 59.962 59.978 mm (2.3607 2.3613 in) 59.942 59.958 mm (2.3599 2.3605 in) 59.742 59.758 mm (2.3520 2.3527 in) 59.992 60.008 mm (2.3619 2.3625 in) 59.962 59.978 mm (2.3607 2.3613 in) 59.942 59.958 mm (2.3599 2.3605 in) 59.742 59.758 mm (2.3520 2.3527 in) 0.030 0.115 mm (0.0012 0.0045 in) 0.25 mm (0.0098 in) 0.010 0.030 mm (0.0004 0.0012 in) 0.040 mm (0.0016 in)
Piston
Piston pin
Piston ring
Connecting rod
Bend twist per 100 mm (3.94 in) in length Side clearance
Connecting rod bearing
Connecting rod bushing
Crankshaft
STD Limit STD Oil clearance Limit STD 0.03 mm (0.0012 in) US Thickness at center portion 0.05 mm (0.0020 in) US 0.25 mm (0.0098 in) US Clearance between piston pin STD and bushing Limit Bend limit Out-of-roundness Crank pin and crank journal Grinding limit STD 0.03 mm (0.0012 in) US Crank pin outer diameter 0.05 mm (0.0020 in) US 0.25 mm (0.0098 in) US STD 0.03 mm (0.0012 in) US #1, #3 0.05 mm (0.0020 in) US 0.25 mm (0.0098 in) US Crank journal outer diameter STD 0.03 mm (0.0012 in) US #2, #4, #5 0.05 mm (0.0020 in) US 0.25 mm (0.0098 in) US STD Thrust clearance Limit STD Oil clearance Limit
ME(SOHC)-4
GENERAL DESCRIPTION
STD 0.03 mm 0.05 mm 0.25 mm STD 0.03 mm 0.05 mm 0.25 mm
Mechanical
#1, #3 Crankshaft bearing Crankshaft bearing thickness #2, #4, #5
(0.0012 in) US (0.0020 in) US (0.0098 in) US (0.0012 in) US (0.0020 in) US (0.0098 in) US
1.998 2.011 mm (0.0787 0.0792 in) 2.017 2.020 mm (0.0794 0.0795 in) 2.027 2.030 mm (0.0798 0.0799 in) 2.127 2.130 mm (0.0837 0.0839 in) 2.000 2.013 mm (0.0787 0.0793 in) 2.019 2.022 mm (0.0795 0.0796 in) 2.029 2.032 mm (0.0799 0.0800 in) 2.129 2.132 mm (0.0838 0.0839 in)
ME(SOHC)-5
Mechanical
GENERAL DESCRIPTION
S153001A05
B: COMPONENT
1. TIMING BELT
S153001A0501
S2M2242A
(1) Belt cover No. 2 (RH) (2) Timing belt guide (MT vehicles only) (3) Crankshaft sprocket (4) Belt cover No. 2 (LH) (5) Camshaft sprocket No. 1 (6) Belt idler (No. 1) (7) Tensioner bracket (8) Belt idler (No. 2)
(9) Automatic belt tension adjuster ASSY (10) Belt idler No. 2 (11) Camshaft sprocket No. 2 (12) Timing belt (13) Front belt cover (14) Belt cover (LH) (15) Crankshaft pulley
Tightening torque: Nm (kgf-m, ft-lb) T1: 5 (0.5, 3.6) T2: 9.8 (1.0, 7.2) T3: 25 (2.5, 18.1) T4: 39 (4.0, 28.9) T5: 78 (8.0, 57.9) T6: 127 (13.0, 94)
ME(SOHC)-6
GENERAL DESCRIPTION
2. CYLINDER HEAD AND CAMSHAFT
S153001A0502
Mechanical
B2M1954D
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
Rocker cover (RH) Intake valve rocker ASSY Exhaust valve rocker ASSY Camshaft cap (RH) Oil seal Camshaft (RH) Plug Spark plug pipe gasket Cylinder head (RH) Cylinder head gasket
(11) (12) (13) (14) (15) (16) (17) (18) (19)
Cylinder head (LH) Camshaft (LH) Camshaft cap (LH) Oil filler cap Gasket Oil filler pipe O-ring Rocker cover (LH) Stud bolt
Tightening torque: Nm (kgf-m, ft-lb) T1: <Ref. to ME(SOHC)-60,
T2: T3: T4: T5: T6:
INSTALLATION, Cylinder Head Assembly.> 5 (0.5, 3.6) 10 (1.0, 7.2) 18 (1.8, 13.0) 25 (2.5, 18.1) 6.4 (0.65, 4.7)
ME(SOHC)-7
Mechanical
GENERAL DESCRIPTION
S153001A0503
3. VALVE ROCKER ASSEMBLY
B2M1956A
(1) (2) (3) (4) (5)
Intake valve rocker arm Valve rocker nut Valve rocker adjust screw Spring Rocker shaft support
(6) Intake rocker shaft (7) Exhaust rocker shaft (8) Exhaust valve rocker arm
Tightening torque: Nm (kgf-m, ft-lb) T1: 5 (0.5, 3.6) T2: 10 (1.0, 7.2) T3: 25 (2.5, 18.1)
ME(SOHC)-8
GENERAL DESCRIPTION
4. CYLINDER HEAD AND VALVE ASSEMBLY
S153001A0504
Mechanical
B2M1955A
(1) (2) (3) (4)
Exhaust valve Intake valve Intake valve guide Intake valve spring seat
(5) (6) (7) (8)
Intake valve oil seal Valve spring Retainer Retainer key
(9) Exhaust valve guide (10) Exhaust valve spring seat (11) Exhaust valve oil seal
ME(SOHC)-9
Mechanical
GENERAL DESCRIPTION
S153001A0505
5. CYLINDER BLOCK
B2M4154A
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13)
Oil pressure switch Cylinder block (RH) Service hole plug Gasket Oil separator cover Water by-pass pipe Oil pump Front oil seal Rear oil seal O-ring Service hole cover Cylinder block (LH) Water pump
(14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25)
Baffle plate Oil filter connector Oil strainer Gasket Oil pan Drain plug Metal gasket Oil level gauge guide Water pump sealing Oil filter Gasket Water pump hose
Tightening torque: Nm (kgf-m, ft-lb) T1: 5 (0.5, 3.6) T2: 6.4 (0.65, 4.7) T3: 10 (1.0, 7) T4: 25 (2.5, 18.1) T5: 47 (4.8, 34.7) T6: 69 (7.0, 50.6) T7: First 12 (1.2, 8.7)
Second 12 (1.2, 8.7)

T8: 16 (1.6, 11.6) T9: 44 (4.5, 33) T10: 25 (2.5, 18.1)
ME(SOHC)-10
GENERAL DESCRIPTION
MEMO:
Mechanical
ME(SOHC)-11
Mechanical
GENERAL DESCRIPTION
S153001A0506
6. CRANKSHAFT AND PISTON
B2M3429A
ME(SOHC)-12
GENERAL DESCRIPTION
(1) (2) (3) (4) (5) (6) (7) (8) Flywheel (MT) Reinforcement (AT) Drive plate (AT) Top ring Second ring Oil ring Piston Piston pin (9) (10) (11) (12) (13) (14) (15) (16) Circlip Connecting rod bolt Connecting rod Connecting rod bearing Connecting rod cap Crankshaft Woodruff key Crankshaft bearing #1, #3
Mechanical
(17) Crankshaft bearing #2, #4 (18) Crankshaft bearing #5
ME(SOHC)-13
Mechanical
GENERAL DESCRIPTION
S153001A0507
7. ENGINE MOUNTING
EN1005
(1) Front cushion rubber (2) Front engine mounting bracket
Tightening torque: Nm (kgf-m, ft-lb) T1: 35 (3.6, 25.8) T2: 42 (4.2, 31.0) T3: 85 (8.7, 63)
C: CAUTION
S153001A03
Wear working clothing, including a cap, protective goggles, and protective shoes during operation. Remove contamination including dirt and corrosion before removal, installation or disassembly. Keep the disassembled parts in order and protect them from dust or dirt. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly, and replacement. Be careful not to burn your hands, because each part in the vehicle is hot after running. Be sure to tighten fasteners including bolts and nuts to the specified torque. Place shop jacks or safety stands at the specified points. Before disconnecting electrical connectors of sensors or units, be sure to disconnect negative terminal from battery.
All parts should be thoroughly cleaned, paying special attention to the engine oil passages, pistons and bearings. Rotating parts and sliding parts such as piston, bearing and gear should be coated with oil prior to assembly. Be careful not to let oil, grease or coolant contact the timing belt, clutch disc and flywheel. All removed parts, if to be reused, should be reinstalled in the original positions and directions. Bolts, nuts and washers should be replaced with new ones as required. Even if necessary inspections have been made in advance, proceed with assembly work while making rechecks. Remove or install engine in an area where chain hoists, lifting devices, etc. are available for ready use. Be sure not 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. Prior to starting work, prepare the following:
ME(SOHC)-14
GENERAL DESCRIPTION
Service tools, clean cloth, containers to catch coolant and oil, wire ropes, chain hoist, transmission jacks, etc.
Mechanical
Lift-up or lower the vehicle when necessary. Make sure to support the correct positions.
D: PREPARATION TOOL
1. SPECIAL TOOLS
ILLUSTRATION
S153001A1701
S153001A17
TOOL NUMBER 498267800
DESCRIPTION CYLINDER HEAD TABLE
REMARKS Used for replacing valve guides. Used for removing and installing valve springs.
B2M3850
498457000
ENGINE STAND ADAPTER RH
Used with ENGINE STAND (499817000).
B2M3851
498457100
ENGINE STAND ADAPTER LH
B2M3852
498497100
CRANKSHAFT STOPPER
Used for stopping rotation of flywheel when loosening and tightening crankshaft pulley bolt, etc.
B2M3853
ME(SOHC)-15
Mechanical
ILLUSTRATION
GENERAL DESCRIPTION
TOOL NUMBER 498747100 DESCRIPTION PISTON GUIDE REMARKS Used for installing piston in cylinder.
B2M3854
498857100
VALVE OIL SEAL GUIDE
Used for press-fitting of intake and exhaust valve guide oil seals.
B2M3855
499017100
PISTON PIN GUIDE
Used for installing piston pin, piston and connecting rod.
B2M3856
499037100
CONNECTING ROD BUSHING REMOVER & INSTALLER
Used for removing and installing connecting rod bushing.
B2M3857
ME(SOHC)-16
GENERAL DESCRIPTION
ILLUSTRATION TOOL NUMBER 499097700 DESCRIPTION PISTON PIN REMOVER ASSY REMARKS Used for removing piston pin.
Mechanical
B2M3858
499207100
CAMSHAFT SPROCKET WRENCH
Used for removing and installing camshaft sprocket. (LH side)
B2M3859
499207400
Used for removing and installing camshaft sprocket. (RH side)
B2M4158
499587700
CAMSHAFT OIL SEAL INSTALLER
Used for installing cylinder head plug.
B2M3860
ME(SOHC)-17
Mechanical
ILLUSTRATION
GENERAL DESCRIPTION
TOOL NUMBER 499587200 DESCRIPTION CRANKSHAFT OIL SEAL INSTALLER REMARKS Used for installing crankshaft oil seal. Used with CRANKSHAFT OIL SEAL GUIDE (499597100).
B2M3861
499597000
OIL SEAL GUIDE
Used for installing camshaft oil seal. Used with CAMSHAFT OIL SEAL INSTALLER (499587100).
B2M3862
499597100
CRANKSHAFT OIL SEAL GUIDE
Used for installing crankshaft oil seal. Used with CRANKSHAFT OIL SEAL INSTALLER (499587200).
B2M3863
499718000
VALVE SPRING REMOVER
Used for removing and installing valve spring.
B2M3864
ME(SOHC)-18
GENERAL DESCRIPTION
ILLUSTRATION TOOL NUMBER 499767700 (Intake side) 499767800 (Exhaust side) DESCRIPTION VALVE GUIDE ADJUSTER REMARKS Used for installing valve guides.
Mechanical
B2M3865
499767200
VALVE GUIDE REMOVER
Used for removing valve guides.
B2M3867
499767400
VALVE GUIDE REAMER
Used for reaming valve guides.
B2M3868
499817100
ENGINE STAND
Stand used for engine disassembly and assembly. Used with ENGINE STAND ADAPTER RH (498457000) & LH (498457100).
B2M3869
ME(SOHC)-19
Mechanical
ILLUSTRATION
GENERAL DESCRIPTION
TOOL NUMBER 499977300 DESCRIPTION REMARKS CRANK PULLEY Used for stopping rotation of crankshaft pulley WRENCH when loosening and tightening crankshaft pulley bolts.
B2M4157
499987500
CRANKSHAFT SOCKET
Used for rotating crankshaft.
B2M3871
498547000
OIL FILTER WRENCH
Used for removing and installing oil filter.
B2M3872
499497000
TORX PLUS
Used for removing and installing camshaft cap.
B2M3873
ME(SOHC)-20
GENERAL DESCRIPTION
ILLUSTRATION TOOL NUMBER 499587500 DESCRIPTION OIL SEAL INSTALLER
Mechanical
REMARKS Used for installing front camshaft oil seal.
B2M3874
499587100
OIL SEAL INSTALLER
Used for installing oil pump oil seal.
B2M3875
498277200
STOPPER SET
Used for installing automatic transmission assembly to engine.
B3M2043
24082AA150 (Newly adopted tool)
CARTRIDGE
Troubleshooting for electrical systems.
B2M3876
ME(SOHC)-21
Mechanical
ILLUSTRATION
GENERAL DESCRIPTION
TOOL NUMBER 22771AA030 DESCRIPTION SELECT MONITOR KIT REMARKS Troubleshooting for electrical systems. English: 22771AA030 (Without printer) German: 22771AA070 (Without printer) French: 22771AA080 (Without printer) Spanish: 22771AA090 (Without printer)
B2M3877
2. GENERAL PURPOSE TOOLS

TOOL NAME Compression Gauge Tachometer (Secondary pick-up type) Timing Light
S153001A1702
REMARKS Used for measuring compression. Used for measuring idle speed. Used for measuring ignition timing.
E: PROCEDURE
S153001E45
It is possible to conduct the following service procedures with engine on the vehicle, however, the procedures described in this section are based on the condition that the engine is removed from the vehicle. V-belt Timing Belt Valve Rocker Assembly Camshaft Cylinder Head
ME(SOHC)-22
COMPRESSION
Mechanical
2. Compression
A: INSPECTION
S153081
S153081A10
CAUTION: After warming-up, engine becomes very hot. Be careful not to burn yourself during measurement. 1) After warming-up the engine, turn ignition switch to OFF. 2) Make sure that the battery is fully charged. 3) Release fuel pressure. <Ref. to FU(SOHC)-52, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.> or <Ref. to FU(SOHCw/ oOBD)-41, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.> 4) Remove all the spark plugs. <Ref. to IG(SOHC)-4, REMOVAL, Spark Plug.> or <Ref. to IG(SOHCw/oOBD)-5, REMOVAL, Spark Plug.> 5) Fully open throttle valve. 6) Check the starter motor for satisfactory performance and operation. 7) Hold the compression gauge tight against the spark plug hole. CAUTION: When using a screw-in type compression gauge, the screw (put into cylinder head spark plug hole) should be less than 18 mm (0.71 in) long. 8) Crank the engine by means of the starter motor, and read the maximum value on the gauge when the pointer is steady.
B2M3133
9) Perform at least two measurements per cylinder, and make sure that the values are correct. Compression (350 rpm and fully open throttle): Standard; 1,275 kPa (13.0 kg/cm2, 185 psi) Limit; 1,020 kPa (10.4 kg/cm2, 148 psi) Difference between cylinders; 49 kPa (0.5 kg/cm2, 7 psi), or less
ME(SOHC)-23
Mechanical
IDLE SPEED
S153082
3. Idle Speed
A: INSPECTION
S153082A10
1) Before checking idle speed, check the following: (1) Ensure that air cleaner element is free from clogging, ignition timing is correct, spark plugs are in good condition, and that hoses are connected properly. (2) Ensure that malfunction indicator light (CHECK ENGINE light) does not illuminate. 2) Warm-up the engine. 3) Stop the engine, and turn ignition switch to OFF. 4) When using SUBARU SELECT MONITOR <Ref. to ME(SOHC)-15, SPECIAL TOOLS, PREPARATION TOOL, General Description.> (1) Insert the cartridge to SUBARU SELECT MONITOR. (2) Connect SUBARU SELECT MONITOR to the data link connector.
5) When using tachometer (Secondary pick-up type). (1) Attach the pick-up clip to No. 1 cylinder spark plug cord. (2) Start the engine, and read engine idle speed.
B2M3131
NOTE: When using the OBD-II general scan tool, carefully read its operation manual. This ignition system provides simultaneous ignition for #1 and #2 plugs. It must be noted that some tachometers may register twice that of actual engine speed. 6) Check idle speed when unloaded. (With headlights, heater fan, rear defroster, radiator fan, air conditioning, etc. OFF) Idle speed (No load and gears in neutral (MT), or N or P (AT) position): With OBD Model; 700100 rpm Without OBD Model; MT: 650100 rpm AT: 675100 rpm 7) Check idle speed when loaded. (Turn air conditioning switch to ON and operate compressor for at least one minute before measurement.) Idle speed [A/C ON, no load and gears in neutral (MT) or N or P (AT) position]: With OBD Model; 850100 rpm Without OBD Model; 800100 rpm CAUTION: Never rotate idle adjusting screw. If idle speed is out of specifications, refer to General Onboard Diagnosis Table under Engine Control System. <Ref. to EN(SOHC)-2, Basic Diagnostic Procedure.> or <Ref. to EN(SOHCw/ oOBD)-2, Basic Diagnostic Procedure.>
S2M2157
(3) Turn ignition switch to ON, and SUBARU SELECT MONITOR switch to ON. (4) Select {2. Each System Check} in Main Menu. (5) Select {Engine Control System} in Selection Menu. (6) Select {1. Current Data Display & Save} in Engine Control System Diagnosis. (7) Select {1.12 Data Display} in Data Display Menu. (8) Start the engine, and read engine idle speed.
ME(SOHC)-24
IGNITION TIMING
Mechanical
4. Ignition Timing
A: INSPECTION
S153086A10
S153086
CAUTION: After warming-up, engine becomes very hot. Be careful not to burn yourself during measurement. 1) Warm-up the engine. 2) To check the ignition timing, connect a timing light to #1 cylinder spark plug cord, and illuminate the timing mark with the timing light. 3) Start the engine at idle speed and check the ignition timing. Ignition timing [BTDC/rpm]: With OBD Model; 1010/700 rpm Without OBD Model; MT: 1010/650 rpm AT: 1010/675 rpm
B2M3130
If the timing is not correct, check the ignition control system. Refer to Engine Control System. <Ref. to EN(SOHC)-2, Basic Diagnostic Procedure.> or <Ref. to EN(SOHCw/oOBD)-2, Basic Diagnostic Procedure.>
ME(SOHC)-25
Mechanical
INTAKE MANIFOLD VACUUM

S153654
5. Intake Manifold Vacuum

A: INSPECTION
S153654A10
By observing the gauge needle movement, the internal condition of the engine can be diagnosed as described below.
1) Warm-up the engine. 2) Disconnect the brake vacuum hose and install the vacuum gauge to the hose fitting on the manifold. 3) Keep the engine at the idle speed and read the vacuum gauge indication.
B2M3134
Vacuum pressure (at idling, A/C OFF): Less than 60.0 kPa (450 mmHg, 17.72 inHg)
Diagnosis of engine condition by measurement of manifold vacuum Vacuum gauge indication Possible engine condition 1. Needle is steady but lower than normal position. This tenLeakage around intake manifold gasket or disconnection or dency becomes more evident as engine temperature rises. damaged vacuum hose 2. When engine speed is reduced slowly from higher speed, Back pressure too high, or exhaust system clogged needle stops temporarily when it is lowering or becomes steady above normal position. 3. Needle intermittently drops to position lower than normal Leakage around cylinder position. 4. Needle drops suddenly and intermittently from normal posi- Sticky valves tion. 5. When engine speed is gradually increased, needle begins to Weak or broken valve springs vibrate rapidly at certain speed, and then vibration increases as engine speed increases. 6. Needle vibrates above and below normal position in narrow Defective ignition system or throttle chamber idle adjustment range.
ME(SOHC)-26
ENGINE OIL PRESSURE
Mechanical
6. Engine Oil Pressure

A: INSPECTION
S153655A10
S153655
7) Start the engine, and measure oil pressure.
S2M0242
G6M0095
2) Remove generator from bracket. (1) Loosen lock bolt and slider bolt, and remove front side V-belt. <Ref. to ME(SOHC)-42, REMOVAL, V-belt.> (2) Remove generator lock bolt. (3) Remove bolt which install generator on bracket.
Oil pressure: 98 kPa (1.0 kg/cm2, 14 psi) or more at 800 rpm 294 kPa (3.0 kg/cm2, 43 psi) or more at 5,000 rpm CAUTION: If oil pressure is out of specification, check oil pump, oil filter and lubrication line. <Ref. to LU-25, INSPECTION, Engine Lubrication System Trouble in General.> If oil pressure warning light is turned ON and oil pressure is in specification, replace oil pressure switch. <Ref. to LU-25, INSPECTION, Engine Lubrication System Trouble in General.> NOTE: The specified data is based on an engine oil temperature of 80C (176F).
S6M0352
8) After measuring oil pressure, install oil pressure switch. <Ref. to LU-21, INSTALLATION, Oil Pressure Switch.> Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft-lb) 9) Install generator and V-belt in the reverse order of removal, and adjust the V-belt deflection. <Ref. to ME(SOHC)-42, INSTALLATION, V-belt.>
3) Disconnect connector from oil pressure switch. 4) Remove oil pressure switch from engine cylinder block. <Ref. to LU-21, REMOVAL, Oil Pressure Switch.> 5) Connect oil pressure gauge hose to cylinder block. 6) Connect battery ground cable.
G6M0095
ME(SOHC)-27
Mechanical
FUEL PRESSURE
S153656
7. Fuel Pressure
A: INSPECTION
S153656A10
WARNING: Before removing fuel pressure gauge, release fuel pressure. NOTE: If out of specification, check or replace pressure regulator and pressure regulator vacuum hose. 1) Release fuel pressure. <Ref. to FU(SOHC)-52, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.> or <Ref. to FU(SOHCw/ oOBD)-41, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.> 2) Open fuel flap lid, and remove fuel filler cap.
5) Start the engine. 6) Measure fuel pressure while disconnecting pressure regulator vacuum hose from intake manifold. Fuel pressure: Standard; 284 314 kPa (2.9 3.2 kg/cm2, 41 46 psi)
S2M0554
7) After connecting pressure regulator vacuum hose, measure fuel pressure. Fuel pressure: Standard; 206 235 kPa (2.1 2.4 kg/cm2, 30 34 psi)
B2M3197
3) Disconnect fuel delivery hoses from fuel damper, and connect fuel pressure gauge.
S2M0554
NOTE: The fuel pressure gauge registers 10 to 20 kPa (0.1 to 0.2 kg/cm2, 1 to 3 psi) higher than standard values during high-altitude operations.
S2M0195
4) Connect connector of fuel pump relay.
S2M0093
ME(SOHC)-28
VALVE CLEARANCE
Mechanical
8. Valve Clearance
A: INSPECTION
S153083A10
S153083
CAUTION: Inspection and adjustment of valve clearance should be performed while engine is cold. 1) 2) 3) 4) Set the vehicle onto the lift. Lift-up the vehicle. Remove under cover. Disconnect battery ground cable.
9) Set #1 cylinder piston to top dead center of compression stroke by rotating crankshaft pulley clockwise using ST. ST 499977300 CRANKSHAFT PULLEY WRENCH NOTE: When arrow mark on camshaft sprocket (LH) comes exactly to the top, #1 cylinder piston is brought to the top dead center of compression stroke.
G6M0095
B2M2027A
5) Lower the vehicle. 6) Remove timing belt cover (LH).
10) Measure #1 cylinder valve clearance by using thickness gauge. CAUTION: Insert the thickness gauge in as horizontal a direction as possible with respect to the valve stem end face. Measure exhaust valve clearances while lifting-up the vehicle. Valve clearance: Intake; 0.200.02 mm (0.00790.0008 in) Exhaust; 0.250.02 mm (0.00980.0008 in)
B2M2031
7) When inspecting #1 and #3 cylinders; (1) Disconnect spark plug cords from spark plugs RH side. <Ref. to IG(SOHC)-4, RH SIDE, REMOVAL, Spark Plug.> or <Ref. to IG(SOHCw/oOBD)-5, RH SIDE, REMOVAL, Spark Plug.> (2) Disconnect PCV hose from rocker cover (RH). (3) Remove bolts, then remove rocker cover (RH). 8) When inspecting #2 and #4 cylinders; (1) Disconnect spark plug cords from spark plugs (LH Side) <Ref. to IG(SOHC)-5, LH SIDE, REMOVAL, Spark Plug.> or <Ref. to IG(SOHCw/oOBD)-6, LH SIDE, REMOVAL, Spark Plug.>. (2) Disconnect PCV hose from rocker cover (LH). (3) Remove bolts, then remove rocker cover (LH).
B2M2028A
11) If necessary, adjust the valve clearance. <Ref. to ME(SOHC)-30, ADJUSTMENT, Valve Clearance.> 12) Similar to measurement procedures used for #1 cylinder, measure #2, #3 and #4 cylinder valve clearances.
ME(SOHC)-29
Mechanical
VALVE CLEARANCE
NOTE: When arrow mark on camshaft sprocket (LH) comes exactly to the top, #1 cylinder piston is brought to the top dead center of compression stroke.
NOTE: Be sure to set cylinder pistons to their respective top dead centers on compression stroke before measuring valve clearances. To set #3, #2 and #4 cylinder pistons to their top dead centers on compression stroke, turn crankshaft pulley clockwise 90 at a time starting with arrow mark on left-hand camshaft sprocket facing up.
B2M2027A
B2M2029A
13) After inspection, install the related parts in the reverse order of removal. Tightening torque: Resonator chamber; 33 Nm (3.4 kgf-m, 24 ft-lb)
2) Adjust the #1 cylinder valve clearance. (1) Loosen the valve rocker nut and screw. (2) Place suitable thickness gauge. (3) While noting valve clearance, tighten valve rocker adjust screw. (4) When specified valve clearance is obtained, tighten valve rocker nut. Tightening torque: 10 Nm (1.0 kgf-m, 7.2 ft-lb) CAUTION: Insert the thickness gauge in as horizontal a direction as possible with respect to the valve stem end face. Adjust exhaust valve clearances while lifting-up the vehicle. Valve clearance: Intake; 0.200.02 mm (0.00790.0008 in) Exhaust; 0.250.02 mm (0.00980.0008 in)
B6M1237
B: ADJUSTMENT
S153083A01
CAUTION: Adjustment of valve clearance should be performed while engine is cold. 1) Set #1 cylinder piston to top dead center of compression stroke by rotating crankshaft pulley clockwise using ST. ST 499977300 CRANKSHAFT PULLEY WRENCH
B2M2030
3) Ensure that valve clearances are within specifications. 4) Turn crankshaft two complete rotations until #1 cylinder piston is again set to top dead center on compression stroke. 5) Ensure that valve clearances are within specifications. If necessary, readjust valve clearances.
ME(SOHC)-30
VALVE CLEARANCE
6) Similar to adjustment procedures used for #1 cylinder, adjust #2, #3 and #4 cylinder valve clearances. NOTE: Be sure to set cylinder pistons to their respective top dead centers on compression stroke before adjusting valve clearances. To set #3, #2 and #4 cylinder pistons to their top dead centers on compression stroke, turn crankshaft pulley clockwise 90 at a time starting with arrow mark on left-hand camshaft sprocket facing up.
Mechanical
B2M2029A
ME(SOHC)-31
Mechanical
ENGINE ASSEMBLY
S153079
9. Engine Assembly
A: REMOVAL
S153079A18
(3) Disconnect A/C pressure hoses from A/C compressor.
1) Set the vehicle on lift arms. 2) Open front hood fully and support with stay. 3) Release fuel pressure. <Ref. to FU(SOHC)-52, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.> or <Ref. to FU(SOHCw/ oOBD)-41, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.> 4) Remove filler cap. 5) Disconnect battery ground terminal.
B2M3385
12) Remove air cleaner case stay. MT model
G6M0095
6) Remove air intake duct and air cleaner case. <Ref. to IN(SOHC)-8, REMOVAL, Air Intake Duct.> and <Ref. to IN(SOHC)-7, REMOVAL , Air Cleaner Case.> 7) Remove canister and bracket. (Without OBD)
S2M0900
AT model
B2M4251 S2M0574
8) Remove under cover. 9) Remove radiator from vehicle. <Ref. to CO-25, REMOVAL, Radiator.> 10) Remove ATF cooler pipe from cylinder head. <Ref. to AT-49, REMOVAL, ATF Cooler Pipe and Hose.> 11) Collect refrigerant, and remove pressure hoses. (With A/C) (1) Place and connect the attachment hose to the refrigerant recycle system. (2) Collect refrigerant from A/C system.
13) Disconnect the following connectors and cables. (1) Front oxygen (A/F) sensor connector (With OBD)
B2M4243
ME(SOHC)-32
ENGINE ASSEMBLY
(2) Front oxygen sensor connector (Without OBD)
Mechanical
(5) Generator connector, terminal and A/C compressor connector
S2M0517
B2M3386B
(3) Engine ground terminal
(A) (B)
Generator connector and terminal A/C compressor connector
(6) Accelerator cable and cruise control cable
S2M0731
(4) Engine harness connectors

B2M3415A
(A) (B)
Accelerator cable Cruise control cable
(7) Pressure switch
S2M0742
B2M4292
ME(SOHC)-33
Mechanical
ENGINE ASSEMBLY
(3) Remove pipe with bracket from intake manifold.
(8) Engine control module connector
S2M0533
14) Disconnect the following hoses. (1) Brake booster vacuum hose
S2M0903
(4) Remove bolts which install power steering pump from bracket.
B2M3419
(2) Heater inlet outlet hose
S2M0488
(5) Remove bolt which installs power steering pump bracket on cylinder head. (6) Place power steering pump on the right side wheel apron.
B2M3390
15) Remove power steering pump from bracket. (1) Remove resonator chamber. (2) Loosen lock bolt and slider bolt, and remove front side V-belt.<Ref. to ME(SOHC)-42, FRONT SIDE BELT, REMOVAL, V-belt.>
S2M0491
16) Remove front and center exhaust pipe. <Ref. to EX(SOHC)-5, REMOVAL, Front Exhaust Pipe.> or <Ref. to EX(SOHCw/oOBD)-6, REMOVAL, Front Exhaust Pipe.>
ME(SOHC)-34
ENGINE ASSEMBLY
17) Remove nuts which hold lower side of transmission to engine. 20) Remove pitching stopper.
Mechanical
S2M0126 B3M2047
18) Remove nuts which install front cushion rubber onto front crossmember.
21) Disconnect fuel delivery hose, return hose and evaporation hose. CAUTION: Disconnect hose with its end wrapped with cloth to prevent fuel from splashing. Catch fuel from hose into container.
S2M1927
19) Separate torque converter clutch from drive plate. (AT model) (1) Lower the vehicle. (2) Remove service hole plug. (3) Remove bolts which hold torque converter clutch to drive plate. (4) Remove other bolts while rotating the engine using ST. ST 499977100 CRANK PULLEY WRENCH
S2M0500
22) Support engine with a lifting device and wire ropes.
B2M3391
S2M0207
ME(SOHC)-35
Mechanical
ENGINE ASSEMBLY
(4) Slowly move engine away from engine compartment. CAUTION: Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc.
23) Support transmission with a garage jack. CAUTION: Before moving engine away from transmission, check to be sure no work has been overlooked. Doing this is very important in order to facilitate re-installation and because transmission lowers under its own weight.
B2M3391 G2M0298
27) Remove front cushion rubbers.
24) Separation of engine and transmission. (1) Remove starter. <Ref. to SC-5, REMOVAL, Starter.> (2) Remove bolts which hold upper side of transmission to engine.
B3M2044
25) Install ST to torque converter clutch case. (AT model) ST 498277200 STOPPER SET
H2M1961A
26) Remove engine from vehicle. (1) Slightly raise engine. (2) Raise transmission with garage jack. (3) Move engine horizontally until main shaft is withdrawn from clutch cover.
ME(SOHC)-36
ENGINE ASSEMBLY B: INSTALLATION

S153079A11
Mechanical
6) Install pitching stopper. Tightening torque: T1: 49 Nm (5.0 kgf-m, 36.2 ft-lb) T2: 57 Nm (5.8 kgf-m, 42 ft-lb)
1) Install front cushion rubbers. Tightening torque: 34 Nm (3.5 kgf-m, 25.3 ft-lb) 2) Install engine onto transmission. (1) Position engine in engine compartment and align it with transmission. CAUTION: Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc.
S2M0126C
7) Remove ST from torque converter clutch case. (AT model) NOTE: Be careful not to drop the ST into the torque converter clutch case when removing ST.
B2M3391
(2) Apply a small amount of grease to spline of main shaft. (MT model) 3) Tighten bolts which hold upper side of transmission to engine. Tightening torque: 50 Nm (5.1 kgf-m, 36.9 ft-lb)
ST 498277200 STOPPER SET 8) Install starter. <Ref. to SC-6, INSTALLATION, Starter.> 9) Install torque converter clutch onto drive plate. (AT model) (1) Tighten bolts which hold torque converter clutch to drive plate. (2) Tighten other bolts while rotating the engine by using ST. CAUTION: Be careful not to drop bolts into torque converter clutch housing. ST 499977300 CRANK PULLEY WRENCH Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
B3M2044
4) Remove lifting device and wire ropes.
S2M0207
(3) Clog plug onto service hole. 10) Install power steering pump on bracket.
B2M3391
5) Remove garage jack.
ME(SOHC)-37
Mechanical
ENGINE ASSEMBLY
(5) Install resonator chamber. Tightening torque: 33 Nm (3.4 kgf-m, 24.6 ft-lb)
(1) Install power steering pump on bracket, and tighten bolts. Tightening torque: 20.1 Nm (2.05 kgf-m, 14.8 ft-lb)
B6M1237 S2M0488
(2) Tighten bolt which installs power steering pump bracket, and install spark plug codes.
11) Tighten nuts which hold lower side of transmission to engine. Tightening torque: 50 Nm (5.1 kgf-m, 36.9 ft-lb)
S2M0903
(3) Connect power steering switch connector.
B3M2047
12) Tighten nuts which install front cushion rubber onto crossmember. Tightening torque: 85 Nm (8.7 kgf-m, 63 ft-lb) CAUTION: Make sure the front cushion rubber mounting bolts (A) and locator (B) are securely installed.
S2M0742
(4) Install front side V-belt, and adjust it. <Ref. to ME(SOHC)-42, FRONT SIDE BELT, INSTALLATION, V-belt.>
B2M3880A
13) Install front and center exhaust pipe. <Ref. to EX(SOHC)-6, INSTALLATION, Front Exhaust Pipe.> and <Ref. to EX(SOHCw/oOBD)-7, INSTALLATION, Front Exhaust Pipe.> 14) Connect the following hoses.
ME(SOHC)-38
ENGINE ASSEMBLY
(1) Fuel delivery hose, return hose and evaporation hose (2) Heater inlet and outlet hoses (3) Brake booster vacuum hose 15) Connect the following connectors. (1) Engine ground terminals Tightening torque: 14 Nm (1.4 kgf-m, 10.1 ft-lb) (2) Engine harness connectors (3) Generator connector and terminal (4) A/C compressor connectors (5) Engine control module connector (Without OBD) 16) Connect the following cables. (1) Accelerator cable (2) Cruise control cables (With cruise control) CAUTION: After connecting each cable, adjust them. 17) Install air cleaner case stay. Tightening torque: 16 Nm (1.6 kgf-m, 11.6 ft-lb) 18) Install A/C pressure hoses. <Ref. to AC-38, INSTALLATION, Flexible Hose.> CAUTION: Use new O-rings. Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
Mechanical
25) Charge A/C system with refrigerant. <Ref. to AC-20, OPERATION, Refrigerant Charging Procedure.> 26) Remove front hood stay, and close front hood. 27) Take off the vehicle from lift arms.
C: INSPECTION
S153079A10
1) Make sure pipes and hoses are installed correctly. 2) Make sure the engine coolant and ATF are at specified levels.
B2M3385
19) Install radiator to vehicle. <Ref. to CO-27, INSTALLATION, Radiator.> 20) Install ATF cooler pipe to cylinder head. <Ref. to AT-50, INSTALLATION, ATF Cooler Pipe and Hose.> 21) Install under cover. 22) Install battery in the vehicle, and connect cables. 23) Fill coolant. <Ref. to CO-14, FILLING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.> 24) Check ATF level and correct if necessary. (AT model) <Ref. to AT-9, INSPECTION, Automatic Transmission Fluid.>
ME(SOHC)-39
Mechanical
ENGINE MOUNTING
S153085
10. Engine Mounting

A: REMOVAL
S153085A18
1) Remove engine assembly. <Ref. to ME(SOHC)-32, REMOVAL, Engine Assembly.> 2) Remove engine mounting from engine assembly.
B: INSTALLATION
S153085A11
Install in the reverse order of removal. Tightening torque: Engine mounting; 35 Nm (3.6 kgf-m, 26.0 ft-lb)
C: INSPECTION
S153085A10
Make sure there are no cracks or other damage.
ME(SOHC)-40
PREPARATION FOR OVERHAUL
Mechanical
11. Preparation for Overhaul

A: PROCEDURE
S153091E45
S153091
1) After removing the engine from the body, secure it in the ST shown below. ST1 498457000 ENGINE STAND ADAPTER RH ST2 498457100 ENGINE STAND ADAPTER LH ST3 499817100 ENGINE STAND
B2M2582A
2) In this section the procedures described under each index are all connected and stated in order. It will be the complete procedure for overhauling of the engine itself when you go through all steps in the process. Therefore, in this section, to conduct the particular procedure within the flow of a section, you need to go back and conduct the procedure described previously in order to do that particular procedure.
ME(SOHC)-41
Mechanical
V-BELT
S153080
12. V-belt
A: REMOVAL
3) Remove the A/C belt. 4) Remove the A/C belt tensioner.

S153080A1801
S153080A18
1. FRONT SIDE BELT
NOTE: Perform the following procedures 1) to 4) with the engine installed to the body. 1) Remove V-belt cover.
B2M2585
B: INSTALLATION
1. FRONT SIDE BELT
S153080A11
S153080A1101
CAUTION: Wipe off any oil or water on the belt and pulley.
B2M3401
2) Loosen the lock bolt (A). 3) Loosen the slider bolt (B). 4) Remove the front side belt (C).
1) Install a belt, and tighten the slider bolt so as to obtain the specified belt tension <Ref. to ME(SOHC)-43, INSPECTION, V-belt.> 2) Tighten the lock bolt (A) 3) Tighten slider bolt (B). Tightening torque: Lock bolt through bolt: 25 Nm (2.5 kgf-m, 18 ft-lb) Slider bolt: 8 Nm (0.8 kgf-m, 5.5 ft-lb)
B2M4291A
2. REAR SIDE BELT
S153080A1802
1) Loosen the lock nut (A). 2) Loosen the slider bolt (B).
B2M4291A
4) Install V-belt cover.
2. REAR SIDE BELT
S153080A1102
1) Install a belt, and tighten the slider bolt (B) so as to obtain the specified belt tension. <Ref. to ME(SOHC)-43, INSPECTION, V-belt.>
B2M2584A
ME(SOHC)-42
V-BELT
2) Tighten the lock nut (A). Tightening torque: Lock nut (A); 22.6 Nm (2.3 kgf-m, 16.6 ft-lb)
Mechanical
B2M2584A
C: INSPECTION
S153080A10
1) Replace belts, if cracks, fraying or wear is found. 2) Check drive belt tension and adjust it if necessary by changing generator installing position and/or idler pulley installing position. Belt tension (A) replaced: 7 9 mm (0.276 0.354 in) reused: 9 11 mm (0.354 0.433 in) (B)* replaced: 7.5 8.5 mm (0.295 0.335 in) reused: 9.0 10.0 mm (0.354 0.394 in)
B2M4123B
ME(SOHC)-43
Mechanical
CRANKSHAFT PULLEY
S153098
13. Crankshaft Pulley

A: REMOVAL
S153098A18
1) Remove V-belt. <Ref. to ME(SOHC)-42, REMOVAL, V-belt.> 2) Remove crankshaft pulley bolt. To lock crankshaft, use ST. ST 499977300 CRANKSHAFT PULLEY WRENCH
CAUTION: If the tightening angle of crankshaft pulley bolt is less than 45 degrees, the bolt should be damaged. In this case, the bolt must be replaced. (1) Replace the crankshaft pulley bolts and clean them. Crankshaft pulley bolt: 12369AA011 (2) Clean the crankshaft thread using an air gun. (3) Tighten the bolts temporarily with tightening torque of 44 Nm (4.5 kgf-m, 33 ft-lb). (4) Tighten the crankshaft pulley bolts keeping them in an angle between 45 degrees and 60 degrees. CAUTION: Conduct the tightening procedures by confirming the turning angle of the crankshaft pulley bolt referring to the gauge indicated on the belt cover. 4) Install A/C belt tensioner.
B2M2586A
3) Remove crankshaft pulley.
B: INSTALLATION
S153098A11
1) Install crankshaft pulley. 2) Install pulley bolt. To lock crankshaft, use ST. ST 499977300 CRANKSHAFT PULLEY WRENCH (1) Clean the crankshaft pulley thread using an air gun. (2) Apply engine oil to the crankshaft pulley bolt seat and thread. (3) Tighten the bolts temporarily with tightening torque of 44 Nm (4.5 kgf-m, 33 ft-lb). (4) Tighten the crankshaft pulley bolts. Tightening torque: 127 Nm (13.0 kgf-m, 94.0 ft-lb)
B2M2585
5) Install A/C belt.
B2M2584
C: INSPECTION
B2M2586A
S153098A10
3) Confirm that the tightening angle of the crankshaft pulley bolt is 45 degrees or more. If not, conduct the following procedures.
1) Make sure the V-belt is not worn or otherwise damaged. 2) Check the tension of the belt. <Ref. to ME(SOHC)-43, INSPECTION, V-belt.>
ME(SOHC)-44
BELT COVER
Mechanical
14. Belt Cover

A: REMOVAL
S153582
S153582A18
1) Remove V-belt. <Ref. to ME(SOHC)-42, REMOVAL, V-belt.> 2) Remove crankshaft pulley. <Ref. to ME(SOHC)-44, REMOVAL, Crankshaft Pulley.> 3) Remove belt cover (LH). 4) Remove front belt cover.
B2M2587A
B: INSTALLATION
1) Install front belt cover.
S153582A11
Tightening torque: 5 Nm (0.5 kgf-m, 3.6 ft-lb) 2) Install belt cover (LH). Tightening torque: 5 Nm (0.5 kgf-m, 3.6 ft-lb)
B2M2587A
3) Install crankshaft pulley. <Ref. to ME(SOHC)44, INSTALLATION, Crankshaft Pulley.> 4) Install V-belt. <Ref. to ME(SOHC)-42, INSTALLATION, V-belt.>
C: INSPECTION
S153582A10
Make sure the cover is not damaged.
ME(SOHC)-45
Mechanical
TIMING BELT ASSEMBLY

S153099
15. Timing Belt Assembly

A: REMOVAL
1. TIMING BELT
S153099A18 S153099A1801
1) Remove V-belt. <Ref. to ME(SOHC)-42, REMOVAL, V-belt.> 2) Remove crankshaft pulley. <Ref. to ME(SOHC)-44, REMOVAL, Crankshaft Pulley.> 3) Remove belt cover. <Ref. to ME(SOHC)-45, REMOVAL, Belt Cover.> 4) Remove timing belt guide. (MT vehicle only)
EN0621 S2M0294
5) If alignment mark (a) and/or arrow mark (which indicates rotation direction) on timing belt fade away, put new marks before removing timing belt as shown in procedures below. (1) Turn crankshaft using ST. Align mark (a) of sprocket to cylinder block notch (b) and ensure that right side cam sprocket mark (c), cam cap and cylinder head matching surface (d) and/or left side cam sprocket mark (e) and belt cover notch (f) are properly adjusted. ST 499987500 CRANKSHAFT SOCKET
(2) Using white paint, put alignment and/or arrow marks on timing belts in relation to the crank sprocket and cam sprockets.
B2M2591
Specified data: Z1: 44 tooth length Z2: 40.5 tooth length
B2M2590A
B2M2592A
ME(SOHC)-46

6) Remove belt idler (No. 2). 7) Remove belt idler No. 2.
Mechanical
S153099A11
B: INSTALLATION
1. AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER

S153099A1101
1) Preparation for installation of automatic belt tension adjuster assembly; CAUTION: Always use a vertical type pressing tool to move the adjuster rod down. Do not use a lateral type vise. Push adjuster rod vertically. Be sure to slowly move the adjuster rod down applying a pressure of 294 N (30 kgf, 66 lb). Press-in the push adjuster rod gradually taking more than three minutes. Do not allow press pressure to exceed 9,807 N (1,000 kgf, 2,205 lb). Press the adjuster rod as far as the end surface of the cylinder. Do not press the adjuster rod into the cylinder. Doing so may damage the cylinder. Do not release press pressure until stopper pin is completely inserted. (1) Attach the automatic belt tension adjuster assembly to the vertical pressing tool. (2) Slowly move the adjuster rod down with a pressure of 294 N (30 kgf, 66 lb) until the adjuster rod is aligned with the stopper pin hole in the cylinder.
S2M1008
8) Remove timing belt.
B2M2594
2. BELT IDLER AND AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY S153099A1802

1) Remove belt idler (No. 1).
B2M2596
2) Remove automatic belt tension adjuster assembly.
H2M2382
H2M2375
ME(SOHC)-47
Mechanical

(1) Turn camshaft sprocket No. 2 using ST1, and turn camshaft sprocket No. 1 using ST2 so that their alignment marks come to top positions. ST1 499207100 CAMSHAFT SPROCKET WRENCH ST2 499207400 CAMSHAFT SPROCKET WRENCH
(3) With a 2 mm (0.08 in) dia. stopper pin or a 2 mm (0.08 in) (nominal) dia. hex bar wrench inserted into the stopper pin hole in the cylinder, secure the adjuster rod.
H2M2383A
2) Install automatic belt tension adjuster assembly. Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft-lb)
B2M2602A
(2) While aligning alignment mark on timing belt with marks on sprockets, position timing belt properly. CAUTION: Ensure belts rotating direction is correct.
H2M2384
3) Install belt idler (No. 1). Tightening torque: 39 Nm (4.0 kgf-m, 28.9 ft-lb)
B2M2603A
3) Install belt idler No. 2. Tightening torque: 39 Nm (4.0 kgf-m, 28.9 ft-lb) 4) Install belt idler (No. 2). Tightening torque: 39 Nm (4.0 kgf-m, 28.9 ft-lb)
B2M2596
2. TIMING BELT
S153099A1102
1) Preparation for installation of automatic belt tension adjuster assembly. <Ref. to ME(SOHC)47, AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER, INSTALLATION, Timing Belt Assembly.> 2) Installation of timing belt
S2M1008
ME(SOHC)-48

5) After ensuring that the marks on timing belt and camshaft sprockets are aligned, remove stopper pin from belt tensioner adjuster. (3) Tighten remaining bolts. Tightening torque: 9.8 Nm (1.0 kgf-m, 7.2 ft-lb)
Mechanical
H2M2387A
H2M2415
6) Install timing belt guide. (MT vehicles only) (1) Temporarily tighten remaining bolts.
7) Install belt cover. <Ref. to ME(SOHC)-45, INSTALLATION, Belt Cover.> 8) Install crankshaft pulley. <Ref. to ME(SOHC)44, INSTALLATION, Crankshaft Pulley.> 9) Install V-belt. <Ref. to ME(SOHC)-42, INSTALLATION, V-belt.>
C: INSPECTION
1. TIMING BELT
S153099A10
S153099A1001
S2M0294
(2) Check and adjust clearance between timing belt and timing belt guide by using thickness gauge. Clearance: 1.00.5 mm (0.0390.020 in)
1) Check timing belt teeth for breaks, cracks, and wear. If any fault is found, replace belt. 2) Check the condition of back side of belt; if any crack is found, replace belt. CAUTION: Be careful not to let oil, grease or coolant contact the belt. Remove quickly and thoroughly if this happens. Do not bend the belt sharply. Bending radius: h 60 mm (2.36 in) or more
S2M0297
G2M0115
2. AUTOMATIC BELT TENSION ADJUSTER S153099A1002

1) Visually check oil seals for leaks, and rod ends for abnormal wear or scratches. If necessary, replace faulty parts.
ME(SOHC)-49
Mechanical

3) Check tension pulley for grease leakage.
CAUTION: Slight traces of oil at rods oil seal does not indicate a problem. 2) Check that the adjuster rod does not move when a pressure of 294 N (30 kgf, 66 lb) is applied to it. This is to check adjuster rod stiffness. 3) If the adjuster rod is not stiff and moves freely when applying 294 N (30 kgf, 66 lb), check it using the following procedures: (1) Slowly press the adjuster rod down to the end surface of the cylinder. Repeat this motion 2 or 3 times. (2) With the adjuster rod moved all the way up, apply a pressure of 294 N (30 kgf, 66 lb) to it. Check adjuster rod stiffness. (3) If the adjuster rod is not stiff and moves down, replace the automatic belt tension adjuster assembly with a new one. CAUTION: Always use a vertical type pressing tool to move the adjuster rod down. Do not use a lateral type vise. Push adjuster rod vertically. Press-in the push adjuster rod gradually taking more than three minutes. Do not allow press pressure to exceed 9,807 N (1,000 kgf, 2,205 lb). Press the adjuster rod as far as the end surface of the cylinder. Do not press the adjuster rod into the cylinder. Doing so may damage the cylinder. 4) Measure the extension of rod beyond the body. If it is not within specifications, replace with a new one. Rod extension: H 5.70.5 mm (0.2240.020 in)
4. BELT IDLER
S153099A1004
1) Check belt idler for smooth rotation. Replace if noise or excessive play is noted. 2) Check belt outer contacting surfaces of idler pulley for abnormal wear and scratches. 3) Check belt idler for grease leakage.
H2M2381A
3. BELT TENSION PULLEY
S153099A1003
1) Check mating surfaces of timing belt and contact point of adjuster rod for abnormal wear or scratches. Replace automatic belt tension adjuster assembly if faulty. 2) Check tension pulley for smooth rotation. Replace if noise or excessive play is noted.
ME(SOHC)-50
CAMSHAFT SPROCKET
Mechanical
S153097A11
16. Camshaft Sprocket

A: REMOVAL
1. REMOVAL
S153097A18 S153097A1801
S153097
B: INSTALLATION
1) Remove V-belt. <Ref. to ME(SOHC)-42, REMOVAL, V-belt.> 2) Remove crankshaft pulley. <Ref. to ME(SOHC)-44, REMOVAL, Crankshaft Pulley.> 3) Remove belt cover. <Ref. to ME(SOHC)-45, REMOVAL, Belt Cover.> 4) Remove timing belt assembly. <Ref. to ME(SOHC)-46, REMOVAL, Timing Belt Assembly.> 5) Remove camshaft position sensor. (With OBD) <Ref. to FU(SOHC)-30, REMOVAL, Camshaft Position Sensor.> 6) Remove camshaft sprocket No. 2. To lock camshaft, use ST. ST 499207100 CAMSHAFT SPROCKET WRENCH
1) Install camshaft sprocket No. 1. To lock camshaft, use ST. ST 499207400 CAMSHAFT SPROCKET WRENCH Tightening torque: 78 Nm (8.0 kgf-m, 57.9 ft-lb) CAUTION: Do not confuse left and right side camshaft sprockets during installation. The camshaft sprocket No. 2 is identified by a projection used to monitor camshaft position sensor.
B2M2599A
2) Install camshaft sprocket No. 2. To lock camshaft, use ST. ST 499207100 CAMSHAFT SPROCKET WRENCH
H2M2377A
7) Remove camshaft sprocket No. 1. To lock camshaft, use ST. ST 499207400 CAMSHAFT SPROCKET WRENCH
H2M2377A
B2M2599A
3) Install camshaft position sensor. (With OBD) <Ref. to FU(SOHC)-30, INSTALLATION, Camshaft Position Sensor.> 4) Install timing belt assembly. <Ref. to ME(SOHC)-47, INSTALLATION, Timing Belt Assembly.> 5) Install belt cover. <Ref. to ME(SOHC)-45, INSTALLATION, Belt Cover.> 6) Install crankshaft pulley. <Ref. to ME(SOHC)44, INSTALLATION, Crankshaft Pulley.> 7) Install V-belt. <Ref. to ME(SOHC)-42, INSTALLATION, V-belt.>
ME(SOHC)-51
Mechanical
CAMSHAFT SPROCKET
S153097A10
C: INSPECTION
1) Check sprocket teeth for abnormal wear and scratches. 2) Make sure there is no free play between sprocket and key. 3) Check camshaft sprocket notch for sensor for damage and contamination of foreign matter.
ME(SOHC)-52
CRANKSHAFT SPROCKET
Mechanical
S153101A10
17. Crankshaft Sprocket

A: REMOVAL
S153101A18
S153101
C: INSPECTION
1) Remove V-belt. <Ref. to ME(SOHC)-42, REMOVAL, V-belt.> 2) Remove crankshaft pulley. <Ref. to ME(SOHC)-44, REMOVAL, Crankshaft Pulley.> 3) Remove belt cover. <Ref. to ME(SOHC)-45, REMOVAL, Belt Cover.> 4) Remove timing belt assembly. <Ref. to ME(SOHC)-46, REMOVAL, Timing Belt Assembly.> 5) Remove camshaft sprocket. <Ref. to ME(SOHC)-51, REMOVAL, Camshaft Sprocket.> 6) Remove crankshaft sprocket.
1) Check sprocket teeth for abnormal wear and scratches. 2) Make sure there is no free play between sprocket and key. 3) Check crankshaft sprocket notch for sensor for damage and contamination of foreign matter.
S2M0414
B: INSTALLATION
S153101A11
1) Install crankshaft sprocket.
S2M0414
2) Install camshaft sprocket. <Ref. to ME(SOHC)51, INSTALLATION, Camshaft Sprocket.> 3) Install timing belt assembly. <Ref. to ME(SOHC)-47, INSTALLATION, Timing Belt Assembly.> 4) Install belt cover. <Ref. to ME(SOHC)-45, INSTALLATION, Belt Cover.> 5) Install crankshaft pulley. <Ref. to ME(SOHC)44, INSTALLATION, Crankshaft Pulley.> 6) Install V-belt. <Ref. to ME(SOHC)-42, INSTALLATION, V-belt.>
ME(SOHC)-53
Mechanical
VALVE ROCKER ASSEMBLY

S153094
18. Valve Rocker Assembly

A: REMOVAL
S153094A18
1) Remove V-belt. <Ref. to ME(SOHC)-42, REMOVAL, V-belt.> 2) Remove crankshaft pulley. <Ref. to ME(SOHC)-44, REMOVAL, Crankshaft Pulley.> 3) Remove belt cover. <Ref. to ME(SOHC)-45, REMOVAL, Belt Cover.> 4) Remove timing belt assembly. <Ref. to ME(SOHC)-46, REMOVAL, Timing Belt Assembly.> 5) Remove camshaft sprocket. <Ref. to ME(SOHC)-51, REMOVAL, Camshaft Sprocket.> 6) Disconnect PCV hose and remove rocker cover. 7) Removal of valve rocker assembly (1) Remove bolts (a) through (h) in alphabetical sequence. CAUTION: Leave two or three threads of bolts (g and h) engaged to retain valve rocker assembly.
(2) Tighten bolts (e) through (h) to specified torque. (3) Tighten bolts (a) through (d) to specified torque. Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
B2M2605A
2) Adjust the valve clearances. <Ref. to ME(SOHC)-30, ADJUSTMENT, Valve Clearance.> 3) Install rocker cover and connect PCV hose. 4) Install camshaft sprocket. <Ref. to ME(SOHC)51, INSTALLATION, Camshaft Sprocket.> 5) Install timing belt assembly. <Ref. to ME(SOHC)-47, INSTALLATION, Timing Belt Assembly.> 6) Install belt cover. <Ref. to ME(SOHC)-45, INSTALLATION, Belt Cover.> 7) Install crankshaft pulley. <Ref. to ME(SOHC)44, INSTALLATION, Crankshaft Pulley.> 8) Install V-belt. <Ref. to ME(SOHC)-42, INSTALLATION, V-belt.>
C: DISASSEMBLY
B2M2605F
S153094A06
(2) Remove valve rocker assembly.
1) Remove bolts which secure rocker shaft. 2) Extract rocker shaft. Remove valve rocker arms, springs and shaft supports from rocker shaft. CAUTION: Arrange all removed parts in order so that they can be installed in their original positions. 3) Remove nut and adjuster screw from valve rocker.
D: ASSEMBLY
B2M2606
S153094A02
B: INSTALLATION
1) Install adjuster screw and nut to valve rocker. 2) Arrange valve rocker arms, springs and shaft supports in assembly order and insert valve rocker shaft. Tightening torque (Shaft supports installing bolts): 5 Nm (0.5 kgf-m, 3.6 ft-lb) CAUTION: Valve rocker arms, rocker shaft and shaft supports have identification marks. Ensure parts with same markings are properly assembled.
S153094A11
1) Installation of valve rocker assembly (1) Temporarily tighten bolts (a) through (d) equally as shown in figure. CAUTION: Do not allow valve rocker assembly to gouge knock pins.
ME(SOHC)-54
VALVE ROCKER ASSEMBLY

3) Install valve rocker shaft securing bolts.
Mechanical
E: INSPECTION
S153094A10
4) If oil clearance exceeds the limit, replace rocker shaft support or shaft, whichever shows greater amount of wear. Rocker shaft support inside diameter: 22.005 22.026 mm (0.8663 0.8672 in) Rocker shaft diameter: 21.987 22.000 mm (0.8656 0.8661 in) 5) If cam or valve contact surface of valve rocker arm is worn or dented excessively, replace valve rocker arm. 6) Check that valve rocker arm roller rotates smoothly. If not, replace valve rocker arm.
1. VALVE ROCKER ARM
S153094A1001
1) Measure inside diameter of valve rocker arm and outside diameter of valve rocker shaft, and determine the difference between the two (= oil clearance). Clearance between arm and shaft: Standard 0.020 0.054 mm (0.0008 0.0021 in) Limit 0.10 mm (0.0039 in)
2. INTAKE AND EXHAUST VALVE ROCKER SHAFT S153094A1002

Visually check oil relief valve of shaft end for any of the following abnormalities. Breaks in check ball body Foreign particles caught in valve spring Oil leakage at check ball CAUTION: Repair or replace valve rocker shaft as necessary.
B2M0072
B2M0073
2) If oil clearance exceeds the limit, replace valve rocker arm or shaft, whichever shows greater amount of wear. Rocker arm inside diameter: 22.020 22.041 mm (0.8669 0.8678 in) Rocker shaft diameter: 21.987 22.000 mm (0.8656 0.8661 in) 3) Measure inside diameter of rocker shaft support and outside diameter of valve rocker shaft, and determine the difference between the two (= oil clearance). Clearance between support and shaft: Standard 0.005 0.039 mm (0.0002 0.0015 in) Limit 0.05 mm (0.0020 in)
ME(SOHC)-55
Mechanical
CAMSHAFT
S153092
19. Camshaft
A: REMOVAL
(1) Remove bolts (a) through (b) in alphabetical sequence.
S153092A18
1) Remove V-belt. <Ref. to ME(SOHC)-42, INSTALLATION, V-belt.> 2) Remove crankshaft pulley. <Ref. to ME(SOHC)-44, REMOVAL, Crankshaft Pulley.> 3) Remove belt cover. <Ref. to ME(SOHC)-45, REMOVAL, Belt Cover.> 4) Remove timing belt assembly. <Ref. to ME(SOHC)-46, REMOVAL, Timing Belt Assembly.> 5) Remove camshaft sprocket. <Ref. to ME(SOHC)-51, REMOVAL, Camshaft Sprocket.> 6) Remove crankshaft sprocket. <Ref. to ME(SOHC)-53, REMOVAL, Crankshaft Sprocket.> 7) Remove belt cover No. 2 (LH). 8) Remove belt cover No. 2 (RH). CAUTION: Do not damage or lose the seal rubber when removing belt covers.
B2M2612B
(2) Equally loosen bolts (c) through (j) all the way in alphabetical sequence.
B2M2612C
(3) Remove bolts (k) through (p) in alphabetical sequence using ST. ST 499497000 TORX PLUS
B2M2601
9) Remove tensioner bracket.
B2M2612D
(4) Remove camshaft cap.
H2M2380
10) Remove camshaft position sensor support. (LH side only) 11) Remove oil level gauge guide. (LH side only) 12) Remove valve rocker assembly. <Ref. to ME(SOHC)-54, REMOVAL, Valve Rocker Assembly.> 13) Remove camshaft cap. 14) Remove camshaft. 15) Remove oil seal.
B2M2613
ME(SOHC)-56
CAMSHAFT
16) Remove plug from rear side of camshaft. CAUTION: Do not remove oil seal unless necessary. Do not scratch journal surface when removing oil seal. (3) Install valve rocker assembly.
Mechanical
B: INSTALLATION
S153092A11
1) Apply a coat of engine oil to camshaft journals and install camshaft. 2) Install camshaft cap. (1) Apply liquid gasket on the around of camshaft cap. Liquid gasket: THREE BOND 1280B P/N K0877YA018
B2M2615
(4) Tighten bolts (a) through (h) in alphabetical sequence. Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
B2M2619 B2M2621B
NOTE: Apply a coat of 3 mm (0.12 in) dia. liquid gasket along edge of cam cap mating surface.
(5) Tighten TORX bolts (i) through (n) in alphabetical sequence using ST. ST 499427000 TORX PLUS Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft-lb)
S2M1199A
(2) Temporarily tighten bolts (g) through (j) in alphabetical sequence.

B2M2621C
B2M2612E
ME(SOHC)-57
Mechanical
CAMSHAFT
8) Install camshaft position sensor support. (LH side only) 9) Install tensioner bracket. Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
(6) Tighten bolts (o) through (v) in alphabetical sequence. Tightening torque: 10 Nm (1.0 kgf-m, 7.2 ft-lb)
B2M2621D
(7) Tighten bolts (w) through (x) in alphabetical sequence. Tightening torque: 10 Nm (1.0 kgf-m, 7.2 ft-lb)
H2M2380
10) Install belt cover No. 2 (RH). Tightening torque: 5 Nm (0.5 kgf-m, 3.6 ft-lb) 11) Install belt cover No. 2 (LH). Tightening torque: 5 Nm (0.5 kgf-m, 3.6 ft-lb)
B2M2621E
3) Apply a coat of grease to oil seal lips and install oil seal (A) on camshaft using ST1 and ST2. CAUTION: Use a new oil seal. ST1 ST2 499597000 499587500 OIL SEAL GUIDE OIL SEAL INSTALLER
B2M2601
S2M1123A
4) Install plug using ST. ST 499587700 OIL SEAL INSTALLER 5) Adjust the valve clearance. <Ref. to ME(SOHC)-30, ADJUSTMENT, Valve Clearance.> 6) Install rocker cover and connect PCV hose. 7) Install oil level gauge guide. (LH side only)
12) Install crankshaft sprocket. <Ref. to ME(SOHC)-53, INSTALLATION, Crankshaft Sprocket.> 13) Install camshaft sprocket. <Ref. to ME(SOHC)-51, INSTALLATION, Camshaft Sprocket.> 14) Install timing belt assembly. <Ref. to ME(SOHC)-47, INSTALLATION, Timing Belt Assembly.> 15) Install belt cover. <Ref. to ME(SOHC)-45, INSTALLATION, Belt Cover.> 16) Install crankshaft pulley. <Ref. to ME(SOHC)44, INSTALLATION, Crankshaft Pulley.> 17) Install V-belt. <Ref. to ME(SOHC)-42, INSTALLATION, V-belt.>
ME(SOHC)-58
CAMSHAFT C: INSPECTION
1. CAMSHAFT
S153092A10
Mechanical
S153092A1001
Cam base circle diameter A: IN: 34.00 mm (1.3386 in) EX: 34.00 mm (1.3386 in)
1) Measure the bend, and repair or replace if necessary. Limit: 0.025 mm (0.0010 in)
B2M1209A
2. CAMSHAFT SUPPORT
B2M2617
S153092A1002
2) Check journal for damage and wear. Replace if faulty. 3) Measure outside diameter of camshaft journal and inside diameter of cylinder head journal, and determine the difference between the two (= oil clearance). If oil clearance exceeds specifications, replace camshaft or cylinder head as necessary.
Unit: mm (in) 0.055 0.090 (0.0022 0.0035) 0.10 (0.0039) 31.928 31.945 (1.2570 Camshaft journal O.D. 1.2577) 32.000 32.018 (1.2598 Journal hole I.D. 1.2605) Clearance Standard at journal Limit
Measure the thrust clearance of camshaft with dial gauge. If the clearance exceeds the limit, replace camshaft support. Standard: 0.030 0.090 mm (0.0012 0.0035 in) Limit: 0.10 mm (0.0039 in)
4) Check cam face condition; remove minor faults by grinding with oil stone. Measure the cam height H; replace if the limit has been exceeded. Cam height: H
Item Intake STD Limit Exhaust STD Limit Unit: mm (in) 38.732 38.832 (1.5249 1.528885) 39.632 (1.5209) 39.257 39.357 (1.5455 1.5495) 39.157 (1.5416)
B2M2618A
ME(SOHC)-59
Mechanical
CYLINDER HEAD ASSEMBLY

S153093
20. Cylinder Head Assembly

A: REMOVAL
S153093A18
12) Remove bolts (a) and (b) to remove cylinder head.
1) Remove V-belt. <Ref. to ME(SOHC)-42, REMOVAL, V-belt.> 2) Remove crankshaft pulley. <Ref. to ME(SOHC)-44, REMOVAL, Crankshaft Pulley.> 3) Remove belt cover. <Ref. to ME(SOHC)-45, REMOVAL, Belt Cover.> 4) Remove timing belt assembly. <Ref. to ME(SOHC)-46, REMOVAL, Timing Belt Assembly.> 5) Remove camshaft sprocket. <Ref. to ME(SOHC)-51, REMOVAL, Camshaft Sprocket.> 6) Remove intake manifold. <Ref. to FU(SOHC)15, REMOVAL, Intake Manifold.> or <Ref. to FU(SOHCw/oOBD)-12, REMOVAL, Intake Manifold.> 7) Remove bolt which installs A/C compressor bracket on cylinder head. 8) Remove valve rocker assembly. <Ref. to ME(SOHC)-54, REMOVAL, Valve Rocker Assembly.> 9) Remove camshaft. <Ref. to ME(SOHC)-56, REMOVAL, Camshaft.> 10) Remove cylinder head bolts in alphabetical sequence shown in figure. CAUTION: Leave bolts (a) and (c) engaged by three or four threads to prevent cylinder head from falling.
S2M1589A
13) Remove cylinder head gasket. CAUTION: Do not scratch the mating surface of cylinder head and cylinder block. 14) Similarly, remove right side cylinder head.
B: INSTALLATION
S153093A11
1) Install cylinder head and gaskets on cylinder block. CAUTION: Use new cylinder head gaskets. Be careful not to scratch the mating surface of cylinder block and cylinder head. 2) Tighten cylinder head bolts. (1) Apply a coat of engine oil to washers and bolt threads. (2) Tighten all bolts to 29 Nm (3.0 kgf-m, 22 ft-lb) in alphabetical sequence. Then tighten all bolts to 69 Nm (7.0 kgf-m, 51 ft-lb) in alphabetical sequence. (3) Back off all bolts by 180 first; back them off by 180 again. (4) Tighten bolts (a) and (b) to 34 Nm (3.5 kgf-m, 25 ft-lb). (5) Tighten bolts (c), (d), (e) and (f) to 15 Nm (1.5 kgf-m, 11 ft-lb). (6) Tighten all bolts by 80 to 90 in alphabetical sequence. CAUTION: Do not tighten bolts more than 90.
S2M1589A
11) While tapping cylinder head with a plastic hammer, separate it from cylinder block.
ME(SOHC)-60

(7) Further tighten all bolts by 80 to 90 in alphabetical sequence shown in figure below. CAUTION: Ensure that the total re-tightening angle [in the former two steps], do not exceed 180.
Mechanical
S153093A06
C: DISASSEMBLY
1) Place cylinder head on ST. ST 498267800 CYLINDER HEAD TABLE 2) Set ST on valve spring. Compress valve spring and remove the valve spring retainer key. Remove each valve and valve spring. ST 499718000 VALVE SPRING REMOVER CAUTION: Mark each valve to prevent confusion. Use extreme care not to damage the lips of the intake valve oil seals and exhaust valve oil seals.
S2M1589B
3) Install camshaft. <Ref. to ME(SOHC)-57, INSTALLATION, Camshaft.> 4) Install valve rocker assembly. <Ref. to ME(SOHC)-54, INSTALLATION, Valve Rocker Assembly.> 5) Install A/C compressor bracket on cylinder head. 6) Install intake manifold. <Ref. to FU(SOHC)-17, INSTALLATION, Intake Manifold.> or <Ref. to FU(SOHCw/oOBD)-15, INSTALLATION, Intake Manifold.> 7) Install camshaft sprocket. <Ref. to ME(SOHC)51, INSTALLATION, Camshaft Sprocket.> 8) Install timing belt assembly. <Ref. to ME(SOHC)-47, INSTALLATION, Timing Belt Assembly.> 9) Install belt cover. <Ref. to ME(SOHC)-45, INSTALLATION, Belt Cover.> 10) Install crankshaft pulley. <Ref. to ME(SOHC)44, INSTALLATION, Crankshaft Pulley.> 11) Install V-belt. <Ref. to ME(SOHC)-42, INSTALLATION, V-belt.>
B2M2630A
ME(SOHC)-61
Mechanical

S153093A02
D: ASSEMBLY
B2M2629B
(1) (2) (3) (4) (5)
Valve Valve guide Valve spring seat Oil seal Valve spring
(6) (7) (8) (9) (10)
Retainer Retainer key Spark plug gasket Camshaft Oil seal
(11) Plug (12) Camshaft cap (13) Valve rocker ASSY
1) Installation of valve spring and valve (1) Place cylinder head on ST. ST 498267800 CYLINDER HEAD TABLE (2) Coat stem of each valve with engine oil and insert valve into valve guide. CAUTION: When inserting valve into valve guide, use special care not to damage the oil seal lip. (3) Install valve spring and retainer. CAUTION: Be sure to install the valve springs with their close-coiled end facing the seat on the cylinder head.
ST
(4) Set ST on valve spring. 499718000 VALVE SPRING REMOVER
B2M2630A
ME(SOHC)-62

(5) Compress valve spring and fit valve spring retainer key.
Mechanical
CAUTION: Apply engine oil to oil seal before press-fitting. When press-fitting oil seal, do not use hammer or strike in. Differentiate between intake valve oil seal and exhaust valve oil seal by noting their difference in color. ST1 ST2 498267800 498857100 CYLINDER HEAD TABLE VALVE OIL SEAL GUIDE
B2M2634A
Color of rubber part: Intake [Black] Exhaust [Brown] Color of spring part: Intake [Silver] Exhaust [Silver]
(6) After installing, tap valve spring retainers lightly with wooden hammer for better seating.
E: INSPECTION
1. VALVE SPRING
S153093A10
S153093A1001
1) Check valve springs for damage, free length, and tension. Replace valve spring if it is not to the specifications presented below. 2) To measure the squareness of the valve spring, stand the spring on a surface plate and measure its deflection at the top using a try square.
Free length Squareness 54.30 mm (2.1378 in) 2.5, 2.4 mm (0.094 in) 218.7 242.5 N (22.3 24.7 kgf, 49.2 54.5 lb)/ 45.0 mm (1.772 in) 526.6 581.6 N (53.7 59.3 kgf, 118.4 130.8 lb)/34.7 mm (1.366 in)
B2M2633A
Tension/spring height
F: ADJUSTMENT
1. CYLINDER HEAD
S153093A01
S153093A0101
G2M0154
1) Make sure that no crack or other damage exists. In addition to visual inspection, inspect important areas by means of red lead check. Also make sure that gasket installing surface shows no trace of gas and water leaks. 2) Place cylinder head on ST. ST 498267800 CYLINDER HEAD TABLE 3) Measure the warping of the cylinder head surface that mates with crankcase using a straight edge and thickness gauge. If the warping exceeds 0.05 mm (0.0020 in), regrind the surface with a surface grinder. Warping limit: 0.05 mm (0.0020 in) Grinding limit: 0.1 mm (0.004 in) Standard height of cylinder head: 97.5 mm (3.839 in)
2. INTAKE AND EXHAUST VALVE OIL SEAL S153093A1002

Replace oil seal with new one, if lip is damaged or spring out of place, or when the surfaces of intake valve and valve seat are reconditioned or intake valve guide is replaced. Use pliers to pinch and remove oil seal from valve. 1) Place cylinder head on ST1. 2) Press-fit oil seal to the specified dimension indicated in the figure using ST2.
ME(SOHC)-63
Mechanical

3. VALVE GUIDE
S153093A0103
CAUTION: Uneven torque for the cylinder head bolts can cause warping. When reassembling, pay special attention to the torque so as to tighten evenly.
1) Check the clearance between valve guide and stem. The clearance can be checked by measuring the outside diameter of valve stem and the inside diameter of valve guide with outside and inside micrometers respectively. Clearance between the valve guide and valve stem: Standard Intake 0.035 0.062 mm (0.0014 0.0024 in) Exhaust 0.040 0.067 mm (0.0016 0.0026 in) Limit 0.15 mm (0.0059 in)
G2M0148
2. VALVE SEAT
S153093A0102
Inspect intake and exhaust valve seats, and correct the contact surfaces with valve seat cutter if they are defective or when valve guides are replaced. Valve seat width: W Intake Standard 1.0 mm (0.039 in) Limit 1.7 mm (0.067 in) Exhaust Standard 1.4 mm (0.055 in) Limit 2.1 mm (0.083 in)
B2M0387A
B2M0076A G2M0149
2) If the clearance between valve guide and stem exceeds the limit, replace valve guide or valve itself whichever shows greater amount of wear. See following procedure for valve guide replacement. Valve guide inner diameter: 6.000 6.012 mm (0.2362 0.2367 in) Valve stem outer diameters: Intake 5.950 5.965 mm (0.2343 0.2348 in) Exhaust 5.945 5.960 mm (0.2341 0.2346 in) (1) Place cylinder head on ST1 with the combustion chamber upward so that valve guides enter the holes in ST1.
B2M0074
ME(SOHC)-64

(2) Insert ST2 into valve guide and press it down to remove valve guide. ST1 498267800 CYLINDER HEAD TABLE ST2 499767200 VALVE GUIDE REMOVER
Mechanical
(5) Put new valve guide, coated with sufficient oil, in cylinder, and insert ST1 into valve guide. Press in until the valve guide upper end is flush with the upper surface of ST2. ST1 499767200 VALVE GUIDE REMOVER Intake side: ST2 499767700 VALVE GUIDE ADJUSTER Exhaust side: ST2 499767800 VALVE GUIDE ADJUSTER
G2M0150
(3) Turn cylinder head upside down and place ST as shown in the figure. Intake side: ST 499767700 VALVE GUIDE ADJUSTER Exhaust side: ST 499767800 VALVE GUIDE ADJUSTER
B2M2632A
(6) Check the valve guide protrusion. Valve guide protrusion: L Intake 20.0 20.5 mm (0.787 0.807 in) Exhaust 16.5 17.0 mm (0.650 0.669 in)
B2M0077B
(4) Before installing new oversize valve guide, make sure that neither scratches nor damages exist on the inside surface of the valve guide holes in cylinder head.
B2M0077A
ME(SOHC)-65
Mechanical

4. INTAKE AND EXHAUST VALVE
S153093A0104
(7) Ream the inside of valve guide with ST. Gently rotate the reamer clockwise while pressing it lightly into valve guide, and return it also rotating clockwise. After reaming, clean valve guide to remove chips. CAUTION: Apply engine oil to the reamer when reaming. If the inner surface of the valve guide is torn, the edge of the reamer should be slightly ground with an oil stone. If the inner surface of the valve guide becomes lustrous and the reamer does not chips, use a new reamer or remedy the reamer. ST 499767400 VALVE GUIDE REAMER
1) Inspect the flange and stem of valve, and replace if damaged, worn, or deformed, or if H is less than the specified limit. H: Intake Standard 1.0 mm (0.039 in) Limit 0.6 mm (0.024 in) Exhaust Standard 1.2 mm (0.047 in) Limit 0.6 mm (0.024 in) Valve overall length: Intake 120.6 mm (4.75 in) Exhaust 121.7 mm (4.79 in)
B2M0078
(8) Recheck the contact condition between valve and valve seat after replacing valve guide.
G2M0153
2) Put a small amount of grinding compound on the seat surface and lap the valve and seat surface. <Ref. to ME(SOHC)-64, Valve Seat, ADJUSTMENT, Cylinder Head Assembly.> Install a new intake valve oil seal after lapping.
ME(SOHC)-66
CYLINDER BLOCK
Mechanical
21. Cylinder Block

A: REMOVAL
S153090A18
S153090
12) Remove bolts (a) and (b) to remove cylinder head.
NOTE: Before conducting this procedure, drain engine oil completely if applicable. 1) Remove intake manifold. <Ref. to FU(SOHC)15, REMOVAL, Intake Manifold.> or <Ref. to FU(SOHCw/oOBD)-12, REMOVAL, Intake Manifold.> 2) Remove V-belt. <Ref. to ME(SOHC)-42, REMOVAL, V-belt.> 3) Remove crankshaft pulley. <Ref. to ME(SOHC)-44, REMOVAL, Crankshaft Pulley.> 4) Remove belt cover. <Ref. to ME(SOHC)-45, REMOVAL, Belt Cover.> 5) Remove timing belt assembly. <Ref. to ME(SOHC)-46, REMOVAL, Timing Belt Assembly.> 6) Remove camshaft sprocket. <Ref. to ME(SOHC)-51, REMOVAL, Camshaft Sprocket.> 7) Remove crankshaft sprocket. <Ref. to ME(SOHC)-44, REMOVAL, Crankshaft Pulley.> 8) Remove generator and A/C compressor with their brackets. 9) Remove rocker cover. 10) Remove cylinder head bolts in alphabetical sequence shown in figure. CAUTION: Leave bolts (a) and (b) engaged by three or four threads to prevent cylinder head from falling.
B2M2628A
13) Remove cylinder head gasket. CAUTION: Do not scratch the mating surface of cylinder head and cylinder block. 14) Similarly, remove right side cylinder head. 15) Remove clutch housing cover (MT vehicles only). 16) Remove flywheel (MT vehicles only) or drive plate (AT vehicles only). Using ST, lock crankshaft. ST 498497100 CRANKSHAFT STOPPER
S2M1818C
B2M2628A
11) While tapping cylinder head with a plastic hammer, separate it from cylinder block.
S2M1870C
17) Remove oil separator cover. 18) Remove water by-pass pipe for heater. 19) Remove water pump.
ME(SOHC)-67
Mechanical
CYLINDER BLOCK
22) 23) 24) 25) ST Remove oil strainer stay. Remove oil strainer. Remove baffle plate. Remove oil filter using ST. 498547000 OIL FILTER WRENCH
20) Remove oil pump from cylinder block. Use a flat-bladed screwdriver as shown in figure when removing oil pump. CAUTION: Be careful not to scratch the mating surface of cylinder block and oil pump.
B2M2611A S2M1819
26) Remove water pipe.
21) Removal of oil pan (1) Turn cylinder block with #2 and #4 piston sides facing upward. (2) Remove bolts which secure oil pan to cylinder block. (3) Insert a oil pan cutter blade between cylinder block-to-oil pan clearance and remove oil pan. CAUTION: Do not use a screwdriver or similar tool in place of oil pan cutter.
B2M2638
S2M1820
ME(SOHC)-68
CYLINDER BLOCK
Mechanical
S2M1590B
(1) Service hole plug (2) Gasket
(3) Circlip (4) Piston pin
(5) Service hole cover (6) O-ring
27) Remove service hole cover and service hole plugs using hexagon wrench [14 mm (0.55 in)].
28) Rotate crankshaft to bring #1 and #2 pistons to bottom dead center position, then remove piston circlip through service hole of #1 and #2 cylinders.
B2M2620 G2M0165
ME(SOHC)-69
Mechanical
CYLINDER BLOCK
30) Similarly remove piston pins from #3 and #4 pistons. 31) Remove bolts which connect cylinder block on the side of #2 and #4 cylinders. 32) Back off bolts which connect cylinder block on the side of #1 and #3 cylinders two or three turns. 33) Set up cylinder block so that #1 and #3 cylinders are on the upper side, then remove cylinder block connecting bolts. 34) Separate left-hand and right-hand cylinder blocks. CAUTION: When separating cylinder block, do not allow the connecting rod to fall and damage the cylinder block.
G2M0166
29) Draw out piston pin from #1 and #2 pistons using ST. ST 499097700 PISTON PIN REMOVER CAUTION: Be careful not to confuse original combination of piston, piston pin and cylinder.
B2M2408A
(1) Cylinder block (2) Rear oil seal
(3) Crankshaft (4) Crankshaft bearing
(5) Piston
35) Remove rear oil seal. 36) Remove crankshaft together with connecting rod. 37) Remove crankshaft bearings from cylinder block using hammer handle.
CAUTION: Do not confuse combination of crankshaft bearings. Press bearing at the end opposite to locking lip. 38) Draw out each piston from cylinder block using wooden bar or hammer handle.
ME(SOHC)-70
CYLINDER BLOCK
CAUTION: Do not confuse combination of piston and cylinder.
Mechanical
B: INSTALLATION
S153090A11
B2M2407A
(1) Crankshaft bearing (2) Crankshaft (3) Cylinder block
(4) Rear oil seal
Tightening torque: Nm (kgf-m, ft-lb) T1: 25 (2.5, 18.1) T2: 47 (4.8, 34.7)
CAUTION: Remove oil in the mating surface of bearing and cylinder block before installation. Also apply a coat of engine oil to crankshaft pins. 1) Position crankshaft on the #2 and #4 cylinder block. 2) Apply fluid packing to the mating surface of #1 and #3 cylinder block, and position it on #2 and #4 cylinder block. Fluid packing: THREE BOND 1215 or equivalent
CAUTION: Do not allow fluid packing to jut into O-ring grooves, oil passages, bearing grooves, etc.
S2M1826A
ME(SOHC)-71
Mechanical
CYLINDER BLOCK
6) Install rear oil seal using ST1 and ST2. ST1 499597100 OIL SEAL GUIDE ST2 499587200 OIL SEAL INSTALLER
3) Temporarily tighten 10 mm cylinder block connecting bolts in alphabetical sequence shown in figure.
B2M0088D
S2M1827A
4) Tighten 10 mm cylinder block connecting bolts in alphabetical sequence. Tightening torque: 47 Nm (4.8 kgf-m, 34.7 ft-lb)
(A) (B)
Rear oil seal Flywheel attaching bolt
7) Position the top ring gap at (A) or (B) in the figure.
B2M0088D
S2M1529A
5) Tighten 8 mm and 6 mm cylinder block connecting bolts in alphabetical sequence shown in figure. Tightening torque: (A) (G): 25 Nm (2.5 kgf-m, 18.1 ft-lb) (H): 6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
8) Position the second ring gap at 180 on the reverse side for the top ring gap. 9) Position the upper rail gap at (C) or (D) in the figure.
S2M1530A B2M0089F
10) Position the expander gap at 180 of the reverse side for the upper rail gap.
ME(SOHC)-72
CYLINDER BLOCK
11) Position the lower rail gap at (E) or (F) in the figure. CAUTION: Ensure ring gaps do not face the same direction. Ensure ring gaps are not within the piston skirt area. CAUTION: Use new circlips.
Mechanical
B2M1403A
CAUTION: Piston front mark faces towards the front of the engine.
S2M1530A
12) Install circlip. Install circlips in piston holes located opposite service holes in cylinder block, when positioning all pistons in the corresponding cylinders.
S2M1531C
B2M1322J
(1) Piston (2) Piston pin (3) Circlip
(4) Gasket (5) Service hole plug
ME(SOHC)-73
Mechanical
CYLINDER BLOCK
CAUTION: Use new circlips.
13) Installing piston (1) Turn cylinder block so that #1 and #2 cylinders face upward. (2) Using ST1, turn crankshaft so that #1 and #2 connecting rods are set at bottom dead center. ST1 499987500 CRANKSHAFT SOCKET (3) Apply a coat of engine oil to pistons and cylinders and insert pistons in their cylinders using ST2. ST2 498747100 PISTON GUIDE
S2M1828
(4) Apply fluid packing around the service hole plug. Fluid packing: THREE BOND 1215 or equivalent
S2M0306A
14) Installing piston pin (1) Insert ST3 into service hole to align piston pin hole with connecting rod small end. CAUTION: Apply a coat of engine oil to ST3 before insertion. ST3 499017100 PISTON PIN GUIDE CAUTION: Use a new gasket.
B2M2625
(5) Install service hole plug and gasket.
G2M0189
(2) Apply a coat of engine oil to piston pin and insert piston pin into piston and connecting rod through service hole. (3) Install circlip.
B2M2620
ME(SOHC)-74
CYLINDER BLOCK
Mechanical
B2M1323K
(1) (2) (3) (4)
Piston Piston pin Circlip Gasket
(5) Service hole plug (6) Service hole cover (7) O-ring
(6) Turn cylinder block so that #3 and #4 cylinders face upward. Using the same procedures as used for #1 and #2 cylinders, install pistons and piston pins.
ME(SOHC)-75
Mechanical
CYLINDER BLOCK
15) Install water pipe.
B2M2638
16) Install baffle plate. Tightening torque: 6.4 Nm (0.65 kgf-m, 4.7 ft-lb) 17) Install oil strainer and O-ring Tightening torque: 10 Nm (1.0 kgf-m, 7 ft-lb) 18) Install oil strainer stay. 19) Apply fluid packing to matching surfaces and install oil pan. Fluid packing: THREE BOND 1215 or equivalent
S2M1818C
S2M1870C
22) Install housing cover. 23) Installation of oil pump. (1) Discard front oil seal after removal. Replace with a new one using ST. ST 499587100 OIL SEAL INSTALLER
S2M1833A
20) Apply fluid packing to matching surfaces and install oil separator cover. Fluid packing: THREE BOND 1215 or equivalent
S2M0235
S2M1834A
21) Install flywheel or drive plate. To lock crankshaft, use ST. ST 498497100 CRANKSHAFT STOPPER
ME(SOHC)-76
CYLINDER BLOCK
(2) Apply fluid packing to matching surface of oil pump. Fluid packing: THREE BOND 1215 or equivalent
Mechanical
CAUTION: Be sure to use a new gasket. When installing water pump, tighten bolts in two stages in alphabetical sequence as shown in figure.
S2M0739B
H2M1568B
(3) Apply a coat of engine oil to the inside of the oil seal.
25) Install water by-pass pipe for heater. 26) Install oil filter using ST. ST 498547000 OIL FILTER WRENCH
S2M0118B
(4) Install oil pump on cylinder block. Be careful not to damage oil seal during installation. Tightening torque: 6.4 Nm (0.65 kgf-m, 4.7 ft-lb) CAUTION: Do not forget to install O-ring and seal when installing oil pump. Align flat surface of oil pumps inner rotor with crankshaft before installation. 24) Install water pump and gasket. Tightening torque: First; 12 Nm (1.2 kgf-m, 8.7 ft-lb) Second; 12 Nm (1.2 kgf-m, 8.7 ft-lb)
B2M2611A
27) Tighten cylinder head bolts. (1) Apply a coat of engine oil to washers and bolt threads. (2) Tighten all bolts to 29 Nm (3.0 kgf-m, 22 ft-lb) in alphabetical sequence. Then tighten all bolts to 69 Nm (7.0 kgf-m, 51 ft-lb) in alphabetical sequence. (3) Back off all bolts by 180 first; back them off by 180 again. (4) Tighten bolts (a) and (b) to 34 Nm (3.5 kgf-m, 25 ft-lb). (5) Tighten bolts (c), (d), (e) and (f) to 15 Nm (1.5 kgf-m, 11 ft-lb). (6) Tighten all bolts by 80 to 90 in alphabetical sequence. CAUTION: Do not tighten bolts more than 90. (7) Further tighten all bolts by 80 to 90 in alphabetical sequence.
ME(SOHC)-77
Mechanical
CYLINDER BLOCK
CAUTION: Ensure that the total re-tightening angle [in the former two steps], do not exceed 180.
B2M2628B
28) Install oil level gauge guide and tighten attaching bolt (left side only). 29) Install rocker cover. 30) Install crankshaft sprocket. <Ref. to ME(SOHC)-53, INSTALLATION, Crankshaft Sprocket.> 31) Install camshaft sprocket. <Ref. to ME(SOHC)-51, INSTALLATION, Camshaft Sprocket.> 32) Install timing belt assembly. <Ref. to ME(SOHC)-47, INSTALLATION, Timing Belt Assembly.> 33) Install belt cover. <Ref. to ME(SOHC)-45, INSTALLATION, Belt Cover.> 34) Install crankshaft pulley. <Ref. to ME(SOHC)44, INSTALLATION, Crankshaft Pulley.> 35) Install generator and A/C compressor brackets on cylinder head. 36) Install V-belt. <Ref. to FU(SOHC)-17, INSTALLATION, Intake Manifold.> <Ref. to ME(SOHC)-42, INSTALLATION, V-belt.> 37) Install intake manifold. <Ref. to FU(SOHC)17, INSTALLATION, Intake Manifold.> or <Ref. to FU(SOHCw/oOBD)-15, INSTALLATION, Intake Manifold.>
ME(SOHC)-78
CYLINDER BLOCK C: DISASSEMBLY

S153090A06
Mechanical
B2M1320I
(1) Connecting rod cap (2) Connecting rod bearing
(3) Top ring (4) Second ring
(5) Oil ring (6) Circlip
1) Remove connecting rod cap. 2) Remove connecting rod bearing. CAUTION: Arrange removed connecting rod, connecting rod cap and bearing in order to prevent confusion. 3) Remove piston rings using the piston ring expander. 4) Remove the oil ring by hand. CAUTION: Arrange the removed piston rings in good order to prevent confusion. 5) Remove circlip.
ME(SOHC)-79
Mechanical
CYLINDER BLOCK
S153090A02
D: ASSEMBLY
B2M1320J
(1) (2) (3) (4)
Connecting rod bearing Connecting rod Connecting rod cap Oil ring
(5) Second ring (6) Top ring (7) Circlip
1) Install connecting rod bearings on connecting rods and connecting rod caps. CAUTION: Apply oil to the surfaces of the connecting rod bearings. 2) Install connecting rod on crankshaft. CAUTION: Position each connecting rod with the side marked facing forward. 3) Install connecting rod cap with connecting rod nut. Ensure the arrow on connecting rod cap faces the front during installation. CAUTION: Each connecting rod has its own mating cap. Make sure that they are assembled correctly by checking their matching number. When tightening the connecting rod nuts, apply oil on the threads. 4) Install oil ring spacer, upper rail and lower rail in this order by hand. Then install second ring and top ring with a piston ring expander.
E: INSPECTION
S153090A10
1. CYLINDER BLOCK
S153090A1001
1) Visually check for cracks and damage. Especially, inspect important parts by means of red lead check. 2) Check the oil passages for clogging. 3) Inspect crankcase surface that mates with cylinder head for warping by using a straight edge, and correct by grinding if necessary. Warping limit: 0.05 mm (0.0020 in) Grinding limit: 0.1 mm (0.004 in) Standard height of cylinder block: 201.0 mm (7.91 in)
ME(SOHC)-80
CYLINDER BLOCK
2. CYLINDER AND PISTON
S153090A1002
Mechanical
1) The cylinder bore size is stamped on the cylinder blocks front upper surface. CAUTION: Measurement should be performed at a temperature 20C (68F). NOTE: Standard sized pistons are classified into two grades, A and B. These grades should be used as a guide line in selecting a standard piston. Standard diameter: A: 92.005 92.015 mm (3.6222 3.6226 in) B: 91.995 92.005 mm (3.6218 3.6222 in)
2) How to measure the inner diameter of each cylinder Measure the inner diameter of each cylinder in both the thrust and piston pin directions at the heights shown in the figure, using a cylinder bore gauge. CAUTION: Measurement should be performed at a temperature 20C (68F). Taper: Standard 0.015 mm (0.0006 in) Limit 0.050 mm (0.0020 in) Out-of-roundness: Standard 0.010 mm (0.0004 in) Limit 0.050 mm (0.0020 in)
H2M1732C
(A) (B) (C) (D) (E) (F)
Main jourual size mark Cylinder block RH-LH combination mark #1 cylinder bore size mark #2 cylinder bore size mark #3 cylinder bore size mark #4 cylinder bore size mark
S2M1821A
(A) (B)
Piston pin direction Thrust direction
3) When piston is to be replaced due to general or cylinder wear, determine a suitable sized piston by measuring the piston clearance.
ME(SOHC)-81
Mechanical
CYLINDER BLOCK
(2) If the cylinder inner diameter exceeds the limit after boring and honing, replace the crankcase. CAUTION: Immediately after reboring, the cylinder diameter may differ from its real diameter due to temperature rise. Thus, pay attention to this when measuring the cylinder diameter. Limit of cylinder enlarging (boring): 0.5 mm (0.020 in)
4) How to measure the outer diameter of each piston Measure the outer diameter of each piston at the height shown in the figure. (Thrust direction) CAUTION: Measurement should be performed at a temperature of 20C (68F). Piston grade point H: 40.0 mm (1.575 in) Piston outer diameter: Standard A: 91.985 91.995 mm (3.6214 3.6218 in) B: 91.975 91.985 mm (3.6211 3.6214 in) 0.25 mm (0.0098 in) oversize 92.225 92.235 mm (3.6309 3.6313 in) 0.50 mm (0.0197 in) oversize 92.475 92.485 mm (3.6407 3.6411 in)
3. PISTON AND PISTON PIN
S153090A1003
1) Check pistons and piston pins for damage, cracks, and wear and the piston ring grooves for wear and damage. Replace if defective. 2) Measure the piston-to-cylinder clearance at each cylinder. <Ref. to ME(SOHC)-81, CYLINDER AND PISTON, INSPECTION, Cylinder Block.> If any of the clearances is not to specification, replace the piston or bore the cylinder to use an oversize piston. 3) Make sure that piston pin can be inserted into the piston pin hole with a thumb at 20C (68F). Replace if defective. Standard clearance between piston pin and hole in piston: Standard 0.004 0.008 mm (0.0002 0.0003 in) Limit 0.020 mm (0.0008 in)
B2M1305A
5) Calculate the clearance between cylinder and piston. CAUTION: Measurement should be performed at a temperature of 20C (68F). Cylinder to piston clearance at 20C (68F): Standard 0.010 0.030 mm (0.0004 0.0012 in) Limit 0.050 mm (0.0020 in) 6) Boring and honing (1) If the value of taper, out-of-roundness, or cylinder-to-piston clearance measured exceeds the specified limit or if there is any damage on the cylinder wall, rebore it to use an oversize piston. CAUTION: When any of the cylinders needs reboring, all other cylinders must be bored at the same time, and use oversize pistons. Do not perform boring on one cylinder only, nor use an oversize piston for one cylinder only.
B2M1401
B2M0084A
ME(SOHC)-82
CYLINDER BLOCK
4) Check circlip installation groove on the piston for burr (A). If necessary, remove burr from the groove so that piston pin can lightly move.
Mechanical
2) Squarely place piston ring and oil ring in cylinder, and measure the piston ring gap with a thickness gauge.
Standard 0.20 0.35 (0.0079 0.0138) 0.35 0.50 (0.0138 0.0197) 0.20 0.70 (0.0079 0.0276) Unit: mm (in) Limit 1.0 (0.039) 1.0 (0.039) 1.5 (0.059)
Top ring Piston ring gap Second ring Oil ring rail
B2M0420A
5) Check piston pin circlip for distortion, cracks and wear.
4. PISTON RING
S153090A1004
1) If piston ring is broken, damaged, or worn, or if its tension is insufficient, or when the piston is replaced, replace piston ring with a new one of the same size as the piston. CAUTION: Marks are shown on the end of the top and second rings. When installing the rings to the piston, face these marks upward. The oil ring is a combined ring consisting of two rails and a spacer in between. When installing, be careful to assemble correctly.
G2M0174
3) Measure the clearance between piston ring and piston ring groove with a thickness gauge. CAUTION: Before measuring the clearance, clean the piston ring groove and piston ring.
Standard 0.040 0.080 (0.0016 0.0031) 0.030 0.070 (0.0012 0.0028) Unit: mm (in) Limit 0.15 (0.0059)
Clearance between piston ring and piston ring groove
Top ring Second ring
0.15 (0.0059)
EN1006
(A) (B) (C) (a) (b) (c)
Top ring Second ring Oil ring Upper rail Spacer Lower rail
B2M1402A
5. CONNECTING ROD
S153090A1005
1) Replace connecting rod, if 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.
ME(SOHC)-83
Mechanical
CYLINDER BLOCK
4) Inspect connecting rod bearing for scar, peeling, seizure, melting, wear, etc. 5) Measure the oil clearance on individual connecting rod bearings by means of plastigauge. If any oil clearance is not within specification, replace the defective bearing with a new one of standard size or undersize as necessary. (See the table below.) Connecting rod oil clearance: Standard 0.010 0.038 mm (0.0004 0.0015 in) Limit 0.05 mm (0.0020 in)
Bearing size (Thickness at center) 1.492 1.501 (0.0587 0.0591) 1.510 1.513 (0.0594 0.0596) 1.520 1.523 (0.0598 0.0600) 1.620 1.623 (0.0638 0.0639) Unit: mm (in) Outer diameter of crank pin 51.984 52.000 (2.0466 2.0472) 51.954 51.970 (2.0454 2.0461) 51.934 51.950 (2.0446 2.0453) 51.734 51.750 (2.0368 2.0374)
Limit of bend or twist per 100 mm (3.94 in) in length: 0.10 mm (0.0039 in)
Bearing Standard 0.03 (0.0012) undersize 0.05 (0.0020) undersize 0.25 (0.0098) undersize
B2M1184B
(A) (B)
Thickness gauge Connecting rod
3) Install connecting rod fitted with bearing to crankshaft and measure the side clearance (thrust clearance). Replace connecting rod if the side clearance exceeds the specified limit. Connecting rod side clearance: Standard 0.070 0.330 mm (0.0028 0.0130 in) Limit 0.4 mm (0.016 in)
EN0335
ME(SOHC)-84
CYLINDER BLOCK
6) Inspect bushing at connecting rod small end, and replace if worn or damaged. Also measure the piston pin clearance at the connecting rod small end. Clearance between piston pin and bushing: Standard 0 0.022 mm (0 0.0009 in) Limit 0.030 mm (0.0012 in)
Mechanical
6. CRANKSHAFT AND CRANKSHAFT BEARING S153090A1006

1) Clean crankshaft completely and check for cracks by means of red lead check etc., and replace if defective. 2) Measure the crankshaft bend, and correct or replace if it exceeds the limit. CAUTION: If a suitable V-block is not available, install #1 and #5 crankshaft bearing on cylinder block, position crankshaft on these bearings and measure crankshaft bend using a dial gauge. Crankshaft bend limit: 0.035 mm (0.0014 in)
B2M0085
EN0339
EN0337
7) Replacement procedure is as follows. (1) Remove bushing from connecting rod with ST and press. (2) Press bushing with ST after applying oil on the periphery of bushing. ST 499037100 CONNECTING ROD BUSHING REMOVER AND INSTALLER
3) Inspect the crank journal and crank pin for wear. If they are not within the specifications, replace bearing with a suitable (undersize) one, and replace or recondition crankshaft as necessary. When grinding crank journal or crank pin, finish them to the specified dimensions according to the undersize bearing to be used. Crank pin and crank journal: Out-of-roundness 0.020 mm (0.0008 in) or less Taper limit 0.07 mm (0.0028 in) Grinding limit 0.250 mm (0.0098 in)
G2M0177
(3) Make two 3 mm (0.12 in) holes in bushing. Ream the inside of bushing. (4) After completion of reaming, clean bushing to remove chips.
G2M0179
ME(SOHC)-85
Mechanical
CYLINDER BLOCK
Unit: mm (in) Crank journal diameter #1, #3 #2, #4, #5 59.992 60.008 59.992 60.008 (2.3619 2.3625) (2.3619 2.3625) 1.998 2.011 (0.0787 0.0792) 59.962 59.978 (2.3607 2.3613) 2.017 2.020 (0.0794 0.0795) 59.942 59.958 (2.3599 2.3605) 2.027 2.030 (0.0798 0.0799) 59.742 59.758 (2.3520 2.3527) 2.127 2.130 (0.0837 0.0839) 2.000 2.013 (0.0787 0.0793) 59.962 59.978 (2.3607 2.3613) 2.019 2.022 (0.0795 0.0796) 59.942 59.958 (2.3599 2.3605) 2.029 2.032 (0.0799 0.0800) 59.742 59.758 (2.3520 2.3527) 2.129 2.132 (0.0838 0.0839) Crank pin diameter 51.984 52.000 (2.0466 2.0472) 1.492 1.501 (0.0587 0.0591) 51.954 51.970 (2.0454 2.0461) 1.510 1.513 (0.0594 0.0596) 51.934 51.950 (2.0446 2.0453) 1.520 1.523 (0.0598 0.0600) 51.734 51.750 (2.0368 2.0374) 1.620 1.623 (0.0638 0.0639)
Journal O.D. Standard Bearing size (Thickness at center) Journal O.D. 0.03 (0.0012) undersize Bearing size (Thickness at center) Journal O.D. 0.05 (0.0020) undersize Bearing size (Thickness at center) Journal O.D. 0.25 (0.0098) undersize Bearing size (Thickness at center)
O.D. ... Outer Diameter
4) Measure the thrust clearance of crankshaft at center bearing. If the clearance exceeds the limit, replace bearing. Crankshaft thrust clearance: Standard 0.030 0.115 mm (0.0012 0.0045 in) Limit 0.25 mm (0.0098 in)
6) Measure the oil clearance on each crankshaft bearing by means of plastigauge. If the measurement is not within the specification, replace defective bearing with an undersize one, and replace or recondition crankshaft as necessary.
Unit: mm (in) Crankshaft oil clearance Standard 0.010 0.030 (0.0004 0.0012) Limit 0.040 (0.0016)
EN0341
5) Inspect individual crankshaft bearings for signs of flaking, seizure, melting, and wear.
ME(SOHC)-86
ENGINE TROUBLE IN GENERAL
Mechanical
22. Engine Trouble in General

S153095
A: INSPECTION
S153095A10
NOTE: RANK shown in the chart refer to the possibility of reason for the trouble in order (Very often to Rarely) A Very often B Sometimes C Rarely
TROUBLE 1. Engine will not start. 1) Starter does not turn. PROBLEM PARTS, ETC. Starter POSSIBLE CAUSE RANK B C C B A A B C C C C A A B B B C C C C C B C B B
2) Initial combustion does not occur.
Defective battery-to-starter harness Defective starter switch Defective inhibitor switch or neutral switch Defective starter Battery Poor terminal connection Run-down battery Defective charging system Friction Seizure of crankshaft and connecting rod bearing Seized camshaft Seized or stuck piston and cylinder Starter Defective starter Engine control system <Ref. to EN(SOHC)-2, Basic Diagnostic Procedure.> or <Ref. to EN(SOHCw/oOBD)-2, Basic Diagnostic Procedure.> Fuel line Defective fuel pump and relay Lack of or insufficient fuel Belt Defective Defective timing Compression Incorrect valve clearance Loosened spark plugs or defective gasket Loosened cylinder head bolts or defective gasket Improper valve seating Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity)
ME(SOHC)-87
Mechanical
TROUBLE 3) Initial combustion occur.

PROBLEM PARTS, ETC. POSSIBLE CAUSE Engine control system <Ref. to EN(SOHC)-2, Basic Diagnostic Procedure.> or <Ref. to EN(SOHCw/oOBD)-2, Basic Diagnostic Procedure.> Intake system Defective intake manifold gasket Defective throttle body gasket Fuel line Defective fuel pump and relay Clogged fuel line Lack of or insufficient fuel Belt Defective Defective timing Compression Incorrect valve clearance Loosened spark plugs or defective gasket Loosened cylinder head bolts or defective gasket Improper valve seating Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity) Engine control system <Ref. to EN(SOHC)-2, Basic Diagnostic Procedure.> or <Ref. to EN(SOHCw/oOBD)-2, Basic Diagnostic Procedure.> Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective intake manifold gasket Defective throttle body gasket Dirty air cleaner element Fuel line Clogged fuel line Lack of or insufficient fuel Belt Defective Defective timing Compression Incorrect valve clearance Loosened spark plugs or defective gasket Loosened cylinder head bolts or defective gasket Improper valve seating Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity) RANK A B B C C B B B C C C C C B C B B A B C C B B C C B B B C C C C C B C B B
4) Engine stalls after initial combustion.
ME(SOHC)-88

TROUBLE 2. Rough idle and engine stall
Mechanical
RANK A A A A B B C B C C C B C B B B B C B B A B B C C A B C
PROBLEM PARTS, ETC. POSSIBLE CAUSE Engine control system <Ref. to EN(SOHC)-2, Basic Diagnostic Procedure.> or <Ref. to EN(SOHCw/oOBD)-2, Basic Diagnostic Procedure.> Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective intake manifold gasket Defective throttle body gasket Defective PCV valve Loosened oil filter cap Dirty air cleaner element Fuel line Defective fuel pump and relay Clogged fuel line Lack of or insufficient fuel Belt Defective timing Compression Incorrect valve clearance Loosened spark plugs or defective gasket Loosened cylinder head bolts or defective gasket Improper valve seating Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity) Lubrication system Incorrect oil pressure Defective rocker cover gasket Cooling system Overheating Others Malfunction of evaporative emission control system Stuck or damaged throttle valve Accelerator cable out of adjustment
ME(SOHC)-89
Mechanical

RANK A A A B B B B B A B B C B B B B B C B C A B B C C A A A A A B B B B B B B C B B C C C C C C A B B C
TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE 3. Low output, hesitation and Engine control system <Ref. to EN(SOHC)-2, Basic Diagnostic Procedure.> or poor acceleration <Ref. to EN(SOHCw/oOBD)-2, Basic Diagnostic Procedure.> Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective intake manifold gasket Defective throttle body gasket Defective PCV valve Loosened oil filter cap Dirty air cleaner element Fuel line Defective fuel pump and relay Clogged fuel line Lack of or insufficient fuel Belt Defective timing Compression Incorrect valve clearance Loosened spark plugs or defective gasket Loosened cylinder head bolts or defective gasket Improper valve seating Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity) Lubrication system Incorrect oil pressure Cooling system Overheating Over cooling Others Malfunction of evaporative emission control system 4. Surging Engine control system <Ref. to EN(SOHC)-2, Basic Diagnostic Procedure.> or <Ref. to EN(SOHC)-2, Basic Diagnostic Procedure.> Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective intake manifold gasket Defective throttle body gasket Defective PCV valve Loosened oil filter cap Dirty air cleaner element Fuel line Defective fuel pump and relay Clogged fuel line Lack of or insufficient fuel Belt Defective timing Compression Incorrect valve clearance Loosened spark plugs or defective gasket Loosened cylinder head bolts or defective gasket Improper valve seating Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity) Cooling system Overheating Others Malfunction of evaporative emission control system
ME(SOHC)-90

TROUBLE 5. Engine does not return to idle.
Mechanical
RANK A A A B A B B A C C B B C B B C C B C C C A C C C A B B C B A A B C A A B B B B B B
6. Dieseling (Run-on)
7. After burning in exhaust system
8. Knocking
9. Excessive engine oil consumption
PROBLEM PARTS, ETC. POSSIBLE CAUSE Engine control system <Ref. to EN(SOHC)-2, Basic Diagnostic Procedure.> or <Ref. to EN(SOHCw/oOBD)-2, Basic Diagnostic Procedure.> Intake system Loosened or cracked vacuum hose Others Stuck or damaged throttle valve Accelerator cable out of adjustment Engine control system <Ref. to EN(SOHC)-2, Basic Diagnostic Procedure.> or <Ref. to EN(SOHCw/oOBD)-2, Basic Diagnostic Procedure.> Cooling system Overheating Others Malfunction of evaporative emission control system Engine control system <Ref. to EN(SOHC)-2, Basic Diagnostic Procedure.> or <Ref. to EN(SOHCw/oOBD)-2, Basic Diagnostic Procedure.> Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective PCV valve Loosened oil filler cap Belt Defective timing Compression Incorrect valve clearance Loosened spark plugs or defective gasket Loosened cylinder head bolts or defective gasket Improper valve seating Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Lubrication system Incorrect oil pressure Cooling system Over cooling Others Malfunction of evaporative emission control system Engine control system <Ref. to EN(SOHC)-2, Basic Diagnostic Procedure.> or <Ref. to EN(SOHCw/oOBD)-2, Basic Diagnostic Procedure.> Intake system Loosened oil filter cap Belt Defective timing Compression Incorrect valve clearance Incorrect valve timing Cooling system Overheating Intake system Loosened or cracked PCV hose Defective PCV valve Loosened oil filter cap Compression Defective valve stem Worn or stuck piston rings, cylinder and piston Lubrication system Loosened oil pump attaching bolts and defective gasket Defective oil filter seal Defective crankshaft oil seal Defective rocker cover gasket Loosened oil drain plug or defective gasket Loosened oil pan fitting bolts or defective oil pan
ME(SOHC)-91
Mechanical

RANK A A B B C C B C C B B C C B
TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE 10. Excessive fuel consump- Engine control system <Ref. to EN(SOHC)-2, Basic Diagnostic Procedure.> or tion <Ref. to EN(SOHCw/oOBD)-2, Basic Diagnostic Procedure.> Intake system Dirty air cleaner element Belt Defective timing Compression Incorrect valve clearance Loosened spark plugs or defective gasket Loosened cylinder head bolts or defective gasket Improper valve seating Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Lubrication system Incorrect oil pressure Cooling system Over cooling Others Accelerator cable out of adjustment
ME(SOHC)-92
ENGINE NOISE
Mechanical
23. Engine Noise

A: INSPECTION
Type of sound
S153096
S153096A10
Possible cause Valve mechanism is defective. Incorrect valve clearance Sound increases as engine Regular clicking sound Worn valve rocker speed increases. Worn camshaft Broken valve spring Worn crankshaft main bearing Oil pressure is low. Worn connecting rod bearing (big end) Heavy and dull clank Loose flywheel mounting bolts Oil pressure is normal. Damaged engine mounting Ignition timing advanced High-pitched clank (Spark Sound is noticeable when Accumulation of carbon inside combustion chamber knock) accelerating with an overload. Wrong spark plug Improper gasoline Worn crankshaft main bearing Sound is reduced when fuel Clank when engine speed is injector connector of noisy cyl- Worn bearing at crankshaft end of connecting rod medium (1,000 to 2,000 rpm). inder is disconnected. (NOTE*) Worn cylinder liner and piston ring Sound is reduced when fuel injector connector of noisy cyl- Broken or stuck piston ring Worn piston pin and hole at piston end of connecting rod Knocking sound when engine inder is disconnected. is operating under idling speed (NOTE*) and engine is warm Sound is not reduced if each Unusually worn valve lifter fuel injector connector is dis Worn cam gear connected in turn. (NOTE*) Worn camshaft journal bore in crankcase Squeaky sound Insufficient generator lubrication Rubbing sound Defective generator brush and rotor contact Gear scream when starting Defective ignition starter switch engine Worn gear and starter pinion Sound like polishing glass with Loose drive belt a dry cloth Defective water pump shaft Loss of compression Hissing sound Air leakage in air intake system, hoses, connections or manifolds Loose timing belt Timing belt noise Belt contacting case/adjacent part Valve tappet noise Incorrect valve clearance NOTE*: When disconnecting fuel injector connector, Malfunction Indicator Light (CHECK ENGINE light) illuminates and trouble code is stored in ECM memory. Therefore, carry out the CLEAR MEMORY MODE <Ref. to EN(SOHC)-45, OPERATION, Clear Memory Mode.> or <Ref. to EN(SOHCw/oOBD)-31, OPERATION, Clear Memory Mode.> and INSPECTION MODE <Ref. to EN(SOHC)-42, OPERATION, Inspection Mode.> or <Ref. to EN(SOHCw/oOBD)-29, OPERATION, Inspection Mode.> after connecting fuel injector connector.
Condition
ME(SOHC)-93
Mechanical
ENGINE NOISE
MEMO:
ME(SOHC)-94
EXHAUST
EX(SOHC)
1. 2. 3. 4. 5. Page General Description.....................................................................................2 Front Exhaust Pipe......................................................................................5 Center Exhaust Pipe ...................................................................................8 Rear Exhaust Pipe ......................................................................................9 Muffler ........................................................................................................11
Exhaust
GENERAL DESCRIPTION
S152001
A: COMPONENT
S152001A05
S2M2132A
EX(SOHC)-2
GENERAL DESCRIPTION
(1) Upper front exhaust pipe cover CTR (2) Lower front exhaust pipe cover CTR (3) Front exhaust pipe (4) Front oxygen (A/F) sensor (5) Front catalytic converter (6) Upper front catalytic converter cover (7) Lower front catalytic converter cover (8) Clamp (9) Upper center exhaust pipe cover (10) Lower center exhaust pipe cover (11) Gasket (12) Upper rear catalytic converter cover (13) Lower rear catalytic converter cover (14) Rear catalytic converter (15) Center exhaust pipe (16) Protector (17) Rear oxygen sensor (18) Gasket (19) Spring (20) Rear exhaust pipe (21) (22) (23) (24) Gasket Self-lock nut Muffler Cushion rubber
Exhaust
Tightening torque: Nm (kgf-m, ft-lb) T1: 8 (0.8, 5.8) T2: 13 (1.3, 9.4) T3: 18 (1.8, 13.0) T4: 30 (3.1, 22.4) T5: 35 (3.6, 26.0) T6: 48 (4.9, 35.4)
EX(SOHC)-3
Exhaust
GENERAL DESCRIPTION
S152001A03
B: CAUTION
EX(SOHC)-4
FRONT EXHAUST PIPE
Exhaust
2. Front Exhaust Pipe

A: REMOVAL
S152065A18
S152065
6) Separate front and center exhaust pipe assembly from rear exhaust pipe. WARNING: Be careful, exhaust pipe is hot.
G6M0095
B2M0055
2) Disconnect front oxygen (A/F) sensor connector.
7) Remove bolts which hold front exhaust pipe onto cylinder heads. CAUTION: Be careful not to pull down front and center exhaust pipe assembly.
B2M4243
3) Disconnect rear oxygen sensor connector.

B2M3200
8) Remove bolt which installs front and center exhaust pipe assembly to hanger bracket.
B2M4244
4) Lift-up the vehicle. 5) Remove under cover. <Ref. EI-11, REMOVAL, Front Under Cover.>
B2M3111
9) Remove front and center exhaust pipe assembly from the vehicle. CAUTION: Be careful not to let front and center exhaust pipe assembly fall off when removing as it is quite heavy. After removing front and center exhaust assembly, do not apply excessive pulling force on rear exhaust pipe.
EX(SOHC)-5
Exhaust
FRONT EXHAUST PIPE

10) Separate front exhaust pipe from center exhaust pipe.
S2M0923
B: INSTALLATION
S152065A11
B2M3200
1) Install front exhaust pipe to center exhaust pipe. CAUTION: Replace gaskets with new ones. Tightening torque: 30 Nm (3.1 kgf-m, 22.4 ft-lb)
5) Tighten bolts which install front and center exhaust pipe assembly to rear exhaust pipe. Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft-lb)
B2M0055
S2M0923
6) Tighten bolt which holds front and center exhaust pipe assembly to hanger bracket. Tightening torque: 35 Nm (3.6 kgf-m, 26.0 ft-lb)
2) Install front and center exhaust pipe assembly to the vehicle. 3) Temporarily tighten bolt which installs front and center exhaust pipe assembly to hanger bracket.
B2M3111
B2M3111
7) Install under cover. <Ref. INSTALLATION, Front Under Cover.> 8) Lower the vehicle.
EI-11,
EX(SOHC)-6
FRONT EXHAUST PIPE

9) Connect rear oxygen sensor connector.
Exhaust
B2M4244
10) Connect front oxygen (A/F) sensor connector.
B2M4243
G6M0095
C: INSPECTION
S152065A10
EX(SOHC)-7
Exhaust
CENTER EXHAUST PIPE

S152067
3. Center Exhaust Pipe

A: REMOVAL
S152067A18
After removing the center and front exhaust pipes as one unit, separate them. Refer to the procedure for removing the front exhaust pipe. <Ref. to EX(SOHC)-5 REMOVAL, Front Exhaust Pipe.>
B: INSTALLATION
S152067A11
Install the center exhaust pipe and front exhaust pipe as one unit. Refer to the procedure for installing the front exhaust pipe. <Ref. to EX(SOHC)-6 INSTALLATION, Front Exhaust Pipe.>
C: INSPECTION
S152067A10
EX(SOHC)-8
REAR EXHAUST PIPE
Exhaust
S152068A11
4. Rear Exhaust Pipe

A: REMOVAL
S152068A18
S152068
B: INSTALLATION
CAUTION: Replace gaskets with new ones. 1) Install rear exhaust pipe bracket to rubber cushion. NOTE: To facilitate removal, apply a coat of SUBARU CRC to mating area of rubber cushion in advance. SUBARU CRC (Part No. 004301003)
1) Separate rear exhaust pipe from center exhaust pipe. CAUTION: Be careful, exhaust pipe is hot.
S2M0558
2) Separate rear exhaust pipe from muffler. CAUTION: Be careful not to pull down rear exhaust pipe.
S2M0560
2) Install rear exhaust pipe to muffler. Tightening torque: 48 Nm (4.9 kgf-m, 35.4 ft-lb)
S2M0559
3) Remove rear exhaust pipe bracket from rubber cushion. NOTE: To facilitate removal, apply a coat of SUBARU CRC to pipe bracket in advance. SUBARU CRC (Part No. 004301003) Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft-lb)
S2M0559
3) Install rear exhaust pipe to center exhaust pipe.
S2M0558 S2M0560
EX(SOHC)-9
Exhaust
REAR EXHAUST PIPE

S152068A10
C: INSPECTION
1) Make sure there are no exhaust leaks from connections and welds. 2) Make sure there are no holes or rusting. 3) Make sure the cushion rubber is not worn or cracked.
EX(SOHC)-10
MUFFLER
Exhaust
5. Muffler
S152066
3) Remove front rubber cushion, and detach muffler assembly. NOTE: To facilitate removal, apply a coat of SUBARU CRC to mating area of rubber cushion in advance. SUBARU CRC (Part No. 004301003)
A: REMOVAL
S152066A18
1) Separate muffler from rear exhaust pipe. CAUTION: Be careful, exhaust pipe is hot.
S2M0559
S2M0609
2) Remove left and right rubber cushions. CAUTION: Be careful not to drop the muffler during removal. NOTE: To facilitate removal, apply a coat of SUBARU CRC to mating area of rubber cushions in advance. SUBARU CRC (Part No. 004301003)
B: INSTALLATION
S152066A11
Install in the reverse order of removal. CAUTION: Replace gasket with a new one. Tightening torque: 48 Nm (4.9 kgf-m, 35.4 ft-lb)
S2M0559
S2M0608
C: INSPECTION
S152066A10
EX(SOHC)-11
Exhaust
MUFFLER
MEMO:
EX(SOHC)-12
COOLING
CO
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Page General Description.....................................................................................2 Radiator Main Fan System .........................................................................8 Radiator Sub Fan System .........................................................................11 Engine Coolant..........................................................................................14 Water Pump ..............................................................................................16 Thermostat ................................................................................................23 Radiator .....................................................................................................25 Radiator Cap .............................................................................................31 Radiator Main Fan and Fan Motor............................................................32 Radiator Sub Fan and Fan Motor .............................................................34 Reservoir Tank ..........................................................................................36 Coolant Filler Tank ....................................................................................37 Engine Cooling System Trouble in General..............................................38
Cooling
GENERAL DESCRIPTION
S176001
A: SPECIFICATIONS
Model Cooling system
S176001E49
Total engine coolant capacity Type
(US qt, Imp qt)
Discharge performance I
Discharge performance II
Water pump Discharge performance III
Discharge Pump speedtotal engine coolant head Engine coolant temperature Discharge Pump speedtotal engine coolant head Engine coolant temperature Discharge Pump speedtotal engine coolant head Engine coolant temperature
Non-turbo Turbo Electric fan + Forced engine coolant circulation system AT: Approx. 6.3 (6.7, 5.5) Approx. 7.2 MT: Approx. 6.4 (6.8, (7.6, 6.3) 5.6) Centrifugal impeller type 20 (5.3 US gal, 4.4 Imp gal)/min. 700 rpm 0.3 mAq (1.0 ftAq) 85C (185F) (26.4 US gal, 22.0 Imp gal)/min.
100
3,000 rpm 5.0 mAq (16.4 ftAq) 85C (185F) (52.8 US gal, 44.0 Imp gal)/min.
200
6,000 rpm 23.0 mAq (75.5 ftAq) 85C (185F) 76 mm (2.99 in) 8 60 mm (2.36 in) 0.5 0.7 mm (0.020 0.028 in) 1.0 mm (0.039 in) 0.5 mm (0.020 in) Wax pellet type 76 80C (169 176F) 91C (196F) 9.0 mm (0.354 in) or more 35 mm (1.38 in) 70 W 70 W 320 mm (12.60 in) 5 (main fan) 320 mm (12.60 in) 7 (sub fan) Down flow, pressure type 691.5 340 16 mm (27.22 13.39 0.63 in) Above: 10815 kPa (1.10.15 kg/cm2, 162 psi) Below: 1.0 to 4.9 kPa (0.01 to 0.05 kg/cm2, 0.1 to 0.7 psi) Corrugated fin type 0.45 (0.5 US qt, 0.4 Imp qt)
Impeller diameter Number of impeller vanes Pump pulley diameter Standard Limit Thrust runout of impeller end Type Starts to open Fully opened Valve lift Valve bore Main fan Motor Sub fan Clearance between impeller and case Fan diameter Blade Type Core dimensions Radiator Pressure range in which cap valve is open Fins Capacity
Thermostat
Radiator fan
Reservoir tank
CO-2
GENERAL DESCRIPTION B: COMPONENT

1. WATER PUMP
S176001A05
Cooling
S176001A0501
NON-TURBO MODEL
H2M2354A
(1) (2) (3) (4)
Water pump ASSY Gasket Heater by-pass hose Thermostat
(5) Gasket (6) Thermostat cover
Tightening torque: Nm (kgf-m, ft-lb) T1: First 12 (1.2, 8.7)
Second 12 (1.2, 8.7)

T2: 6.4 (0.65, 4.7)
CO-3
Cooling
GENERAL DESCRIPTION
TURBO MODEL
H2M1785B
(1) (2) (3) (4) (5)
Thermostat case Gasket Thermostat Water pump ASSY Gasket
(6) Header by-pass hose (7) Coolant filler tank by-pass hose (8) Water by-pass pipe
Tightening torque: Nm (kgf-m, ft-lb) T1: First 12 (1.2, 8.7)
Second 12 (1.2, 8.7)

T2: 6.4 (0.65, 4.7)
CO-4
GENERAL DESCRIPTION
2. RADIATOR AND RADIATOR FAN NON-TURBO MODEL
S176001A0502
Cooling
S2M1739A
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12)
Radiator lower cushion Radiator Radiator upper cushion Radiator upper bracket Clamp Radiator inlet hose Engine coolant reservoir tank cap Over flow hose Engine coolant reservoir tank Sub fan shroud Radiator sub fan Radiator sub fan motor
(13) (14) (15) (16) (17) (18) (19) (20)
Main fan shroud Radiator main fan Radiator main fan motor ATF hose clamp (AT vehicles only) ATF inlet hose A (AT vehicles only) ATF outlet hose A (AT vehicles only) ATF pipe (AT vehicles only) ATF outlet hose B (AT vehicles only)
(21) ATF inlet hose B (AT vehicles only) (22) Radiator outlet hose (23) Radiator drain plug
Tightening torque: Nm (kgf-m, ft-lb) T1: 4.4 (0.45, 3.3) T2: 12 (1.2, 8.7) T3: 18 (1.8, 13.0) T4: 3.4 (0.35, 2.5) T5: 4.9 (0.50, 3.6)
CO-5
Cooling
GENERAL DESCRIPTION
TURBO MODEL
S2M1740A
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)
Radiator lower cushion Radiator Radiator upper cushion Radiator upper bracket Clamp Radiator inlet hose Engine coolant reservoir tank cap Over flow hose Engine coolant reservoir tank Sub fan shroud Radiator sub fan
(12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23)
Radiator sub fan motor Main fan shroud Radiator main fan Radiator main fan motor Oil cooler hose clamp Oil cooler inlet hose A Oil cooler outlet hose A Oil cooler pipe Oil cooler outlet hose B Oil cooler inlet hose B Radiator outlet hose Radiator drain plug
(24) (25) (26) (27)
Engine coolant Engine coolant Engine coolatn Radiator under vehicle)
filler tank hose filler tank cap cover (AT
Tightening torque: Nm (kgf-m, ft-lb) T1: 4.4 (0.45, 3.3) T2: 18 (1.8, 13.0) T3: 3.4 (0.35, 2.5) T4: 4.9 (0.50, 3.6)
CO-6

S176001A03
Cooling
Be careful not to burn your hands, because each part in the vehicle is hot after running. Be sure to tighten fasteners including bolts and nuts to the specified torque. Place shop jacks or safety stands at the specified points. Before disconnecting electrical connectors of sensors or units, be sure to disconnect negative terminal from battery.
D: PREPARATION TOOL
ILLUSTRATION
S176001A17
DESCRIPTION CRANK PULLEY WRENCH
REMARKS Used for stopping crankshaft pulley when loosening and tightening crankshaft pulley bolts.
B2M4157
499207100
Used for removing and installing camshaft sprocket. (Non-turbo LH side only)
B2M3859
499207400
Used for removing and installing camshaft sprocket.
B2M4158
CO-7
Cooling
RADIATOR MAIN FAN SYSTEM

S176732
2. Radiator Main Fan System

A: SCHEMATIC
S176732A21
S2M2148
CO-8
RADIATOR MAIN FAN SYSTEM B: INSPECTION

S176732A10
Cooling
DETECTING CONDITION: Condition: Engine coolant temperature is above 95C (203F).

No. 1 Step CHECK POWER SUPPLY TO MAIN FAN MOTOR. CAUTION: Be careful not to overheat engine during repair. 1) Turn ignition switch to OFF. 2) Disconnect connector from main fan motor. 3) Start the engine, and warm it up until engine coolant temperature increases over 95C (203F). 4) Stop the engine and turn ignition switch to ON. 5) Measure voltage between main fan motor connector and chassis ground. Connector & terminal (F17) No. 2 (+) Chassis ground (): CHECK GROUND CIRCUIT OF MAIN FAN MOTOR. 1) Turn ignition switch to OFF. 2) Measure resistance between main fan motor connector and chassis ground. Connector & terminal (F17) No. 1 Chassis ground: CHECK POOR CONTACT. Check poor contact in main fan motor connector. CHECK MAIN FAN MOTOR. Connect battery positive (+) terminal to terminal No. 2, and negative () terminal to terminal No. 1 of main fan motor connector. CHECK POWER SUPPLY TO MAIN FAN RELAY. 1) Turn ignition switch to OFF. 2) Remove main fan relay from A/C relay holder. 3) Measure voltage between main fan relay terminal and chassis ground. Connector & terminal (F66) No. 26 (+) Chassis ground (): CHECK POWER SUPPLY TO MAIN FAN RELAY. 1) Turn ignition switch to ON. 2) Measure voltage between main fan relay terminal and chassis ground. Connector & terminal (F66) No. 28 (+) Chassis ground (): CHECK 20 A FUSE. 1) Remove 20 A fuse from A/C relay holder. 2) Check condition of fuse.
Vehicle speed is below 19 km/h (12 MPH). TROUBLE SYMPTOM: Radiator main fan does not rotate under the above conditions.
Check Yes Is the voltage more than 10 Go to step 2. V?
No Go to step 5.
Is the resistance less than 5 ?
Go to step 3.
Repair open circuit in harness between main fan motor connector and chassis ground. Go to step 4.
Is there poor contact in main fan motor connector? Does the main fan rotate?
Repair poor contact in main fan motor connector. Repair poor contact in main fan motor connector.
Replace main fan motor with a new one. Go to step 7.
Is the voltage more than 10 Go to step 6. V?
Go to step 9.
Is the fuse blown-out?
Replace fuse.
Go to step 8.
CO-9
Cooling
No. 8
RADIATOR MAIN FAN SYSTEM

Step CHECK POWER SUPPLY TO A/C RELAY HOLDER 20 A FUSE TERMINAL. Measure voltage of harness between A/C relay holder 20 A fuse terminal and chassis ground. Connector & terminal (F27) No. 1 (+) Chassis ground (): CHECK FUSE. 1) Turn ignition switch to OFF. 2) Remove fuse No. 18 from joint box. 3) Check condition of fuse. CHECK MAIN FAN RELAY. 1) Turn ignition switch to OFF. 2) Remove main fan relay. 3) Measure resistance of main fan relay. Terminal No. 26 No. 25: CHECK MAIN FAN RELAY. 1) Connect battery to terminals No. 27 and No. 28 of main fan relay. 2) Measure resistance of main fan relay. Terminal No. 26 No. 25: CHECK HARNESS BETWEEN MAIN FAN RELAY TERMINAL AND MAIN FAN MOTOR CONNECTOR. Measure resistance of harness between main fan motor connector and main fan relay terminal. Connector & terminal (F17) No. 2 (F66) No. 25: CHECK HARNESS BETWEEN MAIN FAN RELAY AND ECM. 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM. 3) Measure resistance of harness between main fan relay connector and ECM connector. Connector & terminal (F66) No. 27 (B134) No. 3 (SOHC MODEL): (F66) No. 27 (B84) No. 2 (SOHC w/o OBD MODEL): (F66) No. 27 (B137) No. 17 (DOHC TURBO MODEL): CHECK POOR CONTACT. Check poor contact in connector between main fan and ECM. Check Yes Is the voltage more than 10 Repair open cirV? cuit in harness between 20 A fuse and main fan relay terminal. No Repair open circuit in harness between main fuse box connector and 20 A fuse terminal. Repair open circuit in harness between main fan relay and ignition switch. Replace main fan relay.
Replace fuse.
10
Is the resistance more than Go to step 11. 1 M?
11
Go to step 12.
Replace main fan relay.
12
Go to step 13.
Repair open circuit in harness between main fan motor connector and main fan relay terminal.
13
Go to step 14.
Repair open circuit in harness between main fan relay and ECM.
14
Is there poor contact in connector between main fan motor and ECM?
Repair poor contact connector.
Contact your Subaru distributor.
NOTE: Inspection by your Subaru distributor is required, because probable cause is deterioration of multiple parts.
CO-10
RADIATOR SUB FAN SYSTEM
Cooling
3. Radiator Sub Fan System

A: SCHEMATIC
S176733A21
S176733
S2M2148
CO-11
Cooling

S176733A10
B: INSPECTION
Vehicle speed is below 19 km/h (12 MPH). Condition (2): Engine coolant temperature is above 100C (212F). A/C switch is turned OFF. Vehicle speed is below 19 km/h (12 MPH). TROUBLE SYMPTOM: Radiator sub fan does not rotate under conditions (1) and (2) above.
No Go to step 5.
NOTE: System for A/C equipped vehicles only. DETECTING CONDITION: Condition (1): Engine coolant temperature is below 95C (203F). A/C switch is turned ON.
No. 1 Step CHECK POWER SUPPLY TO SUB FAN MOTOR. CAUTION: Be careful not to overheat engine during repair. 1) Turn ignition switch to OFF. 2) Disconnect connector from sub fan motor and main fan motor. 3) Start the engine, and warm it up until engine coolant temperature increases over 100C (212F). 4) Stop the engine and turn ignition switch to ON. 5) Measure voltage between sub fan motor connector and chassis ground. Connector & terminal (F16) No. 2 (+) Chassis ground (): CHECK GROUND CIRCUIT OF SUB FAN MOTOR. 1) Turn ignition switch to OFF. 2) Measure resistance between sub fan motor connector and chassis ground. Connector & terminal (F16) No. 1 Chassis ground: CHECK POOR CONTACT. Check poor contact in sub fan motor connector. CHECK SUB FAN MOTOR. Connect battery positive (+) terminal to terminal No. 2, and negative () terminal to terminal No. 1 of sub fan motor connector. CHECK POWER SUPPLY TO SUB FAN RELAY. 1) Turn ignition switch to OFF. 2) Remove sub fan relay from A/C relay holder. 3) Measure voltage between sub fan relay terminal and chassis ground. Connector & terminal (F28) No. 23 (+) Chassis ground (): CHECK POWER SUPPLY TO SUB FAN RELAY. 1) Turn ignition switch to ON. 2) Measure voltage between sub fan relay terminal and chassis ground. Connector & terminal (F28) No. 21 (+) Chassis ground ():
Go to step 3.
Repair open circuit in harness between sub fan motor connector and chassis ground. Go to step 4.
Is there poor contact in sub Repair poor confan motor connector? tact in sub fan motor connector. Does the sub fan rotate? Repair poor contact in sub fan motor connector. Is the voltage more than 10 Go to step 6. V?
Replace sub fan motor with a new one. Go to step 7.
Go to step 9.
CO-12

No. 7 Step CHECK 20 A FUSE. 1) Remove 20 A fuse from A/C relay holder. 2) Check condition of fuse. CHECK POWER SUPPLY TO A/C RELAY HOLDER 20 A FUSE TERMINAL. Measure voltage of harness between A/C relay holder 20 A fuse terminal and chassis ground. Connector & terminal (F27) No. 3 (+) Chassis ground (): CHECK FUSE. 1) Turn ignition switch to OFF. 2) Remove fuse No. 17 from joint box. 3) Check condition of fuse. CHECK SUB FAN RELAY. 1) Turn ignition switch to OFF. 2) Measure resistance of sub fan relay. Terminal No. 23 No. 24: CHECK SUB FAN RELAY. 1) Connect battery to terminals No. 21 and No. 22 of sub fan relay. 2) Measure resistance of sub fan relay. Terminal No. 23 No. 24: CHECK HARNESS BETWEEN SUB FAN RELAY TERMINAL AND SUB FAN MOTOR CONNECTOR. Measure resistance of harness between sub fan motor connector and sub fan relay terminal. Connector & terminal (F16) No. 2 (F28) No. 24: CHECK HARNESS BETWEEN SUB FAN RELAY AND ECM. 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM. 3) Measure resistance of harness between sub fan relay connector and ECM connector. Connector & terminal (F28) No. 22 (B134) No. 12 (SOHC MODEL): (F28) No. 22 (B84) No. 10 (SOHC w/o OBD MODEL): (F28) No. 22 (B137) No. 28 (DOHC TURBO MODEL): CHECK POOR CONTACT. Check poor contact in connector between sub fan and ECM. Check Is the fuse blown-out? Yes Replace fuse.
Cooling
No Go to step 8.
Is the voltage more than 10 Repair open cirV? cuit in harness between 20 A fuse and sub fan relay terminal.
Repair open circuit in harness between main fuse box connector and 20 A fuse terminal. Repair open circuit in harness between sub fan relay and ignition switch. Replace sub fan relay.
Replace fuse.
10
11
Go to step 12.
Replace sub fan relay.
12
Go to step 13.
Repair open circuit in harness between sub fan motor and sub fan relay connector.
13
Go to step 14.
Repair open circuit in harness between sub fan relay and ECM.
14
Is there poor contact in Repair poor conconnector between sub fan tact connector. motor and ECM?
Contact your Subaru distributor.
NOTE: Inspection by your Subaru distributor is required, because probable cause is deterioration of multiple parts.
CO-13
Cooling
ENGINE COOLANT
S176060
4. Engine Coolant
A: REPLACEMENT
S176060A2001
2) Fill engine coolant into reservoir tank up to upper level.
S176060A20
1. DRAINING OF ENGINE COOLANT

1) Lift-up the vehicle. 2) Remove under cover. 3) Remove drain cock to drain engine coolant into container. NOTE: Remove radiator cap so that engine coolant will drain faster.
S2M0552A
3) Warm-up engine completely for more than five minutes at 2,000 to 3,000 rpm. 4) If engine coolant level drops in radiator, add engine coolant to filler neck position. 5) If engine coolant level drops from upper level of reservoir tank, add engine coolant to upper level. 6) Attach radiator cap and reservoir tank cap properly.
B: INSPECTION
EN0073
S176060A10
2. FILLING OF ENGINE COOLANT
S176060A2002
1) Fill engine coolant into radiator up to filler neck position. Coolant capacity (fill up to FULL level): Non-turbo AT model Approx. 6.4 (6.8 US qt, 5.6 Imp qt) Non-turbo MT model Approx. 6.3 (6.7 US qt, 5.5 Imp qt) Turbo model Approx. 7.2 (7.6 US qt, 6.3 Imp qt) CAUTION: The SUBARU Genuine Coolant containing antifreeze and anti-rust agents is especially made for SUBARU engine, which has an aluminum crankcase. Always use SUBARU Genuine Coolant, since other coolant may cause corrosion.
1. RELATIONSHIP OF SUBARU COOLANT CONCENTRATION AND FREEZING TEMPERATURE S176060A1001

The concentration and safe operating temperature of the SUBARU coolant is shown in the diagram. Measuring the temperature and specific gravity of the coolant will provide this information.
CO-14
ENGINE COOLANT
[Example] If the coolant temperature is 25C (77F) and its specific gravity is 1.054, the concentration is 35% (point A), the safe operating temperature is 14C (7F) (point B), and the freezing temperature is 20C (4F) (point C).
Cooling
[Example] Assume that the coolant concentration must be increased from 25% to 40%. Find point A, where the 25% line of coolant concentration intersects with the 40% curve of the necessary coolant concentration, and read the scale on the vertical axis of the graph at height A. The quantity of coolant to be drained is 2.1 liters (2.2 US qt, 1.8 Imp qt). Drain 2.1 liters (2.2 US qt, 1.8 Imp qt) of coolant from the cooling system and add 2.1 liters (2.2 US qt, 1.8 Imp qt) of the undiluted solution of SUBARU coolant. If a coolant concentration of 50% is needed, drain all the coolant and refill with the undiluted solution only.
B2M3128A
2. PROCEDURE TO ADJUST THE CONCENTRATION OF THE COOLANT

S176060A1002
To adjust the concentration of the coolant according to temperature, find the proper fluid concentration in the above diagram and replace the necessary amount of coolant with an undiluted solution of SUBARU genuine coolant (concentration 50%). The amount of coolant that should be replaced can be determined using the diagram.
B2M3129A
CO-15
Cooling
WATER PUMP
S176061
5. Water Pump
A: REMOVAL
8) Disconnect over flow hose.
S176061A18
1. NON-TURBO MODEL
S176061A1801
1) Disconnect ground cable from the battery.
S2M0930
9) Remove reservoir tank.
G6M0095
2) Lift-up the vehicle. 3) Remove under cover. 4) Drain engine coolant completely. <Ref. to CO-14, DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.> 5) Disconnect connectors from radiator main fan (A) and sub fan (B) motors.
S2M0931
S2M0893A
10) Remove radiator main fan and sub fan assemblies. <Ref. to CO-32, REMOVAL, Radiator Main Fan and Fan Motor.> and <Ref. to CO-34, REMOVAL, Radiator Sub Fan and Fan Motor.> 11) Remove V-belts. <Ref. to ME(SOHC)-42, REMOVAL, V-belt.> 12) Remove timing belt. <Ref. to ME(SOHC)-46, TIMING BELT, REMOVAL, Timing Belt Assembly.> 13) Remove automatic belt tension adjuster.
6) Disconnect radiator outlet hose and heater hose from water pump.
H2M2375
H2M1794
7) Lower the vehicle.
CO-16
WATER PUMP
14) Remove belt idler No. 2. 19) Remove water pump.
Cooling
S2M0024
B2M3894
15) Remove left-hand camshaft sprocket by using ST. ST 499207100 CAMSHAFT SPROCKET WRENCH
2. TURBO MODEL
S176061A1802
WARNING: The radiator is pressurized. Wait until engine cools down before working on the radiator. 1) Set the vehicle on the lift. 2) Disconnect ground cable from the battery.
B2M2039A
16) Remove left-hand belt cover No. 2.

G6M0095
B2M2040
3) Lift-up the vehicle. 4) Remove under cover. 5) Drain engine coolant completely. <Ref. to CO-14, DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.> 6) Disconnect connectors from radiator main fan and sub fan motors. 7) Remove bolt which installs water by-pass pipe of oil cooler onto oil pump.
S2M0027 H2M2380
18) Disconnect heater hose from water pump.
8) Disconnect radiator outlet hose (A) and heater hose (B) from water pump.
CO-17
Cooling
WATER PUMP
20) Remove left-hand camshaft sprockets by using ST. ST 499207400 CAMSHAFT SPROCKET WRENCH
9) Disconnect water by-pass hose (C) and oil cooler hose (D).
S2M1159A
10) Lower the vehicle. 11) Disconnect over flow hose. 12) Remove reservoir tank.
S2M1161A
21) Remove left-hand belt cover No. 2.
S2M0931
S2M1162
13) Remove radiator main fan and sub fan assemblies. <Ref. to CO-32, REMOVAL, Radiator Main Fan and Fan Motor.> and <Ref. to CO-34, REMOVAL, Radiator Sub Fan and Fan Motor.> 14) Remove V-belts. <Ref. to ME(DOHC TURBO)-44, REMOVAL, V-belt.> 15) Remove timing belt. <Ref. to ME(DOHC TURBO)-48, REMOVAL, Timing Belt Assembly.> 16) Remove automatic belt tension adjuster (A). 17) Remove belt idler (B). 18) Remove belt idler No. 2 (C).
S2M1163
23) Disconnect heater hose from water pump. 24) Remove water pump.
S2M1160A
19) Remove camshaft position sensor. <Ref. to FU(DOHC TURBO)-31, REMOVAL, Camshaft Position Sensor.>
S2M1829
CO-18
WATER PUMP B: INSTALLATION

S176061A11
Cooling
1. NON-TURBO MODEL
S176061A1101
1) Install water pump onto left-hand cylinder head. CAUTION: Replace gasket with a new one. When installing water pump, tighten bolts in two stages in alphabetical sequence as shown in figure. Tightening torque: First: 12 Nm (1.2 kgf-m, 8.7 ft-lb) Second: 12 Nm (1.2 kgf-m, 8.7 ft-lb)
4) Install left-hand camshaft sprockets by using ST. ST 4992707100 CAMSHAFT SPROCKET WRENCH Tightening torque: 78 Nm (8.0 kgf-m, 57.9 ft-lb)
B2M2039A
5) Install belt idler No. 2. Tightening torque: 39 Nm (4.0 kgf-m, 28.9 ft-lb)
S2M0760A
2) Install left-hand belt cover No. 2. Tightening torque: 5 Nm (0.5 kgf-m, 3.6 ft-lb)
S2M0024
B2M2040
3) Install tensioner bracket. Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
6) Install automatic belt tension adjuster which tension rod is holded with pin. <Ref. to ME(SOHC)47, AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER, INSTALLATION, Timing Belt Assembly.> 7) Install timing belt. <Ref. to ME(SOHC)-48, TIMING BELT, INSTALLATION, Timing Belt Assembly.> 8) Install V-belts. <Ref. to ME(SOHC)-42, INSTALLATION, V-belt.> 9) Install radiator main fan and sub fan motor assemblies. <Ref. to CO-32, INSTALLATION, Radiator Main Fan and Fan Motor.> and <Ref. to CO-34, INSTALLATION, Radiator Sub Fan and Fan Motor.>
H2M2380
CO-19
Cooling
WATER PUMP
10) Install reservoir tank.
S2M0931
G6M0095
11) Connect over flow hose.
18) Fill coolant. <Ref. to CO-14, FILLING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>
2. TURBO MODEL
S176061A1102
1) Install water pump onto left-hand cylinder head. CAUTION: Replace gasket with a new one. When installing water pump, tighten bolts in two stages in alphabetical sequence as shown in figure. Tightening torque: First: 12 Nm (1.2 kgf-m, 8.7 ft-lb) Second: 12 Nm (1.2 kgf-m, 8.7 ft-lb)
S2M0930
12) Lift-up the vehicle. 13) Connect radiator outlet hose and heater hose to water pump.
H2M1794
14) Connect connectors to radiator main fan (A) and sub fan (B) motors.
H2M1846C
2) Install left-hand belt cover No. 2. Tightening torque: 5 Nm (0.5 kgf-m, 3.6 ft-lb)
S2M0893A
15) Install under cover. 16) Lower the vehicle.
S2M1162
CO-20
WATER PUMP
3) Install tensioner bracket. Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft-lb) Tightening torque: 39.4 Nm (4.0 kgf-m, 28.9 ft-lb)
Cooling
S2M1160A S2M1163
4) Install left-hand camshaft sprockets by using ST. ST 499207400 CAMSHAFT SPROCKET WRENCH Tightening torque: 98 Nm (10.0 kgf-m, 72.4 ft-lb)
9) Install timing belt. <Ref. to ME(DOHC TURBO)50, TIMING BELT, INSTALLATION, Timing Belt Assembly.> 10) Install V-belts. <Ref. to ME(DOHC TURBO)44, INSTALLATION, V-belt.> 11) Install radiator main fan and sub fan motor assemblies. <Ref. to CO-32, INSTALLATION, Radiator Main Fan and Fan Motor.> and <Ref. to CO-34, INSTALLATION, Radiator Sub Fan and Fan Motor.> 12) Install reservoir tank.
S2M1161A
5) Install camshaft position sensor. <Ref. to FU(DOHC TURBO)-31, INSTALLATION, Camshaft Position Sensor.> 6) Install belt idler No. 2 (C). 7) Install belt idler (B). 8) Install automatic belt tension adjuster (A) which has a tension rod held by a pin. <Ref. to ME(DOHC TURBO)-49, AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER, INSTALLATION, Timing Belt Assembly.>
S2M0931
13) Connect over flow hose. 14) Lift-up the vehicle. 15) Connect radiator outlet hose (A) and heater hose (B) to water pump. 16) Connect water by-pass hose (C) and oil cooler hose (D).
S2M1159A
CO-21
Cooling
WATER PUMP
4) Check clearance between impeller and pump case. Clearance between impeller and pump case: Standard 0.5 0.7 mm (0.020 0.028 in) Limit 1.0 mm (0.039 in)
17) Install bolt which installs water by-pass pipe onto oil pump.
S2M0027
18) sub 19) 20) 21)
Connect connectors to radiator main fan and fan motors. Install under cover. Lower the vehicle. Connect battery ground cable.
G2M0212
5) After water pump installation, check pulley shaft for engine coolant leaks. If leaks are noted, replace water pump assembly.
G6M0095
C: INSPECTION
S176061A10
1) Check water pump bearing for smooth rotation. 2) Check water pump pulley for abnormalities. 3) Using a dial gauge, measure impeller runout in thrust direction while rotating the pulley. Thrust runout limit: 0.5 mm (0.020 in)
G2M0211
CO-22
THERMOSTAT
Cooling
6. Thermostat
A: REMOVAL
S176062
5) Remove thermostat cover and gasket, and pull out the thermostat.
S176062A18
1) Lift-up the vehicle. 2) Remove under cover. 3) Drain engine coolant completely. <Ref. to CO-14, DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>
G2M0214
B: INSTALLATION
S176062A11
1) Install the thermostat in the water pump, and install the thermostat cover together with a gasket.
EN0073
4) Disconnect radiator outlet hose from thermostat cover. Non-Turbo model
CAUTION: When reinstalling the thermostat, use a new gasket. The thermostat must be installed with the jiggle pin (A) facing to front side. At this time, set the jiggle pin of thermostat for front side. Tightening torque: 6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
EN0112
Turbo model
EN0100
C: INSPECTION
EN0107
S176062A10
Replace the thermostat if the valve does not close completely at an ambient temperature or if the following test shows unsatisfactory results. Immerse the thermostat and a thermometer in water. Raise water temperature gradually, and measure the temperature and valve lift when the valve begins to open and when the valve is fully opened. During the test, agitate the water for even temperature distribution. The measurement should be to the specification.
CO-23
Cooling
THERMOSTAT
Starts to open: 76 80C (169 176F) Fully opens: 91C (196F)
H2M2357A
(A) (B)
Thermometer Thermostat
CO-24
RADIATOR
Cooling
7. Radiator
A: REMOVAL
S176058
8) Remove V-belt covers.
S176058A18
1. NON-TURBO MODEL
S176058A1801
S2M0896
G6M0095
2) Lift-up the vehicle. 3) Drain engine coolant completely. <Ref. to CO-14, DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.> 4) Disconnect connectors of radiator main fan (A) and sub fan (B) motor.
S2M0930
S2M0893A
5) Disconnect radiator outlet hose (A) from thermostat cover. 6) Disconnect ATF cooler hoses (B) from radiator. (AT vehicles only)
S2M0934
11) Disconnect radiator inlet hose from radiator.
S2M2150A
S2M0897
CO-25
Cooling
RADIATOR
6) Disconnect connectors of radiator main fan (A) and sub fan motor (B).
12) Remove radiator upper brackets.
S2M1167
13) While slightly lifting radiator, slide it to left. 14) Lift radiator up and away from vehicle.
EN0077
2. TURBO MODEL
S176058A1802
WARNING: The radiator is pressurized. Wait until engine cools down before working on the radiator. 1) Set the vehicle on the lift. 2) Disconnect battery ground cable.
EN0078
7) Disconnect oil cooler hoses from oil cooler pipes. (if equipped)
G6M0095
3) Lift-up the vehicle. 4) Remove under cover. 5) Drain engine coolant completely. <Ref. to CO-14, DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>
S2M1743
8) Disconnect radiator outlet hose from thermostat cover.
EN0107
9) Lower the vehicle. 10) Disconnect over flow hose.
CO-26
RADIATOR
Cooling
S176058A11
B: INSTALLATION
1. NON-TURBO MODEL
S176058A1101
1) Attach radiator mounting cushions to pins on the lower side of radiator.
S2M0931
12) Remove V-belt covers.

S2M0944
2) Install radiator while fitting radiator pins to cushions. NOTE: Fit pins on lower side of radiator into cushions on body side.
S2M2235
13) Disconnect radiator inlet hose (A) and water tank hose (B) from radiator.
S2M0033
3) Install radiator brackets and tighten bolts. Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft-lb)
S2M1166A
S2M1167
S2M1167
15) While slightly lifting radiator, slide it to left. 16) Lift radiator up and away from vehicle.
CO-27
Cooling
RADIATOR
9) Connect connectors to radiator main fan motor (A) and sub fan motor (B).
4) Connect radiator inlet hose.
S2M0897
5) Install reservoir tank. Tightening torque: 4.9 Nm (0.50 kgf-m, 3.6 ft-lb) 10) Install under cover. 11) Lower the vehicle. 12) Install V-belt covers.
S2M0893A
S2M0934 S2M0896
6) Lift-up the vehicle. 7) Connect radiator outlet hose (A). 8) Connect ATF cooler hoses (B). (AT vehicles only)
G6M0095
S2M2150A
14) Fill coolant. <Ref. to CO-14, FILLING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.> 15) Check ATF level. <Ref. to AT-9, INSPECTION, Automatic Transmission Fluid.>
CO-28
RADIATOR
2. TURBO MODEL
S176058A1102
Cooling
4) Install reservoir tank. Tightening torque: 4.9 Nm (0.50 kgf-m, 3.6 ft-lb)
1) Attach radiator mounting cushions (A) to pins on the lower side of radiator under cover (B).
S2M1168B
S2M0934
2) Install radiator brackets and tighten bolts. Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft-lb)
5) Connect over flow hose. 6) Lift-up the vehicle. 7) Connect connectors to radiator main fan motor (A) and sub fan motor (B).
S2M1167 EN0077
3) Connect radiator inlet hose (A) and water tank hose (B).
EN0078 S2M1166A
8) Connect oil cooler hoses. (if equipped)
S2M1743
CO-29
Cooling
RADIATOR C: INSPECTION
S176058A10
9) Connect radiator outlet hose.
1) Remove radiator cap, top off radiator, and attach tester to radiator in place of cap. Non-Turbo model
EN0107
10) Install under cover. 11) Lower the vehicle. 12) Install V-belt covers. Turbo model
S2M2149
S2M2235
EN0116
2) Apply a pressure of 157 kPa (1.6 kg/cm2, 23 psi) to radiator to check if: (1) Engine coolant leaks at/around radiator. (2) Engine coolant leaks at/around hoses or connections. CAUTION: Engine should be off. Wipe engine coolant from check points in advance. Be careful to prevent engine coolant from spurting out when removing tester. Be careful also not to deform filler neck of radiator when installing or removing tester.
G6M0095
CO-30
RADIATOR CAP
Cooling
8. Radiator Cap
A: INSPECTION
S176064
S176064A10
1) Attach radiator cap to tester.
G2M0223
2) Increase pressure until tester gauge pointer stops. Radiator cap is functioning properly if it holds the service limit pressure for five to six seconds. Standard pressure: 93 123 kPa (0.95 1.25 kg/cm2, 14 18 psi) Service limit pressure: 83 kPa (0.85 kg/cm2, 12 psi) CAUTION: Be sure to remove foreign matter and rust from the cap in advance otherwise, results of pressure test will be incorrect.
CO-31
Cooling
RADIATOR MAIN FAN AND FAN MOTOR

9. Radiator Main Fan and Fan Motor

S176059
A: REMOVAL
S176059A18
S2M0931
G6M0095
10) Lift-up radiator main fan motor assembly. 11) While lifting up radiator main fan motor assembly, detach oil cooler hose attached to a clip under the radiator main fan shroud. (Oil cooler equipped vehicles only)
2) Lift-up the vehicle. 3) Remove under cover. 4) Disconnect connector of main fan motor. 5) Remove bolts which install radiator onto radiator cover. (Turbo model)
H2M3592
12) Remove radiator main fan motor assembly.
B: INSTALLATION
S2M1169
S176059A11
Install in the reverse order of removal. NOTE: When the main fan motor assembly cannot be installed as is, loosen the sub fan motor assembly securing bolts to install it. Tightening torque: 4.9 Nm (0.50 kgf-m, 3.6 ft-lb)
6) Lower the vehicle. 7) Remove V-belt cover.
S2M2235

S2M0933
CO-32
RADIATOR MAIN FAN AND FAN MOTOR

Cooling
3) Remove bolts which install fan motor onto shroud.
S2M0934
H2M3593
C: DISASSEMBLY
S176059A06
D: ASSEMBLY
S176059A02
1) Remove clip which holds motor connector onto shroud.
Assemble in the reverse order of disassembly. Tightening torque: 4.4 Nm (0.45 kgf-m, 3.3 ft-lb)
S2M0937
2) Remove nut which holds fan itself onto fan motor and shroud assembly.
H2M3593
S2M0936 S2M0936
CO-33
Cooling
RADIATOR SUB FAN AND FAN MOTOR C: DISASSEMBLY

S176074A06
10. Radiator Sub Fan and Fan Motor

S176074
A: REMOVAL
1) Remove clip which holds motor harness onto shroud.
S176074A18
S2M0937
G6M0095
2) Remove nut which holds fan itself onto fan motor and shroud assembly.
2) Lift-up the vehicle. 3) Remove under cover. 4) Disconnect connector of sub fan motor. 5) Lower the vehicle. 6) Remove bolts which hold sub fan shroud to radiator. 7) Remove radiator sub fan shroud through the under side of vehicle.
S2M0939
3) Remove bolts which install fan motor onto shroud.
S2M0935
B: INSTALLATION
S176074A11
H2M3593
S2M0935
CO-34
RADIATOR SUB FAN AND FAN MOTOR D: ASSEMBLY

S176074A02
Cooling
Assemble in the reverse order of disassembly. Tightening torque: 4.4 Nm (0.45 kgf-m, 3.3 ft-lb)
H2M3593
S2M0939
CO-35
Cooling
RESERVOIR TANK
S176075
11. Reservoir Tank

A: REMOVAL
S176075A18
1) Disconnect over flow hose from radiator filler neck position. 2) Remove bolts which install reservoir tank onto radiator main fan shroud. 3) Remove reservoir tank.
S2M0934
B: INSTALLATION
S176075A11
S2M0934
C: INSPECTION
S176075A10
Make sure the engine coolant level is between full and low.
CO-36
COOLANT FILLER TANK
Cooling
S176764A11
12. Coolant Filler Tank

A: REMOVAL
S176764A18
S176764
B: INSTALLATION
1) Install in the reverse order of removal. Tightening torque: T1: 19 Nm (1.9 kgf-m, 13.7 ft-lb) T2: 21 Nm (2.1 kgf-m, 15.2 ft-lb)
WARNING: The radiator is pressurized. Wait until engine cools down before working on the radiator. 1) Drain coolant about 3.0 (3.2 US qt, 2.6 lmp qt). <Ref. to CO-14, DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.> 2) Remove air cleaner upper cover and air intake boot. <Ref. to IN(DOHC TURBO)-7, REMOVAL, Air Cleaner.> 3) Remove air cleaner element. 4) Disconnect engine coolant hoses from coolant filler tank.
EN0125
5) Remove bolts and nut which install coolant filler tank. 6) Disconnect engine coolant hose which connects the under side of coolant filler tank. 7) Remove coolant filler tank.
EN0127
2) Fill engine coolant. <Ref. to CO-14, FILLING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>
EN0126
CO-37
Cooling
ENGINE COOLING SYSTEM TROUBLE IN GENERAL

S176078
13. Engine Cooling System Trouble in General

A: INSPECTION
Trouble
S176078A10
Possible cause a. Insufficient engine coolant b. Loose timing belt c. Oil on drive belt d. Malfunction of thermostat e. Malfunction of water pump f. Clogged engine coolant passage
g. Improper ignition timing
Over-heating
h. Clogged or leaking radiator i. Improper engine oil in engine coolant
j. Air/fuel mixture ratio too lean
k. Excessive back pressure in exhaust system l. Insufficient clearance between piston and cylinder m. Slipping clutch n. Dragging brake o. Improper transmission oil p. Defective thermostat q. Malfunction of electric fan Over-cooling a. Atmospheric temperature extremely low b. Defective thermostat a. Loosened or damaged connecting units on hoses b. Leakage from water pump c. Leakage from water pipe d. Leakage around cylinder head gasket e. Damaged or cracked cylinder head and crankcase f. Damaged or cracked thermostat case g. Leakage from radiator a. Defective drive belt b. Defective radiator fan c. Defective water pump bearing d. Defective water pump mechanical seal
Engine coolant leaks.
Corrective action Replenish engine coolant, inspect for leakage, and repair. Repair or replace timing belt tensioner. Replace. Replace. Replace. Clean. Inspect and repair ignition control system. <Ref. to EN(SOHC)-2, Basic Diagnostic Procedure.> or <Ref. to EN(SOHCw/oOBD)-2, Basic Diagnostic Procedure.> or <Ref. to EN(DOHC TURBO)-2, PROCEDURE, Basic Diagnostic Procedure.> Clean or repair, or replace. Replace engine coolant. Inspect and repair fuel injection system. <Ref. to EN(SOHC)-2, Basic Diagnostic Procedure.> or <Ref. to EN(SOHCw/oOBD)-2, Basic Diagnostic Procedure.> or <Ref. to EN(DOHC TURBO)-2, PROCEDURE, Basic Diagnostic Procedure.> Clean or replace. Adjust or replace. Repair or replace. Adjust. Replace. Replace. Inspect radiator fan relay, engine coolant temperature sensor or radiator motor and replace there. Partly cover radiator front area. Replace. Repair or replace. Replace. Repair or replace. Retighten cylinder head bolts or replace gasket. Repair or replace. Repair or replace. Repair or replace. Replace. Replace. Replace water pump. Replace water pump.
Noise
CO-38
LUBRICATION
LU
1. 2. 3. 4. 5. 6. 7. 8. 9. Page General Description.....................................................................................2 Oil Pressure System ...................................................................................7 Engine Oil..................................................................................................10 Oil Pump....................................................................................................12 Oil Pan and Strainer..................................................................................16 Oil Pressure Switch...................................................................................21 Engine Oil Cooler ......................................................................................22 Engine Oil Filter.........................................................................................24 Engine Lubrication System Trouble in General ........................................25
Lubrication
GENERAL DESCRIPTION
S178001
A: SPECIFICATIONS
Lubrication method Pump type
S178001E49
Inner rotor Outer rotor Non-Turbo model Outer rotor diameter thickness Turbo-model STANDARD Tip clearance between inner and outer rotor LIMIT Oil pump STANDARD Side clearance between inner rotor and pump case LIMIT STANDARD Case clearance between outer rotor and pump case LIMIT - pressure 700 rpm Discharge quantity Capacity at 80C (176F) - pressure 5,000 rpm Discharge - quantity Relief valve operation pressure Type Filtration area By-pass valve opening pressure Oil filter Outer diameter width Oil filter to engine thread size Relief valve (on rocker shaft) operation pressure Type Working voltage wattage Oil pressure switch Warning light activation pressure Proof pressure Non-Turbo model Oil capacity (at replacement) Turbo model Number of teeth
Forced lubrication Trochoid type 9 10 78 9 mm (3.07 0.35 in) 79 10 mm (3.11 0.39 in) 0.04 0.14 mm (0.0016 0.0055 in) 0.18 mm (0.0071 in) 0.02 0.07 mm (0.0008 0.0028 in) 0.12 mm (0.0047 in) 0.10 0.175 mm (0.0039 0.0069 in) 0.20 mm (0.0079 in) 98 kPa (1.0 kg/cm2, 14 psi) 4.2 (4.4 US qt, 3.7 Imp qt)/min. 294 kPa (3.0 kg/cm2, 43 psi) 42.0 (11.10 US gal, 9.24 Imp gal)/min. 490 kPa (5.0 kg/cm2, 71 psi) Full-flow filter type 1,000 cm2 (155 sq in) 157 kPa (1.6 kg/cm2, 23 psi) 80 70 mm (3.15 2.76 in) M 20 1.5 69 kPa (0.7kg/cm2, 10 psi) Immersed contact point type 12 V 3.4 W or less 14.7 kPa (0.15 kg/cm2, 2.1 psi) More than 981 kPa (10 kg/cm2, 142 psi) 4.0 (4.2 US qt, 3.5 Imp qt) 4.5 (4.8 US qt, 4.0 Imp qt)
LU-2

S178001A05
Lubrication
1. NON-TURBO MODEL
S178001A0501
B2M2235E
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12)
Plug Washer Relief valve spring Relief valve Oil seal Oil pump case Inner rotor Outer rotor Oil pump cover Oil filter O-ring Oil pump ASSY
(13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24)
Oil pressure switch Oil filler duct O-ring Oil filler cap O-ring Baffle plate O-ring Oil strainer Oil level gauge guide O-ring Oil pan Oil level gauge
(25) Drain plug (26) Metal gasket (27) Gasket

Tightening torque: Nm (kgf-m, ft-lb) T1: 5 (0.5, 3.6) T2: 5 (0.5, 3.6) T3: 6.4 (0.65, 4.7) T4: 10 (1.0, 7.2) T5: 44 (4.5, 33) T6: 25 (2.5, 18.1)
LU-3
Lubrication
GENERAL DESCRIPTION
S178001A0502
2. TURBO MODEL
S2M4233A
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14)
Plug Washer Relief valve spring Relief valve Oil seal Oil pump case Inner rotor Outer rotor Oil pump cover Oil filter Connector Water by-pass pipe Oil cooler O-ring
(15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28)
Oil pump ASSY Oil pressure switch Oil filler duct O-ring Cylinder head cover Baffle plate O-ring Oil strainer Gasket Oil level gauge guide Oil pan Oil level gauge Metal gasket Drain plug
(29) O-ring
Tightening torque: Nm (kgf-m, ft-lb) T1: 5 (0.5, 3.6) T2: 5 (0.5, 3.6) T3: 6.4 (0.65, 4.7) T4: 10 (1.0, 7.0) T5: 44 (4.5, 33) T6: 69 (7.0, 50.6) T7: 25 (2.5, 18.1) T8: 54 (5.5, 40)
LU-4

S178001A03
Lubrication
LU-5
Lubrication
GENERAL DESCRIPTION
S178001A17
D: PREPARATION TOOL
ILLUSTRATION
DESCRIPTION CRANK PULLEY WRENCH
REMARKS Used for stopping rotation of crankshaft pulley when loosening and tightening crankshaft pulley bolt.
B2M4157
498547000
OIL FILTER WRENCH
B2M3872
499587100
OIL SEAL INSTALLER
Used for installing oil pump oil seal.
B2M3875
LU-6
OIL PRESSURE SYSTEM
Lubrication
2. Oil Pressure System

A: SCHEMATIC
S178076A21
S178076
1. NON-TURBO MODEL
S178076A2101
S2M2141
LU-7
Lubrication
OIL PRESSURE SYSTEM

S178076A2102
2. TURBO MODEL
S2M2142
LU-8
OIL PRESSURE SYSTEM B: INSPECTION

No. 1
S178076A10
Lubrication
Step CHECK COMBINATION METER. 1) Turn ignition switch to ON. (engine OFF) 2) Check other warning lights.
Check Does the warning lights go on?
Yes Go to step 2.
CHECK HARNESS CONNECTOR BETWEEN COMBINATION METER AND OIL PRESSURE SWITCH. 1) Turn ignition switch to OFF. 2) Disconnect connector from the oil pressure switch. 3) Turn ignition switch to ON. 4) Measure the voltage of harness between the combination meter connector and chassis ground. Connector & terminal (E11) No. 1 Chassis ground: CHECK COMBINATION METER. 1) Turn ignition switch to OFF. 2) Remove the combination meter. 3) Measure the resistance of the combination meter. Terminal No. A2 No. B14:
Is the voltage more than 10 Replace oil presV? sure switch.
No Repair or replace the combination meter. <Ref. to IDI-7, INSPECTION, Combination Meter System, .> Go to step 3.
Replace the harness connector between combination meter and oil pressure switch.
Repair or replace the combination meter and the oil pressure switch warning light bulb.
LU-9
Lubrication
ENGINE OIL
S178077
3. Engine Oil
A: INSPECTION
2) Open engine oil filler cap for quick draining of the engine oil.
S178077A10
1) Park vehicle on a level surface. 2) Remove oil level gauge and wipe it clean. 3) Reinsert the level gauge all the way. Be sure that the level gauge is correctly inserted and in the proper orientation. 4) Remove it again and note the reading. If the engine oil level is below the L line, add oil to bring the level up to the F line. 5) After turning off the engine, wait a few minutes for the oil to drain back into the oil pan before checking the level. 6) Just after driving or while the engine is warm, engine oil level may show in the range between the F line and the notch mark. This is caused by thermal expansion of the engine oil. 7) To prevent overfilling the engine oil, do not add oil above the F line when the engine is cold.
B2M3883A
3) Replace drain plug gasket. 4) Tighten engine oil drain plug after draining engine oil. Tightening torque: 44 Nm (4.5 kgf-m, 33 ft-lb)
S2M2143 B2M3883A
B: REPLACEMENT
S178077A20
1) Drain engine oil by loosening engine oil drain plug.
5) Fill engine oil through filler pipe up to upper point on level gauge. Make sure that vehicle is placed level when checking oil level. Use engine oil of proper quality and viscosity, selected in accordance with the table in figure. Recommended oil API classification SJ or SH with the words Energy Conserving or Energy conserving II, CCMC specification G4 or G5, ACEA specification A1, A2 or A3, or New API mark displayed on the container (If it is impossible to get SJ or SH grade, you may use SG grade.) Engine oil capacity: (Non-Turbo model) Upper level 4.0 (4.2 US qt, 3.5 Imp qt) Lower level 3.0 (3.2 US qt, 2.6 Imp qt)
S2M2143
LU-10
ENGINE OIL
Engine oil capacity: (Turbo model) Upper level 4.5 (4.8 US qt, 4.0 Imp qt) Lower level 3.5 (3.7 US qt, 3.1 Imp qt)
Lubrication
B2M3885A
The proper viscosity helps vehicle get good cold and hot starting by reducing viscous friction and thus increasing cranking speed. CAUTION: When replenishing oil, it does not matter if the oil to be added is a different brand from that in the engine; however, use oil having the API classification and SAE viscosity No. designated by SUBARU. NOTE: If vehicle is used in desert areas with very high temperatures or for other heavy duty applications, the following viscosity oils may be used: API classification: SJ or SH SAE Viscosity No.: 30, 40, 10W-50, 20W-40, 20W50. 6) Close engine oil filler cap. 7) Start engine and warm it up for a time. 8) After engine stops, recheck the oil level. If necessary, add engine oil up to upper level on level gauge.
B2M3883A
LU-11
Lubrication
OIL PUMP
S178070
4. Oil Pump
A: REMOVAL
7) Remove crankshaft position sensor.
S178070A18
B2M1252
G6M0095
2) Lift-up the vehicle. 3) Remove under cover. 4) Remove bolts which install water pipe of oil cooler to oil pump. (Turbo model)
8) Remove V-belts. <Ref. to ME(SOHC)-42, REMOVAL, V-belt.> or <Ref. to ME(DOHC TURBO)-44, REMOVAL, V-belt.> 9) Remove rear side V-belt tensioner.
S2M0113
S2M0027
10) Remove crankshaft pulley by using ST. ST 499977300 CRANKSHAFT PULLEY WRENCH
5) Remove water pipe and hoses between oil cooler and water pump. (Turbo model)
S2M0114
S2M0112
11) Remove water pump. <Ref. to CO-16, REMOVAL, Water Pump.>
6) Remove radiator. <Ref. to CO-25, REMOVAL, Radiator.>
LU-12
OIL PUMP
12) Remove timing belt guide. (MT vehicles only)
Lubrication
S178070A11
B: INSTALLATION
Install in the reverse order of removal. Do the following: 1) Apply fluid packing to matching surfaces of oil pump. Fluid packing: THREE BOND 1215 or equivalent 2) Replace O-ring (A) with a new one.
S2M0115
13) Remove crankshaft sprocket.
S2M0739B
3) Apply a coat of engine oil to the inside of the oil seal.

S2M0116
14) Remove bolts which install oil pump onto cylinder block.
S2M0118B
S2M0117
4) Be careful not to scratch oil seal when installing oil pump on cylinder block. 5) Position the oil pump, aligning the notched area with the crankshaft, and push the oil pump straight. CAUTION: Make sure the oil seal lip is not folded. 6) Install oil pump. Tightening torque: 6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
15) Remove oil pump by using flat bladed screwdriver. CAUTION: Be careful not to scratch mating surfaces of cylinder block and oil pump.
S2M1819
S2M0740B
LU-13
Lubrication
OIL PUMP
S178070A06
C: DISASSEMBLY
D: ASSEMBLY
S178070A02
Remove screws which secure oil pump cover and disassemble oil pump. Inscribe alignment marks on inner and outer rotors so that they can be replaced in their original positions during reassembly. CAUTION: Before removing relief valve, loosen plug when removing oil pump from cylinder block.
1) Install front oil seal by using ST. ST 499587100 OIL SEAL INSTALLER CAUTION: Use a new oil seal.
S2M0235A
2) Apply a coat of engine oil to inner and outer rotors. 3) Install inner and outer rotors in their original positions. 4) Install oil relief valve and relief valve spring. 5) Install oil pump cover. Tightening torque: T1: 5 Nm (0.5 kgf-m, 3.6 ft-lb) T2: 44 Nm (4.5 kgf-m, 33 ft-lb)
S2M0735A
(A) (B) (C) (D) (E) (F) (G) (H) (I)
Oil seal Pump case Inner rotor Outer rotor Pump cover Relief valve Relief valve spring Plug Washer
S2M0735B
LU-14
OIL PUMP E: INSPECTION

S178070A10
Lubrication
S178070A1003
3. SIDE CLEARANCE
1. TIP CLEARANCE
S178070A1001
Measure the tip clearance of rotors. If the clearance exceeds the limit, replace rotors as a matched set. Tip clearance: Standard 0.04 0.14 mm (0.0016 0.0055 in) Limit 0.18 mm (0.0071 in)
Measure clearance between oil pump inner rotor and pump cover. If the clearance exceeds the limit, replace rotor or pump body. Side clearance: Standard 0.02 0.07 mm (0.0008 0.0028 in) Limit 0.12 mm (0.0047 in)
S2M0738
S2M0736
4. OIL RELIEF VALVE
S178070A1004
2. CASE CLEARANCE
S178070A1002
Measure the clearance between the outer rotor and the cylinder block rotor housing. If the clearance exceeds the limit, replace the rotor. Case clearance: Standard 0.10 0.175 mm (0.0039 0.0069 in) Limit 0.20 mm (0.0079 in)
Check the valve for fitting condition and damage, and the relief valve spring for damage and deterioration. Replace the parts if defective. Relief valve spring: Free length 71.8 mm (2.827 in) Installed length 54.7 mm (2.154 in) Load when installed 77.08 N (7.86 kgf, 17.33 lb)
5. OIL PUMP CASE
S178070A1005
Check the oil pump case for worn shaft hole, clogged oil passage, worn rotor chamber, cracks, and other faults.
6. OIL SEAL
S178070A1006
Check the oil seal lips for deformation, hardening, wear, etc. and replace if defective.
S2M0737
LU-15
Lubrication
OIL PAN AND STRAINER

S178071
5. Oil Pan and Strainer

A: REMOVAL
S178071A18
8) Remove pitching stopper.
1) Set the vehicle on lift arms. 2) Remove front wheels. 3) Disconnect battery ground cable.
S2M0126
G6M0095
4) Remove air intake duct and air cleaner case. (Non-Turbo model) <Ref. to IN(SOHC)-8, REMOVAL, Air Intake Duct.> and <Ref. to IN(SOHC)-7, REMOVAL, Air Cleaner Case.> 5) Disconnect connector from mass air flow sensor. (Turbo model)
S2M1167
EN0031
6) Remove air intake boot and air cleaner upper cover. (Turbo model) 11) Lift-up the vehicle. CAUTION: At this time, raise up wire ropes. 12) Remove under cover.
G2M0297
EN0032
7) Remove intercooler (Turbo model) <Ref. to IN(DOHC TURBO)-10, REMOVAL, Intercooler.>
LU-16

13) Drain engine oil. Set container under the vehicle, and remove drain plug from oil pan. Non-Turbo model Non-Turbo model
Lubrication
EN0040
Turbo model
EN0009
Turbo model
EN0041
18) Remove oil strainer.

EN0010
(A) (B)
Gasket Drain plug
14) Remove front and center exhaust pipes. (NonTurbo model) <Ref. to EX(SOHC)-5, REMOVAL, Front Exhaust Pipe.> or <Ref. to EX(SOHCw/ oOBD)-6, REMOVAL, Front Exhaust Pipe.> 15) Remove nuts which install front cushion rubber onto front crossmember. 19) Remove baffle plate.
S2M0238
S2M1831
16) Remove bolts which install oil pan on cylinder block while raising up engine. 17) Insert oil pan cutter blade between cylinder block-to-oil pan clearance. CAUTION: Do not use a screwdriver or similar tool in place of oil pan cutter.
S2M0309
LU-17
Lubrication

S178071A11
B: INSTALLATION
CAUTION: Before installing oil pan, clean sealant from oil pan and engine block. 1) Install baffle plate. Tightening torque: 6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
4) Tighten bolts which install oil pan onto engine block. Tightening torque: 5 Nm (0.5 kgf-m, 3.6 ft-lb) Non-Turbo model
EN0040
Turbo model
S2M0309
2) Install oil strainer onto baffle plate. CAUTION: Replace O-ring with a new one. Tightening torque: 10 Nm (1.0 kgf-m, 7 ft-lb)
EN0041
5) Lower engine onto front crossmember. 6) Tighten nuts which install front cushion rubber onto front crossmember. Tightening torque: 69 Nm (7.0 kgf-m, 51 ft-lb)
S2M0238
3) Apply fluid packing to mating surfaces and install oil pan. Fluid packing: THREE BOND 1215 or equivalent
S2M1831
S2M1833A
LU-18

7) Install front and center exhaust pipes. (NonTurbo model) <Ref. to EX(SOHC)-6, INSTALLATION, Front Exhaust Pipe.> or <Ref. to EX(SOHCw/oOBD)-7, INSTALLATION, Front Exhaust Pipe.> CAUTION: Always use the new gaskets. 12) Install radiator upper brackets.
Lubrication
S2M1167
B2M3200
8) Install under cover. 9) Lower the vehicle. CAUTION: At this time, lower lifting device and release steel cables. 10) Remove lifting device and steel cables.
13) Install air intake duct and air cleaner case. (Non-Turbo model) <Ref. to IN(SOHC)-7, INSTALLATION, Air Cleaner Case.> and <Ref. to IN(SOHC)-8, INSTALLATION, Air Intake Duct.> 14) Install intercooler. (Turbo model) <Ref. to IN(DOHC TURBO)-10, INSTALLATION, Intercooler.> 15) Install air intake boot and air cleaner upper cover. (Turbo model)
EN0032
G2M0297
16) Connect connector to mass air flow sensor. (Turbo model)
11) Install pitching stopper. Tightening torque: T1: 50 Nm (5.1 kgf-m, 37 ft-lb) T2: 58 Nm (5.9 kgf-m, 43 ft-lb)
EN0031
17) Install front wheels.
S2M0126D
LU-19
Lubrication
G6M0095
19) Fill engine oil. <Ref. to LU-10, INSPECTION, Engine Oil.>
C: INSPECTION
S178071A10
By visual check make sure oil pan, oil strainer, oil strainer stay and baffle plate are not damaged.
LU-20
OIL PRESSURE SWITCH
Lubrication
S178069A11
6. Oil Pressure Switch

A: REMOVAL
S178069A18
S178069
B: INSTALLATION
1) Remove generator from bracket. <Ref. to SC-12, REMOVAL, Generator.> 2) Disconnect terminal from oil pressure switch.
1) Apply fluid packing to oil pressure switch threads. Fluid packing: THREE BOND 1215 or equivalent
G2M0091
S2M0124B
3) Remove oil pressure switch.
2) Install oil pressure switch onto engine block. Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
S2M0119
S2M0119
3) Connect terminal of oil pressure switch.
G2M0091
4) Install generator on bracket. <Ref. to SC-13, INSTALLATION, Generator.>
C: INSPECTION
S178069A10
Make sure oil does not leak or seep from where the oil pressure switch is installed.
LU-21
Lubrication
ENGINE OIL COOLER

S178768
7. Engine Oil Cooler

A: REMOVAL
S178768A18
7) Remove connector and remove oil cooler.
1) Lift-up the vehicle. 2) Remove under cover. 3) Drain engine oil. Set container under the vehicle, and remove drain plug from oil pan.
EN0010
(A) (B)
Metal gasket Drain plug

S2M1835A
4) Drain coolant. 5) Remove water by-pass pipe between oil cooler and water pump.
(A) (B) (C)
O-ring Oil cooler Connector
S2M0112
6) Remove engine oil filter. <Ref. to LU-24, REMOVAL, Engine Oil Filter.>
LU-22
ENGINE OIL COOLER B: INSTALLATION

S178768A11
Lubrication
1) Install in the reverse order of removal. Tightening torque: T: 54 Nm (5.5 kgf-m, 39.8 ft-lb) CAUTION: Always use a new O-ring.
G2M0784
C: INSPECTION
S178768A10
1) Check that coolant passages are not clogged using air blow method. 2) Check mating surfaces of cylinder block, O-ring groove and oil filter for damage.
LU-23
Lubrication
ENGINE OIL FILTER

S178585
8. Engine Oil Filter

A: REMOVAL
S178585A18
1) Remove under cover. 2) Remove oil filter with ST. ST 498547000 OIL FILTER WRENCH Non-Turbo model
EN0055
Turbo model
EN0056
B: INSTALLATION
S178585A11
1) Get a new oil filter and apply a thin coat of engine oil to the seal rubber. 2) Install oil filter by turning it by hand, being careful not to damage seal rubber. 3) Tighten more (approximately 2/3 to 3/4 turn) after the seal rubber contacts the oil pump case. Do not tighten excessively, or oil may leak.
C: INSPECTION
S178585A10
1) After installing oil filter, run engine and make sure that no oil is leaking around seal rubber. NOTE: The filter element and filter case are permanently jointed; therefore, interior cleaning is not necessary. 2) Check the engine oil level. <Ref. to LU-10, INSPECTION, Engine Oil.>
LU-24
ENGINE LUBRICATION SYSTEM TROUBLE IN GENERAL
Lubrication
9. Engine Lubrication System Trouble in General

A: INSPECTION
Trouble 1) Oil pressure switch failure
S178100A10
S178100
Before performing diagnostics, make sure that the engine oil level is correct and no oil leakage exists.
Possible cause Cracked diaphragm or oil leakage within switch Broken spring or seized contacts Clogged oil filter Malfunction of oil by-pass valve of oil filter Malfunction of oil relief valve of oil pump Clogged oil passage Excessive tip clearance and side clearance of oil pump rotor and gear Clogged oil strainer or broken pipe Insufficient engine oil Broken pipe of oil strainer Stuck oil pump rotor Corrective action Replace. Replace. Replace. Clean or replace. Clean or replace. Clean. Replace. Clean or replace. Replenish. Replace. Replace. Replace. Replace. Repair. Repair. Repair. Check for the same possible causes as listed in 1.2).
1. Warning light remains 2) Low oil pressure on.
3) No oil pressure 1) 2) 3) 1) 2)
2. Warning light does not go on.
3. Warning light flickers momentarily.
Burn-out bulb Poor contact of switch contact points Disconnection of wiring Poor contact at terminals Defective wiring harness
3) Low oil pressure
LU-25
Lubrication
ENGINE LUBRICATION SYSTEM TROUBLE IN GENERAL
MEMO:
LU-26
SPEED CONTROL SYSTEMS
SP
1. 2. 3. Page General Description.....................................................................................2 Accelerator Pedal ........................................................................................5 Accelerator Control Cable .........................................................................12
Speed Control Systems
GENERAL DESCRIPTION
S177001
A: SPECIFICATION
Accelerator pedal Free play Stroke
S177001A05 S177001A22
At pedal pad At pedal pad
1 4 mm (0.04 0.16 in) 50 55 mm (1.97 2.17 in)
B: COMPONENT
1. LHD MODEL
S177001A0501
B2M4176A
(1) (2) (3) (4) (5) (6)
Accelerator bracket Stopper Bushing Clip Accelerator spring Accelerator pedal spring
(7) (8) (9) (10) (11) (12)
Accelerator Spring pin Accelerator Accelerator Accelerator Clip
pedal lever pedal stopper plate
(13) Kick-down switch (AT model)

SP-2
GENERAL DESCRIPTION
2. RHD MODEL
S177001A0502
S4M0321A
(1) (2) (3) (4) (5) (6) (7) (8)
Accelerator pedal Accelerator pedal spring Spring pin Accelerator pedal pad Stopper Bushing Kick-down switch Pedal bracket
(9) (10) (11) (12) (13) (14) (15) (16)
Clip Stop light switch Accelerator spring Brake pedal spring Brake spacer Brake pedal Spacer Clevis pin
(17) Brake pedal pad (18) Snap pin

SP-3
GENERAL DESCRIPTION
C: CAUTION
S177001A03
Wear work clothing, including a cap, protective goggles, and protective shoes during operation. Remove contamination, including dirt and corrosion, before removal, installation or disassembly. Keep the disassembled parts in order and protect them from dust and dirt. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly, and replacement. Be careful not to burn your hands, because each part in the vehicle is hot after running. Be sure to tighten fasteners including bolts and nuts to the specified torque. Place shop jacks or safety stands at the specified points. Before disconnecting electrical connectors of sensors or units, be sure to disconnect negative terminal from battery.
SP-4
ACCELERATOR PEDAL
2. Accelerator Pedal
A: REMOVAL
1. LHD MODEL
S177005A18 S177005A1801
S177005
SOHC model
1) Disconnect ground cable from battery. 2) Remove lock nut from accelerator cable bracket. 3) Separate accelerator cable from bracket. 4) Remove accelerator cable end from throttle cam. 5) Disconnect accelerator cable from throttle body. CAUTION: Be careful not to kink accelerator cable. SOHC model DOHC TURBO model
EN0920
EN0922
B4M2316A
DOHC TURBO model
(A) (B) (C) (D) (E)
Toe board Accelerator cable To accelerator pedal Brake booster Clip
7) Remove instrument panel lower cover from instrument panel, and connector. 8) Disconnect connector from kick-down switch. (AT model) 9) Remove brake and clutch pedal bracket. <Ref. to BR-54, REMOVAL, Brake Pedal.> 10) Disconnect accelerator cable from accelerator pedal lever.
EN0919
(A) (B) (C) (D)
Lock nut Accelerator cable bracket Accelerator cable Throttle cam
6) Remove clip inside engine compartment.
S4M0482A
(1)
Slot type screwdriver
SP-5
ACCELERATOR PEDAL
DOHC TURBO model
11) Working inside engine compartment, remove casing cap out of the toe board by turning it clockwise.
EN0919
G4M0335
12) Pull out the cable from the toe board hole. 13) Remove accelerator pedal connecting bolt from accelerator pedal bracket.
(A) (B) (C) (D)
Lock nut Accelerator cable bracket Accelerator cable Throttle cam
6) Remove clip inside engine compartment. SOHC model
G4M0321 EN0921
2. RHD MODEL
S177005A1802
1) Disconnect ground cable from battery. 2) Remove lock nut from accelerator cable bracket. 3) Separate accelerator cable from bracket. 4) Remove accelerator cable end from throttle cam. 5) Disconnect accelerator cable from throttle body. CAUTION: Be careful not to kink accelerator cable. SOHC model
DOHC TURBO model
EN0923
(A) (B) (C) (D) (E)
Toe board Accelerator cable To accelerator pedal Brake booster Clip
B4M2316A
7) Remove instrument panel lower cover from instrument panel, and connector. 8) Disconnect connector from kick-down switch. (AT model) 9) Remove clevis pin which secures brake pedal to brake booster operating rod. Also disconnect electrical connectors (for stop light switch, etc.).
SP-6
ACCELERATOR PEDAL
10) Disconnect accelerator cable from accelerator pedal lever.
13) Remove nuts and bolts which secure pedal bracket.
S4M0482A
(1)
11) Remove the casing cap out of the toe board by turning it clockwise.
B4M0157B
(1) (2)
B4M0156B
Accelerator pedal Brake pedal

S177005A11
B: INSTALLATION
(1) (2) (3)
Accelerator cable Toe board hole Casing cap
Install in the reverse order of removal. CAUTION: If cable clamp is damaged, replace it with a new one. Never fail to cover outer cable end with boot. Be careful not to kink accelerator cable. Always use new clevis pins. (RHD model only) Make sure that holder and casing cap are securely connected.
12) Pull out the cable from the toe board hole.
B4M0159B
(1) (2) (3) (4) (5)
Casing cap Accelerator cable Toe board Accelerator pedal bracket Holder
SP-7
ACCELERATOR PEDAL
S177005A06
C: DISASSEMBLY
1) Remove the clip, and then remove the accelerator pedal from the bracket. LHD model
2) Pull out the spring pin, and then remove the accelerator pedal from the accelerator pedal lever.
B2M4176B
(1) (2) (3) (4) (5)
Accelerator bracket Stopper Bushing Clip Accelerator spring
(6) (7) (8) (9) (10)
Accelerator Accelerator Spring pin Accelerator Accelerator
pedal spring pedal lever pedal stopper
(11) Accelerator plate (12) Clip (13) Kick-down switch (AT model)
SP-8
ACCELERATOR PEDAL
RHD model
S4M0321B
(1) (2) (3) (4) (5) (6)
Accelerator pedal Accelerator pedal spring Spring pin Accelerator pedal pad Stopper Bushing
(7) (8) (9) (10) (11) (12)
Kick-down switch Pedal bracket Clip Stop light switch Accelerator spring Brake pedal spring
(13) (14) (15) (16) (17) (18)
Brake spacer Brake pedal Spacer Clevis pin Brake pedal pad Snap pin
SP-9
ACCELERATOR PEDAL
S177005A02
D: ASSEMBLY
F: ADJUSTMENT
S177005A01
Assemble in the reverse order of disassembly. CAUTION: Clean and apply grease to spacer and inside bore of a accelerator pedal.
E: INSPECTION
1) Check pedal stroke and free play by operating accelerator pedal by hand. If it is not within specified value, adjust it by turning nut connecting accelerator cable to throttle body. Free play at pedal pad: L 1 4 mm (0.04 0.16 in) Stroke at pedal pad: A 50 55 mm (1.97 2.17 in)
S177005A10
1. ACCELERATOR PEDAL
S177005A1001
Lightly move pedal pad in lateral the direction to ensure pedal deflection is in specified range. CAUTION: If excessive deflection is noted, replace bushing and clip with new ones. Deflection of accelerator pedal: Service limit 5.0 mm (0.197 in) or less
G4M0333
2. KICK-DOWN SWITCH
S177005A1002
If kick-down switch does not operate properly (or if it does not stop at the specified position), replace with a new one. Specified position: A 2+1.5/0 mm (0.079
+0.059
B4M1739A
(A) (B)
Accelerator pedal Accelerator pedal bracket
/0 in)
Accelerator cable lock nut tightening torque: 14 Nm (1.4 kgf-m, 10.1 ft-lb)
B4M0155A
SP-10
ACCELERATOR PEDAL
2) Check to ensure the kick-down switch operates at the specified value in relation to the stroke of the accelerator pedal. If it is not in specified value, adjust it by adjusting position of kick-down switch. CAUTION: Be careful not to rotate kick-down switch. Kick-down switch stroke: A 481 mm (1.890.04 in) Kick-down switch tightening torque: 8 Nm (0.8 kgf-m, 5.8 ft-lb)
B4M1758A
SP-11
ACCELERATOR CONTROL CABLE

S177759
3. Accelerator Control Cable

A: REMOVAL
S177759A18
1) Remove accelerator pedal. <Ref. to SP-5, REMOVAL, Accelerator Pedal.> 2) Separate accelerator cable and accelerator pedal.
B: INSTALLATION
S177759A11
1) Install in the reverse order of removal. CAUTION: If cable clamp is damaged, replace it with a new one. Never fail to cover outer cable end with boot. Be careful not to kink accelerator cable. Do not apply grease to the throttle cable on the engine side. 2) Adjustment after pedal installation <Ref. to SP-7, INSTALLATION, Accelerator Pedal.>
C: INSPECTION
S177759A10
1) Make sure the inner cable is not twisted or frayed. 2) Make sure the outer cable is not cracked.
SP-12
IGNITION
IG(SOHC)
1. 2. 3. 4. Page General Description.....................................................................................2 Spark Plug...................................................................................................4 Ignition Coil and Ignitor Assembly...............................................................8 Spark Plug Cord........................................................................................10
Ignition
GENERAL DESCRIPTION
S151001
A: SPECIFICATIONS
S151001E49
Item Model Manufacturer Ignition coil Primary coil resistance and ignitor Secondary coil resistance assembly Insulation resistance between primary terminal and case Type and manufacturer Spark plug Thread size Spark gap mm mm (in) Alternate
Designation FH0137 DIAMOND 0.73 10% 12.8 k15% More than 10 M RC10YC4 .......... CHAMPION BKR5E-11 .......... NGK 14, P = 1.25 1.0 1.1 (0.039 0.043)
IG(SOHC)-2

S151001A05
Ignition
S6M0329B
(1) Spark plug (2) Spark plug cord (#1, #3) (3) Ignition coil and ignitor ASSY
(4) Spark plug cord (#2, #4)
Tightening torque: Nm (kgf-m, ft-lb) T1: 21 (2.1, 15) T2: 6.4 (0.65, 4.7)
C: CAUTION
S151001A03
Wear working clothing, including a cap, protective goggles, and protective shoes during operation. Remove contamination including dirt and corrosion before removal, installation or disassembly. Keep the disassembled parts in order and protect them from dust or dirt. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary
removal, installation, disassembly, and replacement. Be careful not to burn your hands, because each part on the vehicle is hot after running. Be sure to tighten fasteners including bolts and nuts to the specified torque. Place shop jacks or safety stands at the specified points. Before disconnecting electrical connectors of sensors or units, be sure to disconnect negative terminal from battery.
IG(SOHC)-3
Ignition
SPARK PLUG
S151003
2. Spark Plug
A: REMOVAL
(3) Remove air intake duct as a unit.
S151003A18
CAUTION: All spark plugs installed on an engine, must be of the same heat range. Spark plug: CHAMPION: RC10YC4 (Alternate) NGK: BKR5E-11
1. RH SIDE
S151003A1805
S6M0353
(4) Remove resonator chamber.
G6M0095
B2M2306
2) Remove air intake duct and resonator chamber. (1) Remove bolt which installs air intake duct on the front side of body.
3) Remove spark plug cords by pulling boot, not cord itself.
B2M4127 S6M0708
4) Remove spark plugs with the spark plug socket.
(2) Remove bolt which installs air intake duct on body.
B2M4286
B2M2284
IG(SOHC)-4
SPARK PLUG
2. LH SIDE
S151003A1806
Ignition
5) Remove spark plugs cord by pulling boot, not cord itself.
G6M0095
B2M4287
2) Disconnect washer motor connector.
6) Remove spark plug with the spark plugs socket.
S2M0546
B6M0926
3) Disconnect rear from washer motor, suitable cap. 4) Remove the two tank, then take the area.
window glass washer hose then plug connection with a bolts which hold the washer tank away from the working
B: INSTALLATION
1. RH SIDE
S151003A1105
S151003A11
Install in the reverse order of removal. Tightening torque (Spark plug): 20.6 Nm (2.10 kgf-m, 15.2 ft-lb) CAUTION: The above torque should be only applied to new spark plugs without oil on their threads. In case their threads are lubricated, the torque should be reduced by approximately 1/3 of the specified torque in order to avoid over-stressing. Tightening torque (Resonator chamber): 32 Nm (3.3 kgf-m, 24 ft-lb)
B2M2023
2. LH SIDE
S151003A1106
Install in the reverse order of removal. Tightening torque (Spark plug): 20.6 Nm (2.10 kgf-m, 15.2 ft-lb) CAUTION: The above torque should be only applied to new spark plugs without oil on their threads. In case their threads are lubricated, the torque should be reduced by approximately 1/3 of the specified torque in order to avoid over-stressing.
IG(SOHC)-5
Ignition
SPARK PLUG
S151003A10
C: INSPECTION
Check electrodes and inner and outer porcelain of plugs, noting the type of deposits and the degree of electrode erosion.
3) Oil fouled Wet black deposits show excessive oil entrance into combustion chamber through worn rings and pistons or excessive clearance between valve guides and stems. If same condition remains after repair, use a hotter plug.
S6M0420A
(A) (B) (C) (D) (E)
Electrode gap Carbon accumulation or wear Cracks Damage Damaged gasket
G6M0089
1) Normal Brown to grayish-tan deposits and slight electrode wear indicate correct spark plug heat range.
4) Overheating White or light gray insulator with black or gray brown spots and bluish burnt electrodes indicate engine overheating. Moreover, the appearance results from incorrect ignition timing, loose spark plugs, wrong selection of fuel, hotter range plug, etc. It is advisable to replace with plugs having colder heat range.
G6M0087
G6M0090
2) Carbon fouled Dry fluffy carbon deposits on insulator and electrode are mostly caused by slow speed driving in city, weak ignition, too rich fuel mixture, dirty air cleaner, etc. It is advisable to replace with plugs having hotter heat range.
D: CLEANING
S151003E56
Clean spark plugs in a sand blast type cleaner. Avoid excessive blasting. Clean and remove carbon or oxide deposits, but do not wear away porcelain. If deposits are too stubborn, replace plugs.
G6M0088
IG(SOHC)-6
SPARK PLUG E: ADJUSTMENT

S151003A01
Ignition
Correct it if the spark plug gap is measured with a gap gauge, and it is necessary. Spark plug gap: L 1.0 1.1 mm (0.039 0.043 in)
S6M0412A
NOTE: Replace with new spark plug if this area is worn to ball shape.
IG(SOHC)-7
Ignition
IGNITION COIL AND IGNITOR ASSEMBLY

3. Ignition Coil and Ignitor Assembly

S151015
A: REMOVAL
S151015A18
B6M0930
B: INSTALLATION
G6M0095
S151015A11
Install in the reverse order of removal. 2) Disconnect spark plug cords from ignition coil and ignitor assembly. Tightening torque: 6.4 Nm (0.65 kgf-m, 4.7 ft-lb) CAUTION: Be sure to connect wires to their proper positions. Failure to do so will damage unit.
S6M0373
B6M0930
B6M0932
IG(SOHC)-8
IGNITION COIL AND IGNITOR ASSEMBLY C: INSPECTION

S151015A10
Ignition
Using accurate tester, inspect the following items, and replace if defective. 1) Primary resistance 2) Secondary coil resistance CAUTION: If the resistance is extremely low, this indicates the presence of a short-circuit. Specified resistance: [Primary side] Between terminal No. 1 and No. 2 0.73 10% Between terminal No. 2 and No. 4 0.73 10%
B6M0931C
[Secondary side] Between (A) and (B) 12.8 k15% Between (C) and (D) 12.8 k15%
B6M0773G
3) Insulation between primary terminal and case: 10 M or more.
IG(SOHC)-9
Ignition
SPARK PLUG CORD

S151014
4. Spark Plug Cord

A: INSPECTION
S151014A10
Check for: 1) Damage to cords, deformation, burning or rust formation of terminals 2) Resistance values of cords Resistance value: #1 cord: 5.6 #2 cord: 7.3 #3 cord: 5.9 #4 cord: 7.3 10.6 13.7 11.1 13.7
S6M0337
IG(SOHC)-10
STARTING/CHARGING SYSTEMS
SC
1. 2. 3. 4. Page General Description.....................................................................................2 Starter..........................................................................................................5 Generator ..................................................................................................12 Battery .......................................................................................................18
Starting/Charging Systems
GENERAL DESCRIPTION
S179001
A: SPECIFICATIONS
Item
S179001E49
Starter
Type Vehicle type Model Manufacturer Voltage and output Direction of rotation Number of pinion teeth Voltage No-load characCurrent teristics Rotating speed Voltage Current Load characteristics Torque Rotating speed Voltage Lock characteris- Current tics Torque Type Model Manufacturer Voltage and output Polarity on ground side Rotating direction Armature connection Output current Regulated voltage
Designation Reduction type MT vehicles M000T83981 Mitsubishi Electric 12 V 1.0 kW 12 V 1.4 kW Counterclockwise (when observed from pinion) 8 9 11 V 90 A or less 2,800 rpm or more 2,400 rpm or more 7.5 V 7.7 V 300 A 400 A 8.6 Nm (0.88 kgf-m, 6.4 ft-lb) or 16.0 Nm (1.63 kgf-m, 11.8 ft-lb) or more more 920 rpm or more 740 rpm or more 4V 3.5 V 650 A or less 940 A or less 14.7 Nm (1.50 kgf-m, 10.8 ft-lb) or 28.9 Nm (2.95 kgf-m, 21.3 ft-lb) or more more Rotating-field three-phase type, Voltage regulator built-in type, with load response control system A2TB6291 Mitsubishi Electric 12 V 75 A Negative Clockwise (when observed from pulley side) 3-phase Y-type 1,500 rpm 30 A or more 2,500 rpm 64 A or more 5,000 rpm 76 A or more 14.1 14.8 V [20C (68F)] 12 V 48 AH 12 V 52 AH 12 V 40 AH 12 V 40 AH AT vehicles M001T86481
Generator
Battery
For Europe Type and capacFor Australia ity Others
SC-2

1. STARTER
S179001A0501 S179001A05
H6M0492C
(1) (2) (3) (4) (5) (6)
Sleeve bearing Front bracket Lever set Magnet switch ASSY Stopper set Over running clutch
(7) (8) (9) (10) (11) (12)
Internal gear ASSY Shaft ASSY Gear ASSY Ball Packing Yoke
(13) (14) (15) (16) (17)
Armature Brush holder Brush Sleeve bearing Rear bracket
SC-3
GENERAL DESCRIPTION
2. GENERATOR
S179001A0502
H6M0493C
(1) (2) (3) (4)
Pulley Front cover Ball bearing Bearing retainer

S179001A03
(5) (6) (7) (8)
Rotor Bearing Stator coil IC regulator with brush
(9) (10) (11) (12)
Brush Rectifier Rear cover Terminal
C: CAUTION
removal, installation, disassembly, and replacement. Be careful not to burn your hands, because each part in the vehicle is hot after running. Be sure to tighten fasteners including bolts and nuts to the specified torque. Place shop jacks or safety stands at the specified points. Before disconnecting electrical connectors of sensors or units, be sure to disconnect negative terminal from battery.
SC-4
STARTER
2. Starter
S179012
AT vehicles
A: REMOVAL
S179012A18
EN0370
5) Disconnect connector and terminal from starter.

G6M0095
2) Remove air cleaner case. (Non-Turbo Model)
S6M0002A
(A) (B)
B6M1221
Terminal Connector
6) Remove starter from transmission.
3) Remove intercooler. (Turbo Model) <Ref. to IN(DOHC TURBO) -10, REMOVAL, Intercooler.> 4) Remove air cleaner case stay. (Non-Turbo Model) MT vehicles
EN1007
EN0369
SC-5
STARTER
S179012A11
B: INSTALLATION
3) Remove both through-bolts and brush holder screws, and detach rear bracket and brush holder.
H6M0494B
EN1007
(A) (B)
Brush holder Rear bracket
C: DISASSEMBLY
S179012A06
4) Remove armature and yoke. Ball used as a bearing will then be removed from the end of armature. CAUTION: Be sure to mark an alignment mark on yoke and front bracket before removing yoke.
1. STARTER ASSEMBLY
S179012A0601
1) Loosen nut which holds terminal M of switch assembly, and disconnect connector. 2) Remove bolts which hold switch assembly, and remove switch assembly, plunger and plunger spring from starter as a unit. CAUTION: Be careful because pinion gap adjustment washer may sometimes be used on the mounting surface of switch assembly.
H6M0495B
(A) (B) (C) (D)
Front bracket Yoke Ball Awature
S6M0396A
(A) (B)
Switch ASSY Plunger
SC-6
STARTER
5) Remove packing A, three planetary gears, packing B and plate.
S6M0399A
S6M0397A
(A) (B) (C) (D)
Packing A Planetary gear Plate Packing B
(A) (B) (C) (D)
Stopper Tool Ring Shaft

S179012A0602
2. BRUSH HOLDER
6) Remove shaft assembly and overrunning clutch as a unit. CAUTION: Record the direction of lever before removing.
Slightly open the metal fitting holding the insulating plate to the brush holder. Remove the insulating plate. NOTE: The brush and spring can be easily removed from the brush holder at this time.
S6M0398A
(A) (B) (C)
Shaft ASSY Overrunning clutch Lever
H6M0497B
7) Remove overrunning clutch from shaft assembly as follows: (1) Remove stopper from ring by lightly tapping a fit tool placed on stopper. (2) Remove ring, stopper and clutch from shaft.
(A) (B) (C)
Brush holder Insulating plate Metal fitting

S179012A02
D: ASSEMBLY
Assembly is in the reverse order of disassembly procedures. Do the following: 1) Carefully assemble all parts in the order of assembly and occasionally inspect nothing has been overlooked. 2) Apply grease to the following parts during assembly. Front and rear bracket 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 planetary gears
SC-7
STARTER
4) Armature short-circuit test Check armature for short-circuit by placing it on growler tester. Hold a hacksaw blade against armature core while slowly rotating armature. A short-circuited armature will cause the blade to vibrate and to be attracted to core. If the hacksaw blade is attracted or vibrates, the armature, which is short-circuited, must be replaced or repaired.
3) After assembling parts correctly, make sure starter operates properly.
E: INSPECTION
1. ARMATURE
S179012A10
S179012A1001
1) Check commutator for any sign of burns of rough surfaces or stepped wear. If wear is of a minor nature, correct it by using sand paper. 2) Run-out test Check the commutator run-out and replace if it exceeds the limit. Commutator run-out: Standard 0.05 mm (0.0020 in) Service limit Less than 0.10 mm (0.0039 in)
S6M0402A
(A) (B)
Iron sheet Grower
S6M0400A
5) Armature ground test Using circuit tester, touch one probe to the commutator segment and the other to shaft. There should be no continuity. If there is a continuity, armature is grounded. Replace armature if it is grounded.
(A)
V-block
3) Depth of segment mold Check the depth of segment mold. Depth of segment mold: 0.5 mm (0.020 in)
G6M0041
2. YOKE
S179012A1002
Make sure pole is set in position.
3. OVERRUNNING CLUTCH
S6M0401A
S179012A1003
(A) (B) (C)
Depth of mold Segment Mold
Inspect teeth of pinion for wear and damage. Replace if it is damaged. Rotate pinion in direction of rotation (counterclockwise). It should rotate smoothly. But in opposite direction, it should be locked. CAUTION: Do not clean overrunning clutch with oil to prevent grease from flowing out.
SC-8
STARTER
4. BRUSH AND BRUSH HOLDER
S179012A1004
1) Brush length Measure the brush length and replace if it exceeds the service limit. Replace if abnormal wear or cracks are noticed. Brush length: Standard 12.3 mm (0.484 in) Service limit 7.0 mm (0.276 in)
Terminal / Specified resistance: S M / Less than 1 S Ground / Less than 1 M B / More than 1 M
S6M0403
6. SWITCH ASSEMBLY OPERATION

S179012A1006
H6M0496B
1) Connect terminal S of switch assembly to positive terminal of battery with a lead wire, and starter body to ground terminal of battery. Pinion should be forced endwise on shaft. CAUTION: With pinion forced endwise on shaft, starter motor can sometimes rotate because current flows, through pull-in coil, to motor. This is not a problem. 2) Disconnect connector from terminal M, and connect positive terminal of battery and terminal M using a lead wire and ground terminal to starter body. In this test set up, pinion should return to its original position even when it is pulled out with a screwdriver.
(A) (B)
Service limit line Brush
2) Brush movement Be sure brush moves smoothly inside brush holder. 3) Brush spring force Measure brush spring force with a spring scale. If it is less than the service limit, replace brush holder. Brush spring force: Standard 21.6 N (2.2 kgf, 4.9 lb) (when new) Service limit 5.9 N (0.6 kgf, 1.3 lb)
5. SWITCH ASSEMBLY
S179012A1005
Be sure there is continuity between terminals S and M, and between terminal S and ground. Use a circuit tester (set in ohm). Also check to be sure there is no continuity between terminal M and B.
S6M0393A
(A) (B)
Terminal S Terminal M
SC-9
STARTER
7. PINION GAP
S179012A1007
1) Measure pinion gap while the pinion is pulled out as shown in the figure. Pinion gap: 0.5 2.0 mm (0.020 0.079 in)
S6M0395A
(A) (B) (C)
Variable resistance Magnetic switch Starter body
S6M0394A
(A) (B) (C)
Pinion Gap Stopper
1) No-load test With switch on, adjust the variable resistance to obtain 11 V, take the ammeter reading and measure the starter speed. Compare these values with the specifications. No-load test (Standard): Voltage / Current 11 V / 90 A max. Rotating speed MT vehicles 2,800 rpm or more AT vehicles 2,400 rpm or more 2) Load test Apply the specified braking torque to starter. The condition is satisfactory if the current draw and starter speed are within specifications. Load test (Standard): Voltage / Load MT vehicles 7.5 V/8.6 Nm (0.88 kgf-m, 6.4 ft-lb) AT vehicles 7.7 V/16.0 Nm (1.63 kgf-m, 11.8 ft-lb) Current / Speed MT vehicles 300 A/920 rpm or more AT vehicles 400 A/740 rpm or more
If motor is running with the pinion forced endwise on the shaft, disconnect connector from terminal M of switch assembly and connect terminal M to ground terminal () of battery with a lead wire. Next, gently push pinion back with your fingertips and measure pinion gap. 2) If pinion gap is outside specified range, remove or add number of adjustment washers used on the mounting surface of switch assembly until correct pinion gap is obtained.
8. PERFORMANCE TEST
S179012A1008
The starter should be submitted to performance tests whenever it has been overhauled, to assure its satisfactory performance when installed on the engine. Three performance tests, no-load test, load test, and lock test, are presented here; however, if the load test and lock test cannot be performed, carry out at least the no-load test. For these performance tests, use the circuit shown in figure.
SC-10
STARTER
3) Lock test With starter stalled, or not rotating, measure the torque developed and current draw when the voltage is adjusted to the specified voltage. Lock test (Standard): Voltage / Current MT vehicles 4 V/650 A or less AT vehicles 3.5 V/940 A or less Torque MT vehicles 14.7 Nm (1.50 kgf-m, 10.8 ft-lb) or more AT vehicles 28.9 Nm (2.95 kgf-m, 21.3 ft-lb) or more
SC-11
GENERATOR
Non-Turbo Model
3. Generator
A: REMOVAL
S179008
S179008A18
S2M0896
Turbo Model
G6M0095
2) Disconnect connector and terminal from generator. Non-Turbo Model
S2M2235
S2M0941
Turbo Model
4) Remove front side V-belt. <Ref. to ME(SOHC) -42, FRONT SIDE, REMOVAL, V-belt.> or <Ref. to ME(DOHC TURBO) -44, FRONT SIDE, REMOVAL, V-belt.> 5) Remove bolts which install generator onto bracket.
S2M2234
S6M0352
3) Remove V-belt cover.
SC-12
GENERATOR B: INSTALLATION
S179008A11
3) Hold rotor with a vise and remove pulley nut.
Install in the reverse order of removal. CAUTION: Check and adjust V-belt tension. <Ref. to ME(SOHC) -43, INSPECTION, V-belt.> and <Ref. to ME(DOHC TURBO) -45, INSPECTION, V-belt.>
G6M0066
CAUTION: When holding rotor with vise, insert aluminum plates or wood pieces on the contact surfaces of the vise to prevent rotor from damage.
S6M0352
C: DISASSEMBLY
S179008A06
1) Heat the portion (A) of rear cover to 50C (122F) with heater drier.
H6M0498B
(A) (B) (C) (D)
Front bracket Pulley Nut Rotor
B6M0476B
4) Unsolder connection between rectifier and stator coil to remove stator coil. CAUTION: Finish the work rapidly (less than three seconds) because the rectifier cannot withstand heat very well.
2) Remove the four through bolts. Then insert the tip of a flat-head screwdriver into the gap between the stator core and front bracket. Pry then apart to disassemble.
G6M0065
G6M0068
SC-13
GENERATOR
CAUTION: Be sure to remove the wire after reassembly.
5) Remove screws which secure IC regulator to rear cover, and unsolder connection between IC regulator and rectifier to remove IC regulator.
S6M0411A G6M0069
6) Remove the brushes by unsoldering at the pigtails.
2) Heat the bearing box in the rear bracket [50 to 60C (122 to 140F)] and press the rear bearing into the rear bracket. CAUTION: Grease should not be applied for the rear bearing. Remove oil completely if it is found on the bearing box. 3) After reassembly, turn the pulley by hand to check that the rotor turns smoothly.
E: INSPECTION
1. DIODE
G6M0070
S179008A1001
S179008A10
7) Remove the nut and insulating bushing at terminal B, and remove rectifier.
CAUTION: Never use a megger tester (measuring use for high voltage) or any other similar measure for this test; otherwise, the diodes may be damaged. 1) Checking positive diode Check for continuity between the diode lead and the positive side heat sink. The positive diode is in good condition if continuity (1 or less) exists only in the direction from the diode lead to the heat sink.
S6M0405A
(A) (B) (C)
Ractifier Rear cover Nut

S179008A02
D: ASSEMBLY
To assemble, reverse order of disassembly. 1) Pulling up brush Before assembling, press the brush down into the brush holder with your finger and secure in that position by passing a [2 mm (0.08 in) dia. length 4 to 5 cm (1.6 to 2.0 in)] wire (A) through the hole shown in the figure.
S6M0406A
(A) (B)
Diode lead Heat sink (Positive side)
2) Checking negative diode Check for continuity between the negative side heat sink and diode lead. The negative diode is in good condition if continuity (1 or less) exists only in the direction from the heat sink to the diode lead.
SC-14
GENERATOR
4) Insulation test Check continuity between slip ring and rotor core or shaft. If continuity (1 or less) exists, the rotor coil is grounded, and so replace rotor assembly.
S6M0407A
(A) (B)
Diode lead Heat sink (Negative side)

S179008A1002
2. ROTOR
G6M0076
1) Slip ring surface Inspect slip rings for contamination or any roughness of the sliding surface. Repair slip ring surface using a lathe or sand paper. 2) Slip ring outer diameter Measure slip ring outer diameter. If slip ring is worn replace rotor assembly. Slip ring outer diameter: Standard 22.7 mm (0.894 in) Limit 22.1 mm (0.870 in) 3) Continuity test Check resistance between slip rings using circuit tester. If the resistance is not within specification, replace rotor assembly. Specified resistance: Approx. 2.7 3.2
5) Ball bearing (rear side) (1) Check rear ball bearing. Replace if it is noisy or if rotor does not turn smoothly. (2) The rear bearing can be removed by using common bearing puller.
G6M0077
3. STATOR
S179008A1003
1) Continuity test Inspect stator coil for continuity between each end of the lead wires. If there is no continuity (1 or more) between individual lead wires, the lead wire is broken, and so replace stator assembly.
G6M0075
G6M0078
SC-15
GENERATOR
2) Checking brush spring for proper pressure Using a spring pressure indicator, push the brush into the brush holder until its tip protrudes 2 mm (0.08 in). Then measure the pressure of the brush spring. If the pressure is less than 2.648 N (270 g, 9.52 oz), replace the brush spring with a new one. The new spring must have a pressure of 4.609 to 5.786 N (470 to 590 g, 16.58 to 20.81 oz).
2) Insulation test Inspect stator coil for continuity (1 or less) between stator core and each end of the lead wire. If there is continuity, the stator coil is grounded, and so replace stator assembly.
G6M0079
4. BRUSH
S179008A1004
G6M0143
1) Measure the length of each brush. If wear exceeds the service limit, replace the brush. Each brush has the service limit mark (A) on it. Brush length: Standard 18.5 mm (0.728 in) Service limit 5.0 mm (0.197 in)
5. BEARING (FRONT SIDE)
S179008A1005
1) Check front ball bearing. If resistance is felt while rotating, or if abnormal noise is heard, replace the ball bearing. 2) Replacing front bearing (1) Remove front bearing retainer. (2) Closely install a fit tool on the bearing inner race. Press the bearing down out of front bracket with a hand press or vise. A socket wrench can serve as the tool.
H6M0499B
S6M0409A
(A) (B)
Front bracket Socket wrench
(3) Set a new bearing and closely install a fit tool on the bearing outer race. Press the bearing down into place with a hand press or vise. A socket wrench can serve as the tool. (4) Install front bearing retainer.
SC-16
GENERATOR
S6M0410A
(A) (B) (C)
Bearing Socket wrench Front bracket
SC-17
BATTERY C: INSPECTION
S179011A10
4. Battery
S179011
A: REMOVAL
S179011A18
1) Disconnect the positive (+) terminal after disconnecting the negative () terminal of battery. 2) Remove flange nuts from battery rods and take off battery holder.
B6M1506
3) Remove battery.
B: INSTALLATION
S179011A11
Install in the reverse order of removal. Tightening torque: 3.4 Nm (0.35 kgf-m, 2.5 ft-lb) NOTE: Clean battery cable terminals and apply grease to retard the formation of corrosion. Connect the positive (+) terminal of battery and then the negative () terminal of the battery.
WARNING: Electrolyte has toxicity; be careful handling the fluid. Avoid contact with skin, eyes or clothing. Especially at contact with eyes, blush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gasses. Keep sparks, flame, cigarettes away. Ventilate when charging or using in enclosed space. For safety, in case an explosion does occur, wear eye protection or shield your eyes when working near any battery. Never lean over a battery. Do not let battery fluid contact eyes, skin, fabrics, or paint-work because battery fluid is corrosive acid. To lessen the risk of sparks, remove rings, metal watch-bands, and other metal jewelry. Never allow metal tools to contact the positive battery terminal and anything connected to it while you are at the same time in contact with any other metallic portion of the vehicle because a short circuit will be caused.
1. EXTERNAL PARTS:
S179011A1001
Check for the existence of dirt or cracks on the battery case, top cover, vent plugs, and terminal posts. If necessary, clean with water and wipe with a dry cloth. Apply a thin coat of grease on the terminal posts to prevent corrosion.
2. ELECTROLYTE LEVEL:
S179011A1002
Check the electrolyte level in each cell. If the level is below MIN LEVEL, bring the level to MAX LEVEL by pouring distilled water into the battery cell. Do not fill beyond MAX LEVEL.
3. SPECIFIC GRAVITY OF ELECTROLYTE: S179011A1003

1) Measure specific gravity of electrolyte using a hydrometer and a thermometer. Specific gravity varies with temperature of electrolyte so that it must be corrected at 20C (68F) using the following equation:
SC-18
BATTERY
S20 = St + 0.0007 (t 20) S20: Specific gravity corrected at electrolyte temperature of 20C St : Measured specific gravity t : Measured temperature (C) Determine whether or not battery must be charged, according to corrected specific gravity. Standard specific gravity: 1.220 1.290 [at 20C (68F)]
2. CHECK HYDROMETER FOR STATE OF CHARGE S179011A1402

Hydrometer indicator Green dot Dark dot Clear dot State of charge Above 65% Below 65% Low electrolyte Required action Load test Charge battery Replace battery* (If cranking complaint)
*: Check electrical system before replacement.
3. NORMAL CHARGING
S179011A1403
Charge the battery at current value specified by manufacturer or at approximately 1/10 of batterys ampere-hour rating.
4. QUICK CHARGING
S179011A1404
G6M0103
2) Measuring the specific gravity of the electrolyte in the battery will disclose the state of charge of the battery. The relation between the specific gravity and the state of charge is as shown in figure.
D: MEASUREMENT
S179011A14
WARNING: Do not bring an open flame close to the battery at this time. CAUTION: Prior to charging, corroded terminals should be cleaned with a brush and common baking soda solution. Be careful since battery electrolyte overflows while charging the battery. Observe instructions when handling battery charger. Before charging the battery on vehicle, disconnect battery ground terminal. Failure to follow this rule may damage alternator s diodes or other electrical units.
Quick charging is a method in which the battery is charged in a short period of time with a relatively large current by using a quick charger. Since a large current flow raises electrolyte temperature, the battery is subject to damage if the large current is used for prolonged time. For this reason, the quick charging must be carried out within a current range that will not increase the electrolyte temperature above 40C (104F). It should be also remembered that the quick charging is a temporary means to bring battery voltage up to a fair value and, as a rule, a battery should be charged slowly with a low current. CAUTION: Observe the items in 1. NORMAL CHARGING. Never use more than 10 amperes when charging the battery because that will shorten battery life.
1. JUDGMENT OF BATTERY IN CHARGED CONDITION S179011A1401

1) Specific gravity of electrolyte is held at a specific value in a range from 1.250 to 1.290 for more than one hour. 2) Voltage per battery cell is held at a specific value in a range from 2.5 to 2.8 volts for more than one hour.
SC-19
BATTERY
MEMO:
SC-20
ENGINE (DIAGNOSTICS)
EN(SOHC)
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. Page Basic Diagnostic Procedure ........................................................................2 Check List for Interview...............................................................................4 General Description.....................................................................................6 Electrical Components Location................................................................10 Engine Control Module (ECM) I/O Signal.................................................24 Engine Condition Data ..............................................................................27 Transmission Control Module (TCM) I/O Signal .......................................28 Data Link Connector .................................................................................31 OBD-II General Scan Tool ........................................................................32 Subaru Select Monitor...............................................................................34 Read Diagnostic Trouble Code .................................................................41 Inspection Mode ........................................................................................42 Clear Memory Mode..................................................................................45 Compulsory Valve Operation Check Mode...............................................46 Engine Malfunction Indicator Lamp (MIL) .................................................48 Diagnostics for Engine Starting Failure ....................................................59 List of Diagnostic Trouble Code (DTC).....................................................80 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ....................86 General Diagnostic Table ........................................................................294
Engine (Diagnostics)
BASIC DIAGNOSTIC PROCEDURE
1. Basic Diagnostic Procedure

S058501
A: PROCEDURE
1. ENGINE
No. 1
S058501E4501
S058501E45
Step Check Does the engine start? CHECK ENGINE START FAILURE. 1) Ask the customer when and how the trouble occurred using the interview check list. <Ref. to EN(SOHC)-4, CHECK, Check List for Interview.> 2) Start the engine.
CHECK ILLUMINATION OF CHECK ENGINE Does CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL). malfunction indicator lamp illuminate?
CHECK INDICATION OF DTC ON DISPLAY. Does the Subaru Select Monitor or OBD-II general 1) Turn ignition switch to OFF. scan tool indicate DTC? 2) Connect the Subaru Select Monitor or the OBD-II general scan tool to data link connector. 3) Turn ignition switch to ON and the Subaru Select Monitor or OBD-II general scan tool switch to ON. 4) Read DTC on the Subaru Select Monitor or OBD-II general scan tool.
PERFORM THE DIAGNOSIS. 1) Perform the clear memory mode. <Ref. to EN(SOHC)-45, Clear Memory Mode.> 2) Perform the inspection mode. <Ref. to EN(SOHC)-42, Inspection Mode.>
Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC?
No Inspection using Diagnostics for Engine Start Failure. <Ref. to EN(SOHC)-59, Diagnostics for Engine Starting Failure.> Go to step 3. Inspection using General Diagnostics Table. <Ref. to EN(SOHC)294, INSPECTION, General Diagnostic Table.> Record diagnostic Repair the related parts. trouble code. Repair the trouble NOTE: If DTC is not cause. <Ref. to shown on display EN(SOHC)-80, OPERATION, List although the MIL illuminates, perof Diagnostic form diagnostics Trouble Code of MIL (CHECK (DTC).> Go to ENGINE malfuncstep 4. tion indicator lamp) circuit or combination meter. <Ref. to EN(SOHC)-48, Engine Malfunction Indicator Lamp (MIL).> Complete the Inspect using Diagnostics Pro- diagnosis. cedure with Diagnostic Trouble Code (DTC). <Ref. to EN(SOHC)-86, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Yes Go to step 2.
EN(SOHC)-2

2. AUTOMATIC TRANSMISSION
S058501E4502
When trouble code about automatic transmission is shown on display, carry out the following basic check. After that, carry out the replacement or repair work. 1) ATF level check <Ref. to AT-9, Automatic Transmission Fluid.> 2) Differential gear oil level check <Ref. to AT-11, Differential Gear Oil.> 3) ATF leak check <Ref. to AT-9, Automatic Transmission Fluid.> 4) Differential gear oil leak check <Ref. to AT-11, Differential Gear Oil.> 5) Stall test <Ref. to AT-13, Stall Test.> 6) Line pressure test <Ref. to AT-16, Line Pressure Test.> 7) Transfer clutch pressure test <Ref. to AT-18, Transfer Clutch Pressure Test.> 8) Time lag test <Ref. to AT-15, Time Lag Test.> 9) Road test <Ref. to AT-12, Road Test.> 10) Shift characteristics <Ref. to AT-18, Transfer Clutch Pressure Test.>
EN(SOHC)-3
CHECK LIST FOR INTERVIEW

S058502
2. Check List for Interview

A: CHECK
Customer s name Date of sale Date of repair Vin no. Weather
S058502A04
Check the following items when problem has occurred. NOTE: Use copies of this page for interviewing customers.
Engine no. Fuel brand Odometer reading
1. CHECK LIST NO. 1
S058502A0401
km miles
Fine Cloudy Rainy Snowy Various/Others: C (F)
Outdoor temperature Hot Warm Cool Cold Highway Suburbs Inner city Uphill Downhill Rough road Others: Cold Warming-up After warming-up Any temperature Others:
Place
Engine temperature
Engine speed Vehicle speed Driving conditions
rpm MPH Not affected At starting While idling At racing While accelerating While cruising While decelerating While turning (RH/LH) ON/ OFF ON/ OFF ON/ OFF ON/ OFF ON/ OFF ON/ OFF
Headlight Blower A/C compressor Cooling fan Front wiper Rear wiper
Rear defogger Radio CD/Cassette Car phone CB
ON/ ON/ ON/ ON/ ON/
OFF OFF OFF OFF OFF
EN(SOHC)-4

2. CHECK LIST NO. 2
S058502A0402
Check the following items about the vehicles state when MIL turns on.
NOTE: Use copies of this page for interviewing customers.
a) Other warning lights or indicators turn on. Yes/ No Low fuel warning light Charge indicator light AT diagnostics indicator light ABS warning light VDC warning light Engine oil pressure warning light b) Fuel level Lack of gasoline: Yes/ No Indicator position of fuel gauge: c) Intentional connecting or disconnecting of harness connectors or spark plug cords: Yes/ No What: d) Intentional connecting or disconnecting of hoses: Yes/ No What: e) Installing of parts other than genuine parts: Yes/ No What: Where: f) Occurrence of noise: Yes/ No From where: What kind: g) Occurrence of smell: Yes/ No From where: What kind: h) Intrusion of water into engine compartment or passenger compartment: Yes/ No i) Troubles occurred Engine does not start. Engine stalls during idling. Engine stalls while driving. Engine speed decreases. Engine speed does not decrease. Rough idling Poor acceleration Back fire After fire No shift Excessive shift shock
EN(SOHC)-5
GENERAL DESCRIPTION
S058001
A: CAUTION
S058001A03
8) Use ECM mounting stud bolts at the body head grounding point when measuring voltage and resistance inside the passenger compartment.
1) Airbag system wiring harness is routed near the engine control module (ECM), main relay and fuel pump relay. CAUTION: All Airbag system wiring harness and connectors are colored yellow. Do not use electrical test equipment on these circuit. Be careful not to damage Airbag system wiring harness when servicing the engine control module (ECM), transmission control module (TCM), main relay and fuel pump relay. 2) Never connect the battery in reverse polarity. The ECM will be destroyed instantly. The fuel injector and other part will be damaged in just a few minutes more. 3) Do not disconnect the battery terminals while the engine is running. A large counter electromotive force will be generated in the alternator, and this voltage may damage electronic parts such as ECM, etc. 4) Before disconnecting the connectors of each sensor and the ECM, be sure to turn OFF the ignition switch. 5) Poor contact has been identified as a primary cause of this problem. To measure the voltage and/or resistance of individual sensors or all electrical control modules at the harness side connector, use a tapered pin with a diameter of less than 0.64 mm (0.025 in). Do not insert the pin more than 5 mm (0.20 in) into the part. 6) Before removing ECM from the located position, disconnect two cables on battery. Otherwise, the ECM may be damaged. CAUTION: When replacing ECM, be careful not to use the wrong spec. ECM to avoid any damage on fuel injection system. 7) The connectors to each sensor in the engine compartment and the harness connectors on the engine side and body side are all designed to be waterproof. However, it is still necessary to take care not to allow water to get into the connectors when washing the vehicle, or when servicing the vehicle on a rainy day.
H2M1154A
9) Use engine grounding terminal or engine proper as the grounding point to the body when measuring voltage and resistance in the engine compartment.
B2M2779
10) Use TCM mounting stud bolts at the body head grounding point when measuring voltage and resistance inside the passenger compartment.
B3M1666E
11) Every MFI-related part is a precision part. Do not drop them. 12) Observe the following cautions when installing a radio in MFI equipped models. CAUTION: The antenna must be kept as far apart as possible from the control unit. (The ECM is located under the steering column, inside of the instrument panel lower trim panel.)
EN(SOHC)-6
GENERAL DESCRIPTION
The antenna feeder must be placed as far apart as possible from the ECM and MFI harness. Carefully adjust the antenna for correct matching. When mounting a large power type radio, pay special attention to the three items above mentioned. Incorrect installation of the radio may affect the operation of the ECM. 13) Before disconnecting the fuel hose, disconnect the fuel pump connector and crank the engine for more than five seconds to release pressure in the fuel system. If engine starts during this operation, run it until it stops. 14) Problems in the electronic-controlled automatic transmission may be caused by failure of the engine, the electronic control system, the transmission proper, or by a combination of these. These three causes must be distinguished clearly when performing diagnostics. 15) Diagnostics should be conducted by rotating with simple, easy operations and proceeding to complicated, difficult operations. The most important thing in diagnostics is to understand the customer s complaint, and distinguish between the three causes. 16) In AT vehicles, do not continue the stall for more than five seconds at a time (from closed throttle, fully open throttle to stall engine speed). 17) On ABS vehicle, when performing driving test in jacked-up or lifted-up position, sometimes the warning light may be lit, but this is not a malfunction of the system. The reason for this is the speed difference between the front and rear wheels. After diagnosis of engine control system, perform the ABS memory clearance procedure of self-diagnosis system.
S058001A1002
2. ENGINE GROUNDING
Make sure the engine grounding terminal is properly connected to the engine.
B2M2779
C: NOTE
S058001A15
1. DESCRIPTION
S058001A1501
B: INSPECTION
S058001A10
Before performing diagnostics, check the following items which might affect engine problems:
1. BATTERY
S058001A1001
1) Measure battery voltage and specific gravity of electrolyte. Standard voltage: 12 V Specific gravity: Above 1.260 2) Check the condition of the main and other fuses, and harnesses and connectors. Also check for proper grounding.
The on-board diagnostics (OBD) system detects and indicates a fault in various inputs and outputs of the complex electronic control. CHECK ENGINE malfunction indicator lamp (MIL) in the combination meter indicates occurrence of a fault or trouble. Further, against such a failure or sensors as may disable the drive, the fail-safe function is provided to ensure the minimal driveability. The OBD system incorporated with the vehicles within this engine family complies with Section 1968.1, California Code of Regulations (OBD-II regulation). The OBD system monitors the components and the system malfunction listed in Engine Section which affects on emissions. When the system decides that a malfunction occurs, MIL illuminates. At the same time of the MIL illumination or blinking, a diagnostic trouble code (DTC) and a freeze frame engine conditions are stored into on-board computer. The OBD system stores freeze frame engine condition data (engine load, engine coolant temperature, fuel trim, engine speed and vehicle speed, etc.) into on-board computer when it detects a malfunction first. If the OBD system detects the various malfunctions including the fault of fuel trim or misfire, the OBD system first stores freeze frame engine conditions about the fuel trim or misfire. When the malfunction does not occur again for three consecutive driving cycles, MIL is turned off, but DTC remains at on-board computer. The OBD-II system is capable of communication with a general scan tool (OBD-II general scan tool) formed by ISO 9141 CARB. The OBD-II diagnostics procedure is different from the usual diagnostics procedure. When troubleshooting OBD-II vehicles, connect Subaru
EN(SOHC)-7
GENERAL DESCRIPTION
Reduced emission of harmful exhaust gases. Reduced in fuel consumption. Increased engine output. Superior acceleration and deceleration. Superior startability and warm-up performance in cold weather since compensation is made for coolant and intake air temperature.
Select Monitor or the OBD-II general scan tool to the vehicle.
2. ENGINE AND EMISSION CONTROL SYSTEM S058001A1502

The Multipoint Fuel Injection (MFI) system is a system that supplies the optimum air-fuel mixture to the engine for all the various operating conditions through the use of the latest electronic technology. With this system fuel, which is pressurized at a constant pressure, is injected into the intake air passage of the cylinder head. The injection quantity of fuel is controlled by an intermittent injection system where the electro-magnetic injection valve (fuel injector) opens only for a short period of time, depending on 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 simple, yet highly precise metering of the fuel. Further, all the operating conditions of the engine are converted into electric signals, and this results in additional features of the system, such as large improved adaptability, easier addition of compensating element, etc. The MFI system also has the following features:
3. AUTOMATIC TRANSMISSION AND ELECTRONIC-HYDRAULIC CONTROL SYSTEM S058001A1503

The electronic-hydraulic control system consists of various sensors and switches, a transmission control module (TCM) and the hydraulic controller including solenoid valves. The system controls the transmission proper including shift control, lock-up control, overrunning clutch control, line pressure control and shift timing control. It also controls the AWD transfer clutch. In other words, the system detects various operating conditions from various input signals and sends output signals to shift solenoids 1, 2 and low clutch timing solenoid and 2-4 brake timing solenoid, line pressure duty solenoid, lock-up duty solenoid, transfer duty solenoid and 2-4 brake duty solenoid (a total of eight solenoids).
D: PREPARATION TOOL
ILLUSTRATION
S058001A17
REMARKS Troubleshooting for electrical systems.
B2M3876
22771AA030
SELECT MONITOR KIT
B2M3877
EN(SOHC)-8
GENERAL DESCRIPTION
MEMO:
EN(SOHC)-9
ELECTRICAL COMPONENTS LOCATION
4. Electrical Components Location

S058507
A: LOCATION
1. ENGINE MODULE
S058507A13
S058507A1301
S2M2069A
S2M2070A
(1) Engine control module (ECM) (2) CHECK ENGINE malfunction indicator lamp (MIL)
(3) Test mode connector
(4) Data link connector (for Subaru Select Monitor and OBD-II general scan tool)
EN(SOHC)-10
B3M1575A
S2M2104C
S2M2240A
S2M2157D
EN(SOHC)-11
SENSOR
H2M3526A
(1) Atmospheric pressure sensor (2) Intake air temperature and pressure sensor
(3) Engine coolant temperature sensor (4) Throttle position sensor
(5) Knock sensor (6) Camshaft position sensor (7) Crankshaft position sensor
EN(SOHC)-12
B2M3713A
B2M3714A
S2M1248B
B2M2240A
B2M2241A
B2M2242A
B2M0213J
EN(SOHC)-13
S2M2222A
(1) Front oxygen (A/F) sensor (2) Rear oxygen sensor
(3) Front catalytic converter (4) Rear catalytic converter
S2M0264A
S2M0265A
OBD0524G
OBD0525G
EN(SOHC)-14
S2M2069B
S2M2070B
(1) Fuel level sensor
(2) Fuel sub level sensor
S2M2080A
S2M0270B
EN(SOHC)-15
SOLENOID VALVE, EMISSION CONTROL SYSTEM PARTS AND IGNITION SYSTEM PARTS
H2M3526B
(1) Air assist injector solenoid valve (2) Idle air control solenoid valve
(3) Purge control solenoid valve (4) Ignition coil & ignitor ASSY
EN(SOHC)-16
B2M3715A
H2M3259A
H2M3258B
B2M3720A
EN(SOHC)-17
S2M2069C
S2M2070C
(1) Inhibitor switch (2) Fuel pump (3) Main relay
(4) Fuel pump relay (5) Radiator main fan relay (6) Radiator sub fan relay
(7) Starter
EN(SOHC)-18
B2M2246A
S2M1184A
S2M0278A
S2M0279A
B2M2247E
EN(SOHC)-19

S058507A1302
2. TRANSMISSION MODULE
S2M2069D
S2M2070D
(1) Transmission Control Module (TCM) (for AT vehicles)
(2) AT diagnostic indicator light (for AT vehicles)
EN(SOHC)-20
B3M1666G
B3M1652B
S2M2104B
EN(SOHC)-21
SENSOR
B2M2258A
B2M2259A
B2M2260A
B2M2261A
OBD0653B
(1) Rear vehicle speed sensor (for AT vehicles) (2) Front vehicle speed sensor (for MT vehicles) (3) Front vehicle speed sensor (for AT vehicles) (4) Torque converter turbine speed sensor (5) ATF temperature sensor (for AT vehicles) (6) Brake light switch
EN(SOHC)-22

SOLENOID VALVE AND SWITCH (AT VEHICLES)
B2M2246F
B2M2263K
B2M2264F
(1) (2) (3) (4) (5) (6) (7) (8) (9)
Inhibitor switch Shift solenoid valve 1 Shift solenoid valve 2 Line pressure duty solenoid Lock-up duty solenoid Transfer duty solenoid 2-4 brake duty solenoid Low clutch timing solenoid valve 2-4 brake timing solenoid valve
SOLENOID VALVE AND SWITCH (MT VEHICLES)
B2M2265A
(1) Neutral position switch
EN(SOHC)-23
ENGINE CONTROL MODULE (ECM) I/O SIGNAL

S058526
5. Engine Control Module (ECM) I/O Signal

A: ELECTRICAL SPECIFICATION
S058526A08
B2M2267A
Content Crankshaft Signal (+) Signal () position sensor Shield Signal (+) Camshaft Signal () position sensor Shield Signal Power supply GND (sensor) Signal Rear oxy- Shield gen sensor GND (sensor) Front oxySignal 1 gen (A/F) sensor Signal 2 heater Rear oxygen sensor heater signal Engine Signal coolant GND (sentemperature sensor sor) Vehicle speed signal Starter switch Throttle position sensor
Connector No. B135 B135 B135 B135 B135 B135 B136 B136 B136 B136 B136 B136 B134 B134 B134 B136 B136 B135 B135
Terminal No. 2 9 10 1 8 10 17 15 16 18 24 16 22 23 21 14 16 24 28
Signal (V) Ignition SW ON Engine ON (Idling) (Engine OFF) 0 7 +7 0 0 0 0 0 7 +7 0 0 0 0 Fully closed: 0.2 1.0 Fully opened: 4.2 4.7 5 0 0 0 0 0 1.0 0 1.0 0 1.0 1.0 1.4 0 0 or 5 0 5 0 0 0.9 0 0 0 1.0 0 1.0 0 1.0 1.0 1.4 0 0 or 5 0
Note Sensor output waveform Sensor output waveform After warm-up the engine. After warm-up the engine. 5 and 0 are repeatedly displayed when vehicle is driven. Cranking: 8 14
EN(SOHC)-24

Connector No. B135 B135 MT B135 Terminal No. 27 7 26 Signal (V) Ignition SW ON Engine ON (Idling) (Engine OFF) ON: 10 13 ON: 13 14 OFF: 0 OFF: 0 10 13 13 14 ON: 120.5 OFF: 0 ON: 0 OFF: 120.5 5 2.8 0 10 13 10 13 10 13 5 0 0 0 10 13 10 13 10 13 10 13 10 13 ON: 0.5, or less OFF: 10 13 ON: 0.5, or less OFF: 10 13 ON: 0.5, or less OFF: 10 13 ON: 0.5, or less OFF: 10 13 5 5 8 ON: 1, or less OFF: 10 13 3.9 4.1 5 0 0.12 4.75 5 2.8 0 13 14 13 14 13 14 5 0 1 3.4 1 3.4 1 14 1 14 1 14 1 14 1 13 1 13 1 13 1 13 13 14 0.5, or less ON: 0.5, or less OFF: 13 14 ON: 0.5, or less OFF: 13 14 ON: 0.5, or less OFF: 13 14 0 13, or more 5 5 8 ON: 1, or less OFF: 13 14 2.0 2.3 5 0 0.12 4.75
Content
Note
A/C switch Ignition switch Neutral position switch
On MT vehicle; Switch is ON when gear is in neutral position. ON AT vehicle; Switch is ON when shift is in N or P position. When connected: 0 Ignition switch OFF: 10 13 Waveform Waveform Waveform Waveform Waveform Waveform Waveform Waveform Waveform Waveform With A/C vehicles only Light ON: 1, or less Light OFF: 10 14 Waveform
AT
B135 B135 B136 B136 B136 B136 B136 B136 B135 B134 B134 B134 B134 B134 B134 B134 B134 B134 B134 B136 B134 B134 B134 B134 B134 B134 B135 B135 B134 B134 B136 B136 B136 B136
26 20 4 25 9 1 2 15 14 25 26 4 13 14 15 5 6 19 20 2 29 17 3 12 11 30 16 17 31 2 29 15 16 27
Test mode connector Knock sen- Signal sor Shield Back-up power supply Control unit power supply Sensor power supply Line end check 1 #1, #2 Ignition control #3, #4 #1 Fuel injec- #2 tor #3 #4 Signal 1 Signal 2 Idle air Signal 3 control solenoid Signal 4 valve Power supply Fuel pump relay control A/C relay control Radiator fan relay 1 control Radiator fan relay 2 control Malfunction indicator lamp Engine speed output Torque control 1 signal Torque control 2 signal Torque control cut signal Purge control solenoid valve Signal AtmoPower supspheric ply pressure GND (sensensor sor) Fuel level sensor
EN(SOHC)-25

Connector No. B135 B136 B136 B135 B136 B136 B136 B136 B136 B136 B135 B136 B134 B134 B134 B136 B136 B134 B134 Terminal No. 4 3 30 21 19 6 7 20 5 13 3 16 7 27 8 21 22 35 34 Signal (V) Ignition SW ON Engine ON (Idling) (Engine OFF) Less than 1 More Less than 1 More than 4 than 4 ON: 0 ON: 0 OFF: 10 13 OFF: 13 14 ON: 0 ON: 0 OFF: 10 13 OFF: 13 14 ON: 0 ON: 0 OFF: 10 13 OFF: 13 14 2.8 3.2 2.4 2.7 0.2 4.9 0.2 4.9 2.4 4.8 2.3 2.5 Less than 1 More than 4 0 0 0 0 0 0 0 0 2.8 3.2 2.4 2.7 0.2 4.9 0.2 4.9 0.4 1.8 1.4 1.6 Less than 1 More than 4 0 0 0 0 0 0 0 0
Content AT diagnosis input signal Small light switch Blower fan switch Rear defogger switch Front oxygen (A/F) sensor signal 1 Front oxygen (A/F) sensor signal 2 Front oxygen (A/F) sensor signal 3 Front oxygen (A/F) sensor signal 4 Pressure sensor Intake air temperature sensor SSM/GST communication line GND (sensors) GND (injectors) GND (ignition system) GND (power supply) GND (control systems) GND (oxygen sensor heater 1) GND (oxygen sensor heater 2)
Note
Waveform
EN(SOHC)-26
ENGINE CONDITION DATA
6. Engine Condition Data

S058530A08
S058530
Content Engine load Specified data 1.6 2.9 (%): Idling 6.4 12.8 (%): 2,500 rpm racing
Measuring condition: After warm-up the engine. Gear position is in N or P position. A/C is turned OFF. All accessory switches are turned OFF.
EN(SOHC)-27
TRANSMISSION CONTROL MODULE (TCM) I/O SIGNAL

S058506
7. Transmission Control Module (TCM) I/O Signal

S058506A08
S2M2131
Content Back-up power supply Ignition power supply
Connector No. B56 B54 B54 B55
P range switch
N range switch
B55
R range switch Inhibitor switch D range switch 3 range switch 2 range switch 1 range switch Brake switch ABS signal
B55
B55
B55
B55
B55
B55 B55
Check with ignition switch ON. Terminal Measuring conditions No. 1 Ignition switch OFF 23 Ignition switch ON (with engine OFF) 24 Select lever in P range Select lever in any other 1 than P range (except N range) Select lever in N range Select lever in any other 14 than N range (except P range) Select lever in R range 3 Select lever in any other than R range Select lever in D range 4 Select lever in any other than D range Select lever in 3 range 5 Select lever in any other than 3 range Select lever in 2 range 6 Select lever in any other than 2 range Select lever in 1 range 7 Select lever in any other than 1 range Brake pedal depressed. 12 Brake pedal released. ABS switch ON 21 ABS switch OFF
Voltage (V) 10 16 10 16 Less than 1 More than 8 Less than 1 More than 8 Less than 1 More than 9.5 Less than 1 More than 9.5 Less than 1 More than 9.5 Less than 1 More than 9.5 Less than 1 More than 9.5 More than 10.5 Less than 1 Less than 1 6.5 15
Resistance to body (ohms)
EN(SOHC)-28

Check with ignition switch ON. Terminal Measuring conditions No. Hold switch ON 16 Hold switch OFF Power switch ON 23 Power switch OFF Throttle fully opened. 11 Throttle fully closed. Light ON 11 Light OFF Light ON 10 Light OFF Throttle fully closed. 3 Throttle fully open. Ignition switch ON (With 2 engine OFF) ATF temperature 20C (68F) 11 ATF temperature 80C (176F) Vehicle stopped. 24 Vehicle speed at least 20 km/h (12 MPH) Vehicle speed at least 20 18 km/h (12 MPH) Engine idling after warm-up. (D range) 8 Engine idling after warm-up. (N range) Vehicle speed at most 10 17 km/h (6 MPH) Ignition switch ON (with engine OFF) 17 Ignition switch ON (with engine ON) When cruise control is set (SET lamp ON) 22 When cruise control is not set (SET lamp OFF) Ignition switch ON (with 5 engine ON) Ignition switch ON (with 14 engine ON) 10 Ignition switch ON 1 22 5 Engine idling after warm-up. 1st or 4th gear 2nd or 3rd gear 1st or 2nd gear 3rd or 4th gear
Content Hold switch Power switch Kick-down switch POWER indicator light AT OIL TEMP indicator light Throttle position sensor Throttle position sensor power supply ATF temperature sensor
Connector No. B55 B55 B55 B56 B56 B54 B54
Voltage (V) Less than 1 More than 8 Less than 1 More than 10 Less than 1 More than 6.5 Less than 1 More than 9 Less than 1 More than 9 0.3 0.7 4.0 4.6 4.8 5.3 1.6 2.0 0.4 0.9 0 More than 1 (AC range) More than 1 (AC range) 0
Resistance to body (ohms) 2.1 2.9 k 275 375 450 650 450 650
B54
Rear vehicle speed sensor Front vehicle speed sensor Torque converter turbine speed sensor Vehicle speed output signal
B55 B55
B55
450 650 More than 1 (AC range) Less than 1 More than 4 More than 10.5 8 11 Less than 1 More than 6.5 4 4 8 1.2 1.8 More than 9 Less than 1 More than 9 Less than 1 10 16 10 16
B56
Engine speed signal
B55
Cruise set signal
B55
Torque control signal 1 Torque control signal 2 Torque control cut signal Intake manifold pressure signal Shift solenoid 1 Shift solenoid 2
B56 B56 B55 B54 B54 B54
EN(SOHC)-29

Check with ignition switch ON. Terminal Measuring conditions No. Ignition switch ON (with engine OFF) Throttle fully closed after warm-up. 9 Ignition switch ON (with engine OFF) Throttle fully open after warm-up. When lock up occurs. 7 When lock up is released. Fuse on FWD switch Fuse removed from FWD 6 switch (with throttle fully open and with select lever in 1st gear). Ignition switch ON (with engine OFF) Throttle fully closed after warm-up. 18 Ignition switch ON (with engine OFF) Throttle fully open after warm-up. 1st gear 16 3rd gear 2nd gear 15 4th gear 20 9 10 19 19 20 Fuse removed. 20 Fuse installed. Fuse ON FWD switch 2 Fuse removed from FWD switch 15 6
Content
Connector No.
Voltage (V)
1.5 4.0 2.0 4.5 Less than 0.5 More than 8.5 Less than 0.5 More than 8.5 Less than 0.5
Line pressure duty solenoid
B54
Lock-up duty solenoid
B54
10 17
Transfer duty solenoid
B54
10 17
1.5 4.0 2.0 4.5 Less than 0.5 Less than 1 More than 9 Less than 1 More than 9 0 0 0 0 0 6 9.1 Less than 1 Less than 1 More than 9
2-4 brake duty solenoid
B54
2-4 brake timing solenoid Low clutch timing solenoid Sensor Sensor Sensor Sensor ground ground ground ground line line line line 1 2 3 4
B54 B54 B54 B55 B54 B54 B56 B54 B55
10 16 10 16 Less Less Less Less than than than than 1 1 1 1
System ground line FWD switch
Less than 1
FWD indicator light Data link signal (Subaru Select Monitor)
B56
B56
EN(SOHC)-30
DATA LINK CONNECTOR
8. Data Link Connector

A: NOTE
S058505A15
S058505
1) This connector is used both for OBD-II general scan tools and the Subaru Select Monitor. 2) Terminal No. 4 to No. 6 of the data link connector is used for the Subaru Select Monitor signal. CAUTION: Do not connect any scan tools other than the OBD-II general scan tools and the Subaru Select Monitor, because the circuit for the Subaru Select Monitor may be damaged.
H2M1280
Terminal No. 1 2 3 4 5 6 7 8
Contents Power supply Blank Blank Subaru Select Monitor signal (ECM to Subaru Select Monitor)* Subaru Select Monitor signal (Subaru Select Monitor to ECM)* Line end check signal 1 Blank Blank
Terminal No. 9 10 11 12 13 14 15 16
Contents Blank K line of ISO 9141 CARB Blank Ground Ground Blank Blank Blank
*: Circuit only for Subaru Select Monitor
EN(SOHC)-31
OBD-II GENERAL SCAN TOOL

S058527
9. OBD-II General Scan Tool

A: OPERATION
S058527A16
1. HOW TO USE OBD-II GENERAL SCAN TOOL S058527A1601

1) Prepare a general scan tool (OBD-II general scan tool) required by SAE J1978. 2) Connect the OBD-II general scan tool to the data link connector (A) located in the lower portion of the instrument panel (on the driver s side).
3) Using the OBD-II general scan tool, call up diagnostic trouble code(s) and freeze frame data. OBD-II general scan tool functions consist of: (1) MODE $01: Current powertrain diagnostic data (2) MODE $02: Powertrain freeze frame data (3) MODE $03: Emission-related powertrain diagnostic trouble codes (4) MODE $04: Clear/Reset emission-related diagnostic information Read out data according to repair procedures. (For detailed operation procedures, refer to the OBD-II General Scan Tool Operation Manual.) NOTE: For details concerning diagnostic trouble codes, refer to the List of Diagnostic Trouble Code (DTC). <Ref. to EN(SOHC)-80, List of Diagnostic Trouble Code (DTC).>
S2M2157B
2. MODE $01 (CURRENT POWERTRAIN DIAGNOSTIC DATA)
S058527A1602
Refers to data denoting the current operating condition of analog input/output, digital input/output and/or the powertrain system. A list of the support data and PID (Parameter Identification) codes are shown in the following table.
PID 01 03 04 05 06 07 0B 0C 0D 0E 0F 10 11 13 15 24 1C Data Number of emission-related powertrain trouble codes and MIL status Fuel system control status Calculated engine load value Engine coolant temperature Short term fuel trim Long term fuel trim Intake manifold absolute pressure Engine revolution Vehicle speed Ignition timing advance Intake air temperature Air flow rate from pressure sensor Throttle valve opening angle Check whether oxygen sensor is installed. Oxygen sensor output voltage and short term fuel trim associated with oxygen sensorbank 2 A/F sensor 1 output voltage and short term fuel trim associated with A/F sensor 1 On-board diagnosis system Unit of measure ON/OFF % C % % kPa rpm km/h C g/sec % V and % V and %
NOTE: Refer to OBD-II general scan tool manufacturer s instruction manual to access generic OBD-II PIDs (MODE $01).
EN(SOHC)-32

3. MODE $02 (POWERTRAIN FREEZE FRAME DATA)
S058527A1603
Refers to data denoting the operating condition when trouble is sensed by the on-board diagnosis system. A list of the support data and PID (Parameter Identification) codes are shown in the following table.
PID 02 03 04 05 06 07 0B 0C 0D Data Trouble code that caused CARB required freeze frame data storage Fuel system control status Calculated engine load value Engine coolant temperature Short term fuel trim Long term fuel trim Intake manifold absolute pressure Engine revolution Vehicle speed Unit of measure % C % % kPa rpm km/h
NOTE: Refer to OBD-II general scan tool manufacturer s instruction manual to access freeze frame data (MODE $02).
4. MODE $03 (EMISSION-RELATED POWERTRAIN DIAGNOSTIC TROUBLE CODE)
S058527A1604
Refer to Read Diagnostic Trouble Code for information about data denoting emission-related powertrain diagnostic trouble codes. <Ref. to EN(SOHC)-41, Read Diagnostic Trouble Code.>
5. MODE $04 (CLEAR/RESET EMISSION-RELATED DIAGNOSTIC INFORMATION)
S058527A1605
Refers to the mode used to clear or reset emission-related diagnostic information (OBD-II trouble diagnostic information). NOTE: Refer to OBD-II general scan tool manufacturer s instruction manual to clear or reset emission-related diagnostic information (MODE $04).
EN(SOHC)-33
SUBARU SELECT MONITOR

S058503
10. Subaru Select Monitor

A: OPERATION
S058503A16
CAUTION: Do not connect scan tools except for Subaru Select Monitor and OBD-II general scan tool. 5) Turn ignition switch to ON (engine OFF) and Subaru Select Monitor switch to ON.
1. HOW TO USE SUBARU SELECT MONITOR S058503A1601

1) Prepare Subaru Select Monitor kit. <Ref. to EN(SOHC)-8, PREPARATION TOOL, General Description.>
S2M0288A
S2M0285
6) Using Subaru Select Monitor, call up diagnostic trouble code(s) and various data, then record them.
2) Connect diagnosis cable to Subaru Select Monitor. 3) Insert cartridge into Subaru Select Monitor. <Ref. to EN(SOHC)-8, PREPARATION TOOL, General Description.>
2. READ DIAGNOSTIC TROUBLE CODE (DTC) FOR ENGINE. (NORMAL MODE)

S058503A1602
Refer to Read Diagnostic Trouble Code for information about how to indicate DTC. <Ref. to EN(SOHC)-41, Read Diagnostic Trouble Code.>
3. READ DIAGNOSTIC TROUBLE CODE (DTC) FOR ENGINE. (OBD MODE) S058503A1603
Refer to Read Diagnostic Trouble Code for information about how to indicate DTC. <Ref. to EN(SOHC)-41, Read Diagnostic Trouble Code.>
S2M0286A
4) Connect Subaru Select Monitor to data link connector. (1) Data link connector (A) located in the lower portion of the instrument panel (on the driver s side).
S2M2157B
(2) Connect diagnosis cable to data link connector.
EN(SOHC)-34

4. READ CURRENT DATA FOR ENGINE. (NORMAL MODE)
S058503A1604
1) On the Main Menu display screen, select the {Each System Check} and press the [YES] key. 2) On the System Selection Menu display screen, select the {Engine Control System} and press the [YES] key. 3) Press the [YES] key after displayed the information of engine type. 4) On the Engine Diagnosis display screen, select the {Current Data Display & Save} and press the [YES] key. 5) On the Data Display Menu display screen, select the {Data Display} and press the [YES] key. 6) Using the scroll key, move the display screen up or down until the desired data is shown. A list of the support data is shown in the following table.
Contents Battery voltage Vehicle speed signal Engine speed signal Engine coolant temperature signal Ignition timing signal Throttle position signal Throttle position signal Injection pulse width Idle air control signal Engine load data Front oxygen (A/F) sensor output signal Rear oxygen sensor output signal Short term fuel trim Knock sensor signal Atmospheric absolute pressure signal Intake manifold relative pressure signal Intake manifold absolute pressure signal A/F correction (short term fuel trim) by rear oxygen sensor Long term whole fuel trim Front oxygen (A/F) sensor heater current Rear oxygen sensor heater current Canister purge control solenoid valve duty ratio Fuel level signal Intake air temperature signal Learned ignition timing Ignition switch signal Test mode connector signal Neutral position switch signal Air conditioning switch signal Air conditioning signal Radiator main fan relay signal Fuel pump relay signal Knocking signal Radiator sub fan relay signal Power steering switch signal Engine torque control signal #1 Engine torque control signal #2 Engine torque control permission signal Rear oxygen sensor rich signal Display Battery Voltage Vehicle Speed Engine Speed Coolant Temp. Ignition Timing Throttle Opening Angle Throttle Sensor Voltage Fuel Injection #1 Pulse ISC Valve Step Engine Load A/F Sensor #1 Rear O2 Sensor A/F Correction #1 Knocking Correction Atmosphere Pressure Mani. Relative Pressure Mani. Absolute Pressure A/F Correction #3 A/F Learning #1 Front O2 Heater #1 Rear O2 Heater Current CPC Valve Duty Ratio Fuel Level Intake Air Temp. Learned Ignition Timing Ignition Switch Test Mode Signal Neutral Position Switch A/C Switch A/C Compressor Signal Radiator Fan Relay #1 Fuel Pump Relay Knocking Signal Radiator Fan Relay #2 P/S Switch Torque Control Signal #1 Torque Control Signal #2 Torque Permission Signal Rear O2 Rich Signal Unit of measure V km/h or MPH rpm C or F deg % V ms STEP % V % deg mmHg or kPa or inHg or psi mmHg or kPa or inHg or psi mmHg or kPa or inHg or psi % % A A % V C or F deg ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF
EN(SOHC)-35
Contents Starter switch signal Idle switch signal Crankshaft position sensor signal Camshaft position sensor signal Rear defogger switch signal Blower fan switch signal Small light switch signal Air assist injector solenoid valve signal AT vehicle ID signal

Display Starter Switch Signal Idle Switch Signal Crankshaft Position Sig. Camshaft Position Sig. Rear Defogger Switch Blower Fan Switch Light Switch Assist Air Sol. Valve AT Vehicle ID Signal Unit of measure ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF
NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.
EN(SOHC)-36

5. READ CURRENT DATA FOR ENGINE. (OBD MODE)
S058503A1605
1) On the Main Menu display screen, select the {Each System Check} and press the [YES] key. 2) On the System Selection Menu display screen, select the {Engine Control System} and press the [YES] key. 3) Press the [YES] key after displayed the information of engine type. 4) On the Engine Diagnosis display screen, select the {OBD System} and press the [YES] key. 5) On the OBD Menu display screen, select the {Current Data Display & Save} and press the [YES] key. 6) On the Data Display Menu display screen, select the {Data Display} and press the [YES] key. 7) Using the scroll key, move the display screen up or down until the desired data is shown. A list of the support data is shown in the following table.
Contents Number of diagnosis code Malfunction indicator lamp status Monitoring test of misfire Monitoring test of fuel system Monitoring test of comprehensive component Test of catalyst Test of heated catalyst Test of evaporative emission purge control system Test of secondary air system Test of air conditioning system refrigerant Test of oxygen sensor Test of oxygen sensor heater Test of EGR system Air fuel ratio control system for bank 1 Engine load data Engine coolant temperature signal Short term fuel trim by front oxygen (A/F) sensor Long term fuel trim by front oxygen (A/F) sensor Intake manifold absolute pressure signal Engine speed signal Vehicle speed signal Ignition timing advance for #1 cylinder Intake air temperature signal Intake air amount Throttle position signal A/F sensor equipment Rear oxygen sensor output signal Air fuel ratio correction by rear oxygen sensor On-board diagnostic system Display Number of Diagnosis Code MI (MIL) Misfire monitoring Fuel system monitoring Component monitoring Catalyst Diagnosis Heated catalyst Evaporative purge system Secondary air system A/C system refrigerant Oxygen sensor O2 Heater Diagnosis EGR system Fuel System for Bank 1 Calculated load value Coolant Temp. Short term fuel trim B1 Long term fuel trim B1 Mani. Absolute Pressure Engine Speed Vehicle Speed Ignition timing adv. #1 Intake Air Temp. Mass Air Flow Throttle Opening Angle A/F sensor Oxygen Sensor #12 Short term fuel trim #12 OBD System Unit of measure Complete or incomplete Complete or incomplete Complete or incomplete Complete or incomplete No support No support No support No support No support Complete or incomplete Complete or incomplete No support % C or F % % mmHg or kPa or inHg or psi rpm km/h or MPH C or F g/s % ON or OFF V %
EN(SOHC)-37

S058503A1606
6. READ FREEZE FRAME DATA FOR ENGINE. (OBD MODE)
1) On the Main Menu display screen, select the {Each System Check} and press the [YES] key. 2) On the System Selection Menu display screen, select the {Engine Control System} and press the [YES] key. 3) Press the [YES] key after displayed the information of engine type. 4) On the Engine Diagnosis display screen, select the {OBD System} and press the [YES] key. 5) On the OBD Menu display screen, select the {Freeze Frame Data} and press the [YES] key. A list of the support data is shown in the following table.
Contents Diagnostic trouble code (DTC) for freeze frame data Air fuel ratio control system for bank 1 Engine load data Engine coolant temperature signal Short term fuel trim by front oxygen (A/F) sensor Long term fuel trim by front oxygen (A/F) sensor Intake manifold absolute pressure signal Engine speed signal Vehicle speed signal Display Freeze frame data Fuel system for Bank1 Engine Load Coolant Temp. Short term fuel trim B1 Long term fuel trim B1 Mani. Absolute Pressure Engine Speed Vehicle Speed Unit of measure DTC ON or OFF % C or F % % mmHg or kPa or inHg or psi rpm km/h or MPH
7. READ OXYGEN SENSOR MONITORING TEST RESULTS DATA FOR ENGINE. (OBD MODE) S058503A1607
1) On the Main Menu display screen, select the {Each System Check} and press the [YES] key. 2) On the System Selection Menu display screen, select the {Engine Control System} and press the [YES] key. 3) Press the [YES] key after displayed the information of engine type. 4) On the Engine Diagnosis display screen, select the {OBD System} and press the [YES] key. 5) On the OBD Menu display screen, select the {O2 Sensor Monitor} and press the [YES] key. 6) On the O2 Sensor Select display screen, select the {Bank 1-Sensor1} or {Bank 1-Sensor2} and press the [YES] key. Bank 1-Sensor1 indicates the front oxygen or A/F sensor, and Bank 1-Sensor2 indicates the rear oxygen sensor. A list of the support data is shown in the following table.
Contents Oxygen sensor for monitoring test Rich to lean oxygen sensor threshold voltage Lean to rich oxygen sensor threshold voltage Low oxygen sensor voltage for switch time calculation High oxygen sensor voltage for switch time calculation Rich to lean oxygen sensor switch time Lean to rich oxygen sensor switch time Maximum oxygen sensor voltage for test cycle Minimum oxygen sensor voltage for test cycle Display <O2 Sensor Monitor (-------)> Rich to lean sensor volt Lean to rich sensor volt Low sensor voltage High sensor voltage Rich to lean switch time Lean to rich switch time Maximum sensor Voltage Minimum sensor Voltage Unit of measure V V V V sec sec V V
EN(SOHC)-38

8. LED OPERATION MODE FOR ENGINE
S058503A1608
1) On the Main Menu display screen, select the {Each System Check} and press the [YES] key. 2) On the System Selection Menu display screen, select the {Engine Control System} and press the [YES] key. 3) Press the [YES] key after displayed the information of engine type. 4) On the Engine Diagnosis display screen, select the {Current Data Display & Save} and press the [YES] key. 5) On the Data Display Menu display screen, select the {Data & LED Display} and press the [YES] key. 6) Using the scroll key, move the display screen up or down until the desired data is shown. A list of the support data is shown in the following table.
Contents Ignition switch signal Test mode connector signal Neutral position switch signal Air conditioning switch signal Air conditioning relay signal Radiator main fan relay signal Fuel pump relay signal Knocking signal Radiator sub fan relay signal Engine torque control signal #1 Engine torque control signal #2 Engine torque control permission signal Front oxygen (A/F) sensor rich signal Rear oxygen sensor rich signal Starter switch signal Idle switch signal Crankshaft position sensor signal Camshaft position sensor signal Display Ignition Switch Test Mode Signal Neutral Position Switch A/C Switch A/C Relay Radiator Fan Relay #1 Fuel Pump Relay Knocking Signal Radiator Fan Relay #2 Torque Control Signal #1 Torque Control Signal #2 Torque Control Permit Front O2 Rich Signal #1 Rear O2 Rich Signal Starter Switch Signal Idle Switch Signal Crankshaft Position Sig. Camshaft Position Sig. Message ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF LED ON requirements When ignition switch is turned ON. When test mode connector is connected. When neutral position signal is entered. When air conditioning switch is turned ON. When air conditioning relay is in function. When radiator main fan relay is in function. When fuel pump relay is in function. When knocking signal is entered. When radiator sub fan relay is in function. When engine torque control signal 1 is entered. When engine torque control signal 2 is entered. When engine torque control permission signal is entered. When front oxygen (A/F) sensor mixture ratio is rich. When rear oxygen sensor mixture ratio is rich. When starter switch signal is entered. When idle switch signal is entered. When crankshaft position sensor signal is entered. When camshaft position sensor signal is entered.
EN(SOHC)-39

S058503A1609
9. READ CURRENT DATA FOR AT.
1) On the Main Menu display screen, select the {Each System Check} and press the [YES] key. 2) On the System Selection Menu display screen, select the {Transmission Control System} and press the [YES] key. 3) Press the [YES] key after displayed the information of transmission type. 4) On the Transmission Diagnosis display screen, select the {Current Data Display & Save} and press the [YES] key. 5) On the Data Display Menu display screen, select the {Data Display} and press the [YES] key. 6) Using the scroll key, move the display screen up or down until the desired data is shown. A list of the support data is shown in the following table.
Contents Battery voltage Rear vehicle speed sensor signal Front vehicle speed sensor signal Engine speed signal Automatic transmission fluid temperature signal Throttle position signal Gear position Line pressure control duty ratio Lock up clutch control duty ratio Transfer clutch control duty ratio Power supply for throttle position sensor Torque converter turbine speed signal 2-4 brake timing pressure control duty ratio Intake manifold pressure sensor voltage 2 wheel drive switch signal Kick down switch signal Stop lamp switch signal Anti lock brake system signal Cruise control system signal Neutral/Parking range signal Reverse range signal Drive range signal 3rd range signal 2nd range signal 1st range signal Shift control solenoid A Shift control solenoid B Torque control output signal #1 Torque control output signal #2 Torque control cut signal 2-4 brake timing control solenoid valve Low clutch timing control solenoid valve Automatic transmission diagnosis indicator lamp Display Battery Voltage Vehicle Speed #1 Vehicle Speed #2 Engine Speed ATF Temp. Throttle Sensor Voltage Gear Position Line Pressure Duty Ratio Lock Up Duty Ratio Transfer Duty Ratio Throttle Sensor Power AT Turbine Speed 2-4B Duty Ratio Mani. Pressure Voltage 2WD Switch Kick Down Switch Stop Lamp Switch ABS Signal Cruise Control Signal N/P Range Signal R Range Signal D Range Signal 3rd Range Signal 2nd Range Signal 1st Range Signal Shift Solenoid #1 Shift Solenoid #2 Torque Control Signal #1 Torque Control Signal #2 Torque Control Cut Sig. 2-4 Brake Timing Sol. Low Clutch Timing Sol. AT Diagnosis Lamp Unit of measure V km/h or MPH km/h or MPH rpm C or F V % % % V rpm % V ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF
EN(SOHC)-40
READ DIAGNOSTIC TROUBLE CODE
S058508A1603
11. Read Diagnostic Trouble Code

S058508
3. OBD-II GENERAL SCAN TOOL
A: OPERATION
S058508A16
1. SUBARU SELECT MONITOR (NORMAL MODE) S058508A1601

1) On the Main Menu display screen, select the {Each System Check} and press the [YES] key. 2) On the System Selection Menu display screen, select the {Engine Control System} and press the [YES] key. 3) Press the [YES] key after displayed the information of engine type. 4) On the Engine Diagnosis display screen, select the {Diagnostic Code(s) Display} and press the [YES] key. 5) On the Diagnostic Code(s) Display display screen, select the {Current Diagnostic Code(s)} or {History Diagnostic Code(s)} and press the [YES] key. NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. For detailed concerning diagnostic trouble codes, refer to the List of Diagnostic Trouble Code (DTC). <Ref. to EN(SOHC)-80, List of Diagnostic Trouble Code (DTC).>
Refers to data denoting emission-related powertrain diagnostic trouble codes. For details concerning diagnostic trouble codes, refer to the List of Diagnostic Trouble Code (DTC). <Ref. to EN(SOHC)-80, List of Diagnostic Trouble Code (DTC).> NOTE: Refer to OBD-II general scan tool manufacturer s instruction manual to access emission-related powertrain diagnostic trouble codes (MODE $03).
2. SUBARU SELECT MONITOR (OBD MODE) S058508A1602

1) On the Main Menu display screen, select the {2. Each System Check} and press the [YES] key. 2) On the System Selection Menu display screen, select the {Engine Control System} and press the [YES] key. 3) Press the [YES] key after displayed the information of engine type. 4) On the Engine Diagnosis display screen, select the {OBD System} and press the [YES] key. 5) On the OBD Menu display screen, select the {Diagnosis Code(s) Display} and press the [YES] key. 6) Make sure that a diagnostic trouble code (DTC) is shown on the display screen. NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. For detailed concerning diagnostic trouble codes, refer to the List of Diagnostic Trouble Code (DTC). <Ref. to EN(SOHC)-80, List of Diagnostic Trouble Code (DTC).>
EN(SOHC)-41
INSPECTION MODE
S058510
12. Inspection Mode

A: OPERATION
S058510A16
1. PREPARATION FOR THE INSPECTION MODE S058510A1601

Raise the vehicle using a garage jack and place on safety stands or drive the vehicle onto free rollers. WARNING: Before raising the vehicle, ensure parking brakes are applied. Do not use a pantograph jack in place of a safety stand. Secure a rope or wire to the front and rear towing or tie-down hooks to prevent the lateral runout of front wheels. Do not abruptly depress/release clutch pedal or accelerator pedal during works even when engine is operating at low speeds since this may cause vehicle to jump off free rollers. In order to prevent the vehicle from slipping due to vibration, do not place any wooden blocks or similar items between the safety stands and the vehicle. Since the rear wheels will also rotate, do not place anything near them. Also, make sure that nobody goes in front of the vehicle.
S2M0285
S2M0286A
4) Connect test mode connector (A) at the lower portion of instrument panel (on the driver s side), to the side of the center console box.
S2M2244A
B2M2969A
2. SUBARU SELECT MONITOR
S058510A1602
After performing diagnostics and clearing the memory, check for any remaining unresolved trouble data.
EN(SOHC)-42
INSPECTION MODE
5) Connect Subaru Select Monitor to data link connector. (1) Connect Subaru Select Monitor to data link connector located in the lower portion of the instrument panel (on the driver s side).
NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. For detailed concerning diagnostic trouble codes, refer to the List of Diagnostic Trouble Code (DTC). <Ref. to EN(SOHC)-80, List of Diagnostic Trouble Code (DTC).> Release the parking brake. The speed difference between front and rear wheels may light either the ABS warning light, but this indicates no malfunctions. When engine control diagnosis is finished, perform the ABS memory clearance procedure of self-diagnosis system.
S2M2157
S058510A1603
(2) Connect diagnosis cable to data link connector. CAUTION: Do not connect scan tools except for Subaru Select Monitor and OBD-II general scan tool. 6) Turn ignition switch to ON (engine OFF) and Subaru Select Monitor switch to ON.
After performing diagnostics and clearing the memory, check for any remaining unresolved trouble data: 1) Connect test mode connector (A) at the lower side of the instrument panel (on the driver s side), to the side of the center console box.
S2M2244A
S2M0288A
7) On the Main Menu display screen, select the {2. Each System Check} and press the [YES] key. 8) On the System Selection Menu display screen, select the {Engine Control System} and press the [YES] key. 9) Press the [YES] key after displayed the information of engine type. 10) On the Engine Diagnosis display screen, select the {Dealer Check Mode Procedure} and press the [YES] key. 11) When the Perform Inspection (Dealer Check) Mode? is shown on the display screen, press the [YES] key. 12) Perform subsequent procedures as instructed on the display screen. If trouble still remains in the memory, the corresponding diagnostic trouble code (DTC) appears on the display screen.
2) Connect the OBD-II general scan tool to its data link connector (A) in the lower portion of the instrument panel (on the driver s side). CAUTION: Do not connect the scan tools except for Subaru Select Monitor and OBD-II general scan tool.
S2M2157B
EN(SOHC)-43
INSPECTION MODE
3) Start the engine. NOTE: Ensure the selector lever is placed in the P position before starting. (AT vehicles) Depress clutch pedal when starting the engine. (MT vehicles) 4) Using the selector lever or shift lever, turn the P position switch and the N position switch to ON. 5) Depress the brake pedal to turn the brake switch ON. (AT vehicles) 6) Keep engine speed in the 2,500 3,000 rpm range for 40 seconds. NOTE: On models without tachometer, use the tachometer (Secondary pickup type). 7) Place the selector lever or shift lever in the D position (AT vehicles) or 1st gear (MT vehicles) and drive the vehicle at 5 to 10 km/h (3 to 6 MPH). NOTE: On AWD vehicles, release the parking brake. The speed difference between front and rear wheels may light the ABS warning light, but this indicates no malfunctions. When engine control diagnosis is finished, perform the ABS memory clearance procedure of self-diagnosis system. 8) Using the OBD-II general scan tool, check for diagnostic trouble code(s) and record the result(s). NOTE: For detailed operation procedures, refer to the OBD-II General Scan Tool Instruction Manual. For detailed concerning diagnostic trouble codes, refer to the List of Diagnostic Trouble Code (DTC). <Ref. to EN(SOHC)-80, List of Diagnostic Trouble Code (DTC).>
EN(SOHC)-44
CLEAR MEMORY MODE
S058513A1603
13. Clear Memory Mode

A: OPERATION
S058513A16
S058513

1) On the Main Menu display screen, select the {2. Each System Check} and press the [YES] key. 2) On the System Selection Menu display screen, select the {Engine Control System} and press the [YES] key. 3) Press the [YES] key after displayed the information of engine type. 4) On the Engine Diagnosis display screen, select the {Clear Memory} and press the [YES] key. 5) When the Done and Turn Ignition Switch OFF are shown on the display screen, turn the Subaru Select Monitor and ignition switch to OFF. NOTE: After the memory has been cleared, the idle air control solenoid valve must be initialized. To do this, turn the ignition switch to the ON position. Wait 3 seconds before starting the engine. For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.
For clear memory procedures using the OBD-II general scan tool, refer to the OBD-II General Scan Tool Instruction Manual. After the memory has been cleared, the idle air control solenoid valve must be initialized. To do this, turn the ignition switch to the ON position. Wait 3 seconds before starting the engine.

1) On the Main Menu display screen, select the {2. Each System Check} and press the [YES] key. 2) On the System Selection Menu display screen, select the {Engine Control System} and press the [YES] key. 3) Press the [YES] key after displayed the information of engine type. 4) On the Engine Diagnosis display screen, select the {OBD System} and press the [YES] key. 5) On the OBD Menu display screen, select the {4. Diagnosis Code(s) Cleared} and press the [YES] key. 6) When the Clear Diagnostic Code? is shown on the display screen, press the [YES] key. 7) Turn Subaru Select Monitor and ignition switch to OFF. NOTE: After the memory has been cleared, the idle air control solenoid valve must be initialized. To do this, turn the ignition switch to the ON position. Wait 3 seconds before starting the engine. For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.
EN(SOHC)-45
COMPULSORY VALVE OPERATION CHECK MODE

5) Connect Subaru Select Monitor to data link connector. (1) Connect Subaru Select Monitor to data link connector located in the lower portion of the instrument panel (on the driver s side).
14. Compulsory Valve Operation Check Mode

A: OPERATION
S058528A16
S058528
S2M2157
S2M0285
S2M0288A S2M0286A
S2M2244A
7) On the Main Menu display screen, select the {2. Each System Check} and press the [YES] key. 8) On the System Selection Menu display screen, select the {Engine Control System} and press the [YES] key. 9) Press the [YES] key after displayed the information of engine type. 10) On the Engine Diagnosis display screen, select the {System Operation Check Mode} and press the [YES] key. 11) On the System Operation Check Mode display screen, select the {Actuator ON/OFF Operation} and press the [YES] key. 12) Select the desired compulsory actuator on the Actuator ON/OFF Operation display screen and press the [YES] key. 13) Pressing the [NO] key completes the compulsory operation check mode. The display will then return to the Actuator ON/OFF Operation screen.
EN(SOHC)-46

A list of the support data is shown in the following table.
Compulsory Compulsory Compulsory Compulsory Compulsory Contents fuel pump relay operation check radiator fan relay operation check air conditioning relay operation check purge control solenoid valve operation check air assist injector solenoid valve operation check
Display Fuel Pump Relay Radiator Fan Relay A/C Compressor Relay CPC Solenoid Valve AAI Solenoid Valve
NOTE: The following parts will be displayed but not functional because they are not installed on the vehicle.
Display EGR Solenoid Valve ASV Solenoid Valve PCV Solenoid Valve Vent Control Solenoid Valve FICD Solenoid Pressure Switching Sol. 1 Pressure Switching Sol. 2 Fuel Tank Sensor Control Valve
For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.
EN(SOHC)-47
ENGINE MALFUNCTION INDICATOR LAMP (MIL)
15. Engine Malfunction Indicator Lamp (MIL)

A: PROCEDURE
S058653E45
S058653
1. Activation of check engine malfunction indicator lamp (MIL). <Ref. to EN(SOHC)-49, ACTIVATION OF CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL), Engine Malfunction Indicator Lamp (MIL).> 2. Check engine malfunction indicator lamp (MIL) does not come on. <Ref. to EN(SOHC)-50, CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT COME ON., Engine Malfunction Indicator Lamp (MIL).> 3. Check engine malfunction indicator lamp (MIL) does not go off. <Ref. to EN(SOHC)-53, CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT GO OFF., Engine Malfunction Indicator Lamp (MIL).> 4. Check engine malfunction indicator lamp (MIL) does not blink at a cycle of 3 Hz. <Ref. to EN(SOHC)-54, CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT BLINK AT A CYCLE OF 3 HZ., Engine Malfunction Indicator Lamp (MIL).> 5. Check engine malfunction indicator lamp (MIL) remains blinking at a cycle of 3 Hz. <Ref. to EN(SOHC)-56, CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) REMAINS BLINKING AT A CYCLE OF 3 HZ., Engine Malfunction Indicator Lamp (MIL).>
EN(SOHC)-48
ENGINE MALFUNCTION INDICATOR LAMP (MIL) B: ACTIVATION OF CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL)
S058653E89
3) If the diagnosis system senses a misfire which could damage the catalyzer, the MIL will blink at a cycle of 1 Hz.
1) When ignition switch is turned to ON (engine off), the CHECK ENGINE malfunction indicator lamp (MIL) in the combination meter illuminates. NOTE: If the MIL does not illuminate, perform diagnostics of the CHECK ENGINE light circuit or the combination meter circuit. <Ref. to EN(SOHC)-50, CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT COME ON., Engine Malfunction Indicator Lamp (MIL).>
OBD0054A
4) When ignition switch is turned to ON (engine off) or to START with the test mode connector connected, the MIL blinks at a cycle of 3 Hz.
S2M2104A
(A)
Malfunction indicator lamp (MIL)

OBD0055A
2) After starting the engine, the MIL goes out. If it does not, either the engine or the emission control system is malfunctioning.
OBD0053A
EN(SOHC)-49
C: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT COME ON.
S058653E90
DIAGNOSIS: The CHECK ENGINE malfunction indicator lamp (MIL) circuit is open or shorted. TROUBLE SYMPTOM: When ignition switch is turned ON (engine OFF), MIL does not come on. WIRING DIAGRAM:
S2M2071
No. 1
Step CHECK OUTPUT SIGNAL FROM ECM. 1) Turn ignition switch to ON. 2) Measure voltage between ECM connector and chassis ground. Connector & terminal (B134) No. 11 (+) Chassis ground ():
Check Is the voltage less than 1 V?
Yes Go to step 4.
No Go to step 2.
EN(SOHC)-50

No. 2 Step CHECK POOR CONTACT. Check Does the MIL come on when shaking or pulling ECM connector and harness? Is ECM connector correctly connected?
No Go to step 3.
Yes Repair poor contact in ECM connector. Replace ECM. <Ref. to FU(SOHC)-49, Engine Control Module.> Go to step 5.
CHECK ECM CONNECTOR.
Repair connection of ECM connector.
CHECK HARNESS BETWEEN COMBINATION METER AND ECM CONNECTOR. 1) Turn ignition switch to OFF. 2) Remove combination meter. <Ref. to IDI15, Combination Meter Assembly.> 3) Disconnect connector from ECM and combination meter. 4) Measure resistance of harness between ECM and combination meter connector. Connector & terminal (B134) No. 11 (i10) No. 9:
Is resistance less than 1 ?
CHECK POOR CONTACT. Is there poor contact in Repair poor conCheck poor contact in combination meter con- combination meter connec- tact in combinanector. tor? tion meter connector. Is voltage more than 10 V? Go to step 7. CHECK HARNESS BETWEEN COMBINATION METER AND IGNITION SWITCH CONNECTOR. 1) Turn ignition switch to ON. 2) Measure voltage between combination meter connector and chassis ground. Connector & terminal (i10) No. 2 (+) Chassis ground ():
Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ECM and combination meter connector Poor contact in coupling connector (i2) Go to step 6.
Check the following and repair if necessary. NOTE: Broken down ignition relay. Blown out fuse (No. 5). If replaced fuse (No. 5) blows easily, check the harness for short circuit of harness between fuse (No. 5) and ignition relay connector. Open or short circuit in harness between fuse (No. 5) and battery terminal Open circuit in harness between fuse (No. 5) and ignition relay connector Poor contact in ignition relay connector Poor contact in ignition switch connector
EN(SOHC)-51
No. 7

Check Yes Is lamp bulb condition OK? Repair combination meter connector. No Replace lamp bulb.
Step CHECK LAMP BULB. Remove engine malfunction indicator lamp bulb.
EN(SOHC)-52
D: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT GO OFF.

S058653E91
DIAGNOSIS: The CHECK ENGINE malfunction indicator lamp (MIL) circuit is shorted. TROUBLE SYMPTOM: Although MIL comes on when engine runs, trouble code is not shown on Subaru select monitor or OBD-II general scan tool display. WIRING DIAGRAM:
S2M2071
No. 1
Step CHECK HARNESS BETWEEN COMBINATION METER AND ECM CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM. 3) Turn ignition switch to ON.
Check Does the MIL come on?
Yes Repair short circuit in harness between combination meter and ECM connector.
No Replace ECM. <Ref. to FU(SOHC)-49, Engine Control Module.>
EN(SOHC)-53
E: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT BLINK AT A CYCLE OF 3 Hz.
S058653E92
DIAGNOSIS: The CHECK ENGINE malfunction indicator lamp (MIL) circuit is open or shorted. Test mode connector circuit is in open. TROUBLE SYMPTOM: When inspection mode, MIL does not blink at a cycle of 3 Hz. WIRING DIAGRAM:
S2M2072
EN(SOHC)-54

No. 1 Step CHECK STATUS OF CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL). 1) Turn ignition switch to OFF. 2) Disconnect test mode connector. 3) Turn ignition switch to ON. (engine OFF) Check Does the MIL come on? Yes Go to step 2.
No Repair the MIL circuit. <Ref. to EN(SOHC)-50, CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT COME ON., Engine Malfunction Indicator Lamp (MIL).> Go to step 3.
CHECK HARNESS BETWEEN COMBINATION METER AND ECM CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM. 3) Turn ignition switch to ON. CHECK HARNESS BETWEEN TEST MODE CONNECTOR AND CHASSIS GROUND. 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM. 3) Measure resistance of harness between test mode connector and chassis ground. Connector & terminal (B76) No. 1 Chassis ground:
Does the MIL come on?
CHECK POOR CONTACT. Check poor contact in ECM connector. CHECK HARNESS BETWEEN ECM AND TEST MODE CONNECTOR. 1) Connect test mode connector. 2) Measure resistance of harness between ECM and chassis ground. Connector & terminal (B135) No. 14 Chassis ground: CHECK POOR CONTACT. Check poor contact in ECM connector.
Is there poor contact in ECM connector? Is resistance less than 1 ?
Repair ground short circuit in harness between combination meter and ECM connector. Go to step 4. Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between test mode connector and chassis ground Repair poor con- Go to step 5. tact in ECM connector. Go to step 6. Repair open circuit in harness between ECM and test mode connector.
Is there poor contact in ECM connector?
Repair poor contact in ECM connector.
Replace ECM. <Ref. to FU(SOHC)-49, Engine Control Module.>
EN(SOHC)-55
F: CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) REMAINS BLINKING AT A CYCLE OF 3 Hz.
S058653E93
DIAGNOSIS: Test mode connector circuit is shorted. TROUBLE SYMPTOM: MIL blinks at a cycle of 3 Hz when ignition switch is turned to ON. WIRING DIAGRAM:
S2M2072
No. 1
Step CHECK TEST MODE CONNECTOR. 1) Disconnect test mode connector. 2) Turn ignition switch to ON.
Check Yes Does MIL flash on and off? Go to step 2.
No System is in good order. NOTE: MIL blinks at a cycle of 3 Hz when test mode connector is connected.
EN(SOHC)-56

No. 2 Step CHECK HARNESS BETWEEN ECM CONNECTOR AND ENGINE GROUNDING TERMINAL. 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM. 3) Measure resistance of harness between ECM connector and chassis ground. Connector & terminal (B135) No. 14 Chassis ground: Check Is resistance less than 5 ? Yes Repair short circuit in harness between ECM and test mode connector.
No Replace ECM. <Ref. to FU(SOHC)-49, Engine Control Module.>
EN(SOHC)-57
MEMO:
EN(SOHC)-58
DIAGNOSTICS FOR ENGINE STARTING FAILURE
16. Diagnostics for Engine Starting Failure

A: PROCEDURE
S058533E45
S058533
1. Inspection of starter motor circuit. <Ref. to EN(SOHC)-60, STARTER MOTOR CIRCUIT, Diagnostics for Engine Starting Failure.> 2. Inspection of ECM power supply and ground line. <Ref. to EN(SOHC)-64, CONTROL MODULE POWER SUPPLY AND GROUND LINE, Diagnostics for Engine Starting Failure.> 3. Inspection of ignition control system. <Ref. to EN(SOHC)-68, IGNITION CONTROL SYSTEM, Diagnostics for Engine Starting Failure.> 4. Inspection of fuel pump circuit. <Ref. to EN(SOHC)-72, FUEL PUMP CIRCUIT, Diagnostics for Engine Starting Failure.> 5. Inspection of fuel injector circuit. <Ref. to EN(SOHC)-76, FUEL INJECTOR CIRCUIT, Diagnostics for Engine Starting Failure.>
EN(SOHC)-59

S058533E94
B: STARTER MOTOR CIRCUIT
CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to EN(SOHC)-45, Clear Memory Mode.> and INSPECTION MODE <Ref. to EN(SOHC)-42, Inspection Mode.>. WIRING DIAGRAM:
S2M2073
EN(SOHC)-60

No. 1 2 Step Check CHECK OPERATION OF STARTER MOTOR. Does starter motor operate when the switch starts? CHECK DTC. Is the trouble code stored <Ref. to EN(SOHC)-41, OPERATION, Read in memory? <Ref. to Diagnostic Trouble Code.> EN(SOHC)-80, LIST, List of Diagnostic Trouble Code (DTC).> Yes Go to step 2.
No Go to step 3.
CHECK INPUT SIGNAL FOR STARTER MOTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from starter motor. 3) Turn ignition switch to ST. 4) Measure power supply voltage between starter motor connector terminal and engine ground. Connector & terminal (B14) No. 1 (+) Engine ground (): NOTE: On AT vehicles, place the selector lever in the P or N position. CHECK GROUND CIRCUIT OF STARTER MOTOR. 1) Turn ignition switch to OFF. 2) Disconnect terminal from starter motor. 3) Measure resistance of ground cable between ground cable terminal and engine ground. CHECK HARNESS BETWEEN ECM AND STARTER MOTOR CIRCUIT. 1) Turn ignition switch to OFF. 2) Measure resistance between starter motor and ECM. Connector & terminal (B14) No. 1 Engine ground: CHECK HARNESS BETWEEN ECM AND STARTER MOTOR CIRCUIT. 1) Turn ignition switch to START. 2) Measure resistance of fuse. Connector & terminal (B14) No. 1 Engine ground: CHECK HARNESS BETWEEN BATTERY AND IGNITION SWITCH CONNECTOR. 1) Ignition switch to OFF. 2) Disconnect connector from ignition switch. 3) Measure power supply voltage between ignition switch connector and chassis ground. Connector & terminal (B72) No. 1 (+) Chassis ground (): CHECK HARNESS BETWEEN BATTERY AND IGNITION SWITCH CONNECTOR. 1) Connect connector to ignition switch. 2) Turn ignition switch to START. 3) Measure voltage between ignition switch and chassis ground. Connector & terminal (B72) No. 3 (+) Chassis ground ():
Go to step 3. Record DTC. Repair the trouble case. <Ref. to EN(SOHC)-86, Engine Control Module (ECM) I/O Signal.> Is the voltage more than 10 Go to step 4. Go to step 5. V?
Check starter motor. <Ref. to SC-5, Starter.>
Repair open circuit of ground cable.
Repair ground short circuit.
Go to step 6.
Go to step 7.
Repair open circuit in harness between ignition switch and battery.
Replace ignition switch.
EN(SOHC)-61
No. 9

Check Is the vehicle AT? Yes Go to step 10. No Repair open circuit between ignition switch and starter motor circuit. Go to step 11.
Step CHECK TRANSMISSION TYPE.
10
11
12
CHECK INHIBITOR SWITCH CIRCUIT. 1) Turn ignition switch to OFF. 2) Place the selector lever in the P or N position. 3) Separate transmission harness connector. 4) Measure resistance between transmission harness connector receptacles terminals. Connector & terminal (T3) No. 11 No. 12: CHECK TRANSMISSION HARNESS. 1) Disconnect connector from inhibitor switch. 2) Measure resistance of harness between transmission harness and inhibitor switch connector. Connector & terminal (T3) No. 11 (T7) No. 7: CHECK POOR CONTACT. Check poor contact in inhibitor switch connector.
Repair open circuit in harness between starter motor and ignition switch connector.
Go to step 12.
Repair open circuit in harness between transmission harness and inhibitor switch connector. Replace inhibitor switch.
Is there poor contact in inhibitor switch connector?
Repair poor contact in inhibitor switch connector.
EN(SOHC)-62

MEMO:
EN(SOHC)-63

S058533E37
C: CONTROL MODULE POWER SUPPLY AND GROUND LINE
CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to EN(SOHC)-45, Clear Memory Mode.> and INSPECTION MODE. <Ref. to EN(SOHC)-42, Inspection Mode.> WIRING DIAGRAM:
S2M2074
No. 1
Step Check Is the resistance less than CHECK MAIN RELAY. 10 ? 1) Turn the ignition switch to OFF. 2) Remove main relay. 3) Connect battery to main relay terminals No. 1 and No. 2. 4) Measure resistance between main relay terminals. Terminals No. 3 No. 5: No. 4 No. 6:
Yes Go to step 2.
No Replace main relay.
EN(SOHC)-64

No. 2 Step CHECK GROUND CIRCUIT OF ECM. 1) Disconnect connector from ECM. 2) Measure resistance of harness between ECM and chassis ground. Connector & terminal (B136) No. 21 Chassis ground: (B136) No. 22 Chassis ground: (B134) No. 27 Chassis ground: (B134) No. 8 Chassis ground: (B134) No. 7 Chassis ground: (B134) No. 34 Chassis ground: (B134) No. 35 Chassis ground: CHECK INPUT VOLTAGE OF ECM. Measure voltage between ECM connector and chassis ground. Connector & terminal (B136) No. 9 (+) Chassis ground (): CHECK INPUT VOLTAGE OF ECM. 1) Turn ignition switch to ON. 2) Measure voltage between ECM connector and chassis ground. Connector & terminal (B135) No. 7 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND MAIN RELAY CONNECTOR. 1) Turn ignition switch to OFF. 2) Measure resistance between ECM and chassis ground. Connector & terminal (B135) No. 19 Chassis ground: CHECK OUTPUT VOLTAGE FROM ECM. 1) Connect connector to ECM. 2) Turn ignition switch to ON. 3) Measure voltage between ECM connector and chassis ground. Connector & terminal (B135) No. 19 (+) Chassis ground (): CHECK INPUT VOLTAGE OF MAIN RELAY. Check voltage between main relay connector and chassis ground. Connector & terminal (B47) No. 2 (+) Chassis ground (): CHECK GROUND CIRCUIT OF MAIN RELAY. 1) Turn ignition switch to OFF. 2) Measure resistance between main relay connector and chassis ground. Connector & terminal (B47) No. 1 Chassis ground: CHECK INPUT VOLTAGE OF MAIN RELAY. Measure voltage between main relay connector and chassis ground. Connector & terminal (B47) No. 5 (+) Chassis ground (): (B47) No. 6 (+) Chassis ground (): Check Is the resistance less than 5 ? Yes Go to step 3.
No Repair open circuit in harness between ECM connector and engine grounding terminal.
Repair open or ground short circuit of power supply circuit. Repair open or ground short circuit of power supply circuit.
Repair ground short circuit in harness between ECM connector and main relay connector, then replace ECM. Replace ECM.
Go to step 9.
Repair open circuit in harness between ECM connector and main relay connector. Repair open circuit between main relay and chassis ground.
Repair open or ground short circuit in harness of power supply circuit.
EN(SOHC)-65
No. 10

No Repair open or ground short circuit in harness between ECM connector and main relay connector.
Step Check Yes Is the voltage more than 10 Check ignition CHECK INPUT VOLTAGE OF ECM. V? control system. 1) Connect main relay connector. <Ref. to 2) Turn ignition switch to ON. EN(SOHC)-68, 3) Measure voltage between ECM connector IGNITION CONand chassis ground. TROL SYSTEM, Connector & terminal Diagnostics for (B136) No. 1 (+) Chassis ground (): Engine Starting (B136) No. 2 (+) Chassis ground (): Failure.>
EN(SOHC)-66

MEMO:
EN(SOHC)-67

S058533E95
D: IGNITION CONTROL SYSTEM
B2M4187
EN(SOHC)-68

No. 1 Step CHECK IGNITION SYSTEM FOR SPARKS. 1) Remove plug cord cap from each spark plug. 2) Install new spark plug on plug cord cap. CAUTION: Do not remove spark plug from engine. 3) Contact spark plugs thread portion on engine. 4) While opening throttle valve fully, crank engine to check that spark occurs at each cylinder. CHECK POWER SUPPLY CIRCUIT FOR IGNITION COIL & IGNITOR ASSEMBLY. 1) Turn ignition switch to OFF. 2) Disconnect connector from ignition coil & ignitor assembly. 3) Turn ignition switch to ON. 4) Measure power supply voltage between ignition coil & ignitor assembly connector and engine ground. Connector & terminal (E12) No. 2 (+) Engine ground (): Check Does spark occur at each cylinder?
Yes No Check fuel pump Go to step 2. system. <Ref. to EN(SOHC)-72, FUEL PUMP CIRCUIT, Diagnostics for Engine Starting Failure.>
CHECK HARNESS OF IGNITION COIL & IGNITOR ASSEMBLY GROUND CIRCUIT. 1) Turn ignition switch to OFF. 2) Measure resistance between ignition coil & ignitor assembly connector and engine ground. Connector & terminal (E12) No. 3 Engine ground:
Is the resistance between less than 5 ?
Go to step 4.
CHECK IGNITION COIL & IGNITOR ASSEMBLY. 1) Remove spark plug cords. 2) Measure resistance between spark plug cord contact portions to check secondary coil. Terminals No. 1 No. 2: CHECK IGNITION COIL & IGNITOR ASSEMBLY. Measure resistance between spark plug cord contact portions to check secondary coil. Terminals No. 3 No. 4:
Is the resistance between 10 and 15 k?
Go to step 5.
Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ignition coil & ignitor assembly, and ignition switch connector Poor contact in coupling connectors (B22) Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ignition coil & ignitor assembly connector and engine grounding terminal Replace ignition coil & ignitor assembly. <Ref. to IG(SOHC)-8, Ignition Coil and Ignitor Assembly.> Replace ignition coil & ignitor assembly. <Ref. to IG(SOHC)-8, Ignition Coil and Ignitor Assembly.>
Is the resistance between 10 and 15 k?
Go to step 6.
EN(SOHC)-69
No. 6

Check Yes Is the voltage more than 10 Go to step 7. V? No Replace ignition coil & ignitor assembly. <Ref. to IG(SOHC)-8, Ignition Coil and Ignitor Assembly.>
Step CHECK INPUT SIGNAL FOR IGNITION COIL & IGNITOR ASSEMBLY. 1) Connect connector to ignition coil & ignitor assembly. 2) Check if voltage varies synchronously with engine speed when cranking, while monitoring voltage between ignition coil & ignitor assembly connector and engine ground. Connector & terminal (E12) No. 1 (+) Engine ground (): CHECK INPUT SIGNAL FOR IGNITION COIL & IGNITOR ASSEMBLY. Check if voltage varies synchronously with engine speed when cranking, while monitoring voltage between ignition coil & ignitor assembly connector and engine ground. Connector & terminal (E12) No. 4 (+) Engine ground (): CHECK HARNESS BETWEEN ECM AND IGNITION COIL & IGNITOR ASSEMBLY CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM. 3) Disconnect connector from ignition coil & ignitor assembly. 4) Measure resistance of harness between ECM and ignition coil & ignitor assembly connector. Connector & terminal (B134) No. 25 (E12) No. 1:
Replace ignition coil & ignitor assembly. <Ref. to IG(SOHC)-8, Ignition Coil and Ignitor Assembly.>
Go to step 9.
Is the resistance less than CHECK HARNESS BETWEEN ECM AND 1 ? IGNITION COIL & IGNITOR ASSEMBLY CONNECTOR. Measure resistance of harness between ECM and ignition coil & ignitor assembly connector. Connector & terminal (B134) No. 26 (E12) No. 4:
Go to step 10.
10
Is the resistance more than Go to step 11. CHECK HARNESS BETWEEN ECM AND 1 M? IGNITION COIL & IGNITOR ASSEMBLY CONNECTOR. Measure resistance of harness between ECM and engine ground. Connector & terminal: (B134) No. 25 Engine ground:
Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ECM and ignition coil & ignitor assembly connector Poor contact in coupling connector (B22) Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ECM and ignition coil & ignitor assembly connector Poor contact in coupling connector (B22) Repair ground short circuit in harness between ECM and ignition coil & ignitor assembly connector.
EN(SOHC)-70

No. 11 Step CHECK HARNESS BETWEEN ECM AND IGNITION COIL & IGNITOR ASSEMBLY CONNECTOR. Measure resistance of harness between ECM and engine ground. Connector & terminal (B134) No. 26 Engine ground: CHECK POOR CONTACT. Check poor contact in ECM connector. Check Yes Is the resistance more than Go to step 12. 1 M?
No Repair ground short circuit in harness between ECM and ignition coil & ignitor assembly connector. Check fuel pump circuit. <Ref. to EN(SOHC)-72, FUEL PUMP CIRCUIT, Diagnostics for Engine Starting Failure.>
12
EN(SOHC)-71

S058533E96
E: FUEL PUMP CIRCUIT
S2M2075
EN(SOHC)-72

No. 1 Step CHECK OPERATING SOUND OF FUEL PUMP. Make sure that fuel pump is in operation for two seconds when turning ignition switch to ON. NOTE: Fuel pump operation can also be executed using Subaru Select Monitor (Function mode: FD01). For the procedure, refer to Compulsory Valve Operation Check Mode. <Ref. to EN(SOHC)46, Compulsory Valve Operation Check Mode.> CHECK GROUND CIRCUIT OF FUEL PUMP. 1) Turn ignition switch to OFF. 2) Remove fuel pump access hole lid located on the right rear of trunk compartment floor (Sedan) or luggage compartment floor (Wagon). 3) Disconnect connector from fuel pump. 4) Measure resistance of harness connector between fuel pump and chassis ground. Connector & terminal (R58) No. 4 Chassis ground: Check Does fuel pump produce operating sound?
Yes No Check fuel injec- Go to step 2. tor circuit. <Ref. to EN(SOHC)-76, FUEL INJECTOR CIRCUIT, Diagnostics for Engine Starting Failure.>
Go to step 3.
CHECK POWER SUPPLY TO FUEL PUMP. 1) Turn ignition switch to ON. 2) Measure voltage of power supply circuit between fuel pump connector and chassis ground. Connector & terminal (R58) No. 1 (+) Chassis ground (): CHECK HARNESS BETWEEN FUEL PUMP AND FUEL PUMP RELAY CONNECTOR. 1) Turn ignition switch to OFF. 2) Measure resistance of harness connector between fuel pump and fuel pump relay. Connector & terminal (R58) No. 1 (B46) No. 4:
Is the voltage more than 10 Replace fuel V? pump. <Ref. to FU(SOHC)-62, Fuel Pump.>
Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between fuel pump connector and chassis grounding terminal Poor contact in coupling connector (R15) Go to step 4.
Go to step 5.
CHECK HARNESS BETWEEN FUEL PUMP AND FUEL PUMP RELAY CONNECTOR. Measure resistance of harness between fuel pump and fuel pump relay connector. Connector & terminal (R58) No. 1 Chassis ground:
Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between fuel pump connector and chassis grounding terminal Poor contact in coupling connectors R15 and B97 Repair short circuit in harness between fuel pump and fuel pump relay connector.
EN(SOHC)-73
No. 6

Check Is the resistance less than 10 ? Yes Go to step 7. No Replace fuel pump relay. <Ref. to FU(SOHC)-51, Fuel Pump Relay.>
Step CHECK FUEL PUMP RELAY. 1) Disconnect connectors from fuel pump relay and main relay. 2) Remove fuel pump relay and main relay with bracket. 3) Connect battery to fuel pump relay connector terminals No. 1 and No. 3. 4) Measure resistance between connector terminals of fuel pump relay. Terminals No. 2 No. 4: CHECK HARNESS BETWEEN ECM AND FUEL PUMP RELAY CONNECTOR. 1) Disconnect connectors from ECM. 2) Measure resistance of harness between ECM and fuel pump relay connector. Connector & terminal (B134) No. 29 (B46) No. 3: CHECK POOR CONTACT. Check poor contact in ECM connector.
Go to step 8.
Repair open circuit in harness between ECM and fuel pump relay connector.
Check fuel injector circuit. <Ref. to EN(SOHC)-76, FUEL INJECTOR CIRCUIT, Diagnostics for Engine Starting Failure.>
EN(SOHC)-74

MEMO:
EN(SOHC)-75

S058533E97
F: FUEL INJECTOR CIRCUIT
CAUTION: Check or repair only faulty parts. After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to EN(SOHC)45, Clear Memory Mode.> and INSPECTION MODE. <Ref. to EN(SOHC)-42, Inspection Mode.> WIRING DIAGRAM:
S2M2076
No. 1
Step CHECK OPERATION OF EACH FUEL INJECTOR. While cranking the engine, check that each fuel injector emits operating sound. Use a sound scope or attach a screwdriver to injector for this check.
Check Is the fuel injector emits operating sound?
Yes Check fuel pressure. <Ref. to ME(SOHC)-28, INSPECTION, Fuel Pressure.>
No Go to step 2.
EN(SOHC)-76

No. 2 Step Check Yes Is the voltage more than 10 Go to step 3. CHECK POWER SUPPLY TO EACH FUEL V? INJECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from #1 cylinder fuel injector. 3) Turn ignition switch to ON. 4) Measure power supply voltage between the fuel injector terminal and engine ground. Connector & terminal #1 (E5) No. 2 (+) Engine ground (): #2 (E16) No. 2 (+) Engine ground (): #3 (E6) No. 2 (+) Engine ground (): #4 (E17) No. 2 (+) Engine ground ():
No Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between main relay and fuel injector connector Poor contact in main relay connector Poor contact in coupling connector (B22) Poor contact in fuel injector connector Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ECM and fuel injector connector Poor contact in coupling connector (B22) Go to step 5.
CHECK HARNESS BETWEEN ECM AND FUEL INJECTOR CONNECTOR. 1) Disconnect connector from ECM. 2) Measure resistance of harness between ECM and fuel injector connector. Connector & terminal (B134) No. 4 (B136) No. 2:
Is the resistance between 5 Go to step 4. and 20 ?
CHECK HARNESS BETWEEN ECM AND FUEL INJECTOR CONNECTOR. Measure resistance of harness between ECM and fuel injector connector. Connector & terminal (B134) No. 4 Chassis ground: CHECK HARNESS BETWEEN ECM AND FUEL INJECTOR CONNECTOR. Measure resistance of harness between ECM and fuel injector connector. Connector & terminal (B134) No. 13 (B136) No. 2:
Repair ground short circuit in harness between ECM and fuel injector connector.
Is the resistance less than CHECK HARNESS BETWEEN ECM AND 1 ? FUEL INJECTOR CONNECTOR. Measure resistance of harness between ECM and fuel injector connector. Connector & terminal (B134) No. 13 Chassis ground:
Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ECM and fuel injector connector Poor contact in coupling connector (B22) Go to step 7.
EN(SOHC)-77
No. 7

No Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ECM and fuel injector connector Poor contact in coupling connector (B22) Go to step 9.
Step Check Yes Is the resistance between 5 Go to step 8. CHECK HARNESS BETWEEN ECM AND and 20 ? FUEL INJECTOR CONNECTOR. Measure resistance of harness between ECM and fuel injector connector. Connector & terminal (B134) No. 14 (B136) No. 2:
CHECK HARNESS BETWEEN ECM AND FUEL INJECTOR CONNECTOR. Measure resistance of harness between ECM and fuel injector connector. Connector & terminal (B134) No. 14 Chassis ground: CHECK HARNESS BETWEEN ECM AND FUEL INJECTOR CONNECTOR. Measure resistance of harness between ECM and fuel injector connector. Connector & terminal (B134) No. 15 (B136) No. 2:
10
11
12
CHECK HARNESS BETWEEN ECM AND FUEL INJECTOR CONNECTOR. Measure resistance of harness between ECM and fuel injector connector. Connector & terminal (B134) No. 15 Chassis ground: CHECK EACH FUEL INJECTOR. 1) Turn ignition switch to OFF. 2) Measure resistance between each fuel injector terminals. Terminals No. 1 No. 2: CHECK POOR CONTACT. Check poor contact in ECM connector.
Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ECM and fuel injector connector Poor contact in coupling connector (B22) Go to step 11.
Replace faulty fuel injector.
Inspection using General Diagnostic Table. <Ref. to EN(SOHC)-294, INSPECTION, Genera Diagnostic Table.>
EN(SOHC)-78

MEMO:
EN(SOHC)-79
LIST OF DIAGNOSTIC TROUBLE CODE (DTC)
17. List of Diagnostic Trouble Code (DTC)

S058525
A: LIST
DTC No. P0031
S058525A12
Item Front oxygen (A/F) sensor heater circuit low input
Index
P0032
P0037
P0038
P0066
P0067
P0106
P0107
P0108
P0111
P0112
P0113
P0117
P0118
P0121
P0122
P0123
<Ref. to EN(SOHC)-86, DTC P0031 FRONT OXYGEN (A/F) SENSOR HEATER CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Front oxygen (A/F) sensor heater <Ref. to EN(SOHC)-90, DTC P0032 FRONT OXYGEN (A/F) SENSOR circuit high input HEATER CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Rear oxygen sensor heater circuit <Ref. to EN(SOHC)-92, DTC P0037 REAR OXYGEN SENSOR malfunction HEATER CIRCUIT MALFUNCTION , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Rear oxygen sensor heater circuit <Ref. to EN(SOHC)-96, DTC P0038 REAR OXYGEN SENSOR high input HEATER CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Air assist injector solenoid valve cir- <Ref. to EN(SOHC)-98, DTC P0066 AIR ASSIST INJECTOR SOLEcuit low input NOID VALVE CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Air assist injector solenoid valve cir- <Ref. to EN(SOHC)-100, DTC P0067 AIR ASSIST INJECTOR SOLEcuit high input NOID VALVE CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Pressure sensor circuit range/ <Ref. to EN(SOHC)-102, DTC P0106 PRESSURE SENSOR CIRCUIT performance problem (low input) RANGE/PERFORMANCE PROBLEM (LOW INPUT) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Pressure sensor circuit low input <Ref. to EN(SOHC)-106, DTC P0107 PRESSURE SENSOR CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Pressure sensor circuit high input <Ref. to EN(SOHC)-110, DTC P0108 PRESSURE SENSOR CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Intake air temperature sensor circuit <Ref. to EN(SOHC)-114, DTC P0111 INTAKE AIR TEMPERATURE range/performance problem SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Intake air temperature sensor circuit <Ref. to EN(SOHC)-116, DTC P0112 INTAKE AIR TEMPERATURE low input SENSOR CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Intake air temperature sensor circuit <Ref. to EN(SOHC)-118, DTC P0113 INTAKE AIR TEMPERATURE high input SENSOR CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Engine coolant temperature sensor <Ref. to EN(SOHC)-122, DTC P0117 ENGINE COOLANT TEMPERAcircuit low input TURE SENSOR CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Engine coolant temperature sensor <Ref. to EN(SOHC)-124, DTC P0118 ENGINE COOLANT TEMPERAcircuit high input TURE SENSOR CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Throttle position sensor circuit <Ref. to EN(SOHC)-128, DTC P0121 THROTTLE POSITION SENSOR range/performance problem (high CIRCUIT RANGE/PERFORMANCE PROBLEM (HIGH INPUT) , Diaginput) nostic Procedure with Diagnostic Trouble Code (DTC).> Throttle position sensor circuit low <Ref. to EN(SOHC)-130, DTC P0122 THROTTLE POSITION SENSOR input CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Throttle position sensor circuit high <Ref. to EN(SOHC)-134, DTC P0123 THROTTLE POSITION SENSOR input CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(SOHC)-80

DTC No. P0125 Item Insufficient coolant temperature for closed loop fuel control Index
P0130
P0131
P0132
P0133
P0136
P0139
P0170 P0301
P0302
P0303
P0304
P0327 P0328
P0335
P0336
P0340
P0341
P0420
<Ref. to EN(SOHC)-136, DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL -, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Front oxygen (A/F) sensor circuit <Ref. to EN(SOHC)-138, DTC P0130 FRONT OXYGEN (A/F) SENSOR range/performance problem (Lean) CIRCUIT RANGE/PERFORMANCE PROBLEM (LEAN) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Front oxygen (A/F) sensor circuit <Ref. to EN(SOHC)-142, DTC P0131 FRONT OXYGEN (A/F) SENSOR malfunction (open circuit) CIRCUIT MALFUNCTION (OPEN CIRCUIT) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Front oxygen (A/F) sensor circuit <Ref. to EN(SOHC)-144, DTC P0132 FRONT OXYGEN (A/F) SENSOR malfunction (short circuit) CIRCUIT MALFUNCTION (SHORT CIRCUIT) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Front oxygen (A/F) sensor circuit <Ref. to EN(SOHC)-146, DTC P0133 FRONT OXYGEN (A/F) SENSOR slow response CIRCUIT SLOW RESPONSE , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Rear oxygen sensor circuit malfunc- <Ref. to EN(SOHC)-148, DTC P0136 REAR OXYGEN SENSOR CIRtion CUIT MALFUNCTION , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Rear oxygen sensor circuit slow <Ref. to EN(SOHC)-152, DTC P0139 REAR OXYGEN SENSOR CIRresponse CUIT SLOW RESPONSE , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Fuel trim malfunction <Ref. to EN(SOHC)-154, DTC P0170 FUEL TRIM MALFUNCTION , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Cylinder 1 misfire detected <Ref. to EN(SOHC)-156, DTC P0301 CYLINDER 1 MISFIRE DETECTED , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Cylinder 2 misfire detected <Ref. to EN(SOHC)-156, DTC P0302 CYLINDER 2 MISFIRE DETECTED , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Cylinder 3 misfire detected <Ref. to EN(SOHC)-156, DTC P0303 CYLINDER 3 MISFIRE DETECTED , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Cylinder 4 misfire detected <Ref. to EN(SOHC)-158, DTC P0304 CYLINDER 4 MISFIRE DETECTED , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Knock sensor circuit low input <Ref. to EN(SOHC)-166, DTC P0327 KNOCK SENSOR CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Knock sensor circuit high input <Ref. to EN(SOHC)-168, DTC P0328 KNOCK SENSOR CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Crankshaft position sensor circuit <Ref. to EN(SOHC)-170, DTC P0335 CRANKSHAFT POSITION SENmalfunction SOR CIRCUIT MALFUNCTION , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Crankshaft position sensor circuit <Ref. to EN(SOHC)-172, DTC P0336 CRANKSHAFT POSITION SENrange/performance problem SOR CIRCUIT RANGE/PERFORMANCE PROBLEM , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Camshaft position sensor circuit <Ref. to EN(SOHC)-174, DTC P0340 CAMSHAFT POSITION SENSOR malfunction CIRCUIT MALFUNCTION , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Camshaft position sensor circuit <Ref. to EN(SOHC)-176, DTC P0341 CAMSHAFT POSITION SENSOR range/performance problem CIRCUIT RANGE/PERFORMANCE PROBLEM , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Catalyst system efficiency below <Ref. to EN(SOHC)-180, DTC P0420 CATALYST SYSTEM EFFIthreshold CIENCY BELOW THRESHOLD , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(SOHC)-81
DTC No. P0444

Item Index
P0445
P0461
P0462
P0463
P0464
P0480
P0483
P0500
P0506
P0507
P0512
P0513 P0562
P0563
P0604
P0703
P0705 P0710 P0715
Evaporative emission control system <Ref. to EN(SOHC)-182, DTC P0444 EVAPORATIVE EMISSION CONpurge control valve circuit low input TROL SYSTEM PURGE CONTROL VALVE CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Evaporative emission control system <Ref. to EN(SOHC)-186, DTC P0445 EVAPORATIVE EMISSION CONpurge control valve circuit high input TROL SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Fuel level sensor circuit range/ <Ref. to EN(SOHC)-188, DTC P0461 FUEL LEVEL SENSOR CIRCUIT performance problem RANGE/PERFORMANCE PROBLEM , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Fuel level sensor circuit low input <Ref. to EN(SOHC)-190, DTC P0462 FUEL LEVEL SENSOR CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Fuel level sensor circuit high input <Ref. to EN(SOHC)-194, DTC P0463 FUEL LEVEL SENSOR CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Fuel level sensor intermittent input <Ref. to EN(SOHC)-198, DTC P0464 FUEL LEVEL SENSOR INTERMITTENT INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Cooling fan relay 1 circuit low input <Ref. to EN(SOHC)-200, DTC P0480 COOLING FAN RELAY 1 CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Cooling fan function problem <Ref. to EN(SOHC)-204, DTC P0483 COOLING FAN FUNCTION PROBLEM , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Vehicle speed sensor malfunction <Ref. to EN(SOHC)-208, DTC P0500 VEHICLE SPEED SENSOR MALFUNCTION , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Idle control system RPM lower than <Ref. to EN(SOHC)-210, DTC P0506 IDLE CONTROL SYSTEM RPM expected LOWER THAN EXPECTED , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Idle control system RPM higher than <Ref. to EN(SOHC)-212, DTC P0507 IDLE CONTROL SYSTEM RPM expected HIGHER THAN EXPECTED , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Starter switch circuit high input <Ref. to EN(SOHC)-214, DTC P0512 STARTER SWITCH CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Incorrect immobilizer key <Ref. to IM-34, DTC P0153 INCORRECT IMMOBILIZER KEY (USE OF UNREGISTERED KEY) , Diagnostics Chart with Trouble Code.> Charge system cricuit low input <Ref. to EN(SOHC)-216, DTC P0562 CHARGE SYSTEM CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Charge system cricuit high input <Ref. to EN(SOHC)-218, DTC P0563 CHARGE SYSTEM CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Internal control module memory <Ref. to EN(SOHC)-220, DTC P0604 INTERNAL CONTROL MODULE check sum error MEMORY CHECK SUM ERROR , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Brake switch input malfunction <Ref. to EN(SOHC)-222, DTC P0703 BRAKE SWITCH INPUT MALFUNCTION , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Transmission range sensor circuit <Ref. to AT-122, CHECK INHIBITOR SWITCH., Diagnostic Procedure for malfunction No-trouble Code.> Transmission fluid temperature sen- <Ref. to AT-46, TROUBLE CODE 27 ATF TEMPERATURE SENSOR sor circuit malfunction , Diagnostic Procedure with Trouble Code.> Torque converter turbine speed sen- <Ref. to AT-64, TROUBLE CODE 36 TORQUE CONVERTER TURBINE sor circuit malfunction SPEED SENSOR , Diagnostic Procedure with Trouble Code.>
EN(SOHC)-82

DTC No. P0720 P0725 P0731 P0732 P0733 P0734 P0741 Item Output speed sensor (Front vehicle speed sensor) circuit malfunction Engine speed input circuit malfunction Gear 1 incorrect ratio Gear 2 incorrect ratio Gear 3 incorrect ratio Gear 4 incorrect ratio Torque converter clutch system malfunction Torque converter clutch system (Lock-up duty solenoid) electrical Pressure control solenoid (Line pressure duty solenoid) electrical Shift solenoid A (Shift solenoid 1) electrical Shift solenoid B (Shift solenoid 2) electrical 2-4 brake pressure control solenoid valve circuit malfunction 2-4 brake timing control solenoid valve circuit malfunction Atmospheric pressure sensor low input Atmospheric pressure sensor high input Atmospheric pressure sensor range/ performance problem Front oxygen (A/F) sensor circuit range/perfomance problem Throttle position sensor circuit range/performance problem (low input) Pressure sensor circuit range/ performance problem (high input) Fuel level sensor circuit range/ performance problem 2 Cooling fan relay 1 circuit high input Index
P0743 P0748 P0753 P0758 P0778 P0785 P1110
P1111
P1112
P1137
P1142
P1146
P1442
P1480
P1507
Idle control system malfunction (failsafe)
<Ref. to AT-58, TROUBLE CODE 33 FRONT VEHICLE SPEED SENSOR , Diagnostic Procedure with Trouble Code.> <Ref. to AT-42, TROUBLE CODE 11 ENGINE SPEED SIGNAL , Diagnostic Procedure with Trouble Code.> <Ref. to EN(SOHC)-224, DTC P0731 GEAR 1 INCORRECT RATIO , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(SOHC)-224, DTC P0732 GEAR 2 INCORRECT RATIO , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(SOHC)-224, DTC P0733 GEAR 3 INCORRECT RATIO , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(SOHC)-225, DTC P0734 GEAR 4 INCORRECT RATIO , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(SOHC)-226, DTC P0741 TORQUE CONVERTER CLUTCH SYSTEM MALFUNCTION , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to AT-96, TROUBLE CODE 77 LOCK-UP DUTY SOLENOID , Diagnostic Procedure with Trouble Code.> <Ref. to AT-88, TROUBLE CODE 75 LINE PRESSURE DUTY SOLENOID , Diagnostic Procedure with Trouble Code.> <Ref. to AT-72, TROUBLE CODE 71 SHIFT SOLENOID 1 , Diagnostic Procedure with Trouble Code.> <Ref. to AT-76, TROUBLE CODE 72 SHIFT SOLENOID 2 , Diagnostic Procedure with Trouble Code.> <Ref. to AT-92, TROUBLE CODE 76 2-4 BRAKE DUTY SOLENOID , Diagnostic Procedure with Trouble Code.> <Ref. to AT-84, TROUBLE CODE 74 2-4 BRAKE TIMING SOLENOID , Diagnostic Procedure with Trouble Code.> <Ref. to EN(SOHC)-228, DTC P1110 ATMOSPHERIC PRESSURE SENSOR CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(SOHC)-232, DTC P1111 ATMOSPHERIC PRESSURE SENSOR CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(SOHC)-236, DTC P1112 ATMOSPHERIC PRESSURE SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(SOHC)-238, DTC P1137 FRONT OXYGEN (A/F) SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(SOHC)-242, DTC P1142 THROTTLE POSITION SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (LOW INPUT) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(SOHC)-244, DTC P1146 PRESSURE SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (HIGH INPUT) , Diagnostic Procedure with Diagnostic Trouble Code (DTC) for.> <Ref. to EN(SOHC)-248, DTC P1442 FUEL LEVEL SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM 2 , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(SOHC)-250, DTC P1480 COOLING FAN RELAY 1 CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(SOHC)-254, DTC P1507 IDLE CONTROL SYSTEM MALFUNCTION (FAIL-SAFE) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(SOHC)-83
DTC No. P1510

Item Index <Ref. to EN(SOHC)-256, DTC P1510 IDLE AIR CONTROL SOLENOID VALVE SIGNAL 1 CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(SOHC)-256, DTC P1511 IDLE AIR CONTROL SOLENOID VALVE SIGNAL 1 CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(SOHC)-256, DTC P1512 IDLE AIR CONTROL SOLENOID VALVE SIGNAL 2 CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(SOHC)-256, DTC P1513 IDLE AIR CONTROL SOLENOID VALVE SIGNAL 2 CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(SOHC)-256, DTC P1514 IDLE AIR CONTROL SOLENOID VALVE SIGNAL 3 CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(SOHC)-256, DTC P1515 IDLE AIR CONTROL SOLENOID VALVE SIGNAL 3 CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(SOHC)-258, DTC P1516 IDLE AIR CONTROL SOLENOID VALVE SIGNAL 4 CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(SOHC)-262, DTC P1517 IDLE AIR CONTROL SOLENOID VALVE SIGNAL 4 CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(SOHC)-264, DTC P1518 STARTER SWITCH CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(SOHC)-266, DTC P1540 VEHICLE SPEED SENSOR MALFUNCTION 2 , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(SOHC)-268, DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to IM-35, DTC P1570 ANTENNA , Diagnostics Chart with Trouble Code.> <Ref. to IM-26, DTC P1571 REFERENCE CODE INCOMPATIBILITY , Diagnostics Chart with Trouble Code.> <Ref. to IM-27, DTC P1572 IMM CIRCUIT FAILURE (EXCEPT ANTENNA CIRCUIT) , Diagnostics Chart with Trouble Code.> <Ref. to IM-33, DTC P1574 KEY COMMUNICATION FAILURE , Diagnostics Chart with Trouble Code.> <Ref. to IM-34, DTC P1576 EGI CONTROL MODULE EEPROM , Diagnostics Chart with Trouble Code.> <Ref. to IM-34, DTC P1577 IMM CONTROL MODULE EEPROM , Diagnostics Chart with Trouble Code.> <Ref. to EN(SOHC)-270, DTC P1590 NEUTRAL POSITION SWITCH CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(SOHC)-274, DTC P1591 NEUTRAL POSITION SWITCH CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(SOHC)-276, DTC P1592 NEUTRAL POSITION SWITCH CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Idle air control solenoid valve signal 1 circuit low input Idle air control solenoid valve signal 1 circuit high input Idle air control solenoid valve signal 2 circuit low input Idle air control solenoid valve signal 2 circuit high input Idle air control solenoid valve signal 3 circuit low input Idle air control solenoid valve signal 3 circuit high input Idle air control solenoid valve signal 4 circuit low input Idle air control solenoid valve signal 4 circuit high input Starter switch circuit low input
P1511
P1512
P1513
P1514
P1515
P1516
P1517
P1518
P1540
Vehicle speed sensor malfunction 2
P1560
Back-up voltage circuit malfunction
P1570 P1571 P1572 P1574 P1576 P1577 P1590
Antennna Reference code incompatibility IMM circuit failure except antenna circuit Key communication failure EGI control module EEPROM IMM control module EEPROM Neutral position switch circuit high input (AT model) Neutral position switch circuit low input (AT model) Neutral position switch circuit (MT model)
P1591
P1592
EN(SOHC)-84

DTC No. P1594 Item Automatic transmission diagnosis input signal circuit malfunction Index
P1595
P1596
P1698
P1699
P1700 P1701
P1703 P1711
P1712
<Ref. to EN(SOHC)-278, DTC P1594 AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL CIRCUIT MALFUNCTION , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Automatic transmission diagnosis <Ref. to EN(SOHC)-280, DTC P1595 AUTOMATIC TRANSMISSION input signal circuit low input DIAGNOSIS INPUT SIGNAL CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Automatic transmission diagnosis <Ref. to EN(SOHC)-282, DTC P1596 AUTOMATIC TRANSMISSION input signal circuit high input DIAGNOSIS INPUT SIGNAL CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Engine torque control cut signal cir- <Ref. to EN(SOHC)-284, DTC P1698 ENGINE TORQUE CONTROL cuit low input CUT SIGNAL CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Engine torque control cut signal cir- <Ref. to EN(SOHC)-286, DTC P1699 ENGINE TORQUE CONTROL cuit high input CUT SIGNAL CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Throttle position sensor circuit mal- <Ref. to AT-50, TROUBLE CODE 31 THROTTLE POSITION SENSOR function for automatic transmission , Diagnostic Procedure with Trouble Code.> Cruise control set signal circuit mal- <Ref. to EN(SOHC)-288, DTC P1701 CRUISE CONTROL SET SIGNAL function for automatic transmission CIRCUIT MALFUNCTION FOR AUTOMATIC TRANSMISSION , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Low clutch timing control solenoid <Ref. to AT-80, TROUBLE CODE 73 LOW CLUTCH TIMING SOLEvalve circuit malfunction NOID , Diagnostic Procedure with Trouble Code.> Engine torque control signal 1 circuit <Ref. to EN(SOHC)-290, DTC P1711 ENGINE TORQUE CONTROL malfunction SIGNAL 1 CIRCUIT MALFUNCTION , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Engine torque control signal 2 circuit <Ref. to EN(SOHC)-292, DTC P1712 ENGINE TORQUE CONTROL malfunction SIGNAL 2 CIRCUIT MALFUNCTION , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(SOHC)-85
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC)

S058521
18. Diagnostic Procedure with Diagnostic Trouble Code (DTC)

S058521F83
A: DTC P0031 FRONT OXYGEN (A/F) SENSOR HEATER CIRCUIT LOW INPUT
DTC DETECTING CONDITION: Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(SOHC)-45, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)-42, OPERATION, Inspection Mode.>. WIRING DIAGRAM:
S2M2077
EN(SOHC)-86

No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. Check Yes Go to step 2. Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0031 and P0037 at the same time? Is the voltage more than 10 Go to step 3. V? No Go to step 5.
CHECK POWER SUPPLY TO FRONT OXYGEN (A/F) SENSOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from front oxygen (A/F) sensor. 3) Turn ignition switch to ON. 4) Measure voltage between front oxygen (A/F) sensor connector and engine ground. Connector & terminal (E24) No. 2 (+) Engine ground ():
Is the resistance less than CHECK GROUND CIRCUIT OF ECM. Measure resistance of harness between ECM 5 ? connector and chassis ground. Connector & terminal (B134) No. 35 Chassis ground: (B134) No. 34 Chassis ground:
Go to step 4.
CHECK CURRENT DATA. 1) Start engine 2) Read data of front oxygen (A/F) sensor heater current using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(SOHC)-34, Subaru Select Monitor.> OBD-II scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Instruction Manual. CHECK OUTPUT SIGNAL FROM ECM. 1) Start and idle the engine. 2) Measure voltage between ECM connector and chassis ground. Connector & terminal (B134) No. 22 (+) Chassis ground ():
Is the value more than 0.2 A?
Repair poor contact in connector. NOTE: In this case, repair the following: Poor contact in front oxygen (A/F) sensor connector Poor contact in ECM connector
Repair power supply line. NOTE: In this case, repair the following: Open circuit in harness between main relay and front oxygen (A/F) sensor connector Poor contact in front oxygen (A/F) sensor connector Poor contact in main relay connector Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ECM and engine ground terminal Poor contact in ECM connector Poor contact in coupling connector (B22) Go to step 5.
Is the voltage less than 1.0 Go to step 7. V?
Go to step 6.
EN(SOHC)-87
No. 6

Step CHECK OUTPUT SIGNAL FROM ECM. Measure voltage between ECM connector and chassis ground. Connector & terminal (B134) No. 22 (+) Chassis ground (): CHECK OUTPUT SIGNAL FROM ECM. Measure voltage between ECM connector and chassis ground. Connector & terminal (B134) No. 23 (+) Chassis ground (): CHECK OUTPUT SIGNAL FROM ECM. Measure voltage between ECM connector and chassis ground. Connector & terminal (B134) No. 23 (+) Chassis ground (): CHECK FRONT OXYGEN (A/F) SENSOR. 1) Turn ignition switch to OFF. 2) Measure resistance between front oxygen (A/F) sensor connector terminals. Terminals No. 2 No. 5: Check Does the voltage change less than 1.0 V by shaking harness and connector of ECM while monitoring the value with voltage meter? Yes Repair poor contact in ECM connector. No Go to step 7.
Go to step 8.
Does the voltage change less than 1.0 V by shaking harness and connector of ECM while monitoring the value with voltage meter? Is the resistance less than 10 ?
Go to step 9.
Repair harness and connector. NOTE: In this case, repair the following: Open or ground short circuit in harness between front oxygen (A/F) sensor and ECM connector Poor contact in front oxygen (A/F) sensor connector Poor contact in ECM connector
Replace front oxygen (A/F) sensor. <Ref. to FU(SOHC)-45, Front Oxygen (A/F) Sensor.>
EN(SOHC)-88

MEMO:
EN(SOHC)-89
B: DTC P0032 FRONT OXYGEN (A/F) SENSOR HEATER CIRCUIT HIGH INPUT
S058521F84
S2M2077
EN(SOHC)-90

No. 1 Step CHECK OUTPUT SIGNAL FROM ECM. 1) Turn ignition switch to ON. 2) Measure voltage between ECM connector and chassis ground. Connector & terminal (B134) No. 23 (+) Chassis ground (): CHECK OUTPUT SIGNAL FROM ECM. Measure voltage between ECM connector and chassis ground. Connector & terminal (B134) No. 22 (+) Chassis ground (): CHECK FRONT OXYGEN (A/F) SENSOR HEATER CURRENT. 1) Turn ignition switch to OFF. 2) Repair battery short circuit in harness between ECM and front oxygen (A/F) sensor connector. 3) Turn ignition switch to ON. 4) Read data of front oxygen (A/F) sensor heater current using Subaru Select Monitor or the OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(SOHC)-34, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedure, refer to the OBD-II General Scan Tool Instruction Manual. CHECK OUTPUT SIGNAL FROM ECM. Measure voltage between ECM connector and chassis ground. Connector & terminal (B134) No. 23 (+) Chassis ground (): CHECK OUTPUT SIGNAL FROM ECM. Measure voltage between ECM connector and chassis ground. Connector & terminal (B134) No. 22 (+) Chassis ground (): Check Is the voltage more than 8 V? Yes Go to step 3. No Go to step 2.
Is the voltage more than 8 V?
Go to step 3.
Go to step 4.
END
Does the voltage change more than 8 V by shaking harness and connector of ECM while monitoring the value with voltage meter? Does the voltage change more than 8 V by shaking harness and connector of ECM while monitoring the value with voltage meter?
Go to step 5. Repair battery short circuit in harness between ECM and front oxygen (A/F) sensor connector. END Repair battery short circuit in harness between ECM and front oxygen (A/F) sensor connector.
EN(SOHC)-91
C: DTC P0037 REAR OXYGEN SENSOR HEATER CIRCUIT MALFUNCTION

S058521F85
DTC DETECTING CONDITION: Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(SOHC)-45, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)-42, OPERATION, Inspection Mode.>. WIRING DIAGRAM:
S2M2078
EN(SOHC)-92

No. 1 Step CHECK GROUND CIRCUIT OF ECM. 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM. 3) Measure resistance of harness between ECM connector and chassis ground. Connector & terminal (B134) No. 35 Chassis ground: CHECK GROUND CIRCUIT OF ECM. 1) Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ECM and engine ground terminal Poor contact in ECM connector Poor contact in coupling connector (B22) 2) Measure resistance of harness between ECM connector and chassis ground. Connector & terminal (B134) No. 34 Chassis ground: Check Is the resistance less than 5 ? Yes Go to step 3. No Go to step 2.
Go to step 3.
CHECK CURRENT DATA. 1) Start engine. 2) Read data of rear oxygen sensor heater current using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(SOHC)-34, Subaru Select Monitor.> OBD-II scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Instruction Manual. CHECK OUTPUT SIGNAL FROM ECM. 1) Start and idle the engine. 2) Measure voltage between ECM connector and chassis ground. Connector & terminal (B134) No. 21 (+) Chassis ground (): CHECK OUTPUT SIGNAL FROM ECM. Measure voltage between ECM connector and chassis ground. Connector & terminal (B134) No. 21 (+) Chassis ground (): CHECK OUTPUT SIGNAL FROM ECM. 1) Disconnect connector from rear oxygen sensor. 2) Measure voltage between ECM connector and chassis ground. Connector & terminal (B134) No. 21 (+) Chassis ground ():
Repair connector. NOTE: In this case, repair the following: Poor contact in rear oxygen sensor connector Poor contact in rear oxygen sensor connecting harness connector Poor contact in ECM connector Is the voltage less than 1.0 Go to step 7. Go to step 5. V?
Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ECM and engine ground terminal Poor contact in ECM connector Poor contact in coupling connector (B22) Go to step 4.
Does the voltage change less than 1.0 V by shaking harness and connector of ECM while monitoring the value with voltage meter?
Go to step 6.
Is the voltage less than 1.0 Replace ECM. V? <Ref. to FU(SOHC)-49, Engine Control Module.>
Repair battery short circuit in harness between ECM and rear oxygen sensor connector. After repair, replace ECM. <Ref. to FU(SOHC)-49, Engine Control Module.>
EN(SOHC)-93
No. 7

Step Check Yes Is the voltage more than 10 Go to step 8. CHECK POWER SUPPLY TO REAR OXYV? GEN SENSOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from rear oxygen sensor. 3) Turn ignition switch to ON. 4) Measure voltage between rear oxygen sensor connector and engine ground or chassis ground. Connector & terminal (E25) No. 2 (+) Chassis ground (): No Repair power supply line. NOTE: In this case, repair the following: Open circuit in harness between main relay and rear oxygen sensor connector Poor contact in rear oxygen sensor connector Poor contact in coupling connector (E1) Replace rear oxygen sensor. <Ref. to FU(SOHC)-47, Rear Oxygen Sensor.>
CHECK REAR OXYGEN SENSOR. 1) Turn ignition switch to OFF. 2) Measure resistance between rear oxygen sensor connector terminals. Terminals No. 1 No. 2:
Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between rear oxygen sensor and ECM connector Poor contact in rear oxygen sensor connector Poor contact in ECM connector Poor contact in coupling connector (E1)
EN(SOHC)-94

MEMO:
EN(SOHC)-95
D: DTC P0038 REAR OXYGEN SENSOR HEATER CIRCUIT HIGH INPUT

S058521F86
S2M2078
No. 1
Step CHECK INPUT SIGNAL FOR ECM. Measure voltage between ECM connector and chassis ground. Connector & terminal (B134) No. 21 (+) Chassis ground ():
Check Is the voltage more than 8 V?
Yes Go to step 2.
No Go to step 3.
EN(SOHC)-96

No. 2 Step CHECK CURRENT DATA. 1) Turn ignition switch to OFF. 2) Repair battery short circuit in harness between ECM and rear oxygen sensor connector. 3) Turn ignition switch to ON. 4) Read data of rear oxygen sensor heater current using Subaru Select Monitor or the OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(SOHC)-34, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedure, refer to the OBD-II General Scan Tool Instruction Manual. CHECK POOR CONTACT. Check poor contact in ECM connector. Check Is the value more than 7 A? Yes Replace ECM. <Ref. to FU(SOHC)-49, Engine Control Module.> No END
END
EN(SOHC)-97
E: DTC P0066 AIR ASSIST INJECTOR SOLENOID VALVE CIRCUIT LOW INPUT
S058521F88
DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: Erroneous idling Engine stalls. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(SOHC)-45, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)-42, OPERATION, Inspection Mode.>. WIRING DIAGRAM:
S2M2079
EN(SOHC)-98

No. 1 Step CHECK OUTPUT SIGNAL FROM ECM. 1) Turn ignition switch to ON. 2) Measure voltage between ECM and chassis ground. Connector & terminal (B134) No. 24 (+) Chassis ground (): CHECK POWER SUPPLY TO AIR ASSIST INJECTOR SOLENOID VALVE. 1) Turn ignition switch to OFF. 2) Disconnect connector from air assist injector solenoid valve. 3) Turn ignition switch to ON. 4) Measure voltage between air assist injector solenoid valve and engine ground. Connector & terminal (E42) No. 2 (+) Engine ground (): Check Yes Is the voltage more than 10 Repair poor conV? tact in ECM connector. No Go to step 2.
CHECK HARNESS BETWEEN ECM AND AIR ASSIST INJECTOR SOLENOID VALVE CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM. 3) Measure resistance of harness between ECM and air assist injector solenoid valve connector. Connector & terminal (B134) No. 24 (E42) No. 1:
Go to step 4.
CHECK HARNESS BETWEEN ECM AND AIR ASSIST INJECTOR SOLENOID VALVE CONNECTOR. Measure resistance of harness between ECM and chassis ground. Connector & terminal (B134) No. 24 Chassis ground: CHECK POOR CONTACT. Check poor contact in ECM and air assist injector solenoid valve connectors.
Repair ground short circuit in harness between ECM and air assist injector solenoid valve connector. Is there poor contact in Repair poor conECM and air assist injector tact in ECM and solenoid valve connectors? air assist injector solenoid valve connectors.
Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between air assist injector solenoid valve and main relay connector Poor contact in coupling connector (B22) Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ECM and air assist injector solenoid valve connector Poor contact in coupling connector (B22) Go to step 5.
Replace air assist injector solenoid valve. <Ref. to FU(SOHC)-39, Air Assist Injector Solenoid Valve.>
EN(SOHC)-99
F: DTC P0067 AIR ASSIST INJECTOR SOLENOID VALVE CIRCUIT HIGH INPUT
S058521G72
DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: Erroneous idling Engine stalls. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(SOHC)-45, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)-42, OPERATION, Inspection Mode.>. WIRING DIAGRAM:
S2M2079
EN(SOHC)-100

No. 1 Step CHECK OUTPUT SIGNAL FROM ECM. 1) Turn ignition switch to ON. 2) Measure voltage between ECM and chassis ground. Connector & terminal (B134) No. 24 (+) Chassis ground (): CHECK OUTPUT SIGNAL FROM ECM. 1) Turn ignition switch to OFF. 2) Disconnect connector from air assist injector solenoid valve. 3) Turn ignition switch to ON. 4) Measure voltage between ECM and chassis ground. Connector & terminal (B134) No. 24 (+) Chassis ground (): Check Yes Is the voltage more than 10 Go to step 2. V? No Go to step 3.
CHECK OUTPUT SIGNAL FROM ECM. Measure voltage between ECM and chassis ground. Connector & terminal (B134) No. 24 (+) Chassis ground ():
Is the voltage more than 10 Repair battery V? short circuit in harness between ECM and air assist injector solenoid valve connector. After repair, replace ECM. <Ref. to FU(SOHC)-49, Engine Control Module.> Repair battery Does the voltage change more than 10 V by shaking short circuit in harness between harness and connector of ECM and air ECM while monitoring the assist injector value with voltage meter? solenoid valve connector. After repair, replace ECM. <Ref. to FU(SOHC)-49, Engine Control Module.>
Replace air assist injector solenoid valve <Ref. to FU(SOHC)-39, Air Assist Injector Solenoid Valve.> and ECM <Ref. to FU(SOHC)-49, Engine Control Module.>
Contact your Subaru distributor. NOTE: Inspection by DTM is required, because probable cause is deterioration of multiple parts.
EN(SOHC)-101
G: DTC P0106 PRESSURE SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (LOW INPUT)

S058521F90
S2M2097
EN(SOHC)-102

No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. NOTE: In this case, it is not necessary to inspect DTC P0106. Yes Inspect DTC P0107, P0108 or P1112 using 17. List of Diagnostic Trouble Code (DTC). <Ref. to EN(SOHC)-80, List of Diagnostic Trouble Code (DTC).> Are there holes, loose bolts Repair air intake or disconnection of hose on system. air intake system? Is the value within the Go to step 4. specifications? Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0107, P0108 or P1112? No Go to step 2.
CHECK AIR INTAKE SYSTEM.
Go to step 3.
CHECK PRESSURE SENSOR. 1) Start the engine and warm-up engine until coolant temperature is greater than 60C (140F). 2) Place the shift lever in the selector lever in N or P position. 3) Turn A/C switch to OFF. 4) Turn all accessory switches to OFF. 5) Read data of intake manifold pressure sensor signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(SOHC)-34, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedure, refer to the OBD-II General Scan Tool Instruction Manual. Specification: Intake manifold absolute pressure Ignition ON 73.3 106.6 kPa (550 800 mmHg, 21.65 31.50 inHg) Idling 20.0 46.7 kPa (150 350 mmHg, 5.91 13.78 inHg) CHECK THROTTLE POSITION. Read data of throttle position signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(SOHC)-34, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedure, refer to the OBD-II General Scan Tool Instruction Manual.
Replace intake air temperature sensor and pressure sensor. <Ref. to FU(SOHC)-36, Intake Air Temperature and Pressure Sensor.>
Is throttle positioning ratio equal to or less than 5% when throttle is fully closed?
Go to step 5.
Adjust or replace throttle position sensor. <Ref. to FU(SOHC)-33 Throttle Position Sensor.>
EN(SOHC)-103
No. 5

Step CHECK THROTTLE POSITION. Check Is throttle positioning ratio equal to or more than 85% when throttle is fully open? Yes Replace intake air temperature and pressure sensor. <Ref. to FU(SOHC)-36, Intake Air Temperature and Pressure Sensor.> No Replace throttle position sensor. <Ref. to FU(SOHC)-33, Throttle Position Sensor.>
EN(SOHC)-104

MEMO:
EN(SOHC)-105

S058521B12
H: DTC P0107 PRESSURE SENSOR CIRCUIT LOW INPUT

DTC DETECTING CONDITION: Immediately at fault recognition
CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(SOHC)-45, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)-42, OPERATION, Inspection Mode.>. WIRING DIAGRAM:
S2M2097
EN(SOHC)-106

No. 1 Step CHECK CURRENT DATA. 1) Start engine. 2) Read the data of intake manifold absolute pressure signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(SOHC)-34, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Instruction Manual. CHECK POOR CONTACT. Check poor contact in ECM and pressure sensor connector. Check Is the value less than 13.3 kPa (100 mmHg, 3.94 inHg)? Yes Go to step 3. No Go to step 2.
Is there poor contact in ECM or pressure sensor connector?
Repair poor contact in ECM or pressure sensor connector. Go to step 5.
CHECK INPUT SIGNAL FOR ECM. Measure voltage between ECM connector and chassis ground. Connector & terminal (B136) No. 15 (+) Chassis ground (): CHECK INPUT SIGNAL FOR ECM. Measure voltage between ECM connector and chassis ground. Connector & terminal (B136) No. 15 (+) Chassis ground ():
Is the voltage more than 4.5 V?
Even if MIL lights up, the circuit has returned to a normal condition at this time. Go to step 4.
Repair poor conDoes the voltage change more than 4.5 V by shaking tact in ECM connector. harness and connector of ECM while monitoring the value with voltage meter?
CHECK INPUT SIGNAL FOR ECM. Measure voltage between ECM and chassis ground. Connector & terminal (B136) No. 5 (+) Chassis ground (): CHECK INPUT SIGNAL FOR ECM. (USING SUBARU SELECT MONITOR.) Read data of atmospheric absolute pressure signal using Subaru Select Monitor. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(SOHC)-34, Subaru Select Monitor.>
Contact your Subaru distributor. NOTE: Inspection by DTM is required, because probable cause is deterioration of multiple parts. Go to step 6.
Repair poor conDoes the value change tact in ECM conmore than 13.3 kPa (100 mmHg, 3.94 inHg) by shak- nector. ing harness and connector of ECM while monitoring the value with Subaru Select Monitor?
Go to step 7.
EN(SOHC)-107
No. 7

Step CHECK HARNESS BETWEEN ECM AND INTAKE AIR TEMPERATURE AND PRESSURE SENSOR CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from intake air temperature and pressure sensor. 3) Turn ignition switch to ON. 4) Measure voltage between intake air temperature sensor and pressure sensor connector and engine ground. Connector & terminal (E20) No. 3 (+) Engine ground (): CHECK HARNESS BETWEEN ECM AND INTAKE AIR TEMPERATURE AND PRESSURE SENSOR CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM. 3) Measure resistance of harness between ECM and intake air temperature and pressure sensor connector. Connector & terminal (B136) No. 16 (E20) No. 1: CHECK HARNESS BETWEEN ECM AND INTAKE AIR TEMPERATURE AND PRESSURE SENSOR CONNECTOR. Measure resistance of harness between intake air temperature and pressure sensor connector and engine ground. Connector & terminal (E20) No. 4 Engine ground: CHECK POOR CONTACT. Check poor contact in intake manifold pressure sensor connector. Check Is the voltage more than 4.5 V? Yes Go to step 8. No Repair open circuit in harness between ECM and intake air temperature and pressure sensor connector.
Go to step 9.
Repair open circuit in harness between ECM and intake air temperature and pressure sensor connector.
Is the resistance more than Go to step 10. 500 k?
Repair ground short circuit in harness between ECM and intake air temperature and pressure sensor connector. Replace intake air temperature and pressure sensor. <Ref. to FU(SOHC)-36, Intake Air Temperature and Pressure Sensor.>
10
Is there poor contact in intake manifold pressure sensor connector?
Repair poor contact in intake air temperature and pressure sensor connector.
EN(SOHC)-108

MEMO:
EN(SOHC)-109

S058521B13
I: DTC P0108 PRESSURE SENSOR CIRCUIT HIGH INPUT

S2M2097
EN(SOHC)-110

No. 1 Step CHECK CURRENT DATA. 1) Start engine. 2) Read the data of intake manifold absolute pressure signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(SOHC)-34, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Instruction Manual. CHECK INPUT SIGNAL FOR ECM. Measure voltage between ECM connector and chassis ground. Connector & terminal (B136) No. 15 (+) Chassis ground (): CHECK INPUT SIGNAL FOR ECM. Measure voltage between ECM connector and chassis ground. Connector & terminal (B136) No. 15 (+) Chassis ground (): Check Is the value more than 119.5 kPa (896.5 mmHg, 35.29 inHg)? Yes Go to step 10. No Go to step 2.
Go to step 4.
Go to step 3.
CHECK INPUT SIGNAL FOR ECM. Measure voltage between ECM connector and chassis ground. Connector & terminal (B136) No. 5 (+) Chassis ground (): CHECK INPUT SIGNAL FOR ECM. (USING SUBARU SELECT MONITOR.) Read data of atmospheric absolute pressure signal using Subaru Select Monitor. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(SOHC)-34, Subaru Select Monitor.> CHECK HARNESS BETWEEN ECM AND INTAKE AIR TEMPERATURE AND PRESSURE SENSOR CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from intake air temperature and pressure sensor. 3) Turn ignition switch to ON. 4) Measure voltage between intake air temperature and pressure sensor connector and engine ground. Connector & terminal (E20) No. 3 (+) Engine ground ():
Repair poor conDoes the value change tact in ECM conmore than 13.3 kPa (100 mmHg, 3.94 inHg) by shak- nector. ing harness and connector of ECM while monitoring the value with Subaru Select Monitor?
Go to step 6.
Go to step 7.
EN(SOHC)-111
No. 7

Step CHECK HARNESS BETWEEN ECM AND INTAKE AIR TEMPERATURE AND PRESSURE SENSOR CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM. 3) Measure resistance of harness between ECM and intake air temperature and pressure sensor connector. Connector & terminal (B136) No. 5 (E20) No. 4: CHECK HARNESS BETWEEN ECM AND INTAKE AIR TEMPERATURE AND PRESSURE SENSOR CONNECTOR. Measure resistance of harness between ECM and intake air temperature and pressure sensor connector. Connector & terminal (B136) No. 16 (E20) No. 1: CHECK POOR CONTACT. Check poor contact in intake air temperature and pressure sensor connector. Check Is the resistance less than 1 ? Yes Go to step 8. No Repair open circuit in harness between ECM and intake air temperature and pressure sensor connector.
Go to step 9.
Is there poor contact in intake manifold pressure sensor connector?
Repair poor contact in intake air temperature and pressure sensor connector.
10
Is the value more than CHECK HARNESS BETWEEN ECM AND 119.5 kPa (896.5 mmHg, INTAKE AIR TEMPERATURE AND PRES35.29 inHg)? SURE SENSOR CONNECTOR. 1) Turn ignition switch to OFF and Subaru Select Monitor or the OBD-II general scan tool switch to OFF. 2) Disconnect connector from intake air temperature and pressure sensor. 3) Turn ignition switch to ON and Subaru Select Monitor or the OBD-II general scan tool switch to ON. 4) Read data of intake manifold absolute pressure signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(SOHC)-34, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Instruction Manual.
Replace intake air temperature and pressure sensor. <Ref. to FU(SOHC)-36, Intake Air Temperature and Pressure Sensor.> Replace intake air Repair battery temperature and short circuit in harness between pressure sensor. <Ref. to ECM and intake FU(SOHC)-36, air temperature and pressure sen- Intake Air Temperature and sor connector. Pressure Sensor.>
EN(SOHC)-112

MEMO:
EN(SOHC)-113
J: DTC P0111 INTAKE AIR TEMPERATURE SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM

S058521B14
DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: Erroneous idling Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(SOHC)-45, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)-42, OPERATION, Inspection Mode.>. WIRING DIAGRAM:
S2M2097
EN(SOHC)-114

No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0112, P0113, P0117, P0118 or P0125? Yes Inspect DTC P0112, P0113, P0117, P0118 or P0125 using 17. List of Diagnostic Trouble Code (DTC). <Ref. to EN(SOHC)-80, List of Diagnostic Trouble Code (DTC).> NOTE: In this case, it is not necessary to inspect DTC P0111. Replace intake air temperature and pressure sensor. <Ref. to FU(SOHC)-36, Intake Air Temperature and Pressure Sensor.> No Go to step 2.
Is the engine coolant temCHECK ENGINE COOLANT TEMPERAperature between 75C TURE. 1) Start the engine and warm it up completely. (167F) and 95C (203F)? 2) Measure engine coolant temperature using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(SOHC)-34, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Instruction Manual.
Inspect DTC P0125 using 17. List of Diagnostic Trouble Code (DTC). <Ref. to EN(SOHC)-80, List of Diagnostic Trouble Code (DTC).>
EN(SOHC)-115
K: DTC P0112 INTAKE AIR TEMPERATURE SENSOR CIRCUIT LOW INPUT

S058521B15
S2M2097
EN(SOHC)-116

No. 1 Step Check Is the value greater than CHECK CURRENT DATA. 120C (248F)? 1) Start engine. 2) Read data of intake air temperature sensor signal using Subaru Select Monitor or the OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(SOHC)-34, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedure, refer to the OBD-II General Scan Tool Instruction Manual. Yes Go to step 2.
CHECK HARNESS BETWEEN INTAKE AIR Is the value less than TEMPERATURE AND PRESSURE SENSOR 40C (40F)? AND ECM CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from intake air temperature and pressure sensor. 3) Turn ignition switch to ON. 4) Read data of intake air temperature sensor signal using Subaru Select Monitor or the OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(SOHC)-34, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedure, refer to the OBD-II General Scan Tool Instruction Manual.
No Repair poor contact. NOTE: In this case, repair the following: Poor contact in intake air temperature and pressure sensor Poor contact in ECM Poor contact in coupling connector (B21) Poor contact in joint connector (B83, B122) Replace intake air Repair ground short circuit in temperature and harness between pressure sensor. intake air tem<Ref. to perature sensor FU(SOHC)-36, and ECM connecIntake Air Temtor. perature and Pressure Sensor.>
EN(SOHC)-117
L: DTC P0113 INTAKE AIR TEMPERATURE SENSOR CIRCUIT HIGH INPUT

S058521B16
S2M2097
EN(SOHC)-118

No. 1 Step Check Is the value less than CHECK CURRENT DATA. 40C (40F)? 1) Start engine. 2) Read data of intake air temperature sensor signal using Subaru Select Monitor or the OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(SOHC)-34, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedure, refer to the OBD-II General Scan Tool Instruction Manual. Yes Go to step 2.
No Repair poor contact. NOTE: In this case, repair the following: Poor contact in intake air temperature and pressure sensor Poor contact in ECM Poor contact in coupling connector (B21) Poor contact in joint connector (B83, B122) Go to step 3.
CHECK HARNESS BETWEEN INTAKE AIR TEMPERATURE AND PRESSURE SENSOR AND ECM CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from intake air temperature and pressure sensor. 3) Measure voltage between intake air temperature and pressure sensor connector and engine ground. Connector & terminal (E20) No. 2 (+) Engine ground (): CHECK HARNESS BETWEEN INTAKE AIR TEMPERATURE AND PRESSURE SENSOR AND ECM CONNECTOR. 1) Turn ignition switch to ON. 2) Measure voltage between intake air temperature and pressure sensor connector and engine ground. Connector & terminal (E20) No. 2 (+) Engine ground ():
Is the voltage more than 10 Repair battery V? short circuit in harness between intake air temperature and pressure sensor and ECM connector.
Go to step 4. Is the voltage more than 10 Repair battery V? short circuit in harness between intake air temperature and pressure sensor and ECM connector.
EN(SOHC)-119
No. 4

Step CHECK HARNESS BETWEEN INTAKE AIR TEMPERATURE AND PRESSURE SENSOR AND ECM CONNECTOR. Measure voltage between intake air temperature and pressure sensor connector and engine ground. Connector & terminal (E20) No. 2 (+) Engine ground (): Check Is the voltage more than 3 V? Yes Go to step 5. No Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between intake air temperature and pressure sensor and ECM connector Poor contact in intake air temperature and pressure sensor Poor contact in ECM Poor contact in coupling connector (B21) Poor contact in joint connector (B83, B122) Replace intake air Repair harness and connector. temperature and NOTE: pressure sensor. In this case, <Ref. to repair the followFU(SOHC)-36, ing: Intake Air Tem Open circuit in perature and Pressure Sensor.> harness between intake air temperature and pressure sensor and ECM connector Poor contact in intake air temperature and pressure sensor Poor contact in ECM Poor contact in coupling connector (B21) Poor contact in joint connector (B83, B122)
CHECK HARNESS BETWEEN INTAKE AIR TEMPERATURE AND PRESSURE SENSOR AND ECM CONNECTOR. 1) Turn ignition switch to OFF. 2) Measure resistance of harness between intake air temperature and pressure sensor connector and engine ground. Connector & terminal (E20) No. 1 Engine ground:
EN(SOHC)-120

MEMO:
EN(SOHC)-121
M: DTC P0117 ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT LOW INPUT

S058521F91
DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: Hard to start Erroneous idling Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(SOHC)-45, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)-42, OPERATION, Inspection Mode.>. WIRING DIAGRAM:
S2M2081
EN(SOHC)-122

No. 1 Step Check Is the value greater than CHECK CURRENT DATA. 150C (302F)? 1) Start engine. 2) Read data of engine coolant temperature sensor signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(SOHC)-34, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Instruction Manual. Yes Go to step 2.
Is the value less than CHECK HARNESS BETWEEN ENGINE 40C (40F)? COOLANT TEMPERATURE SENSOR AND ECM CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from engine coolant temperature sensor. 3) Turn ignition switch to ON. 4) Read data of engine coolant temperature sensor signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(SOHC)-34, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Instruction Manual.
No Repair poor contact. NOTE: In this case, repair the following: Poor contact in engine coolant temperature sensor Poor contact in ECM Poor contact in coupling connector (B21) Poor contact in joint connector LHD: B122 RHD: B83 Repair ground Replace engine coolant tempera- short circuit in ture sensor. <Ref. harness between to FU(SOHC)-28, engine coolant temperature senEngine Coolant Temperature Sen- sor and ECM connector. sor.>
EN(SOHC)-123
N: DTC P0118 ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT HIGH INPUT

S058521F92
DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: Hard to start Erroneous idling Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(SOHC)-45, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)-42, OPERATION, Inspection Mode.>. WIRING DIAGRAM:
S2M2081
EN(SOHC)-124

No. 1 Step Check Is the value less than CHECK CURRENT DATA. 40C (40F)? 1) Start engine. 2) Read data of engine coolant temperature sensor signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(SOHC)-34, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Instruction Manual. Yes Go to step 2.
No Repair poor contact. NOTE: In this case, repair the following: Poor contact in engine coolant temperature sensor Poor contact in ECM Poor contact in coupling connector (B21) Poor contact in joint connector LHD: B122 RHD: B83 Go to step 3.
CHECK HARNESS BETWEEN ENGINE COOLANT TEMPERATURE SENSOR AND ECM CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from engine coolant temperature sensor. 3) Measure voltage between engine coolant temperature sensor connector and engine ground. Connector & terminal (E8) No. 1 (+) Engine ground (): CHECK HARNESS BETWEEN ENGINE COOLANT TEMPERATURE SENSOR AND ECM CONNECTOR. 1) Turn ignition switch to ON. 2) Measure voltage between engine coolant temperature sensor connector and engine ground. Connector & terminal (E8) No. 1 (+) Engine ground ():
Is the voltage more than 10 Repair battery V? short circuit in harness between ECM and engine coolant temperature sensor connector.
Go to step 4.
EN(SOHC)-125
No. 4

Step Check Is the voltage more than 4 CHECK HARNESS BETWEEN ENGINE V? COOLANT TEMPERATURE SENSOR AND ECM CONNECTOR. Measure voltage between engine coolant temperature sensor connector and engine ground. Connector & terminal (E8) No. 1 (+) Engine ground (): Yes Go to step 5. No Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ECM and engine coolant temperature sensor connector Poor contact in engine coolant temperature sensor connector Poor contact in ECM connector Poor contact in coupling connector (B21) Poor contact in joint connector LHD: B122 RHD: B83 Repair harness Replace engine coolant tempera- and connector. ture sensor. <Ref. NOTE: to FU(SOHC)-28, In this case, repair the followEngine Coolant Temperature Sen- ing: Open circuit in sor.> harness between ECM and engine coolant temperature sensor connector Poor contact in engine coolant temperature sensor connector Poor contact in ECM connector Poor contact in coupling connector (B21) Poor contact in joint connector LHD: B122 RHD: B83
CHECK HARNESS BETWEEN ENGINE COOLANT TEMPERATURE SENSOR AND ECM CONNECTOR. 1) Turn ignition switch to OFF. 2) Measure resistance of harness between engine coolant temperature sensor connector and engine ground. Connector & terminal (E8) No. 2 Engine ground:
EN(SOHC)-126

MEMO:
EN(SOHC)-127
O: DTC P0121 THROTTLE POSITION SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (HIGH INPUT)
S058521B19
DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: Erroneous idling Engine stalls. Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(SOHC)-45 OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)-42 OPERATION, Inspection Mode.>. WIRING DIAGRAM:
S2M2082
EN(SOHC)-128

No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0122 or P0123? Yes Inspect DTC P0122 or P0123 using 17. List of Diagnostic Trouble Code (DTC). <Ref. to EN(SOHC)-80, List of Diagnostic Trouble Code (DTC).> NOTE: In this case, it is not necessary to inspect DTC P0121.
No Replace throttle position sensor. <Ref. to FU(SOHC)-33, Throttle Position Sensor.>
EN(SOHC)-129

S058521B20
P: DTC P0122 THROTTLE POSITION SENSOR CIRCUIT LOW INPUT

DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: Erroneous idling Engine stalls. Poor driving performance
S2M2082
EN(SOHC)-130

No. 1 Step Check Is the value less than 0.1 CHECK CURRENT DATA. V? 1) Start engine. 2) Read data of throttle position sensor signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(SOHC)-34, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Instruction Manual. Yes Go to step 2.
No Even if MIL lights up, the circuit has returned to a normal condition at this time. A temporary poor contact of the connector may be the cause. NOTE: In this case, repair the following: Poor contact in throttle position sensor connector Poor contact in ECM connector Poor contact in coupling connector (B21) Go to step 3.
CHECK INPUT SIGNAL FOR ECM. Measure voltage between ECM connector and chassis ground while throttle valve is fully closed. Connector & terminal (B136) No. 15 (+) Chassis ground (): CHECK INPUT SIGNAL FOR ECM. Measure voltage between ECM connector and chassis ground. Connector & terminal (B136) No. 15 (+) Chassis ground ():
Go to step 4.
CHECK INPUT SIGNAL FOR ECM. Measure voltage between ECM connector and chassis ground. Connector & terminal (B136) No. 17 (+) Chassis ground (): CHECK INPUT SIGNAL FOR ECM. (USING SUBARU SELECT MONITOR.) Measure voltage between ECM connector and chassis ground.
Repair poor conDoes the voltage change more than 0.1 V by shaking tact in ECM connector. harness and connector of ECM while monitoring the value with Subaru Select Monitor?
Go to step 6.
EN(SOHC)-131
No. 6

Step CHECK HARNESS BETWEEN ECM AND THROTTLE POSITION SENSOR CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connectors from throttle position sensor. 3) Turn ignition switch to ON. 4) Measure voltage between throttle position sensor connector and engine ground. Connector & terminal (E13) No. 4 (+) Engine ground (): Check Is the voltage more than 4.5 V? Yes Go to step 7. No Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between throttle position sensor and ECM connector Poor contact in throttle position sensor connector Poor contact in ECM connector Poor contact in coupling connector (B21) Poor contact in joint connector LHD: B122 RHD: B83 Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between throttle position sensor and ECM connector Poor contact in ECM connector Poor contact in throttle position sensor connector Poor contact in coupling connector (B21) Go to step 9.
CHECK HARNESS BETWEEN ECM AND THROTTLE POSITION SENSOR CONNECTOR. 1) Turn ignition switch to OFF. 2) Measure resistance of harness between ECM connector and throttle position sensor connector. Connector & terminal (B136) No. 17 (E13) No. 3:
Go to step 8.
CHECK HARNESS BETWEEN ECM AND THROTTLE POSITION SENSOR CONNECTOR. Measure resistance of harness between throttle position sensor connector and engine ground. Connector & terminal (E13) No. 3 Engine ground: CHECK POOR CONTACT. Check poor contact in throttle position sensor connector.
Repair ground short circuit in harness between throttle position sensor and ECM connector.
Is there poor contact in Repair poor conthrottle position sensor contact in throttle nector? position sensor connector.
Replace throttle position sensor. <Ref. to FU(SOHC)-33, Throttle Position Sensor.>
EN(SOHC)-132

MEMO:
EN(SOHC)-133

S058521B21
Q: DTC P0123 THROTTLE POSITION SENSOR CIRCUIT HIGH INPUT

S2M2082
EN(SOHC)-134

No. 1 Step Check Is the value more than 4.9 CHECK CURRENT DATA. V? 1) Start engine. 2) Read data of throttle position sensor signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(SOHC)-34, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Instruction Manual. Yes Go to step 2.
No Even if MIL lights up, the circuit has returned to a normal condition at this time. A temporary poor contact of the connector may be the cause. NOTE: In this case, repair the following: Poor contact in throttle position sensor connector Poor contact in ECM connector Poor contact in coupling connector (B21) Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between throttle position sensor and ECM connector Poor contact in coupling connector (B21) Poor contact in joint connector LHD: B122 RHD: B83 Replace throttle position sensor. <Ref. to FU(SOHC)-33 Throttle Position Sensor.>
CHECK HARNESS BETWEEN THROTTLE POSITION SENSOR AND ECM CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from throttle position sensor. 3) Measure resistance of harness between throttle position sensor connector and engine ground. Connector & terminal (E13) No. 2 Engine ground:
Go to step 3.
CHECK HARNESS BETWEEN THROTTLE POSITION SENSOR AND ECM CONNECTOR. 1) Turn ignition switch to ON. 2) Measure voltage between throttle position sensor connector and engine ground. Connector & terminal (E13) No. 3 (+) Engine ground ():
Repair battery short circuit in harness between throttle position sensor and ECM connector. After repair, replace ECM. <Ref. to FU(SOHC)-49, Engine Control Module.>
EN(SOHC)-135
R: DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL
S058521B22
DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: Engine would not return to idling. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(SOHC)-45, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)-42, OPERATION, Inspection Mode.>. WIRING DIAGRAM:
S2M2081
EN(SOHC)-136

No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0117 or P0118? Yes Inspect DTC P0117 or P0118 using 17. List of Diagnostic Trouble Code (DTC). <Ref. to EN(SOHC)-80, List of Diagnostic Trouble Code (DTC).> NOTE: In this case, it is not necessary to inspect DTC P0125. Replace thermostat. <Ref. to CO-23, Thermostat.> No Go to step 2.
CHECK THERMOSTAT.
Does thermostat remain opened?
Replace engine coolant temperature sensor. <Ref. to FU(SOHC)-28, Engine Coolant Temperature Sensor.>
EN(SOHC)-137
S: DTC P0130 FRONT OXYGEN (A/F) SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (LEAN)
S058521G44
S2M2077
EN(SOHC)-138

No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0131, P0132, P0031 or P0032? Yes Inspect DTC P0131, P0132, P0031 or P0032 using 17. List of Diagnostic Trouble Code (DTC). <Ref. to EN(SOHC)-80, List of Diagnostic Trouble Code (DTC).> Go to step 3. No Go to step 2.
CHECK FRONT OXYGEN (A/F) SENSOR DATA. 1) Start engine. 2) While observing the Subaru Select Monitor or OBD-II general scan tool screen, warm-up the engine until coolant temperature is above 70C (160F). If the engine is already warmed-up, operate at idle speed for at least 1 minute. 3) Read data of front oxygen (A/F) sensor signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(SOHC)-34, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Instruction Manual. CHECK FRONT OXYGEN (A/F) SENSOR DATA. Race engine at speeds from idling to 5,000 rpm for a total of 5 cycles. NOTE: To increase engine speed to 5,000 rpm, slowly depress accelerator pedal, taking approximately 5 seconds, and quickly release accelerator pedal to decrease engine speed. CHECK HARNESS BETWEEN ECM AND FRONT OXYGEN (A/F) SENSOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM and front oxygen (A/F) sensor connector. 3) Measure resistance between ECM and front oxygen (A/F) sensor. Connector & terminals (B136) No. 6 (E24) No. 1: (B136) No. 7 (E24) No. 6: (B136) No. 19 (E24) No. 3: (B136) No. 20 (E24) No. 4:
Is the value equal to or more than 0.85 and equal to less than 1.15 in idling?
Go to step 4.
Is the value more than 1.1 for a moment?
Go to step 6.
Go to step 4.
Go to step 5.
Repair open circuit between ECM and front oxygen (A/F) sensor.
EN(SOHC)-139
No. 5

Step CHECK HARNESS BETWEEN ECM AND FRONT OXYGEN (A/F) SENSOR. Measure resistance between ECM and chassis ground. Connector & terminals (B136) No. 6 Chassis ground: (B136) No. 7 Chassis ground: (B136) No. 19 Chassis ground: (B136) No. 20 Chassis ground: CHECK EXHAUST SYSTEM. Check exhaust system parts. NOTE: Check the following items. Loose installation of portions Damage (crack, hole etc.) of parts Looseness of front oxygen (A/F) sensor Looseness and ill fitting of parts between front oxygen (A/F) sensor and rear oxygen sensor Check Yes Is the resistance more than Go to step 6. 1 M? No Repair ground short circuit between ECM and front oxygen (A/F) sensor.
Is there a fault in exhaust system?
Repair or replace faulty parts.
EN(SOHC)-140

MEMO:
EN(SOHC)-141
T: DTC P0131 FRONT OXYGEN (A/F) SENSOR CIRCUIT MALFUNCTION (OPEN CIRCUIT)
S058521G45
S2M2077
EN(SOHC)-142

No. 1 Step Check Is the resistance less than CHECK HARNESS BETWEEN ECM AND FRONT OXYGEN (A/F) SENSOR CONNEC- 1 ? TOR. 1) Turn ignition switch to OFF. 2) Disconnect connectors from ECM and front oxygen (A/F) sensor connector. 3) Measure resistance of harness between ECM and front oxygen (A/F) sensor connector. Connector & terminal (B136) No. 6 (E24) No. 1: (B136) No. 7 (E24) No. 6: (B136) No. 19 (E24) No. 3: (B136) No. 20 (E24) No. 4: Yes Go to step 2.
No Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ECM and front oxygen (A/F) sensor connector Poor contact in front oxygen (A/F) sensor connector Poor contact in ECM connector Replace front oxygen (A/F) sensor. <Ref. to FU(SOHC)-45, Front Oxygen (A/F) Sensor.>
Is there poor contact in CHECK POOR CONTACT. Check poor contact in front oxygen (A/F) senfront oxygen (A/F) sensor connector? sor connector.
Repair poor contact in front oxygen (A/F) sensor connector.
EN(SOHC)-143
U: DTC P0132 FRONT OXYGEN (A/F) SENSOR CIRCUIT MALFUNCTION (SHORT CIRCUIT)
S058521G46
S2M2077
EN(SOHC)-144

No. 1 Step CHECK HARNESS BETWEEN ECM AND FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM. 3) Measure resistance of harness between ECM connector and chassis ground. Connector & terminal (B136) No. 6 Chassis ground: (B136) No. 7 Chassis ground: (B136) No. 19 Chassis ground: (B136) No. 20 Chassis ground: Check Yes Is the resistance more than Replace front oxy10 ? gen (A/F) sensor. <Ref. to FU(SOHC)-45, Front Oxygen (A/F) Sensor.>
No Repair ground short circuit in harness between ECM and front oxygen (A/F) sensor connector.
EN(SOHC)-145
V: DTC P0133 FRONT OXYGEN (A/F) SENSOR CIRCUIT SLOW RESPONSE

S058521B26
S2M2077
EN(SOHC)-146

No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0131, P0132, P0031 or P0032? Yes Inspect DTC P0131, P0132, P0031 or P0032 using 17. List of Diagnostic Trouble Code (DTC). <Ref. to EN(SOHC)-80, List of Diagnostic Trouble Code (DTC).> NOTE: In this case, it is not necessary to inspect DTC P0133. Repair exhaust system. No Go to step 2.
Is there a fault in exhaust CHECK EXHAUST SYSTEM. system? NOTE: Check the following items. Loose installation of front portion of exhaust pipe onto cylinder heads Loose connection between front exhaust pipe and front catalytic converter Damage of exhaust pipe resulting in a hole
EN(SOHC)-147

S058521B28
W: DTC P0136 REAR OXYGEN SENSOR CIRCUIT MALFUNCTION

DTC DETECTING CONDITION: Two consecutive driving cycles with fault
S2M2078
No. 1
Step CHECK ANY OTHER DTC ON DISPLAY.
Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0131 or P0132?
Yes Go to step 2.
No Go to step 3.
EN(SOHC)-148

No. 2 Step CHECK FAILURE CAUSE OF P0131 or P0132. Inspect DTC P0131 or P0132 using 17. List of Diagnostic Trouble Code (DTC). <Ref. to EN(SOHC)-80, List of Diagnostic Trouble Code (DTC).> Check Is the failure cause of P0131 or P0132 in the fuel system? Yes Check fuel system. NOTE: In this case, it is not necessary to inspect DTC P0136. Go to step 7. No Go to step 3.
Does the value fluctuate? CHECK REAR OXYGEN SENSOR DATA. 1) Warm-up the engine until engine coolant temperature is above 70C (158F), and keep the engine speed at 2,000 rpm to 3,000 rpm for two minutes. 2) Read data of rear oxygen sensor signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA SHOWN ON DISPLAY FOR ENGINE. <Ref. to EN(SOHC)-34, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Instruction Manual. Is the value fixed between CHECK REAR OXYGEN SENSOR DATA. Read data of rear oxygen sensor signal using 0.2 and 0.4 V? Subaru Select Monitor or OBD-II General Scan Tool. CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connectors from ECM and rear oxygen sensor. 3) Measure resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B136) No. 16 (E25) No. 3: CHECK HARNESS BETWEEN REAR OXYGEN SENSOR AND ECM CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from rear oxygen sensor. 3) Turn ignition switch to ON. 4) Measure voltage between rear oxygen sensor harness connector and engine ground or chassis ground. Connector & terminal (E25) No. 4 (+) Engine ground ():
Go to step 4.
Go to step 5.
Is the resistance more than Repair open cir3 ? cuit in harness between ECM and rear oxygen sensor connector.
Replace rear oxygen sensor. <Ref. to FU(SOHC)-47, Rear Oxygen Sensor.> Go to step 6.
Replace rear oxygen sensor. <Ref. to FU(SOHC)-47, Rear Oxygen Sensor.>
Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between rear oxygen sensor and ECM connector Poor contact in rear oxygen sensor connector Poor contact in ECM connector
EN(SOHC)-149
No. 7

Step CHECK EXHAUST SYSTEM. Check exhaust system parts. NOTE: Check the following items. Loose installation of portions Damage (crack, hole etc.) of parts Looseness and ill fitting of parts between front oxygen (A/F) sensor and rear oxygen sensor Check Is there a fault in exhaust system? Yes Repair or replace faulty parts. No Replace rear oxygen sensor. <Ref. to FU(SOHC)-47, Rear Oxygen Sensor.>
EN(SOHC)-150

MEMO:
EN(SOHC)-151

S058521B29
X: DTC P0139 REAR OXYGEN SENSOR CIRCUIT SLOW RESPONSE

S2M2078
EN(SOHC)-152

No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0136? Yes Inspect DTC P0136 using 17. List of Diagnostic Trouble Code (DTC). <Ref. to EN(SOHC)-80, List of Diagnostic Trouble Code (DTC).> NOTE: In this case, it is not necessary to inspect DTC P0139.
No Replace rear oxygen sensor. <Ref. to FU(SOHC)-47, Rear Oxygen Sensor.>
EN(SOHC)-153

S058521B31
Y: DTC P0170 FUEL TRIM MALFUNCTION

DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: Erroneous idling Engine stalls. Poor driving performance
CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(SOHC)-45, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)-42, OPERATION, Inspection Mode.>.
No. 1 2 Step CHECK EXHAUST SYSTEM. Check Are there holes or loose bolts on exhaust system? CHECK AIR INTAKE SYSTEM. Are there holes, loose bolts or disconnection of hose on air intake system? Is fuel pressure between CHECK FUEL PRESSURE. 284 and 314 kPa (2.9 WARNING: Place NO FIRE signs near the working 3.2 kg/cm2, 41 46 psi)? area. Be careful not to spill fuel on the floor. 1) Release fuel pressure. (1) Disconnect connector from fuel pump relay. (2) Start the engine and run it until it stalls. (3) After the engine stalls, crank it for five more seconds. (4) Turn ignition switch to OFF. 2) Connect connector to fuel pump relay. 3) Disconnect fuel delivery hose from fuel filter, and connect fuel pressure gauge. 4) Install fuel filler cap. 5) Start the engine and idle while gear position is neutral. 6) Measure fuel pressure while disconnecting pressure regulator vacuum hose from intake manifold. WARNING: Before removing fuel pressure gauge, release fuel pressure. NOTE: If fuel pressure does not increase, squeeze fuel return hose 2 to 3 times, then measure fuel pressure again. Yes Repair exhaust system. Repair air intake system. Go to step 4. No Go to step 2. Go to step 3.
Repair the following items. Fuel pressure too high Clogged fuel return line or bent hose Fuel pressure too low Improper fuel pump discharge Clogged fuel supply line
EN(SOHC)-154

No. 4 Step Check Is fuel pressure between CHECK FUEL PRESSURE. 206 and 235 kPa (2.1 After connecting pressure regulator vacuum 2.4 kg/cm2, 30 34 psi)? hose, measure fuel pressure. WARNING: Before removing fuel pressure gauge, release fuel pressure. NOTE: If fuel pressure does not increase, squeeze fuel return hose 2 to 3 times, then measure fuel pressure again. If out of specification as measured at this step, check or replace pressure regulator and pressure regulator vacuum hose. Yes Go to step 5.
No Repair the following items. Fuel pressure too high Faulty pressure regulator Clogged fuel return line or bent hose Fuel pressure too low Faulty pressure regulator Improper fuel pump discharge Clogged fuel supply line Replace engine coolant temperature sensor. <Ref. to FU(SOHC)-28, Engine Coolant Temperature Sensor.>
CHECK ENGINE COOLANT TEMPERATURE SENSOR. 1) Start the engine and warm-up completely. 2) Read data of engine coolant temperature sensor signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(SOHC)-34, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Instruction Manual. CHECK INTAKE MANIFOLD PRESSURE SENSOR SIGNAL. 1) Start the engine and warm-up engine until coolant temperature is greater than 60C (140F). 2) Place the selector lever in N or P position. 3) Turn A/C switch to OFF. 4) Turn all accessory switches to OFF. 5) Read data of intake manifold pressure sensor signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(SOHC)-34, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Instruction Manual. Specification: Idling 24.0 41.3 kPa (180 310 mmHg, 7.09 12.20 inHg) Ignition ON 73.3 106.6 kPa (550 800 mmHg, 21.65 31.50 inHg)
Is temperature between 70C (158F) and 100C (212F)?
Go to step 6.
Is the voltage within the specifications?
Replace intake air temperature and pressure sensor. <Ref. to FU(SOHC)-36, Intake Air Temperature and Pressure Sensor.>
EN(SOHC)-155

S058521B37
Z: DTC P0301 CYLINDER 1 MISFIRE DETECTED
NOTE: For the diagnostic procedure, refer to DTC P0304. <Ref. to EN(SOHC)-158, DTC P0304 CYLINDER 4 MISFIRE DETECTED , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
AA: DTC P0302 CYLINDER 2 MISFIRE DETECTED
S058521B38
AB: DTC P0303 CYLINDER 3 MISFIRE DETECTED
S058521B39
EN(SOHC)-156

MEMO:
EN(SOHC)-157

S058521B40
AC: DTC P0304 CYLINDER 4 MISFIRE DETECTED
DTC DETECTING CONDITION: Two consecutive driving cycles with fault Immediately at fault recognition (A misfire which could damage catalyst occurs.) TROUBLE SYMPTOM: Engine stalls. Erroneous idling Rough driving CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(SOHC)-45, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)-42, OPERATION, Inspection Mode.>. WIRING DIAGRAM:
S2M2083
EN(SOHC)-158
S2M2084
No. 1
Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0106, P0107, P0108, P0117, P0118 or P0125?
Yes Inspect DTC P0106, P0107, P0108, P0117, P0118 or P0125 using 17. List of Diagnostic Trouble Code (DTC). <Ref. to EN(SOHC)-80, List of Diagnostic Trouble Code (DTC).> NOTE: In this case, it is not necessary to inspect DTC P0301, P0302, P0303 and P0304.
No Go to step 2.
EN(SOHC)-159
No. 2

Step CHECK OUTPUT SIGNAL FROM ECM. 1) Turn ignition switch to ON. 2) Measure voltage between ECM connector and chassis ground on faulty cylinders. Connector & terminal #1 (B134) No. 4 (+) Chassis ground (): #2 (B134) No. 13 (+) Chassis ground (): #3 (B134) No. 14 (+) Chassis ground (): #4 (B134) No. 15 (+) Chassis ground (): CHECK HARNESS BETWEEN FUEL INJECTOR AND ECM CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from fuel injector on faulty cylinders. 3) Measure voltage between ECM connector and engine ground on faulty cylinders. Connector & terminal #1 (E5) No. 1 Engine ground: #2 (E16) No. 1 Engine ground: #3 (E6) No. 1 Engine ground: #4 (E17) No. 1 Engine ground: CHECK HARNESS BETWEEN FUEL INJECTOR AND ECM CONNECTOR. Measure resistance of harness connector between ECM connector and fuel injector on faulty cylinders. Connector & terminal #1 (B134) No. 4 (E5) No. 1: #2 (B134) No. 13 (E16) No. 1: #3 (B134) No. 14 (E6) No. 1: #4 (B134) No. 15 (E17) No. 1: Check Yes Is the voltage more than 10 Go to step 7. V? No Go to step 3.
Repair ground short circuit in harness between fuel injector and ECM connector.
Go to step 4.
Go to step 5.
CHECK FUEL INJECTOR. Measure resistance between fuel injector terminals on faulty cylinder. Terminals No. 1 No. 2:
Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ECM and fuel injector connector Poor contact in coupling connector (B22) Replace faulty fuel injector. <Ref. to FU(SOHC)-40, Fuel Injector.>
EN(SOHC)-160

No. 6 Step CHECK POWER SUPPLY LINE. 1) Turn ignition switch to ON. 2) Measure voltage between fuel injector and engine ground on faulty cylinders. Connector & terminal #1 (E5) No. 2 (+) Engine ground (): #2 (E16) No. 2 (+) Engine ground (): #3 (E6) No. 2 (+) Engine ground (): #4 (E17) No. 2 (+) Engine ground (): Check Yes Is the voltage more than 10 Repair poor conV? tact in all connectors in fuel injector circuit.
No Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between main relay and fuel injector connector on faulty cylinders Poor contact in coupling connector Poor contact in main relay connector Poor contact in fuel injector connector on faulty cylinders Go to step 8.
CHECK HARNESS BETWEEN FUEL INJECTOR AND ECM CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from fuel injector on faulty cylinder. 3) Turn ignition switch to ON. 4) Measure voltage between ECM connector and chassis ground on faulty cylinders. Connector & terminal #1 (B134) No. 4 (+) Chassis ground (): #2 (B134) No. 13 (+) Chassis ground (): #3 (B134) No. 14 (+) Chassis ground (): #4 (B134) No. 15 (+) Chassis ground (): CHECK FUEL INJECTOR. 1) Turn ignition switch to OFF. 2) Measure resistance between fuel injector terminals on faulty cylinder. Terminals No. 1 No. 2:
Is the voltage more than 10 Repair battery V? short circuit in harness between ECM and fuel injector. After repair, replace ECM. <Ref. to FU(SOHC)-49, Engine Control Module.>
CHECK INSTALLATION OF CAMSHAFT POSITION SENSOR/CRANKSHAFT POSITION SENSOR. CHECK CRANKSHAFT SPROCKET. Remove timing belt cover.
10
Go to step 9. Replace faulty fuel injector <Ref. to FU(SOHC)-40, Fuel Injector .> and ECM <Ref. to FU(SOHC)-49, Engine Control Module.>. Is camshaft position sensor Tighten camshaft Go to step 10. or crankshaft position sen- position sensor or sor loosely installed? crankshaft position sensor. Go to step 11. Is crankshaft sprocket Replace crankrusted or does it have bro- shaft sprocket. ken teeth? <Ref. to ME(SOHC)-53, Crankshaft Sprocket.> Is the resistance less than 1 ?
EN(SOHC)-161
No. 11

Step Check Is timing belt dislocated CHECK INSTALLATION CONDITION OF from its proper position? TIMING BELT. Turn crankshaft using ST, and align alignment mark on crankshaft sprocket with alignment mark on cylinder block. ST 499987500 CRANKSHAFT SOCKET CHECK FUEL LEVEL. Is the fuel meter indication higher than the Lower level? Yes No Repair installation Go to step 12. condition of timing belt. <Ref. to ME(SOHC)-46, Timing Belt Assembly.> Go to step 13. Replenish fuel so fuel meter indication is higher than the Lower level. After replenishing fuel, Go to step 13. Go to step 15. Go to step 14.
12
13
14
CHECK STATUS OF CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL). 1) Clear memory using Subaru Select Monitor. <Ref. to EN(SOHC)-45, Clear Memory Mode.> 2) Start engine, and drive the vehicle more than 10 minutes. CHECK CAUSE OF MISFIRE DIAGNOSED.
Is the MIL coming on or blinking?
Was the cause of misfire Finish diagnostics diagnosed when the engine operation, if the is running? engine has no abnormality. NOTE: Ex. Remove spark plug cord, etc.
15
Is there a fault in air intake system?
Repair air intake system. NOTE: Check the following items: Are there air leaks or air suction caused by loose or dislocated nuts and bolts? Are there cracks or any disconnection of hoses?
Repair poor contact. NOTE: In this case, repair the following: Poor contact in ignitor connector Poor contact in ignition coil connector Poor contact in fuel injector connector on faulty cylinders Poor contact in ECM connector Poor contact in coupling connector Go to step 16.
EN(SOHC)-162

No. 16 Step CHECK MISFIRE SYMPTOM. 1) Turn ignition switch to ON. 2) Read diagnostic trouble code (DTC). Subaru Select Monitor <Ref. to EN(SOHC)-34, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Operation Manual. NOTE: Perform diagnosis according to the items listed below. CHECK DIAGNOSTIC TROUBLE CODE (DTC) ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate only one DTC? Yes Go to step 21.
No Go to step 17.
17
18
CHECK DIAGNOSTIC TROUBLE CODE (DTC) ON DISPLAY.
19
20
21
ONLY ONE CYLINDER
Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0301 and P0302? Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0303 and P0304? Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0301 and P0303? Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0302 and P0304? Is there a fault in that cylinder?
Go to step 22.
Go to step 18.
Go to step 23.
Go to step 19.
Go to step 24.
Go to step 20.
Go to step 25.
Go to step 26.
22
GROUP OF #1 AND #2 CYLINDERS
Are there faults in #1 and #2 cylinders?
Repair or replace faulty parts. NOTE: Check the following items. Spark plug Spark plug cord Fuel injector Compression ratio Repair or replace faulty parts. NOTE: Check the following items. Spark plugs Fuel injectors Ignition coil Compression ratio If no abnormal is discovered, check for IGNITION CONTROL SYSTEM of #1 and #2 cylinders side. <Ref. to EN(SOHC)-68, IGNITION CONTROL SYSTEM, Diagnostics for Engine Starting Failure.>
Go to DTC P0170. <Ref. to EN(SOHC)-154, DTC P0170 FUEL TRIM MALFUNCTION , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Go to DTC P0170. <Ref. to EN(SOHC)-154, DTC P0170 FUEL TRIM MALFUNCTION , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(SOHC)-163
No. 23

Step GROUP OF #3 AND #4 CYLINDERS Check Are there faults in #3 and #4 cylinders? Yes Repair or replace faulty parts. NOTE: Check the following items. Spark plugs Fuel injectors Ignition coil If no abnormal is discovered, check for 16. D: IGNITION CONTROL SYSTEM of #3 and #4 cylinders side. <Ref. to EN(SOHC)-68, IGNITION CONTROL SYSTEM, Diagnostics for Engine Starting Failure.> Repair or replace faulty parts. NOTE: Check the following items. Spark plugs Fuel injectors Skipping timing belt teeth Repair or replace faulty parts. NOTE: Check the following items. Spark plugs Fuel injectors Compression ratio Skipping timing belt teeth Go to DTC P0170. <Ref. to EN(SOHC)-154, DTC P0170 FUEL TRIM MALFUNCTION , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> No Go to DTC P0170. <Ref. to EN(SOHC)-154, DTC P0170 FUEL TRIM MALFUNCTION , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
24
25
Go to DTC P0170. <Ref. to EN(SOHC)-154, DTC P0170 FUEL TRIM MALFUNCTION , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Go to DTC P0170. <Ref. to EN(SOHC)-154, DTC P0170 FUEL TRIM MALFUNCTION , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Repair or replace faulty parts. NOTE: Check the following items. Spark plugs Fuel injectors Compression ratio
26
CYLINDER AT RANDOM
Is the engine idle rough?
EN(SOHC)-164

MEMO:
EN(SOHC)-165

S058521F94
AD: DTC P0327 KNOCK SENSOR CIRCUIT LOW INPUT

DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: Poor driving performance Knocking occurs.
S2M2085
EN(SOHC)-166

No. 1 Step Check Yes Is the resistance more than Go to step 2. CHECK HARNESS BETWEEN KNOCK 700 k? SENSOR AND ECM CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM. 3) Measure resistance between ECM harness connector and chassis ground. Connector & terminal (B136) No. 4 Chassis ground:
No Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between knock sensor and ECM connector Poor contact in knock sensor connector Poor contact in coupling connector (B21) Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between knock sensor and ECM connector Poor contact in knock sensor connector Poor contact in coupling connector (B21) Tighten knock sensor installation bolt securely.
CHECK KNOCK SENSOR. 1) Disconnect connector from knock sensor. 2) Measure resistance between knock sensor connector terminal and engine ground. Terminal No. 2 Engine ground:
CHECK CONDITION OF KNOCK SENSOR INSTALLATION.
Is the knock sensor installation bolt tightened securely?
Replace knock sensor. <Ref. to FU(SOHC)-31, Knock Sensor.>
EN(SOHC)-167

S058521F95
AE: DTC P0328 KNOCK SENSOR CIRCUIT HIGH INPUT

S2M2085
EN(SOHC)-168

No. 1 Step CHECK HARNESS BETWEEN KNOCK SENSOR AND ECM CONNECTOR. Measure resistance of harness between ECM connector and chassis ground. Connector & terminal (B136) No. 4 Chassis ground: CHECK KNOCK SENSOR. 1) Disconnect connector from knock sensor. 2) Measure resistance between knock sensor connector terminal and engine ground. Terminal No. 2 Engine ground: Check Is the resistance less than 400 k? Yes Go to step 2. No Go to step 3.
Is the resistance less than 400 k?
Is the voltage more than 2 CHECK INPUT SIGNAL FOR ECM. V? 1) Connect connectors to ECM and knock sensor. 2) Turn ignition switch to ON. 3) Measure voltage between ECM and chassis ground. Connector & terminal (B136) No. 4 (+) Chassis ground ():
Repair ground short circuit in harness between knock sensor connector and ECM connector. NOTE: The harness between both connectors is shielded. Repair short circuit of harness together with shield. Even if MIL lights Repair poor conup, the circuit has tact in ECM conreturned to a nor- nector. mal condition at this time. (However, the possibility of poor contact still remains.) NOTE: In this case, repair the following: Poor contact in knock sensor connector Poor contact in ECM connector Poor contact in coupling connector (B21) Replace knock sensor. <Ref. to FU(SOHC)-31, Knock Sensor.>
EN(SOHC)-169
AF: DTC P0335 CRANKSHAFT POSITION SENSOR CIRCUIT MALFUNCTION

S058521B42
DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: Engine stalls. Failure of engine to start CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(SOHC)-45, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)-42, OPERATION, Inspection Mode.>. WIRING DIAGRAM:
S2M2086
EN(SOHC)-170

No. 1 Step Check Yes Is the resistance more than Repair harness CHECK HARNESS BETWEEN CRANK100 k? and connector. SHAFT POSITION SENSOR AND ECM NOTE: CONNECTOR. In this case, 1) Turn ignition switch to OFF. repair the follow2) Disconnect connector from crankshaft posiing: tion sensor. Open circuit in 3) Measure resistance of harness between harness between crankshaft position sensor connector and crankshaft posiengine ground. tion sensor and Connector & terminal ECM connector (E10) No. 1 Engine ground: Poor contact in ECM connector Poor contact in coupling connector (B21) Is the resistance less than Repair ground CHECK HARNESS BETWEEN CRANK10 ? short circuit in SHAFT POSITION SENSOR AND ECM harness between CONNECTOR. crankshaft posiMeasure resistance of harness between tion sensor and crankshaft position sensor connector and ECM connector. engine ground. NOTE: Connector & terminal The harness (E10) No. 1 Engine ground: between both connectors are shielded. Repair ground short circuit in harness together with shield. Is the resistance less than Go to step 4. CHECK HARNESS BETWEEN CRANK5 ? SHAFT POSITION SENSOR AND ECM CONNECTOR. Measure resistance of harness between crankshaft position sensor connector and engine ground. Connector & terminal (E10) No. 2 Engine ground: No Go to step 2.
Go to step 3.
CHECK CONDITION OF CRANKSHAFT POSITION SENSOR.
Is the crankshaft position sensor installation bolt tightened securely?
Go to step 5.
CHECK CRANKSHAFT POSITION SENSOR. Is the resistance between 1 Repair poor conand 4 k? tact in crankshaft 1) Remove crankshaft position sensor. position sensor 2) Measure resistance between connector connector. terminals of crankshaft position sensor. Terminals No. 1 No. 2:
Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between crankshaft position sensor and ECM connector Poor contact in ECM connector Poor contact in coupling connector (B21) Tighten crankshaft position sensor installation bolt securely. Replace crankshaft position sensor. <Ref. to FU(SOHC)-29, Crankshaft Position Sensor.>
EN(SOHC)-171
AG: DTC P0336 CRANKSHAFT POSITION SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM

S058521B43
S2M2086
EN(SOHC)-172

No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0335? Yes Inspect DTC P0335 using 17. List of Diagnostic Trouble Code (DTC). <Ref. to EN(SOHC)-80, List of Diagnostic Trouble Code (DTC).> Go to step 3. No Go to step 2.
CHECK CONDITION OF CRANKSHAFT POSITION SENSOR. Turn ignition switch to OFF. CHECK CRANKSHAFT SPROCKET. Remove front belt cover.
Are crankshaft sprocket Replace crankteeth cracked or damaged? shaft sprocket. <Ref. to ME(SOHC)-46, Crankshaft Sprocket.> Is timing belt dislocated Repair installation CHECK INSTALLATION CONDITION OF from its proper position? condition of timing TIMING BELT. belt. <Ref. to Turn crankshaft using ST, and align alignment ME(SOHC)-46, mark on crankshaft sprocket with alignment Timing Belt mark on cylinder block. Assembly.> ST 499987500 CRANKSHAFT SOCKET
Tighten crankshaft position sensor installation bolt securely. Go to step 4.
Replace crankshaft position sensor. <Ref. to FU(SOHC)-29, Crankshaft Position Sensor.>
EN(SOHC)-173
AH: DTC P0340 CAMSHAFT POSITION SENSOR CIRCUIT MALFUNCTION

S058521B44
B2M4312
EN(SOHC)-174

No. 1 Check Yes Is the resistance more than Repair harness 100 k? and connector. NOTE: In this case, repair the following: Open circuit in harness between camshaft position sensor and ECM connector Poor contact in ECM connector Poor contact in coupling connector (B21) CHECK HARNESS BETWEEN CAMSHAFT Is the resistance less than Repair ground 10 ? short circuit in POSITION SENSOR AND ECM CONNECharness between TOR. camshaft position Measure resistance of harness between camsensor and ECM shaft position sensor connector and engine connector. ground. NOTE: Connector & terminal The harness (E15) No. 1 Engine ground: between both connectors are shielded. Repair ground short circuit in harness together with shield. CHECK HARNESS BETWEEN CAMSHAFT Is the resistance less than Go to step 4. 5 ? POSITION SENSOR AND ECM CONNECTOR. Measure resistance of harness between camshaft position sensor connector and engine ground. Connector & terminal (E15) No. 2 Engine ground: Step CHECK HARNESS BETWEEN CAMSHAFT POSITION SENSOR AND ECM CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from camshaft position sensor. 3) Measure resistance of harness between camshaft position sensor connector and engine ground. Connector & terminal (E15) No. 1 Engine ground: No Go to step 2.
Go to step 3.
CHECK CONDITION OF CAMSHAFT POSITION SENSOR.
Is the camshaft position sensor installation bolt tightened securely?
Go to step 5.
CHECK CAMSHAFT POSITION SENSOR. 1) Remove camshaft position sensor. 2) Measure resistance between connector terminals of camshaft position sensor. Terminals No. 1 No. 2:
Is the resistance between 1 Repair poor conand 4 k? tact in camshaft position sensor connector.
Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between camshaft position sensor and ECM connector Poor contact in ECM connector Poor contact in coupling connector (B21) Tighten camshaft position sensor installation bolt securely. Replace camshaft position sensor. <Ref. to FU(SOHC)-30, Camshaft Position Sensor.>
EN(SOHC)-175
AI: DTC P0341 CAMSHAFT POSITION SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM

S058521B45
B2M4312
EN(SOHC)-176

No. 1 Yes Inspect DTC P0340 using 17. List of Diagnostic Trouble Code (DTC). <Ref. to EN(SOHC)-80, List of Diagnostic Trouble Code (DTC).> CHECK HARNESS BETWEEN CAMSHAFT Is the resistance more than Repair harness 100 k? and connector. POSITION SENSOR AND ECM CONNECNOTE: TOR. In this case, 1) Turn ignition switch to OFF. repair the follow2) Disconnect connector from camshaft posiing: tion sensor. Open circuit in 3) Measure resistance of harness between harness between camshaft position sensor connector and camshaft position engine ground. sensor and ECM Connector & terminal connector (E15) No. 1 Engine ground: Poor contact in ECM connector Poor contact in coupling connector (B21) CHECK HARNESS BETWEEN CAMSHAFT Is the resistance less than Repair ground 10 ? short circuit in POSITION SENSOR AND ECM CONNECharness between TOR. camshaft position Measure resistance of harness between camsensor and ECM shaft position sensor connector and engine connector. ground. NOTE: Connector & terminal The harness (E15) No. 1 Engine ground: between both connectors are shielded. Repair ground short circuit in harness together with shield. CHECK HARNESS BETWEEN CAMSHAFT Is the resistance less than Go to step 5. 5 ? POSITION SENSOR AND ECM CONNECTOR. Measure resistance of harness between camshaft position sensor connector and engine ground. Connector & terminal (E15) No. 2 Engine ground: Step CHECK ANY OTHER DTC ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0340? No Go to step 2.
Go to step 3.
Go to step 4.
Go to step 6.
Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between camshaft position sensor and ECM connector Poor contact in ECM connector Poor contact in coupling connector (B21) Tighten camshaft position sensor installation bolt securely.
EN(SOHC)-177
No. 6

Step CHECK CAMSHAFT POSITION SENSOR. 1) Remove camshaft position sensor. 2) Measure resistance between connector terminals of camshaft position sensor. Terminals No. 1 No. 2: CHECK CONDITION OF CAMSHAFT POSITION SENSOR. Turn ignition switch to OFF. No Replace camshaft position sensor. <Ref. to FU(SOHC)-30, Camshaft Position Sensor.> Is the camshaft position Go to step 8. Tighten camshaft sensor installation bolt position sensor tightened securely? installation bolt securely. Replace camshaft Go to step 9. Are camshaft sprocket CHECK CAMSHAFT SPROCKET. Remove front belt cover. <Ref. to ME(SOHC)- teeth cracked or damaged? sprocket. <Ref. to ME(SOHC)-51, 45, Belt Cover.> Camshaft Sprocket.> Is timing belt dislocated Repair installation Replace camshaft CHECK INSTALLATION CONDITION OF from its proper position? condition of timing position sensor. TIMING BELT. <Ref. to belt. <Ref. to Turn camshaft using ST, and align alignment FU(SOHC)-30, ME(SOHC)-46, mark on camshaft sprocket with alignment Camshaft Position Timing Belt mark on timing belt cover LH. Sensor.> Assembly.> ST 499207100 CAMSHAFT SPROCKET WRENCH Check Yes Is the resistance between 1 Go to step 7. and 4 k?
EN(SOHC)-178

MEMO:
EN(SOHC)-179
AJ: DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD

S058521B46
DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: Engine stalls. Idle mixture is out of specifications. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(SOHC)-45, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)-42, OPERATION, Inspection Mode.>. WIRING DIAGRAM:
S2M2087
EN(SOHC)-180

No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0130, P0133, P0136, P0139, P0037, P0301, P0302, P0303, P0304, P1130, P1131, P0031, P0032 and P0038? Yes Inspect the relevant DTC using 17. List of Diagnostic Trouble Code (DTC). <Ref. to EN(SOHC)-80, List of Diagnostic Trouble Code (DTC).> NOTE: In this case, it is not necessary to inspect DTC P0420. Repair or replace exhaust system. <Ref. to EX(SOHC)-2, General Description.> No Go to step 2.
CHECK EXHAUST SYSTEM. Check for gas leaks or air suction caused by loose or dislocated nuts and bolts, and open hole at exhaust pipes. NOTE: Check the following positions. Between cylinder head and front exhaust pipe Between front exhaust pipe and front catalytic converter Between front catalytic converter and rear catalytic converter CHECK REAR CATALYTIC CONVERTER. Separate rear catalytic converter from rear exhaust pipe.
Go to step 3.
Is there damage at rear face of rear catalyst?
CHECK FRONT CATALYTIC CONVERTER. Remove front catalytic converter.
Is there damage at rear face or front face of front catalyst?
Replace front catalytic converter <Ref. to EC(SOHC)-3. Front Catalytic Converter.> and rear catalytic converter <Ref. to EC(SOHC)-6, Rear Catalytic Converter.>. Replace front catalytic converter. <Ref. to EC(SOHC)-3, Front Catalytic Converter.>
Go to step 4.
EN(SOHC)-181
AK: DTC P0444 EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CONTROL VALVE CIRCUIT LOW INPUT
S058521G47
DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: Erroneous idling CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(SOHC)-45, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)-42, OPERATION, Inspection Mode.>. WIRING DIAGRAM:
S2M2088
EN(SOHC)-182

No. 1 Step Check Yes Is the voltage more than 10 Even if MIL lights CHECK OUTPUT SIGNAL FROM ECM. V? up, the circuit has 1) Turn ignition switch to ON. returned to a nor2) Measure voltage between ECM and chasmal condition at sis ground. this time. Contact Connector & terminal with your Subaru (B134) No. 2 (+) Chassis ground (): distributor. NOTE: Inspection by DTM is required, because probable cause is deterioration of multiple parts. Is the resistance less than Repair ground CHECK HARNESS BETWEEN PURGE 10 ? short circuit in CONTROL SOLENOID VALVE AND ECM harness between CONNECTOR. ECM and purge 1) Turn ignition switch to OFF. control solenoid 2) Disconnect connectors from purge control valve connector. solenoid valve and ECM. 3) Measure resistance of harness between purge control solenoid valve connector and engine ground. Connector & terminal (E4) No. 2 Engine ground: Is the resistance less than Go to step 4. CHECK HARNESS BETWEEN PURGE 1 ? CONTROL SOLENOID VALVE AND ECM CONNECTOR. Measure resistance of harness between ECM and purge control solenoid valve of harness connector. Connector & terminal (B134) No. 2 (E4) No. 2: No Go to step 2.
Go to step 3.
CHECK PURGE CONTROL SOLENOID VALVE. 1) Remove purge control solenoid valve. 2) Measure resistance between purge control solenoid valve terminals. Terminals No. 1 No. 2: CHECK POWER SUPPLY TO PURGE CONTROL SOLENOID VALVE. 1) Turn ignition switch to ON. 2) Measure voltage between purge control solenoid valve and engine ground. Connector & terminal (E4) No. 1 (+) Engine ground ():
Is the resistance between 10 and 100 ?
Go to step 5.
Repair open circuit in harness between ECM and purge control solenoid valve connector. NOTE: In this case, repair the following: Open circuit in harness between ECM and purge control solenoid valve connector Poor contact in coupling connector (B22) Replace purge control solenoid valve. <Ref. to EC(SOHC)-8, Purge Control Solenoid Valve.> Repair open circuit in harness between main relay and purge control solenoid valve connector.
EN(SOHC)-183
No. 6

Step CHECK POOR CONTACT. Check poor contact in purge control solenoid valve connector. Check Is there poor contact in purge control solenoid valve connector? Yes Repair poor contact in purge control solenoid valve connector. No Contact your Subaru distributor. NOTE: Inspection by DTM is required, because probable cause is deterioration of multiple parts.
EN(SOHC)-184

MEMO:
EN(SOHC)-185
AL: DTC P0445 EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH INPUT
S058521G48
S2M2088
EN(SOHC)-186

No. 1 Step CHECK OUTPUT SIGNAL FROM ECM. 1) Turn ignition switch to OFF. 2) Connect test mode connector at the lower portion of instrument panel (on the driver s side), to the side of the center console box. 3) Turn ignition switch to ON. 4) While operating purge control solenoid valve, measure voltage between ECM and chassis ground. NOTE: Purge control solenoid valve operation can be executed using Subaru Select Monitor. For procedure, refer to Compulsory Valve Operation Check Mode. <Ref. to EN(SOHC)-46, Compulsory Valve Operation Check Mode.> Connector & terminal (B134) No. 2 (+) Chassis ground (): CHECK OUTPUT SIGNAL FROM ECM. 1) Turn ignition switch to ON. 2) Measure voltage between ECM and chassis ground. Connector & terminal (B134) No. 2 (+) Chassis ground (): CHECK POOR CONTACT. Check poor contact in ECM connector. Check Does voltage change between 0 and 10 V? Yes Go to step 2.
No Even if MIL light up, the circuit has returned to a normal condition at this time. In this case, repair poor contact in ECM connector.
Go to step 3.
Is the voltage more than 10 Repair battery CHECK HARNESS BETWEEN PURGE V? short circuit in CONTROL SOLENOID VALVE AND ECM harness between CONNECTOR. ECM and purge 1) Turn ignition switch to OFF. control solenoid 2) Disconnect connector from purge control valve connector. solenoid valve. After repair, 3) Turn ignition switch to ON. replace ECM. 4) Measure voltage between ECM and chas<Ref. to sis ground. FU(SOHC)-49, Connector & terminal Engine Control (B134) No. 2 (+) Chassis ground (): Module.> Is the resistance less than Replace purge CHECK PURGE CONTROL SOLENOID 1 ? control solenoid VALVE. valve <Ref. to 1) Turn ignition switch to OFF. EC(SOHC)-8, 2) Measure resistance between purge control Purge Control solenoid valve terminals. Solenoid Valve.> Terminals and ECM <Ref. to No. 1 No. 2: FU(SOHC)-49, Engine Control Module.> Is there poor contact in Repair poor conCHECK POOR CONTACT. Check poor contact in ECM connector. ECM connector? tact in ECM connector.
Replace ECM. <Ref. to FU(SOHC)-49, Engine Control Module.> Go to step 5.
Go to step 6.
EN(SOHC)-187
AM: DTC P0461 FUEL LEVEL SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM

S058521B54
S2M2089
EN(SOHC)-188

No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0462 or P0463? Yes Inspect DTC P0462 or P0463 using 17. List of Diagnostic Trouble Code (DTC). <Ref. to EN(SOHC)-80, List of Diagnostic Trouble Code (DTC).> NOTE: In this case, it is not necessary to inspect this trouble.
No Replace fuel level sensor <Ref. to FU(SOHC)-64, Fuel Level Sensor.> and fuel sub level sensor <Ref. to FU(SOHC)-65, Fuel Sub Level Sensor.>.
EN(SOHC)-189

S058521B55
AN: DTC P0462 FUEL LEVEL SENSOR CIRCUIT LOW INPUT

S2M2089
No. 1
Step CHECK SPEEDOMETER AND TACHOMETER OPERATION IN COMBINATION METER.
Check Does speedometer and tachometer operate normally?
Yes Go to step 2.
No Repair or replace combination meter. <Ref. to IDI-4, Combination Meter System.>
EN(SOHC)-190

No. 2 Step CHECK INPUT SIGNAL FOR ECM. 1) Turn ignition switch to ON. (Engine OFF) 2) Measure voltage between ECM connector and chassis ground. Connector & terminal (B136) No. 27 (+) Chassis ground (): CHECK INPUT SIGNAL FOR ECM. (USING SUBARU SELECT MONITOR.) Read data of fuel level sensor signal using Subaru Select Monitor. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(SOHC)-34, Subaru Select Monitor.> Check Is the voltage less than 0.12 V? Yes Go to step 6. No Go to step 3.
Does the value change less than 0.12 V by shaking harness and connector of ECM while monitoring the value with Subaru Select Monitor?
CHECK INPUT VOLTAGE OF ECM. 1) Turn ignition switch to OFF. 2) Separate fuel tank cord connector (R57) and rear wiring harness connector (R15). 3) Turn ignition switch to ON. 4) Measure voltage of harness between ECM connector and chassis ground. Connector & terminal (B136) No. 27 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND COMBINATION METER. 1) Turn ignition switch to OFF. 2) Disconnect connector from connector (i11) and ECM connector. 3) Measure resistance between ECM and chassis ground. Connector & terminal (B136) No. 27 Chassis ground: CHECK HARNESS BETWEEN ECM AND COMBINATION METER. Measure resistance between ECM and combination meter connector. Connector & terminal (B136) No. 27 (i11) No. 1:
Go to step 4.
Even if MIL lights up, the circuit has returned to a normal condition at this time. A temporary poor contact of the connector may be the cause. NOTE: In this case, repair the following: Poor contact in combination meter connector Poor contact in ECM connector Go to step 7.
Repair ground short circuit in harness between ECM and combination meter connector.
Repair or replace combination meter. <Ref. to IDI-4, Combination Meter System.>
Repair open circuit between ECM and combination meter connector. NOTE: In this case, repair the following: Poor contact in coupling connector (i2)
EN(SOHC)-191
No. 7

Step CHECK FUEL TANK CORD. 1) Turn ignition switch to OFF. 2) Disconnect connector from fuel sub level sensor. 3) Measure resistance between fuel sub level sensor and chassis ground. Connector & terminal (R59) No. 1 Chassis ground: CHECK FUEL TANK CORD. 1) Disconnect connector from fuel pump assembly. 2) Measure resistance between fuel pump assembly and chassis ground. Connector & terminal (R59) No. 2 Chassis ground: CHECK FUEL LEVEL SENSOR. WARNING: During work procedures, if fuel tank is more than 3/4 full, be careful because fuel may spill. 1) Remove fuel pump assembly. <Ref. to FU(SOHC)-62 Fuel Pump.> 2) Measure resistance between fuel level sensor and terminals with its float set to the full position. Terminals No. 3 No. 5: CHECK FUEL SUB LEVEL SENSOR. WARNING: During work procedures, if fuel tank is more than 3/4 full, be careful because fuel may spill. 1) Remove fuel sub level sensor. <Ref. to FU(SOHC)-65, Fuel Sub Level Sensor.> 2) Measure resistance between fuel sub level sensor and terminals with its float set to the full position. Terminals No. 1 No. 2: Check Yes Is the resistance more than Go to step 8. 1 M? No Repair ground short circuit in fuel tank cord.
Repair ground short circuit in fuel tank cord.
Is the resistance between 0.5 and 2.5 ?
Go to step 10.
Replace fuel level sensor.
10
Repair poor contact in harness between ECM and combination meter connector.
Replace fuel sub level sensor.
EN(SOHC)-192

MEMO:
EN(SOHC)-193

S058521B56
AO: DTC P0463 FUEL LEVEL SENSOR CIRCUIT HIGH INPUT

S2M2089
No. 1
Step CHECK SPEEDOMETER AND TACHOMETER OPERATION IN COMBINATION METER.
Check Does speedometer and tachometer operate normally?
Yes Go to step 2.
No Repair or replace combination meter. <Ref. to IDI-4, Combination Meter System.>
EN(SOHC)-194

No. 2 Step CHECK INPUT SIGNAL FOR ECM. 1) Turn ignition switch to ON. (Engine OFF) 2) Measure voltage between ECM connector and chassis ground. Connector & terminal (B136) No. 27 (+) Chassis ground (): Check Is the voltage more than 4.75 V? Yes Go to step 3.
No Even if MIL lights up, the circuit has returned to a normal condition at this time. A temporary poor contact of the connector may be the cause. NOTE: In this case, repair the following: Poor contact in fuel pump connector Poor contact in coupling connector (B22, B37 and R57) Repair battery short circuit between ECM and combination meter connector.
CHECK INPUT VOLTAGE OF ECM. 1) Turn ignition switch to OFF. 2) Disconnect combination meter connector (i11) and ECM connector. 3) Turn ignition switch to ON. 4) Measure voltage of harness between ECM and chassis ground. Connector & terminal (B136) No. 27 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND FUEL TANK CORD. 1) Turn ignition switch to OFF. 2) Separate fuel tank cord connector (R57) and rear wiring harness connector (R15). 3) Measure resistance between ECM and fuel tank cord. Connector & terminal (B136) No. 27 (R15) No. 2: CHECK HARNESS BETWEEN FUEL TANK CORD AND CHASSIS GROUND. Measure resistance between fuel tank cord and chassis ground. Connector & terminal (R15) No. 6 Chassis ground:
Go to step 4.
Go to step 5.
Repair open circuit between ECM and fuel tank cord.
Go to step 6.
Is the resistance less than CHECK FUEL TANK CORD. 10 ? 1) Disconnect connector from fuel level sensor. 2) Measure resistance between fuel level sensor and coupling connector. Connector & terminal (R57) No. 6 (R58) No. 5:
Go to step 7.
Repair open circuit between fuel tank cord and chassis ground. NOTE: In this case, repair the following: Poor contact in coupling connectors (B22 and B99) Repair open circuit between coupling connector and fuel level sensor.
EN(SOHC)-195
No. 7

Step CHECK FUEL TANK CORD. 1) Disconnect connector from fuel sub level sensor. 2) Measure resistance between fuel level sensor and fuel sub level sensor. Connector & terminal (R58) No. 3 (R59) No. 2: CHECK FUEL TANK CORD. Measure resistance between fuel sub level sensor and coupling connector. Connector & terminal (R57) No. 2 (R59) No. 1: CHECK FUEL LEVEL SENSOR. WARNING: During work procedures, if fuel tank is more than 3/4 full, be careful because fuel may spill. 1) Remove fuel pump assembly. <Ref. to FU(SOHC)-62, Fuel Pump.> 2) While moving fuel level sensor float up and down, measure resistance between fuel level sensor terminals. Terminals No. 3 No. 5: CHECK FUEL SUB LEVEL SENSOR. WARNING: During work procedures, if fuel tank is more than 3/4 full, be careful because fuel may spill. 1) Remove fuel sub level sensor. <Ref. to FU(SOHC)-65, Fuel Sub Level Sensor.> 2) While moving fuel sub level sensor float up and down, measure resistance between fuel sub level sensor terminals. Terminals No. 1 No. 2: Check Is the resistance less than 10 ? Yes Go to step 8. No Repair open circuit between fuel level sensor and fuel sub level sensor.
Repair open circuit between coupling connector and fuel sub level sensor. Is the resistance more than Replace fuel level Go to step 10. 54.5 ? sensor. <Ref. to FU(SOHC)-64, Fuel Level Sensor.>
Go to step 9.
10
Is the resistance more than Replace fuel sub 41.5 ? level sensor. <Ref. to FU(SOHC)-65, Fuel Sub Level Sensor.>
Replace combination meter. <Ref. to IDI-15, Combination Meter Assembly.>
EN(SOHC)-196

MEMO:
EN(SOHC)-197

S058521G01
AP: DTC P0464 FUEL LEVEL SENSOR INTERMITTENT INPUT

S2M2089
EN(SOHC)-198

No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0462 or P0463? Yes Inspect DTC P0462 or P0463 using 17. List of Diagnostic Trouble Code (DTC). <Ref. to EN(SOHC)-80, List of Diagnostic Trouble Code (DTC).> Go to step 3. No Go to step 2.
CHECK FUEL LEVEL SENSOR. WARNING: During work procedures, if fuel tank is more than 3/4 full, be careful because fuel may spill. 1) Remove fuel pump assembly. <Ref. to FU(SOHC)-62, Fuel Pump.> 2) While moving fuel level sensor float up and down, make sure that the resistance between fuel level sensor terminals changes smoothly. Terminals No. 3 No. 5: CHECK FUEL SUB LEVEL SENSOR. WARNING: During work procedures, if fuel tank is more than 3/4 full, be careful because fuel may spill. 1) Remove fuel sub level sensor. <Ref. to FU(SOHC)-65, Fuel Sub Level Sensor.> 2) While moving fuel sub level sensor float up and down, make sure that the resistance between fuel level sensor terminals changes smoothly. Terminals No. 1 No. 2:
Does the resistance change smoothly?
Replace fuel level sensor. <Ref. to FU(SOHC)-64, Fuel Level Sensor.>
Does the resistance change smoothly?
Repair poor contact in ECM, combination meter and coupling connectors.
Replace fuel sub level sensor. <Ref. to FU(SOHC)-65, Fuel Sub Level Sensor.>
EN(SOHC)-199

S058521B57
AQ: DTC P0480 COOLING FAN RELAY 1 CIRCUIT LOW INPUT

DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: Radiator fan does not operate properly. Overheating
EN(SOHC)-200

WIRING DIAGRAM:
S2M2090
EN(SOHC)-201
No. 1

Step CHECK OUTPUT SIGNAL FROM ECM. 1) Turn ignition switch to OFF. 2) Connect test mode connector at the lower portion of instrument panel (on the driver s side), to the side of the center console box. 3) Turn ignition switch to ON. 4) While operating radiator fan relay, measure voltage between ECM terminal and ground. NOTE: Radiator fan relay operation can be executed using Subaru Select Monitor. For procedure, refer to Compulsory Valve Operation Check Mode. <Ref. to EN(SOHC)-34, Subaru Select Monitor.> Connector & terminal (B134) No. 3 (+) Chassis ground (): CHECK GROUND SHORT CIRCUIT IN RADIATOR MAIN FAN RELAY CONTROL CIRCUIT. 1) Turn ignition switch to OFF. 2) Disconnect connectors from ECM. 3) Measure resistance of harness between ECM connector and chassis ground. Connector & terminal (B134) No. 3 Chassis ground: CHECK POWER SUPPLY FOR RELAY. 1) Remove main fan relay from A/C relay holder. 2) Turn ignition switch to ON. 3) Measure voltage between fuse and relay box (F/B) connector and chassis ground. Connector & terminal (F66) No. 28 (+) Chassis ground (): CHECK MAIN FAN RELAY. 1) Turn ignition switch to OFF. 2) Measure resistance between main fan relay terminals. Terminal No. 28 No. 27: CHECK OPEN CIRCUIT IN MAIN FAN RELAY CONTROL CIRCUIT. Measure resistance of harness between ECM and main fan relay connector. Connector & terminal (B134) No. 3 (F66) No. 27: Check Does voltage change between 0 and 10 V? Yes Repair poor contact in ECM connector. No Go to step 2.
Repair ground short circuit in radiator main fan relay control circuit.
Go to step 3.
Repair open circuit in harness between ignition switch and fuse and relay box (F/B) connector.
Go to step 5.
Go to step 6.
CHECK POOR CONTACT. Check poor contact in ECM or main fan relay connector.
Is there poor contact in Repair poor conECM or main fan relay contact in ECM or nector? main fan relay connector.
Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ECM and main fan relay connector Poor contact in coupling connector (F45, F46) Contact your Subaru distributor.
EN(SOHC)-202

MEMO:
EN(SOHC)-203

S058521B58
AR: DTC P0483 COOLING FAN FUNCTION PROBLEM

DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: Occurrence of noise Overheating
CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(SOHC)-45, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)-42, OPERATION, Inspection Mode.>. NOTE: If the vehicle, with the engine idling, is placed very close to a wall or another vehicle, preventing normal cooling function, the OBD system may detect malfunction.
EN(SOHC)-204

WIRING DIAGRAM:
S2M2090
EN(SOHC)-205
No. 1

Step CHECK ANY OTHER DTC ON DISPLAY. Check Is there any other DTC on display? Yes Inspect the relevant DTC using 17. List of Diagnostic Trouble Code (DTC). <Ref. to EN(SOHC)-80, List of Diagnostic Trouble Code (DTC).> No Check radiator fan and fan motor. <Ref. to CO-8, Radiator Main Fan System.> and <Ref. to CO-11, Radiator Sub Fan System.>
EN(SOHC)-206

MEMO:
EN(SOHC)-207

S058521B59
AS: DTC P0500 VEHICLE SPEED SENSOR MALFUNCTION

S2M2091
No. 1
Check Is the transmission type AT?
Yes Go to step 2.
No Go to step 3.
EN(SOHC)-208

No. 2 Step CHECK DTC P0720 ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0720?
CHECK SPEEDOMETER OPERATION IN COMBINATION METER.
CHECK HARNESS BETWEEN ECM AND COMBINATION METER CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from combination meter. 3) Measure resistance between ECM and combination meter. Connector & terminal (B135) No. 24 (i10) No. 7:
Yes No Go to step 3. Check front vehicle speed sensor signal circuit. <Ref. to AT-58, TROUBLE CODE 33 FRONT VEHICLE SPEED SENSOR , Diagnostic Procedure with Trouble Code.> Does speedometer operate Go to step 4. Check speedomnormally? eter and vehicle speed sensor. <Ref. to IDI-17, Speedometer.> and <Ref. to AT-32, Front Vehicle Speed Sensor.> and <Ref. to AT-36, Rear Vehicle Speed Sensor.> and <Ref. to AT-37, Torque Converter Turbine Speed Sensor.> Is the resistance less than Repair poor con- Repair harness 10 ? tact in ECM con- and connector. nector. NOTE: In this case, repair the following: Open circuit in harness between ECM and combination meter connector Poor contact in ECM connector Poor contact in combination meter connector Poor contact in coupling connector (i2)
EN(SOHC)-209
AT: DTC P0506 IDLE CONTROL SYSTEM RPM LOWER THAN EXPECTED
S058521B61
DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: Engine is difficult to start. Engine does not start. Erroneous idling Engine stalls. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(SOHC)-45, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)-42, OPERATION, Inspection Mode.>. WIRING DIAGRAM:
S2M2092
EN(SOHC)-210

No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P1510, P1511, P1512, P1513, P1514, P1515, P1516 or P1517? Yes Inspect DTC P1510, P1511, P1512, P1513, P1514, P1515, P1516 or P1517 using 17. List of Diagnostic Trouble Code (DTC). <Ref. to EN(SOHC)-80, List of Diagnostic Trouble Code (DTC).> NOTE: In this case, it is not necessary to inspect DTC P0506. Replace idle air control solenoid valve. <Ref. to FU(SOHC)-38, INSTALLATION, Idle Air Control Solenoid Valve.> No Go to step 2.
Does air flow out? CHECK AIR BY-PASS LINE. 1) Turn ignition switch to OFF. 2) Remove idle air control solenoid valve from throttle body. <Ref. to FU(SOHC)-38, REMOVAL, Idle Air Control Solenoid Valve.> 3) Remove throttle body from intake manifold. <Ref. to FU(SOHC)-14, REMOVAL, Throttle Body.> 4) Using an air gun, force air into idle air control solenoid valve installation area. Confirm that forced air subsequently escapes from throttle body interior.
Replace throttle body. <Ref. to FU(SOHC)-14, INSTALLATION, Throttle Body.>
EN(SOHC)-211
AU: DTC P0507 IDLE CONTROL SYSTEM RPM HIGHER THAN EXPECTED
S058521B62
DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: Engine keeps running at higher revolution than specified idling revolution. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(SOHC)-45, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)-42, OPERATION, Inspection Mode.>. WIRING DIAGRAM:
S2M2092
EN(SOHC)-212

No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P1510, P1511, P1512, P1513, P1514, P1515, P1516 or P1517? Yes Inspect DTC P1510, P1511, P1512, P1513, P1514, P1515, P1516 or P1517 using 17. List of Diagnostic Trouble Code (DTC). <Ref. to EN(SOHC)-80, List of Diagnostic Trouble Code (DTC).> NOTE: In this case, it is not necessary to inspect DTC P0507. Repair air suction and leaks. No Go to step 2.
Is there a fault in air intake CHECK AIR INTAKE SYSTEM. system? 1) Turn ignition switch to ON. 2) Start engine, and idle it. 3) Check the following items. Loose installation of intake manifold, idle air control solenoid valve and throttle body Cracks of intake manifold gasket, idle air control solenoid valve gasket and throttle body gasket Disconnections of vacuum hoses CHECK THROTTLE CABLE. Does throttle cable have play for adjustment?
Go to step 3.
Go to step 4.
Are foreign particles in byCHECK AIR BY-PASS LINE. pass air line? 1) Turn ignition switch to OFF. 2) Remove idle air control solenoid valve from throttle body. <Ref. to FU(SOHC)-38, REMOVAL, Idle Air Control Solenoid Valve.> 3) Confirm that there are no foreign particles in by-pass air line.
Remove foreign particles from bypass air line.
Adjust throttle cable. <Ref. to SP-12, INSTALLATION, Accelerator Control Cable.> Replace idle air control solenoid valve. <Ref. to FU(SOHC)-38, INSTALLATION, Idle Air Control Solenoid Valve.>
EN(SOHC)-213

S058521G02
AV: DTC P0512 STARTER SWITCH CIRCUIT HIGH INPUT

DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: Failure of engine to start
S2M2093
EN(SOHC)-214

No. 1 Step Check CHECK OPERATION OF STARTER MOTOR. Does starter motor operate when ignition switch to NOTE: ON? Place the inhibitor switch in each position. Yes Repair battery short circuit in starter motor circuit. After repair, replace ECM. <Ref. to FU(SOHC)-49, Engine Control Module.>
No Check starter motor circuit. <Ref. to EN(SOHC)-60, STARTER MOTOR CIRCUIT, Diagnostics for Engine Starting Failure.>
EN(SOHC)-215

S058521G81
AW: DTC P0562 CHARGE SYSTEM CIRCUIT LOW INPUT

DTC DETECTING CONDITION: Power source voltage of the ECM is low. TROUBLE SYMPTOM: Charge warning light comes on.
S2M2094
EN(SOHC)-216

No. 1 Step CHECK GENERATOR. 1) Start engine. 2) Idling after warm-up. 3) Measure voltage between generator B terminal and chassis ground. Terminal Generator B terminal (+) Chassis ground (): CHECK GENERATOR. 1) Run engine at 5,000 rpm. 2) Measure voltage between generator B terminal and chassis ground. Terminal Generator B terminal (+) Chassis ground (): CHECK BATTERY TERMINAL. Turn ignition switch to OFF. Check Is the voltage less than 10.8 V? Yes Go to step 2.
No Repair generator. <Ref. to SC-12, Generator.>
Is the voltage less than 10.8 V?
Go to step 3.
Repair generator. <Ref. to SC-12, Generator.>
CHECK INPUT VOLTAGE OF ECM. 1) Run the engine at idle. 2) Measure voltage between ECM connector and chassis ground. Connector & terminal (B136) No. 1 (+) Chassis ground (): (B136) No. 2 (+) Chassis ground (): CHECK POOR CONTACT IN CONNECIs there poor contact in TORS. connectors between generator, battery and ECM? Is the same trouble code CHECK ECM. as in the current diagnosis 1) Connect all connectors. 2) Erase the memory. <Ref. to EN(SOHC)-45, still being output? Clean Memory Mode.> 3) Perform inspection mode. <Ref. to EN(SOHC)-42, Inspection Mode.> 4) Read out the trouble code. <Ref. to EN(SOHC)-41, Read Diagnostic Trouble Code.> CHECK ANY OTHER TROUBLE CODES Are other trouble codes APPEARANCE. being output?
Are the positive and nega- Go to step 4. tive battery terminals tightly clamped? Is the voltage less than Go to step 5. 10.8 V?
Tighten the clamp of terminal. Repair harness connector between battery, main relay and ECM.
Repair connector.
Go to step 6.
Replace generator.
Go to step 7.
Proceed with the diagnosis corresponding to the trouble code.
A temporary poor contact.
EN(SOHC)-217

S058521G82
AX: DTC P0563 CHARGE SYSTEM CIRCUIT HIGH INPUT

DTC DETECTING CONDITION: Power source voltage of the ECM is high. TROUBLE SYMPTOM: Charge warning light comes on.
S2M2094
EN(SOHC)-218

No. 1 Step CHECK GENERATOR. 1) Start engine. 2) Idling after warm-up. 3) Measure voltage between generator B terminal and chassis ground. Terminal Generator B terminal (+) Chassis ground (): CHECK GENERATOR. 1) Run engine at 5,000 rpm. 2) Measure voltage between generator B terminal and chassis ground. Terminal Generator B terminal (+) Chassis ground (): CHECK BATTERY TERMINAL. Turn ignition switch to OFF. Check Is the voltage more than 16.2 V? Yes Go to step 2.
Go to step 3.
CHECK INPUT VOLTAGE OF ECM. 1) Run the engine at idle. 2) Measure voltage between ECM connector and chassis ground. Connector & terminal (B136) No. 1 (+) Chassis ground (): (B136) No. 2 (+) Chassis ground (): CHECK POOR CONTACT IN CONNECIs there poor contact in TORS. connectors between generator, battery and ECM? Is the same trouble code CHECK ECM. as in the current diagnosis 1) Connect all connectors. 2) Erase the memory. <Ref. to EN(SOHC)-45, still being output? Clear Memory Mode.> 3) Perform inspection mode. <Ref. to EN(SOHC)-42, Inspection Mode.> 4) Read out the trouble code. <Ref. to EN(SOHC)-41, Read Diagnostic Trouble Code.> CHECK ANY OTHER TROUBLE CODES Are other trouble codes APPEARANCE. being output?
Are the positive and nega- Go to step 4. tive battery terminals tightly clamped? Is the voltage more than Go to step 5. 16.2 V?
Repair connector.
Go to step 6.
Replace generator.
Go to step 7.
EN(SOHC)-219
AY: DTC P0604 INTERNAL CONTROL MODULE MEMORY CHECK SUM ERROR
S058521G03
DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: Engine does not start. Engine stalls. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(SOHC)-45, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)-42, OPERATION, Inspection Mode.>. WIRING DIAGRAM:
S2M2095
EN(SOHC)-220

No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0601? Yes Replace ECM. <Ref. to FU(SOHC)-49, Engine Control Module.>
No It is not necessary to inspect DTC P0601.
EN(SOHC)-221

S058521B64
AZ: DTC P0703 BRAKE SWITCH INPUT MALFUNCTION

S2M2102
No. 1
Step CHECK OPERATION OF BRAKE LIGHT.
Check Yes Does brake light come on Go to step 2. when depressing the brake pedal?
No Repair or replace brake light circuit.
EN(SOHC)-222

No. 2 Step CHECK HARNESS BETWEEN TCM AND BRAKE LIGHT SWITCH CONNECTOR. 1) Disconnect connectors from TCM and brake light switch. 2) Measure resistance of harness between TCM and brake light switch connector. Connector & terminal (B55) No. 12 (B64) No. 2: (B55) No. 12 (B65) No. 3 (With cruise control): Check Is the resistance less than 1 ? Yes Go to step 3.
No Repair or replace harness and connector. NOTE: In this case, repair the following: Open circuit in harness between TCM and brake light switch connector Poor contact in TCM connector Poor contact in brake light switch connector Repair ground short circuit in harness between TCM and brake light switch connector. Adjust or replace brake light switch. <Ref. to LI-31, STOP LIGHT SWITCH, INSPECTION, Stop Light System.> Adjust or replace brake light switch. <Ref. to LI-31, STOP LIGHT SWITCH, INSPECTION, Stop Light System.> Replace TCM. <Ref. to AT-48, Transmission Control Module.>
CHECK HARNESS BETWEEN TCM AND BRAKE LIGHT SWITCH CONNECTOR. Measure resistance of harness between TCM and chassis ground. Connector & terminal (B55) No. 12 Chassis ground: CHECK INPUT SIGNAL FOR TCM. 1) Connect connectors to TCM and brake light switch. 2) Measure voltage between TCM and chassis ground. Connector & terminal (B55) No. 12 (+) Chassis ground ():
Is the voltage less than 1 V Go to step 5. when releasing the brake pedal?
Is the voltage more than 10 Go to step 6. CHECK INPUT SIGNAL FOR TCM. V when depressing the Measure voltage between TCM and chassis brake pedal? ground. Connector & terminal (B55) No. 12 (+) Chassis ground ():
CHECK POOR CONTACT. Check poor contact in TCM connector.
Is there poor contact in TCM connector?
Repair poor contact in TCM connector.
EN(SOHC)-223

S058521B70
BA: DTC P0731 GEAR 1 INCORRECT RATIO
NOTE: For the diagnostic procedure, refer to DTC P0734. <Ref. to EN(SOHC)-225, DTC P0734 GEAR 4 INCORRECT RATIO , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
BB: DTC P0732 GEAR 2 INCORRECT RATIO
S058521B71
BC: DTC P0733 GEAR 3 INCORRECT RATIO
S058521B72
EN(SOHC)-224
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) BD: DTC P0734 GEAR 4 INCORRECT RATIO
S058521B73
DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: Shift point too high or too low; engine brake not effected in 3 range; excessive shift shock; excessive tight corner braking CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(SOHC)-45, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)-42, OPERATION, Inspection Mode.>. WIRING DIAGRAM:
No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. Check Is there any other DTC on display? Yes Inspect relevant DTC using 17. List of Diagnostic Trouble Code (DTC). <Ref. to EN(SOHC)-80, List of Diagnostic Trouble Code (DTC).> Repair or replace throttle position sensor circuit. No Go to step 2.
CHECK THROTTLE POSITION SENSOR CIRCUIT. Check throttle position sensor circuit. <Ref. to AT-50, TROUBLE CODE 31 THROTTLE POSITION SENSOR , Diagnostic Procedure with Trouble Code.> CHECK FRONT VEHICLE SPEED SENSOR CIRCUIT. Check front vehicle speed sensor circuit. <Ref. to AT-58, TROUBLE CODE 33 FRONT VEHICLE SPEED SENSOR , Diagnostic Procedure with Trouble Code.> CHECK TORQUE CONVERTER TURBINE SPEED SENSOR CIRCUIT. Check torque converter turbine speed sensor circuit. <Ref. to AT-64, TROUBLE CODE 36 TORQUE CONVERTER TURBINE SPEED SENSOR , Diagnostic Procedure with Trouble Code.> CHECK POOR CONTACT. Check poor contact in TCM connector. CHECK MECHANICAL TROUBLE. Check mechanical trouble in automatic transmission.
Is there any trouble in throttle position sensor circuit?
Go to step 3.
Is there any trouble in vehicle speed sensor 2 circuit?
Repair or replace vehicle speed sensor 2 circuit.
Go to step 4.
Is there any trouble in torque converter turbine speed sensor circuit?
Repair or replace torque converter turbine speed sensor circuit.
Go to step 5.
Is there poor contact in TCM connector? Is there any mechanical trouble in automatic transmission?
Repair poor contact in TCM connector. Repair or replace automatic transmission. <Ref. to AT-12, INSPECTION, Road Test.>
Go to step 6.
Replace TCM. <Ref. to AT-48, Transmission Control Module (TCM).>
EN(SOHC)-225
BE: DTC P0741 TORQUE CONVERTER CLUTCH SYSTEM MALFUNCTION

S058521G04
DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: No lock-up (after engine warm-up) No shift or excessive tight corner braking CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(SOHC)-45, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)-42, OPERATION, Inspection Mode.>.
No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. Check Is there any other DTC on display? Yes Inspect the relevant DTC using 17. List of Diagnostic Trouble Code (DTC). <Ref. to EN(SOHC)-80, List of Diagnostic Trouble Code (DTC).> Repair or replace lock-up duty solenoid circuit. No Go to step 2.
CHECK LOCK-UP DUTY SOLENOID CIRCUIT. Check lock-up duty solenoid circuit. <Ref. to AT-96, TROUBLE CODE 77 LOCK-UP DUTY SOLENOID , Diagnostic Procedure with Trouble Code.> CHECK THROTTLE POSITION SENSOR CIRCUIT. Check throttle position sensor circuit. <Ref. to AT-50, TROUBLE CODE 31 THROTTLE POSITION SENSOR , Diagnostic Procedure with Trouble Code.> CHECK TORQUE CONVERTER TURBINE SPEED SENSOR CIRCUIT. Check torque converter turbine speed sensor circuit. <Ref. to AT-64, TROUBLE CODE 36 TORQUE CONVERTER TURBINE SPEED SENSOR , Diagnostic Procedure with Trouble Code.> CHECK ENGINE SPEED INPUT CIRCUIT. Check engine speed input circuit. <Ref. to AT-42, TROUBLE CODE 11 ENGINE SPEED SIGNAL , Diagnostic Procedure with Trouble Code.> CHECK INHIBITOR SWITCH CIRCUIT. Check inhibitor switch circuit. <Ref. to AT-122, CHECK INHIBITOR SWITCH, Diagnostic Procedure for No-trouble Code.> CHECK BRAKE LIGHT SWITCH CIRCUIT. Check brake light switch circuit. <Ref. to AT-111, CHECK BRAKE SWITCH, Diagnostic Procedure for No-trouble Code.>
Is there any trouble in lock-up duty solenoid circuit?
Go to step 3.
Repair or replace throttle position sensor circuit.
Go to step 4.
Go to step 5.
Is there any trouble in engine speed input circuit?
Repair or replace engine speed input circuit.
Go to step 6.
Is there any trouble in inhibitor switch circuit?
Repair or replace inhibitor switch circuit. Repair or replace brake light switch circuit.
Go to step 7.
Is there any trouble in brake light switch circuit?
Go to step 8.
EN(SOHC)-226

No. 8 Step CHECK ATF TEMPERATURE SENSOR CIRCUIT. Check ATF temperature sensor circuit. <Ref. to AT-46, TROUBLE CODE 27 ATF TEMPERATURE SENSOR , Diagnostic Procedure with Trouble Code.> CHECK POOR CONTACT. Check poor contact in TCM connector. CHECK MECHANICAL TROUBLE. Check mechanical trouble in automatic transmission. Check Yes Is there any trouble in ATF Repair or replace temperature sensor circuit? ATF temperature sensor circuit. No Go to step 9.
10
Go to step 10.
EN(SOHC)-227
BF: DTC P1110 ATMOSPHERIC PRESSURE SENSOR CIRCUIT LOW INPUT

S058521B84
S2M2096
EN(SOHC)-228

No. 1 Step CHECK CURRENT DATA. 1) Start engine. 2) Read the data of intake manifold absolute pressure signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(SOHC)-34, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Instruction Manual. CHECK POOR CONTACT. Check poor contact in ECM and pressure sensor connector. Check Is the value less than 0 kPa (0 mmHg, 0 inHg)? Yes Go to step 3. No Go to step 2.
Repair poor contact in ECM or atmospheric pressure sensor connector. Go to step 5.
CHECK INPUT SIGNAL FOR ECM. Measure voltage between ECM and chassis ground. Connector & terminal (B136) No. 29 (+) Chassis ground (): CHECK INPUT SIGNAL FOR ECM. (USING SUBARU SELECT MONITOR.) Read data of atmospheric absolute pressure signal using Subaru Select Monitor. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(SOHC)-34, Subaru Select Monitor.>
Repair poor conDoes the value change more than 0 kPa (0 mmHg, tact in ECM con0 inHg) by shaking harness nector. and connector of ECM while monitoring the value with Subaru select monitor?
Go to step 7.
EN(SOHC)-229
No. 7

Step Check Is the voltage more than CHECK HARNESS BETWEEN ECM AND ATMOSPHERIC PRESSURE SENSOR CON- 4.5 V? NECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from atmospheric pressure sensor. 3) Turn ignition switch to ON. 4) Measure voltage between atmospheric pressure sensor connector and engine ground. Connector & terminal (B2) No. 3 (+) Engine ground (): Yes Go to step 8. No Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ECM and atmospheric pressure sensor connector Poor contact in joint connector LHD: (B122) RHD: (B83) Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ECM and pressure sensor connector Repair ground short circuit in harness between ECM and pressure sensor connector. Replace atmospheric pressure sensor. <Ref. to FU(SOHC)-37, Atmospheric Pressure Sensor .>
Is the resistance less than CHECK HARNESS BETWEEN ECM AND ATMOSPHERIC PRESSURE SENSOR CON- 1 ? NECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM. 3) Measure resistance of harness between ECM and pressure sensor connector. Connector & terminal (B136) No. 16 (B2) No. 1:
Go to step 9.
10
CHECK HARNESS BETWEEN ECM AND ATMOSPHERIC PRESSURE SENSOR CONNECTOR. Measure resistance of harness between pressure sensor connector and engine ground. Connector & terminal (B2) No. 2 Engine ground: CHECK POOR CONTACT. Check poor contact in pressure sensor connector.
Is there poor contact in pressure sensor connector?
Repair poor contact in atmospheric pressure sensor connector.
EN(SOHC)-230

MEMO:
EN(SOHC)-231
BG: DTC P1111 ATMOSPHERIC PRESSURE SENSOR CIRCUIT HIGH INPUT

S058521B85
S2M2096
EN(SOHC)-232

No. 1 Step CHECK CURRENT DATA. 1) Start engine. 2) Read the data of intake manifold absolute pressure signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(SOHC)-34, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Instruction Manual. CHECK INPUT SIGNAL FOR ECM. Measure voltage between ECM connector and chassis ground. Connector & terminal (B136) No. 15 (+) Chassis ground (): CHECK INPUT SIGNAL FOR ECM. Measure voltage between ECM connector and chassis ground. Connector & terminal (B136) No. 15 (+) Chassis ground (): Check Is the value more than 140 kPa (1,050 mmHg, 41.34 inHg)? Yes Go to step 10. No Go to step 2.
Go to step 4.
Go to step 3.
CHECK INPUT SIGNAL FOR ECM. Measure voltage between ECM connector and chassis ground. Connector & terminal (B136) No. 29 (+) Chassis ground (): CHECK INPUT SIGNAL FOR ECM. (USING SUBARU SELECT MONITOR.) Read data of atmospheric absolute pressure signal using Subaru Select Monitor. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(SOHC)-34, Subaru Select Monitor.> CHECK HARNESS BETWEEN ECM AND PRESSURE SENSOR CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from atmospheric pressure sensor. 3) Turn ignition switch to ON. 4) Measure voltage between atmospheric pressure sensor connector and engine ground. Connector & terminal (B2) No. 3 (+) Engine ground ():
Repair poor conDoes the value change more than 0 kPa (0 mmHg, tact in ECM con0 inHg) by shaking harness nector. and connector of ECM while monitoring the value with Subaru select monitor?
Go to step 6.
Go to step 7.
Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ECM and pressure sensor connector Poor contact in joint connector LHD: B122 RHD: B83
EN(SOHC)-233
No. 7

Step CHECK HARNESS BETWEEN ECM AND PRESSURE SENSOR CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM. 3) Measure resistance of harness between ECM and pressure sensor connector. Connector & terminal (B136) No. 29 (B2) No. 2: Check Is the resistance less than 1 ? Yes Go to step 8. No Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ECM and pressure sensor connector Poor contact in joint connector LHD: B122 RHD: B83 Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ECM and pressure sensor connector Poor contact in joint connector LHD: B122 RHD: B83 Replace atmospheric pressure sensor. <Ref. to FU(SOHC)-37, Atmospheric Pressure Sensor .> Replace atmospheric pressure sensor. <Ref. to FU(SOHC)-37, Atmospheric Pressure Sensor.>
Is the resistance less than CHECK HARNESS BETWEEN ECM AND 1 ? PRESSURE SENSOR CONNECTOR. Measure resistance of harness between ECM and pressure sensor connector. Connector & terminal (B136) No. 16 (B2) No. 1:
Go to step 9.
CHECK POOR CONTACT. Check poor contact in pressure sensor connector.
Repair poor contact in atmospheric pressure sensor connector.
10
Is the value more than 140 CHECK CURRENT DATA. kPa (1,050 mmHg, 41.34 1) Turn ignition switch to OFF. inHg)? 2) Disconnect connector from atmospheric pressure sensor. 3) Turn ignition switch to ON. 4) Read data of intake manifold absolute pressure signal using Subaru select monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(SOHC)-34, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Instruction Manual.
Repair battery short circuit in harness between ECM and atmospheric pressure sensor connector.
EN(SOHC)-234

MEMO:
EN(SOHC)-235
BH: DTC P1112 ATMOSPHERIC PRESSURE SENSOR CIRCUIT RANGE/ PERFORMANCE PROBLEM
S058521B86
S2M2096
EN(SOHC)-236

No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. NOTE: In this case, it is not necessary to inspect DTC P0106. Yes Inspect DTC P0106, P0107, P0108, P1110 or P1111 using 17. List of Diagnostic Trouble Code (DTC). <Ref. to EN(SOHC)-80, List of Diagnostic Trouble Code (DTC).> Replace atmoIs atmospheric pressure sensor filter non-functional? spheric pressure sensor filter. (Check for contamination, damage, water leakage, etc.) Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0106, P0107, P0108, P1110 or P1111? No Go to step 2.
CHECK ATMOSPHERIC PRESSURE SENSOR FILTER. 1) Turn ignition switch to OFF. 2) Disconnect connector from atmospheric pressure sensor. 3) Remove atmospheric pressure sensor. 4) Check atmospheric pressure sensor filter. CHECK CURRENT DATA. 1) Turn ignition switch to ON. 2) Read data of intake manifold absolute pressure signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(SOHC)-34, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Instruction Manual.
Go to step 3.
Is the value between 73.3 kPa (550 mmHg, 21.65 inHg) and 106.6 kPa (800 mmHg, 31.50 inHg)?
Replace atmospheric pressure sensor. <Ref. to FU(SOHC)-37, Atmospheric Pressure Sensor .>
Replace intake air temperature and pressure sensor. <Ref. to FU(SOHC)-36, Intake Air Temperature and Pressure Sensor.>
EN(SOHC)-237
BI: DTC P1137 FRONT OXYGEN (A/F) SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM
S058521G49
S2M2077
EN(SOHC)-238

No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0131, P0132, P0031 or P0032? Yes Inspect DTC P0131, P0132, P0031 or P0032 using 17. List of Diagnostic Trouble Code (DTC). <Ref. to EN(SOHC)-80, List of Diagnostic Trouble Code (DTC).> Go to step 3. No Go to step 2.
CHECK FRONT OXYGEN (A/F) SENSOR DATA. 1) Start engine. 2) While observing the Subaru Select Monitor or OBD-II general scan tool screen, warm-up the engine until coolant temperature is above 70C (160F). If the engine is already warmed-up, operate at idle speed for at least 1 minute. 3) Read data of front oxygen (A/F) sensor signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(SOHC)-34, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Instruction Manual. CHECK FRONT OXYGEN (A/F) SENSOR DATA. Race engine at speeds from idling to 5,000 rpm for a total of 5 cycles. NOTE: To increase engine speed to 5,000 rpm, slowly depress accelerator pedal, taking approximately 5 seconds, and quickly release accelerator pedal to decrease engine speed. CHECK HARNESS BETWEEN ECM AND FRONT OXYGEN (A/F) SENSOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM and front oxygen (A/F) sensor connector. 3) Measure resistance between ECM and front oxygen (A/F) sensor. Connector & terminals (B136) No. 6 (E24) No. 1: (B136) No. 7 (E24) No. 6: (B136) No. 19 (E24) No. 3: (B136) No. 20 (E24) No. 4:
Go to step 4.
Is the value more than 1.1 for a moment?
Go to step 6.
Go to step 4.
Go to step 5.
Repair open circuit between ECM and front oxygen (A/F) sensor.
EN(SOHC)-239
No. 5

Step CHECK HARNESS BETWEEN ECM AND FRONT OXYGEN (A/F) SENSOR. Measure resistance between ECM and chassis ground. Connector & terminals (B136) No. 6 Chassis ground: (B136) No. 7 Chassis ground: (B136) No. 19 Chassis ground: (B136) No. 20 Chassis ground: CHECK EXHAUST SYSTEM. Check exhaust system parts. NOTE: Check the following items. Loose installation of portions Damage (crack, hole etc.) of parts Looseness of front oxygen (A/F) sensor Looseness and ill fitting of parts between front oxygen (A/F) sensor and rear oxygen sensor Check Yes Is the resistance more than Go to step 6. 1 M? No Repair ground short circuit between ECM and front oxygen (A/F) sensor.
EN(SOHC)-240

MEMO:
EN(SOHC)-241
BJ: DTC P1142 THROTTLE POSITION SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (LOW INPUT)
S058521B99
DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: Erroneous idling Engine stalls. Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(SOHC)-45, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)-42, OPERATION, Inspection Mode.>. WIRING DIAGRAM:
S2M2082
EN(SOHC)-242

No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0122 or P0123? Yes Inspect DTC P0122 or P0123 using 17. List of Diagnostic Trouble Code (DTC). <Ref. to EN(SOHC)-80, List of Diagnostic Trouble Code (DTC).> NOTE: In this case, it is not necessary to inspect DTC P1142.
No Replace throttle position sensor. <Ref. to FU(SOHC)-33 Throttle Position Sensor.>
EN(SOHC)-243
BK: DTC P1146 PRESSURE SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (HIGH INPUT)
S058521G07
S2M2097
EN(SOHC)-244

No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. NOTE: In this case, it is not necessary to inspect DTC P0106. Yes Inspect DTC P0107, P0108 or P1112 using 17. List of Diagnostic Trouble Code (DTC). <Ref. to EN(SOHC)-80, List of Diagnostic Trouble Code (DTC).> Are there holes, loose bolts Repair air intake or disconnection of hose on system. air intake system? Is the value within the Go to step 4. specifications? Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0107, P0108 or P1112? No Go to step 2.
Go to step 3.
CHECK PRESSURE SENSOR. 1) Start the engine and warm-up engine until coolant temperature is greater than 60C (140F). 2) Place the shift lever in the selector lever in N or P position. 3) Turn A/C switch to OFF. 4) Turn all accessory switches to OFF. 5) Read data of intake manifold pressure sensor signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(SOHC)-34, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedure, refer to the OBD-II General Scan Tool Instruction Manual. Specification: Intake manifold absolute pressure Ignition ON 73.3 106.6 kPa (550 800 mmHg, 21.65 31.50 inHg) Idling 20.0 46.7 kPa (150 350 mmHg, 5.91 13.78 inHg) CHECK THROTTLE POSITION. Read data of throttle position signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(SOHC)-34, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedure, refer to the OBD-II General Scan Tool Instruction Manual.
Replace intake air temperature sensor and pressure sensor. <Ref. to FU(SOHC)-36, Intake Air Temperature and Pressure Sensor.>
Go to step 5.
Adjust or replace throttle position sensor. <Ref. to FU(SOHC)-33, Throttle Position Sensor.>
EN(SOHC)-245
No. 5

Step CHECK THROTTLE POSITION. Check Is throttle positioning ratio equal to or more than 85% when throttle is fully open? Yes Replace intake air temperature and pressure sensor. <Ref. to FU(SOHC)-36, Intake Air Temperature and Pressure Sensor.> No Replace throttle position sensor. <Ref. to FU(SOHC)-33, Throttle Position Sensor.>
EN(SOHC)-246

MEMO:
EN(SOHC)-247
BL: DTC P1442 FUEL LEVEL SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM 2

S058521C11
S2M2089
EN(SOHC)-248

No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0461, P0462 or P0463? Yes Inspect DTC P0461, P0462 or P0463 using 17. List of Diagnostic Trouble Code (DTC). <Ref. to EN(SOHC)-80, List of Diagnostic Trouble Code (DTC).> NOTE: In this case, it is not necessary to inspect this trouble.
No Replace fuel level sensor <Ref. to FU(SOHC)-64, Fuel Level Sensor.> and fuel sub level sensor. <Ref. to FU(SOHC)-65, Fuel Sub Level Sensor.>
EN(SOHC)-249

S058521G08
BM: DTC P1480 COOLING FAN RELAY 1 CIRCUIT HIGH INPUT

EN(SOHC)-250

WIRING DIAGRAM:
S2M2090
EN(SOHC)-251
No. 1

Step CHECK OUTPUT SIGNAL FROM ECM. 1) Turn ignition switch to OFF. 2) Connect test mode connector at the lower portion of instrument panel (on the driver s side), to the side of the center console box. 3) Turn ignition switch to ON. 4) While operating radiator fan relay, measure voltage between ECM and chassis ground. NOTE: Radiator fan relay operation can be executed using Subaru Select Monitor. For procedure, refer to Compulsory Valve Operation Check Mode. <Ref. to EN(SOHC)-46, Compulsory Valve Operation Check Mode.> Connector & terminal (B134) No. 3 (+) Chassis ground (): CHECK SHORT CIRCUIT IN RADIATOR FAN RELAY CONTROL CIRCUIT. 1) Turn ignition switch to OFF. 2) Remove main fan relay and sub fan relay. (with A/C models) 3) Disconnect test mode connector. 4) Turn ignition switch to ON. 5) Measure voltage between ECM and chassis ground. Connector & terminal (B134) No. 3 (+) Chassis ground (): CHECK MAIN FAN RELAY. 1) Turn ignition switch to OFF. 2) Remove main fan relay. 3) Measure resistance between main fan relay terminals. Terminal No. 25 No. 26: CHECK SUB FAN RELAY. 1) Remove sub fan relay. 2) Measure resistance between sub fan relay terminals. Terminal No. 23 No. 24 CHECK POOR CONTACT. Check poor contact in ECM connector. Check Does voltage change between 0 and 10 V? Yes No Even if MIL lights Go to step 2. up, the circuit has returned to a normal condition at this time. In this case, repair poor contact in ECM connector.
Is the voltage more than 10 Repair battery V? short circuit in radiator fan relay control circuit. After repair, replace ECM. <Ref. to FU(SOHC)-49,, Engine Control Module.> Is the resistance less than 1 ? Replace main fan relay and ECM. <Ref. to FU(SOHC)-49, Engine Control Module.> Replace sub fan relay and ECM. <Ref. to FU(SOHC)-49, Engine Control Module.> Repair poor contact in ECM connector.
Go to step 3.
Go to step 4.
Go to step 5.
EN(SOHC)-252

MEMO:
EN(SOHC)-253
BN: DTC P1507 IDLE CONTROL SYSTEM MALFUNCTION (FAIL-SAFE)

S058521C16
DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: Engine keeps running at higher revolution than specified idling revolution. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(SOHC)-45, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)-42, OPERATION, Inspection Mode.>. WIRING DIAGRAM:
S2M2098
EN(SOHC)-254

No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P1510, P1511, P1512, P1513, P1514, P1515, P1516 or P1517? Yes Inspect DTC P1510, P1511, P1512, P1513, P1514, P1515, P1516 or P1517 using 17. List of Diagnostic Trouble Code (DTC). <Ref. to EN(SOHC)-80, List of Diagnostic Trouble Code (DTC).> NOTE: In this case, it is not necessary to inspect DTC P0507. Repair air suction and leaks. No Go to step 2.
Go to step 3.
Go to step 4.
Are foreign particles in byCHECK AIR BY-PASS LINE. pass air line? 1) Turn ignition switch to OFF. 2) Remove idle air control solenoid valve from throttle body. <Ref. to FU(SOHC)-38, Idle Air Control Solenoid Valve.> 3) Confirm that there are no foreign particles in by-pass air line.
Adjust throttle cable. <Ref. to SP-12, INSTALLATION, Accelerator Control Cable.> Replace idle air control solenoid valve. <Ref. to FU(SOHC)-38, Idle Air Control Solenoid Valve.>
EN(SOHC)-255
BO: DTC P1510 IDLE AIR CONTROL SOLENOID VALVE SIGNAL 1 CIRCUIT LOW INPUT
S058521C17
NOTE: For the diagnostic procedure, refer to DTC P1516. <Ref. to EN(SOHC)-258, DTC 1516 IDLE AIR CONTROL SOLENOID VALVE SIGNAL 4 CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
BP: DTC P1511 IDLE AIR CONTROL SOLENOID VALVE SIGNAL 1 CIRCUIT HIGH INPUT
S058521C18
NOTE: For the diagnostic procedure, refer to DTC P1517. <Ref. to EN(SOHC)-262, DTC 1517 IDLE AIR CONTROL SOLENOID VALVE SIGNAL 4 CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
BQ: DTC P1512 IDLE AIR CONTROL SOLENOID VALVE SIGNAL 2 CIRCUIT LOW INPUT
S058521C19
BR: DTC P1513 IDLE AIR CONTROL SOLENOID VALVE SIGNAL 2 CIRCUIT HIGH INPUT
S058521C20
BS: DTC P1514 IDLE AIR CONTROL SOLENOID VALVE SIGNAL 3 CIRCUIT LOW INPUT
S058521C21
BT: DTC P1515 IDLE AIR CONTROL SOLENOID VALVE SIGNAL 3 CIRCUIT HIGH INPUT
S058521C22
EN(SOHC)-256

MEMO:
EN(SOHC)-257
BU: DTC P1516 IDLE AIR CONTROL SOLENOID VALVE SIGNAL 4 CIRCUIT LOW INPUT
S058521C23
DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: Erroneous idling Engine stalls. Engine breathing CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(SOHC)-45, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)-42, OPERATION, Inspection Mode.>. WIRING DIAGRAM:
S2M2098
EN(SOHC)-258

No. 1 Step CHECK POWER SUPPLY TO IDLE AIR CONTROL SOLENOID VALVE. 1) Turn ignition switch to OFF. 2) Disconnect connector from idle air control solenoid valve. 3) Turn ignition switch to ON. 4) Measure voltage between idle air control solenoid valve connector and engine ground. Connector & terminal (E7) No. 2 (+) Engine ground (): Check Yes Is the voltage more than 10 Go to step 2. V?
No Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between idle air control solenoid valve and main relay connector Poor contact in coupling connector (B22) Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between idle air control solenoid valve and main relay connector Poor contact in coupling connector (B22) Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ECM and idle air control solenoid valve connector Poor contact in coupling connector (B21) Go to step 5.
Is the voltage more than 10 Go to step 3. CHECK POWER SUPPLY TO IDLE AIR V? CONTROL SOLENOID VALVE. Measure voltage between idle air control solenoid valve connector and engine ground. Connector & terminal (E7) No. 5 (+) Engine ground ():
Is the resistance less than CHECK HARNESS BETWEEN ECM AND 1 ? IDLE AIR CONTROL SOLENOID VALVE CONNECTOR. 1) Turn ignition switch to OFF. 2) Measure resistance between ECM and idle air control solenoid valve connector. Connector & terminal DTC P1510; (B134) No. 5 (E7) No. 4: DTC P1512; (B134) No. 6 (E7) No. 1: DTC P1514; (B134) No. 19 (E7) No. 6: DTC P1516; (B134) No. 20 (E7) No. 3: Is the resistance less than CHECK HARNESS BETWEEN ECM AND 10 ? IDLE AIR CONTROL SOLENOID VALVE CONNECTOR. 1) Disconnect connector from ECM. 2) Measure resistance between ECM connector and chassis ground. Connector & terminal DTC P1510; (B134) No. 5 Chassis ground: DTC P1512; (B134) No. 6 Chassis ground: DTC P1514; (B134) No. 19 Chassis ground: DTC P1516; (B134) No. 20 Chassis ground:
Go to step 4.
Repair ground short circuit in harness between ECM and idle air control solenoid valve connector.
EN(SOHC)-259
No. 5

Step CHECK POOR CONTACT. Check poor contact in ECM connector and idle air control solenoid valve connector. Check Is there poor contact in ECM connector or idle air control solenoid valve connector? Yes Repair poor contact in ECM connector or idle air control solenoid valve connector. No Replace idle air control solenoid valve. <Ref. to FU(SOHC)-38, Idle Air Control Solenoid Valve.>
EN(SOHC)-260

MEMO:
EN(SOHC)-261
BV: DTC P1517 IDLE AIR CONTROL SOLENOID VALVE SIGNAL 4 CIRCUIT HIGH INPUT
S058521C24
DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: Erroneous idling Engine stalls. Engine breathing CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(SOHC)-45, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)-42, OPERATION, Inspection Mode.>. WIRING DIAGRAM:
S2M2098
EN(SOHC)-262

No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P1511, P1513, P1515 and P1517 at same time? Is the resistance less than 5 ? Yes Go to step 2. No Go to step 3.
CHECK GROUND CIRCUIT FOR ECM. 1) Turn ignition switch to OFF. 2) Measure resistance between ECM connector and chassis ground. Connector & terminal (B134) No. 7 Chassis ground:
Go to step 3.
Is the voltage more than 10 Repair battery CHECK HARNESS BETWEEN ECM AND V? short circuit in IDLE AIR CONTROL SOLENOID VALVE harness between CONNECTOR. ECM and idle air 1) Turn ignition switch to OFF. control solenoid 2) Disconnect connector from idle air control valve connector. solenoid valve. After repair, 3) Turn ignition switch to ON. replace ECM. 4) Measure voltage between ECM connector <Ref. to and chassis ground. FU(SOHC)-49, Connector & terminal Engine Control DTC P1511; (B134) No. 5 (+) Chassis Module.> ground (): DTC P1513; (B134) No. 6 (+) Chassis ground (): DTC P1515; (B134) No. 19 (+) Chassis ground (): DTC P1517; (B134) No. 20 (+) Chassis ground ():
Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ECM connector and engine ground terminal Poor contact in ECM connector Poor contact in coupling connector (B22) Replace ECM. <Ref. to FU(SOHC)-49, Engine Control Module.>
EN(SOHC)-263

S058521G09
BW: DTC P1518 STARTER SWITCH CIRCUIT LOW INPUT

S2M2099
EN(SOHC)-264

No. 1 Step Check CHECK OPERATION OF STARTER MOTOR. Does starter motor operate when ignition switch to NOTE: ST? Place the inhibitor switch in the P or N position. Yes Repair harness and connector. NOTE: In this case, repair the following: Open or ground short circuit in harness between ECM and starter motor connector. Poor contact in ECM connector.
No Check starter motor circuit. <Ref. to EN(SOHC)-60, STARTER MOTOR CIRCUIT, Diagnostic for Engine Starting Failure.>
EN(SOHC)-265

S058521C26
BX: DTC P1540 VEHICLE SPEED SENSOR MALFUNCTION 2

S2M2100
EN(SOHC)-266

Yes No Go to step 2. Check front vehicle speed sensor signal circuit. <Ref. to AT-58, TROUBLE CODE 33 FRONT VEHICLE SPEED SENSOR , Diagnostic Procedure with Trouble Code.> Does speedometer operate Go to step 3. Check speedomnormally? eter and vehicle speed sensor. <Ref. to IDI-17, Speedometer.> Is the resistance less than Repair poor con- Repair harness 10 ? tact in ECM con- and connector. nector. NOTE: In this case, repair the following: Open circuit in harness between ECM and combination meter connector Poor contact in ECM connector Poor contact in combination meter connector Poor contact in coupling connector (i2)
EN(SOHC)-267

S058521C27
BY: DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION

S2M2101
No. 1
Step Check Yes Is the voltage more than 10 Repair poor conCHECK INPUT SIGNAL FOR ECM. V? tact in ECM con1) Turn ignition switch to OFF. nector. 2) Measure voltage between ECM and chassis ground. Connector & terminal (B136) No. 9 (+) Chassis ground ():
No Go to step 2.
EN(SOHC)-268

No. 2 Step CHECK HARNESS BETWEEN ECM AND MAIN FUSE BOX CONNECTOR. 1) Disconnect connector from ECM. 2) Measure resistance of harness between ECM and chassis ground. Connector & terminal (B136) No. 9 Chassis ground: CHECK FUSE SBF-5. Check Is the resistance less than 10 ? Yes Repair ground short circuit in harness between ECM connector and battery terminal. Replace fuse. No Go to step 3.
Is fuse blown?
Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ECM and battery Poor contact in ECM connector Poor contact in battery terminal
EN(SOHC)-269
BZ: DTC P1590 NEUTRAL POSITION SWITCH CIRCUIT HIGH INPUT (AT MODEL)
S058521G83
S2M2099
EN(SOHC)-270

No. 1 Step CHECK DTC P0705 ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0705? Yes Inspect DTC P0705 using 17. List of Diagnostic Trouble Code (DTC). <Ref. to EN(SOHC)-80, List of Diagnostic Trouble Code (DTC).> Go to step 3. No Go to step 2.
CHECK INPUT SIGNAL FOR ECM. 1) Turn ignition switch to ON. 2) Measure voltage between ECM and chassis ground in selector lever N and P positions. Connector & terminal (B135) No. 26 (+) Chassis ground (): CHECK INPUT SIGNAL FOR ECM. Measure voltage between ECM and chassis ground in selector lever except for N and P positions. Connector & terminal (B135) No. 26 (+) Chassis ground (): CHECK POOR CONTACT. Check poor contact in ECM connector.
Is the voltage less than 1 V?
Go to step 5.
Is the voltage between 4.5 and 5.5 V?
Go to step 4.
Go to step 5.
CHECK INPUT SIGNAL FOR ECM. Measure voltage between ECM and chassis ground. Connector & terminal (B135) No. 26 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND INHIBITOR SWITCH CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connectors from ECM and inhibitor switch. 3) Measure resistance of harness between ECM and inhibitor switch connector. Connector & terminal (B135) No. 26 (T7) No. 12:
Is the voltage more than 10 Repair battery V? short circuit in harness between ECM and inhibitor switch connector. Is the resistance less than 1 ? Go to step 7.
Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ECM and inhibitor switch connector Poor contact in coupling connector (B12) Poor contact in inhibitor switch connector Poor contact in ECM connector
EN(SOHC)-271
No. 7

Step CHECK INHIBITOR SWITCH GROUND LINE. Measure resistance of harness between inhibitor switch connector and engine ground. Connector & terminal (T7) No. 7 Engine ground: Check Is the resistance less than 5 ? Yes Go to step 8. No Repair open circuit in harness between inhibitor switch connector and starter motor ground line. NOTE: In this case, repair the following: Open circuit in harness between inhibitor switch connector and starter motor ground line Poor contact in starter motor connector Poor contact in starter motor ground Starter motor Replace inhibitor switch. <Ref. to AT-28, Inhibitor Switch.>
CHECK INHIBITOR SWITCH. Measure resistance between inhibitor switch connector receptacles terminals in selector lever N and P positions. Terminals No. 7 No. 12: CHECK SELECTOR CABLE CONNECTION.
Go to step 9.
Is there any fault in selector cable connection to inhibitor switch?
Repair selector cable connection. <Ref. to CS-11, INSPECTION, Select Cable.>
EN(SOHC)-272

MEMO:
EN(SOHC)-273
CA: DTC P1591 NEUTRAL POSITION SWITCH CIRCUIT LOW INPUT (AT MODEL)
S058521G84
S2M2099
EN(SOHC)-274

No. 1 Step CHECK DTC P0705 ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0705? Yes No Go to step 2. Inspect DTC P0705 using 17. List of Diagnostic Trouble Code (DTC). <Ref. to EN(SOHC)-80, List of Diagnostic Trouble Code (DTC).> Even if MIL lights Go to step 3. up, the circuit has returned to a normal condition at this time.
CHECK INPUT SIGNAL FOR ECM. 1) Turn ignition switch to ON. 2) Measure voltage between ECM and chassis ground. Connector & terminal (B135) No. 26 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND TRANSMISSION HARNESS CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connectors from ECM and transmission harness connector (T3). 3) Measure resistance of harness between ECM connector and chassis ground. Connector & terminal (B135) No. 26 Chassis ground: CHECK TRANSMISSION HARNESS CONNECTOR. 1) Disconnect connector from inhibitor switch. 2) Measure resistance of harness between transmission harness connector and engine ground. Connector & terminal (T3) No. 12 Engine ground: CHECK INHIBITOR SWITCH. Measure resistance between inhibitor switch connector receptacles terminals in selector lever except for N position. Terminals No. 7 No. 12: CHECK SELECTOR CABLE CONNECTION.
Is the voltage between 4.5 and 5.5 V at except N and P positions?
Repair ground short circuit in harness between ECM and transmission harness connector.
Go to step 4.
Repair ground short circuit in harness between transmission harness and inhibitor switch connector.
Go to step 5.
Is the resistance more than Go to step 6. 1 M at except N and P positions?
Replace inhibitor switch. <Ref. to AT-28, Inhibitor Switch.>
Repair selector cable connection. <Ref. to CS-11, INSPECTION, Select Cable.>
EN(SOHC)-275
CB: DTC P1592 NEUTRAL POSITION SWITCH CIRCUIT LOW INPUT (MT MODEL)
S058521G85
S2M2103
EN(SOHC)-276

No. 1 Step CHECK INPUT SIGNAL FOR ECM. 1) Turn ignition switch to ON. 2) Measure voltage between ECM and chassis ground. Connector & terminal (B135) No. 26 (+) Chassis ground (): CHECK INPUT SIGNAL FOR ECM. Measure voltage between ECM and chassis ground. Connector & terminal (B135) No. 26 (+) Chassis ground (): CHECK POOR CONTACT. Check poor contact in ECM connector. CHECK NEUTRAL POSITION SWITCH. 1) Turn ignition switch to OFF. 2) Disconnect connector from transmission harness. 3) Measure resistance between transmission harness and connector terminals. Connector & terminal (T2) No. 1 No. 2: CHECK NEUTRAL POSITION SWITCH. Measure resistance between transmission harness connector terminals. Check Is the voltage more than 10V in neutral position? Yes Go to step 2. No Go to step 4.
Is the voltage less than 1V in other position?
Go to step 3.
Go to step 4.
Is the poor contact in ECM connector?
Repair poor contact in ECM connector. Is the resistance more than Go to step 5. 1M in neutral position?
Contact your distributor. Repair short circuit in transmission harness or replace neutral position switch.
Is the resistance less than 1 in other positions?
Go to step 6.
CHECK HARNESS BETWEEN ECM AND NEUTRAL POSITION SWITCH CONNECTOR. Measure resistance between ECM and chassis ground. Connector & terminal (B135) No. 26 Chassis ground: CHECK HARNESS BETWEEN ECM AND NEUTRAL POSITION SWITCH CONNECTOR. 1) Disconnect connector from ECM. 2) Measure resistance of harness between ECM and transmission harness connector. Connector & terminal LHD: (B135) No. 26 (B25) No. 1: RHD: (B135) No. 26 (B25) No. 2: CHECK HARNESS BETWEEN ECM AND NEUTRAL POSITION SWITCH CONNECTOR. Measure resistance of harness between transmission harness connector and engine ground. Connector & terminal (B25) No. 2 Engine ground: CHECK POOR CONTACT. Check poor contact in transmission harness connector.
Repair ground short circuit in harness between ECM and transmission harness connector. Go to step 8.
Repair short circuit in transmission harness or replace neutral position switch. Go to step 7.
Repair open circuit in harness between ECM and transmission harness connector.
Go to step 9.
Repair open circuit between transmission harness connector and engine ground terminal.
Is there poor contact in transmission harness connector?
Repair poor con- Contact your distributor. tact in transmission harness connector.
EN(SOHC)-277
CC: DTC P1594 AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL CIRCUIT MALFUNCTION
S058521G12
B2M3963
No. 1
Step CHECK DRIVING CONDITION. 1) Start and warm-up the engine until the radiator fan makes one complete rotation. 2) Drive the vehicle.
Check Is AT shift control functioning properly?
Yes Go to step 2.
No Replace TCM. <Ref. to AT-48, Transmission Control Module (TCM).>
EN(SOHC)-278

No. 2 Step CHECK ACCESSORY. Check Are car phone and/or CB installed on vehicle? Yes Repair grounding line of car phone or CB system.
EN(SOHC)-279
CD: DTC P1595 AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL CIRCUIT LOW INPUT
S058521G13
B2M3963
EN(SOHC)-280

No. 1 Step Check Is the voltage less than 1 CHECK HARNESS BETWEEN ECM AND V? TCM CONNECTOR. 1) Turn ignition switch to ON. 2) Measure voltage between ECM and chassis ground. Connector & terminal (B135) No. 4 (+) Chassis ground (): Yes Go to step 2.
No Even if MIL lights up, the circuit has returned to a normal condition at this time. NOTE: In this case, repair the following: Poor contact in ECM connector Poor contact in TCM connector Go to step 3.
CHECK HARNESS BETWEEN ECM AND TCM CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM and TCM. 3) Measure resistance of harness between ECM and chassis ground. Connector & terminal (B135) No. 4 Chassis ground: CHECK OUTPUT SIGNAL FOR ECM. 1) Connect connector to ECM. 2) Turn ignition switch to ON. 3) Measure voltage between ECM and chassis ground. Connector & terminal (B135) No. 4 (+) Chassis ground (): CHECK TROUBLE CODE FOR AUTOMATIC TRANSMISSION. Read trouble code for automatic transmission. <Ref. to AT-22, Read Diagnostic Trouble Code.>
Repair ground short circuit in harness between ECM and TCM connector.
Go to step 4.
Does trouble code appear Inspect trouble for automatic transmission? code for automatic transmission. <Ref. to AT-42, Diagnostic Procedure with Trouble Code.>
EN(SOHC)-281
CE: DTC P1596 AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL CIRCUIT HIGH INPUT
S058521G14
B2M3963
EN(SOHC)-282

No. 1 Step Check Yes Is the voltage more than 10 Repair battery CHECK HARNESS BETWEEN ECM AND V? short circuit in TCM CONNECTOR. harness between 1) Turn ignition switch to ON. ECM and TCM 2) Measure voltage between ECM and chasconnector. After sis ground. repair, replace Connector & terminal ECM. <Ref. to (B135) No. 4 (+) Chassis ground (): FU(SOHC)-49, Engine Control Module.> Is the voltage more than 4 Go to step 5. CHECK HARNESS BETWEEN ECM AND V? TCM CONNECTOR. Measure voltage between ECM connector and chassis ground. Connector & terminal (B135) No. 4 (+) Chassis ground (): Is the voltage less than 1 Repair poor conCHECK HARNESS BETWEEN ECM AND V? tact in ECM conTCM CONNECTOR. nector. Measure voltage between ECM connector and chassis ground. Connector & terminal (B135) No. 4 (+) Chassis ground (): Even if MIL lights Does the voltage change CHECK OUTPUT SIGNAL FROM ECM. from 1 V to 4 V while moni- up, the circuit has Measure voltage between ECM and chassis returned to a nortoring the value with voltground. mal condition at age meter? Connector & terminal this time. (B135) No. 4 (+) Chassis ground (): NOTE: In this case, repair the following: Poor contact in ECM connector Poor contact in TCM connector Is the voltage more than 4 Go to step 6. CHECK HARNESS BETWEEN ECM AND V? TCM CONNECTOR. Measure voltage between TCM and chassis ground. Connector & terminal (B54) No. 4 (+) Chassis ground (): CHECK POOR CONTACT. Is there poor contact in Repair poor conCheck poor contact in TCM connector. TCM connector? tact in TCM connector. No Go to step 2.
Go to step 3.
Go to step 4.
Repair open circuit in harness between ECM and TCM connector. Check TCM power supply line and grounding line.
EN(SOHC)-283
CF: DTC P1698 ENGINE TORQUE CONTROL CUT SIGNAL CIRCUIT LOW INPUT
S058521G15
B2M3960
EN(SOHC)-284

No. 1 Step CHECK OUTPUT SIGNAL FROM ECM. 1) Start engine, and warm-up the engine. 2) Turn ignition switch to OFF. 3) Turn ignition switch to ON. 4) Measure voltage between ECM and chassis ground. Connector & terminal (B134) No. 31 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND TCM CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connectors from ECM and TCM. 3) Measure resistance of harness between ECM and chassis ground. Connector & terminal (B134) No. 31 Chassis ground: CHECK HARNESS BETWEEN ECM AND TCM CONNECTOR. Measure resistance of harness between ECM and TCM connector. Connector & terminal (B134) No. 31 (B54) No. 2: Check Is the voltage more than 3 V? Yes Repair poor contact in ECM connector. No Go to step 2.
Go to step 3.
Repair poor contact in ECM or TCM connector.
Repair open circuit in harness between ECM and TCM connector.
EN(SOHC)-285
CG: DTC P1699 ENGINE TORQUE CONTROL CUT SIGNAL CIRCUIT HIGH INPUT
S058521G16
B2M3960
EN(SOHC)-286

No. 1 Step CHECK OUTPUT SIGNAL FROM ECM. 1) Start engine, and warm-up the engine. 2) Turn ignition switch to OFF. 3) Disconnect connector from TCM. 4) Turn ignition switch to ON. 5) Measure voltage between ECM and chassis ground. Connector & terminal (B134) No. 31 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND TCM CONNECTOR. 1) Turn ignition switch to OFF. 2) Measure voltage between ECM and chassis ground. Connector & terminal (B134) No. 31 (+) Chassis ground (): Check Is the voltage less than 3 V? Yes Go to step 2.
No Repair battery short circuit in harness between ECM and TCM connector. After repair, replace ECM. <Ref. to FU(SOHC)-49, Engine Control Module.> Contact your Subaru distributor. NOTE: Inspection by DTM is required, because probable cause is deterioration of multiple parts.
Does the voltage change more than 10 V by shaking harness and connector of ECM while monitoring the value with voltage meter?
Repair battery short circuit in harness between ECM and TCM connector. After repair, replace ECM. <Ref. to FU(SOHC)-49, Engine Control Module.>
EN(SOHC)-287
CH: DTC P1701 CRUISE CONTROL SET SIGNAL CIRCUIT MALFUNCTION FOR AUTOMATIC TRANSMISSION
S058521C29
B2M3962
EN(SOHC)-288

No. 1 Step CHECK HARNESS BETWEEN TCM AND CCM CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connectors from TCM and CCM. 3) Measure resistance of harness between TCM and CCM connector. Connector & terminal (B54) No. 11 (B94) No. 3: CHECK HARNESS BETWEEN TCM AND CCM CONNECTOR. Measure resistance of harness between TCM and chassis ground. Connector & terminal (B54) No. 11 Chassis ground: CHECK INPUT SIGNAL FOR TCM. 1) Connect connector to TCM and CCM. 2) Lift-up the vehicle or set the vehicle on free rollers. CAUTION: On AWD models, raise all wheels off ground. 3) Start the engine. 4) Cruise control main switch to ON. 5) Move selector lever to D and slowly increase vehicle speed to 50 km/h (31 MPH). 6) Cruise control command switch to ON. 7) Measure voltage between TCM and chassis ground. Connector & terminal (B54) No. 11 (+) Chassis ground (): CHECK POOR CONTACT. Check poor contact in TCM connector. Check Is the resistance less than 1 ? Yes Go to step 2.
No Repair open circuit in harness between TCM and CCM connector.
Go to step 3. Repair short circuit in harness between TCM and CCM connector.
Is the resistance less than 1 V?
Go to step 4.
Check cruise control command switch circuit. <Ref. to CC-10, INSPECTION, Cruise Control Command Switch.>
EN(SOHC)-289
CI: DTC P1711 ENGINE TORQUE CONTROL SIGNAL 1 CIRCUIT MALFUNCTION

S058521G17
DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: Excessive shift shock CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(SOHC)-45, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(SOHC)-42, OPERATION, Inspection Mode.>. WIRING DIAGRAM:
B2M3957
EN(SOHC)-290

No. 1 Step CHECK INPUT SIGNAL FOR ECM. 1) Turn ignition switch to ON. 2) Measure voltage between ECM and chassis ground. Connector & terminal (B135) No. 16 (+) Chassis ground (): CHECK INPUT SIGNAL FOR ECM. Measure voltage between ECM and chassis ground. Connector & terminal (B135) No. 16 (+) Chassis ground (): CHECK POOR CONTACT. Check poor contact in ECM connector. Check Is the voltage more than 4.5 V? Yes Go to step 2. No Go to step 4.
Is the voltage more than 10 Repair battery V? short circuit in harness between ECM and TCM connector. Is there poor contact in ECM connector? Repair poor contact in ECM connector.
Go to step 3.
CHECK HARNESS BETWEEN ECM AND TCM CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connectors from ECM and TCM. 3) Measure resistance of harness between ECM and TCM connector. Connector & terminal (B135) No. 16 (B54) No. 13: CHECK HARNESS BETWEEN ECM AND TCM CONNECTOR. Measure resistance of harness between ECM and chassis ground. Connector & terminal (B135) No. 16 Chassis ground: CHECK POOR CONTACT. Check poor contact in TCM connector.
Go to step 5.
Replace ECM. <Ref. to FU(SOHC)-49, Engine Control Module.> Repair open circuit in harness between ECM and TCM connector.
Repair ground short circuit in harness between ECM and TCM connector. Repair poor contact in TCM connector.
Go to step 6.
EN(SOHC)-291
CJ: DTC P1712 ENGINE TORQUE CONTROL SIGNAL 2 CIRCUIT MALFUNCTION

S058521G18
B2M3958
EN(SOHC)-292

Go to step 3.
Go to step 5.
Replace ECM. <Ref. to FU(SOHC)-49, Engine Control Module.> Repair open circuit in harness between ECM and TCM connector.
Go to step 6.
EN(SOHC)-293
GENERAL DIAGNOSTIC TABLE
19. General Diagnostic Table

S058257
A: INSPECTION
1. ENGINE
S058257A1001
S058257A10
NOTE: Malfunction of parts other than those listed is also possible. <Ref. to ME(SOHC)-87, Engine Trouble in General.>
Symptom Problem parts 1) Idle air control solenoid valve 2) Intake air temperature and pressure sensor 3) Ignition parts (*1) 4) Engine coolant temperature sensor (*2) 5) Crankshaft position sensor (*3) 6) Camshaft position sensor (*3) 7) Fuel injection parts (*4) 1) Idle air control solenoid valve 2) Intake air temperature and pressure sensor 3) Engine coolant temperature sensor (*2) 4) Ignition parts (*1) 5) Air intake system (*5) 6) Fuel injection parts (*4) 7) Throttle position sensor 8) Crankshaft position sensor (*3) 9) Camshaft position sensor (*3) 10) Oxygen sensor 11) Fuel pump and fuel pump relay 1) Idle air control solenoid valve 2) Engine coolant temperature sensor 3) Accelerator cable (*6) 4) Throttle position sensor 5) Intake air temperature and pressure sensor 1) Intake air temperature and pressure sensor 2) Throttle position sensor 3) Fuel injection parts (*4) 4) Fuel pump and fuel pump relay 5) Engine coolant temperature sensor (*2) 6) Crankshaft position sensor (*3) 7) Camshaft position sensor (*3) 8) A/C switch and A/C cut relay 9) Engine torque control signal circuit 10) Ignition parts (*1) 1) Intake air temperature and pressure sensor 2) Engine coolant temperature sensor (*2) 3) Crankshaft position sensor (*3) 4) Camshaft position sensor (*3) 5) Purge control solenoid valve 6) Fuel injection parts (*4) 7) Throttle position sensor 8) Fuel pump and fuel pump relay
1. Engine stalls during idling.
2. Rough idling
3. Engine does not return to idle.
4. Poor acceleration
5. Engine stalls or engine sags or hesitates at acceleration.
EN(SOHC)-294

Symptom Problem parts 1) Intake manifold pressure sensor 2) Intake air temperature sensor 3) Intake air temperature and pressure sensor 4) Engine coolant temperature sensor (*2) 5) Crankshaft position sensor (*3) 6) Camshaft position sensor (*3) 7) Fuel injection parts (*4) 8) Throttle position sensor 9) Fuel pump and fuel pump relay 1) Intake manifold pressure sensor 2) Intake air temperature sensor 3) Intake air temperature and pressure sensor 4) Engine coolant temperature sensor 5) Knock sensor 6) Fuel injection parts (*4) 7) Fuel pump and fuel pump relay 1) Intake manifold pressure sensor 2) Intake air temperature sensor 3) Intake air temperature and pressure sensor 4) Engine coolant temperature sensor (*2) 5) Fuel injection parts (*4) 6) Fuel pump and fuel pump relay
6. Surge
7. Spark knock
*1: Check ignition coil & ignitor assembly and spark plug. *2: Indicate the symptom occurring only in cold temperatures. *3: Ensure the secure installation. *4: Check fuel injector, fuel pressure regulator and fuel filter. *5: Inspect air leak in air intake system. *6: Adjust accelerator cable.
S058257A1002
NOTE: Check general diagnostics table with non-conformity symptom for automatic transmission. <Ref. to AT-2, Basic Diagnostic Procedure.>
EN(SOHC)-295
MEMO:
EN(SOHC)-296
FU(SOHCw/oOBD)
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. Page General Description.....................................................................................2 Throttle Body .............................................................................................11 Intake Manifold ..........................................................................................12 Engine Coolant Temperature Sensor........................................................23 Crankshaft Position Sensor.......................................................................24 Knock Sensor ............................................................................................25 Throttle Position Sensor............................................................................26 Pressure Sensor........................................................................................29 Intake Air Temperature Sensor .................................................................30 Idle Air Control Solenoid Valve .................................................................31 Fuel Injector...............................................................................................32 Oxygen Sensor..........................................................................................36 Engine Control Module..............................................................................38 Main Relay ................................................................................................39 Fuel Pump Relay.......................................................................................40 Fuel............................................................................................................41 Fuel Tank...................................................................................................44 Fuel Filler Pipe ..........................................................................................47 Fuel Pump .................................................................................................50 Fuel Level Sensor .....................................................................................52 Fuel Sub Level Sensor..............................................................................53 Fuel Filter ..................................................................................................54 Fuel Cut Valve...........................................................................................55 Fuel Delivery, Return and Evaporation Lines ...........................................56 Fuel System Trouble in General ...............................................................59
GENERAL DESCRIPTION
S165001
A: SPECIFICATIONS
Model Fuel tank
S165001E49
Fuel pump
Fuel filter
(15.9 US gal, 13.2 Imp gal) Under rear seat Impeller 373 677 kPa (3.8 6.9 kg/cm2, 54 98 psi) More than 65 (17.2 US gal, 14.3 Imp gal)/h [12 V at 300 kPa (3.06 kg/cm2, 43.5 psi)] Cartridge type
60
FU(SOHCw/oOBD)-2

S165001A05
1. INTAKE MANIFOLD
S165001A0501
S2M1856B
(1) (2) (3) (4) (5) (6) (7) (8) (9)
Intake manifold gasket Insulator A Insulator B Fuel injector O-ring Nipple (RHD models) Plug (LHD models) PCV valve Purge control solenoid valve
(10) (11) (12) (13) (14) (15) (16) (17)
Nipple (LHD models) Plug (RHD models) Intake manifold Fuel pipe ASSY Fuel hose Clip Fuel injector pipe RH Fuel injector pipe LH
Tightening torque: Nm (kgf-m, ft-lb) T1: 4.9 (0.5, 3.6) T2: 15.7 (1.6, 11.6) T3: 19 (1.9, 13.7) T4: 17 (1.7, 12) T5: 25 (2.5, 18.1)
FU(SOHCw/oOBD)-3
GENERAL DESCRIPTION
S165001A0502
S2M1524A
(1) (2) (3) (4)
Gasket Throttle position sensor Gasket Idle air control solenoid valve
(5) Pressure sensor (6) Throttle body
Tightening torque: Nm (kgf-m, ft-lb) T1: 2.0 (0.2, 1.4) T2: 3.4 (0.35, 2.5) T3: 22 (2.2, 15.9)
FU(SOHCw/oOBD)-4
GENERAL DESCRIPTION

S165001A0503
S2M1646A
(1) Crankshaft position sensor
(2) Knock sensor
FU(SOHCw/oOBD)-5
GENERAL DESCRIPTION
4. FUEL TANK
S165001A0504
S2M0634A
FU(SOHCw/oOBD)-6
GENERAL DESCRIPTION
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) Heat sealed cover Fuel tank band Protector LH Protector RH Fuel tank Fuel pump gasket Fuel pump ASSY Fuel level sensor Fuel cut valve gasket Fuel cut valve Evaporation hose A Clip (13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) Evaporation hose C Joint pipe Evaporation hose B Evaporation pipe ASSY Evaporation hose D Jet pump hose A Fuel return tube Retainer Quick connector Jet pump hose B Fuel pipe ASSY Evaporation hose E (25) (26) (27) (28)

Fuel return hose B Fuel sub level sensor gasket Jet pump filter Fuel sub level sensor
FU(SOHCw/oOBD)-7
GENERAL DESCRIPTION
5. FUEL LINE
S165001A0505
S2M2168A
(1) (2) (3) (4) (5) (6)
Clamp Fuel delivery hose A Fuel filter bracket Fuel filter holder Fuel filter cup Fuel filter
(7) (8) (9) (10) (11) (12)
Evaporation hose Clip Fuel delivery hose B Fuel return hose Air vent hose Canister
(13) (14) (15) (16) (17) (18)
Canister hose A Two-way valve Canister hose B Canister hose C Canister bracket Fuel pipe ASSY
FU(SOHCw/oOBD)-8
GENERAL DESCRIPTION
6. FUEL FILLER PIPE
S165001A0506
S2M2169A
(1) Fuel filler pipe ASSY (2) Clamp (3) Fuel filler valve
(4) Filler pipe packing (5) Filler ring A (6) Filler ring B
(7) Filler cap (8) Filler pipe protector
FU(SOHCw/oOBD)-9
GENERAL DESCRIPTION
C: CAUTION
S165001A03
D: PREPARATION TOOL
ILLUSTRATION
S165001A17
B2M3876
22771AA030
SELECT MONITOR KIT
B2M3877
498307600
CHECK BOARD KIT Troubleshooting for engine electrical system. (1) CHECK BOARD: 498307610 (2) CHECK BOARD ADAPTER: 498307620
S2M2170A
FU(SOHCw/oOBD)-10
THROTTLE BODY
2. Throttle Body
A: REMOVAL
S165010A18
S165010
S2M1651
G6M0095
2) Remove air cleaner case. <Ref. to IN(SOHC)-7, REMOVAL, Air Cleaner Case.> 3) Disconnect accelerator cable (A). 4) Disconnect cruise control cable (B). (With cruise control model)
S2M1652
8) Remove bolts which install throttle body to intake manifold.
B2M2302A
5) Disconnect connectors from idle air control solenoid valve (A) and intake manifold pressure sensor (B).
S2M1653
B: INSTALLATION
NOTE: Always use a new gasket.
S2M1650A
S165010A11
Tightening torque: Throttle body; 22 Nm (2.2 kgf-m, 15.9 ft-lb) Air cleaner case; 6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
FU(SOHCw/oOBD)-11
INTAKE MANIFOLD
S165034
3. Intake Manifold
A: REMOVAL
S165034A18
(3) Remove bolts which secure power steering pipe brackets to intake manifold. CAUTION: Do not disconnect power steering hose.
1) Release fuel pressure. <Ref. to FU(SOHCw/ oOBD)-41, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.> 2) Open fuel flap lid, and remove fuel filler cap. 3) Disconnect battery ground cable.
S2M1013
(4) Remove bolts which install power steering pump to bracket.

G6M0095
4) Remove air cleaner case and air intake duct. <Ref. to IN(SOHC)-7, REMOVAL, Air Cleaner Case.> and <Ref. to IN(SOHC)-8, REMOVAL, Air Intake Duct.> 5) Disconnect accelerator cable (A). 6) Disconnect cruise control cable (B). (With cruise control model)
S2M0488
(5) Disconnect terminal from power steering pump switch.
B2M2302A
7) Remove power steering pump from bracket. (1) Remove resonator chamber.
S2M0490
S2M0486
(2) Remove V-belts. <Ref. to ME(SOHC)-42, REMOVAL, V-belt.>
FU(SOHCw/oOBD)-12
INTAKE MANIFOLD
(6) Place power steering pump on the right side wheel apron.
11) Disconnect engine coolant hose from throttle body.
S2M0491
S2M1652
8) Disconnect spark plug cords from spark plugs.
12) Remove bolt which installs ground terminal onto cylinder head.
S6M0142
9) Disconnect PCV hose from intake manifold. 13) Disconnect brake booster hose.
S2M1655
S2M1654
10) Disconnect vacuum hose to cruise control diaphragm. (With cruise control models)
S2M1656
14) Disconnect canister hoses from pipes.
S2M0493C
S2M0496
FU(SOHCw/oOBD)-13
INTAKE MANIFOLD
19) Disconnect connector from crankshaft position sensor.
15) Remove air cleaner case stay RH and engine harness bracket (A), and disconnect engine harness connectors (B) from bulkhead harness connectors. 16) Pull out engine harness connector from bracket.
B2M1252
20) Disconnect switch.

S2M1657B
connector
from
oil
pressure
17) Disconnect connector from engine coolant temperature sensor.
B2M1253
21) Disconnect fuel hoses from fuel pipes.

S2M1658
WARNING: Catch fuel from hoses in a container.
S2M0500G S2M1659
(A) (B) (C)
FU(SOHCw/oOBD)-14
INTAKE MANIFOLD
22) Remove bolts which hold intake manifold onto cylinder heads.

S165034A11
B: INSTALLATION
S2M1660
S2M1660
2) Connect fuel hoses.
B2M0160
S2M0500D
(A) (B) (C
Fuel delivery hose Fuel return hose Evaporation hose
3) Connect connector to oil pressure switch.
B2M1253
FU(SOHCw/oOBD)-15
INTAKE MANIFOLD
9) Tighten bolt which installs engine harness ground terminal.
4) Connect connector to crankshaft position sensor.
B2M1252
S2M1655
10) Connect canister hoses to pipes.
S2M1659
S2M0496
6) Connect connectors to engine coolant temperature sensor.
11) Connect brake booster hose.
S2M1656 S2M1658
12) Connect engine coolant hose to throttle body.
7) Hold engine harness connector onto bracket. 8) Install air cleaner case stay RH and engine harness bracket (A), and connect engine harness connectors (B) to bulkhead connectors.
S2M1652
S2M1657B
FU(SOHCw/oOBD)-16
INTAKE MANIFOLD
13) Connect vacuum hose to cruise control diaphragm. (With cruise control models)
(2) Tighten bolts which install power steering pump on bracket. Tightening torque: 20.1 Nm (2.05 kgf-m, 14.8 ft-lb)
S2M0493C
14) Connect PCV hose to intake manifold.

S2M0488
(3) Install power steering pipe brackets on right side intake manifold.
S2M1654
15) Connect spark plug cords to spark plugs.

S2M1013
(4) Install power steering pump drive V-belt. <Ref. to ME(SOHC)-42, INSTALLATION, V-belt.> (5) Install resonator chamber. Tightening torque: T: 33 Nm (3.4 kgf-m, 25 ft-lb)
S6M0142
16) Install power steering pump on bracket. (1) Connect terminal to power steering pump switch.
S2M0481A
S2M0490
FU(SOHCw/oOBD)-17
INTAKE MANIFOLD
3) Disconnect connectors from throttle position sensor (A), idle air control solenoid valve (B) and pressure sensor (C).
17) Connect accelerator cable (A). 18) Connect cruise control cable (B). (With cruise control models)
B2M2302A
S2M1663A
19) Install air cleaner case and air intake duct. <Ref. to IN(SOHC)-7, INSTALLATION, Air Cleaner Case.> and <Ref. to N(SOHC)-8, INSTALLATION, Air Intake Duct.> 20) Connect connector to fuel pump relay. <Ref. to FU(SOHCw/oOBD)-40, INSTALLATION, Fuel Pump Relay.> 21) Connect battery ground cable.
4) Remove throttle body.
S2M1653
5) Disconnect connectors from fuel injectors.
G6M0095
C: DISASSEMBLY
S165034A06
1) Disconnect connector from ignition coil and ignitor assembly. 2) Remove ignition coil and ignitor assembly.
S2M1664
S2M1662
S2M1665
FU(SOHCw/oOBD)-18
INTAKE MANIFOLD
7) Remove harness bands which hold engine harness onto intake manifold.
13) Remove the four bolts which install injector pipe on intake manifold.
S2M1666
S2M1669
8) Remove engine harness from intake manifold. 9) Remove purge control solenoid valve.
14) Remove fuel injectors. CAUTION: Replace O-rings and insulators with new ones.
S2M1667
10) Disconnect pressure regulator vacuum hose (B) from intake manifold. 11) Remove bolt (A) which installs injector pipe on intake manifold.
S2M1687A
(A) (B) (C) (D)
O-ring Insulator A Fuel injector Insulator B
15) Loosen clamp which holds front left side fuel hose to injector pipe and remove the pipe from clamp.
S2M1668B
12) Remove bolts which hold fuel pipes on the left side of intake manifold.
S2M1670
B2M2786
FU(SOHCw/oOBD)-19
INTAKE MANIFOLD
4) Connect right side fuel hose to injector pipe, and tighten clamp screw.
16) Loosen clamp which holds front right side fuel hose to injector pipe and remove the pipe from clamp.
S2M1671 S2M1671
17) Remove the bolt which installs fuel pipes on intake manifold.
5) Connect left side fuel hose to injector pipe, and tighten clamp screw.
S2M1670 S2M1672
6) Install fuel injectors. NOTE: Always use new O-rings and insulators.
18) Remove fuel injector pipe. 19) Remove fuel pipe assembly, regulator, etc. from intake manifold.
pressure
D: ASSEMBLY
S165034A02
1) Install fuel pipe assembly, pressure regulator, etc. to intake manifold. 2) Install fuel injector pipe. 3) Tighten the bolt which installs fuel pipes on intake manifold. Tightening torque: 4.9 Nm (0.5 kgf-m, 3.6 ft-lb)
S2M1687A
(A) (B) (C) (D)
S2M1672
FU(SOHCw/oOBD)-20
INTAKE MANIFOLD
7) Tighten bolt (A) which installs injector pipe on intake manifold and connect pressure regulator vacuum hose (B). Tightening torque: 4.9 Nm (0.5 kgf-m, 3.6 ft-lb)
10) Install purge control solenoid valve.
S2M1667
11) Connect hoses to purge control solenoid valve.

S2M1668B
8) Tighten the two bolts which install fuel pipes on the left side of intake manifold. Tightening torque: 4.9 Nm (0.5 kgf-m, 3.6 ft-lb)
B2M1893C
(A) (B)
B2M2786
To fuel pipe To intake manifold
9) Tighten the four bolts which install injector pipe on intake manifold. Tightening torque: 19 Nm (1.9 kgf-m, 13.7 ft-lb)
12) 13) and 14)
Install engine harness onto intake manifold. Connect connectors and pipes to fuel injectors purge control solenoid valve. Hold engine harness by harness bands.
S2M1666
S2M1669
FU(SOHCw/oOBD)-21
INTAKE MANIFOLD E: INSPECTION

S165034A10
15) Assemble throttle body to intake manifold. NOTE: Replace gasket with a new one. Tightening torque: 22 Nm (2.2 kgf-m, 15.9 ft-lb)
S2M1653
16) Connect connectors to throttle position sensor (A), idle air control solenoid valve (B) and pressure sensor (C).
S2M1663A
17) Install ignition coil and ignitor assembly. Tightening torque: 6.4 Nm (0.65 kgf-m, 4.7 ft-lb) NOTE: Do not forget to installs ground terminal on ignition coil and ignitor assembly.
S2M1662
18) Connect connector to ignition coil and ignitor assembly.
FU(SOHCw/oOBD)-22

S165047A11

S165047
B: INSTALLATION
A: REMOVAL
S165047A18
B2M4275 G6M0095
2) Remove air intake duct and air cleaner case. <Ref. to IN(SOHC)-8, REMOVAL, Air Intake Duct.> and <Ref. to IN(SOHC)-7, REMOVAL, Air Cleaner Case.> 3) Disconnect connector from engine coolant temperature sensor.
B2M4261
FU(SOHCw/oOBD)-23
CRANKSHAFT POSITION SENSOR B: INSTALLATION

S165043A11

S165043

S165043A18
A: REMOVAL
B2M1252B G6M0095
2) Remove bolt which install crankshaft position sensor to cylinder block.
G2M0408
G2M0409
FU(SOHCw/oOBD)-24
KNOCK SENSOR

S165042A11
6. Knock Sensor
A: REMOVAL
S165042A18
S165042
B: INSTALLATION
G6M0095
2) Remove air cleaner case. <Ref. to IN(SOHC)-7, REMOVAL, Air Cleaner Case.> 3) Disconnect knock sensor connector.
H2M3511C
B2M4262
B2M4262
3) Install air cleaner case. <Ref. to IN(SOHC)-7, INSTALLATION, Air Cleaner Case.> 4) Connect battery ground cable.
S2M1673
G6M0095
FU(SOHCw/oOBD)-25

S165039

A: REMOVAL
S165039A18
B: INSTALLATION
S165039A11
Install in the reverse order of removal. Tightening torque: 1.6 Nm (0.16 kgf-m, 1.2 ft-lb) CAUTION: When installing throttle position sensor, adjust to the specified data.
G6M0095

S2M1675
S2M1651
sensor
holding
S2M1675
FU(SOHCw/oOBD)-26
THROTTLE POSITION SENSOR C: ADJUSTMENT

S165039A01
1) Turn ignition switch to OFF. 2) Loosen throttle position sensor holding screws.
(6) Adjust throttle position sensor so that signal voltage on CHECK BOARD may be in specification. Terminal / Specified voltage (C) No. 23 (C) No. 24 / 0.45 0.55 V [Fully closed.]
S2M0520
3) When using voltage meter; (1) Disconnect battery ground cable.
S2M0522A
(7) Tighten throttle position sensor holding screws. Tightening torque: 1.6 Nm (0.16 kgf-m, 1.2 ft-lb) CAUTION: When removing ST from ECM, disconnect battery ground cable.
G6M0095
(2) Disconnect connectors from ECM.
S2M1760
4) When using Subaru Select Monitor; NOTE: For detailed operation procedures, refer to the Subaru Select Monitor Operation Manual. (1) Insert the cartridge to Subaru Select Monitor. <Ref. to FU(SOHCw/oOBD)-10, PREPARATION, General Description.>
S2M0533
(3) Set ST to ECM. ST 498307600 CHECK BOARD KIT (4) Connect battery ground cable. (5) Turn ignition switch to ON.
S2M0286A
FU(SOHCw/oOBD)-27
(2) Connect Subaru Select Monitor to the data link connector. (3) Turn ignition switch to ON, and Subaru Select Monitor switch to ON. (4) Select {2. Each System Check} in Main Menu. (5) Select {Engine Control System} in Selection Menu. (6) Select {1. Current Data Display & Save} in Engine Diagnosis. (7) Select {1.12 Data Display} in Data Display Menu. (8) Adjust throttle position sensor to the proper position to match with the following specifications. Condition: Throttle fully closed Throttle opening angle 0.00% Throttle sensor voltage 0.50 V
S2M0098
(9) Tighten throttle position sensor holding screws. Tightening torque: 1.6 Nm (0.16 kgf-m, 1.2 ft-lb)
S2M1760
FU(SOHCw/oOBD)-28
PRESSURE SENSOR

S165765A11
8. Pressure Sensor
A: REMOVAL
S165765A18
S165765
B: INSTALLATION
G6M0095 S2M1677
2) Disconnect connector from pressure sensor.
S2M1676
3) Remove pressure sensor from throttle body.
S2M1677
FU(SOHCw/oOBD)-29
INTAKE AIR TEMPERATURE SENSOR B: INSTALLATION

S165569A11
9. Intake Air Temperature Sensor

S165569
A: REMOVAL
S165569A18
S2M1678
G6M0095
2) Disconnect connector from intake air temperature sensor.
S2M1647
3) Remove intake air temperature sensor from air cleaner case.
S2M1678
FU(SOHCw/oOBD)-30
IDLE AIR CONTROL SOLENOID VALVE

S165056A11

S165056
B: INSTALLATION
NOTE: Always use new gasket.
A: REMOVAL
S165056A18
G6M0095
S2M1680
S2M1679
S2M1680
FU(SOHCw/oOBD)-31
FUEL INJECTOR
S165051
11. Fuel Injector

A: REMOVAL
1. RH SIDE
S165051A18 S165051A1801
(2) Remove bolts which hold power steering pipe brackets to intake manifold.
1) Release fuel pressure. <Ref. to FU(SOHCw/oOBD)-41, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.> 2) Open fuel flap lid, and remove fuel filler cap. 3) Disconnect battery ground cable.
S2M1013
(3) Remove bolts which secure power steering pump to bracket.
G6M0095
4) Remove air intake duct and air cleaner case. <Ref. to IN(SOHC)-8, REMOVAL, Air Intake Duct.> and <Ref. to IN(SOHC)-7, REMOVAL, Air Cleaner Case.> 5) Remove resonator chamber.
S2M0086
B2M2306
6) Remove spark plug cords from spark plugs (#1 and #3 cylinders).
S2M0490
B2M2014
7) Remove power steering pump and tank from brackets. (1) Remove V-belt. <Ref. to ME(SOHC)-42, REMOVAL, V-belt.>
S2M0491
FU(SOHCw/oOBD)-32
FUEL INJECTOR
8) Disconnect connector from fuel injector.
S2M1664
G6M0095
9) Remove bolts (A) and (B) which install injector pipe to intake manifold.
4) Remove two bolts which install washer tank on body.
S2M1682A
B2M2764
10) Pull up injector pipe, and remove fuel injectors from intake manifold.
5) Disconnect connector from front window washer motor. 6) Disconnect connector from rear gate glass washer motor.
S2M1683
2. LH SIDE
S165051A1802
B6M0562
1) Release fuel pressure. <Ref. to FU(SOHCw/ oOBD)-41, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.> 2) Open fuel flap lid, and remove fuel filler cap.
FU(SOHCw/oOBD)-33
FUEL INJECTOR
12) Remove bolt which holds fuel pipe on the left side intake manifold.
7) Disconnect rear window glass washer hose from washer motor, then plug connection with a suitable cap. 8) Move washer tank, and secure it away from working area.
S2M1684
B2M2023
13) Pull up injector pipe, and remove fuel injectors from intake manifold.
9) Remove spark plug cords from spark plugs (#2 and #4 cylinders).
B2M2768
B2M2024
S2M1681
11) Remove bolt which installs injector pipe to intake manifold.
B2M2767
FU(SOHCw/oOBD)-34
FUEL INJECTOR B: INSTALLATION

1. RH SIDE
S165051A1101 S165051A11

S165051A1102
2. LH SIDE
S2M1687A S2M1687A
(A) (B) (C) (D)
(A) (B) (C) (D)
Tightening torque: Bolt (A) 4.9 Nm (0.50 kgf-m, 3.6 ft-lb) Bolt (B) 19 Nm (1.9 kgf-m, 13.7 ft-lb)
S2M1684
S2M1682A
B2M2767
B2M2306
FU(SOHCw/oOBD)-35
OXYGEN SENSOR
S165712
12. Oxygen Sensor

A: REMOVAL
S165712A18
B: INSTALLATION
S165712A11
1) Before installing oxygen sensor, apply antiseize compound only to threaded portion of oxygen sensor to make the next removal easier. Anti-seize compound: SS-30 by JET LUBE CAUTION: Never apply anti-seize compound to protector of oxygen sensor.
G6M0095
2) Disconnect connector from oxygen sensor.
G2M0412
2) Install oxygen sensor. Tightening torque: 21 Nm (2.1 kgf-m, 15.2 ft-lb)

H2M2977
3) Lift-up the vehicle. 4) Apply SUBARU CRC or its equivalent to threaded portion of oxygen sensor, and leave it for one minute or more. SUBARU CRC (Part No. 004301003) 5) Remove oxygen sensor. CAUTION: When removing the oxygen sensor, wait until exhaust pipe cools, otherwise it will damage exhaust pipe.
G2M0411
3) Lower the vehicle. 4) Connect connector of oxygen sensor.
H2M2977 G2M0411
FU(SOHCw/oOBD)-36
OXYGEN SENSOR
G6M0095
FU(SOHCw/oOBD)-37

S165049

A: REMOVAL
S165049A18
5) Take off ECM from engine compartment.
S2M0535
B: INSTALLATION
G6M0095
S165049A11
2) Remove air intake duct. <Ref. to IN(SOHC)-8, REMOVAL, Air Intake Duct.> 3) Disconnect the two connectors from ECM.
S2M1686 S2M1685
4) Remove bolts which install ECM on right side cylinder head.
S2M1686
FU(SOHCw/oOBD)-38
MAIN RELAY
14. Main Relay

A: REMOVAL
S165050
S165050A18
S2M0137
B: INSTALLATION
G6M0095
S165050A11
S2M0107
S2M0108A
(A) (B) (C)
FU(SOHCw/oOBD)-39
FUEL PUMP RELAY

S165048
15. Fuel Pump Relay

A: REMOVAL
S165048A18
G6M0095
S2M0093
S2M0138
B: INSTALLATION
S165048A11
FU(SOHCw/oOBD)-40
FUEL
16. Fuel
S165052

S165052A16
A: OPERATION
S165052A1601

WARNING: Place No fire signs near the working area. Disconnect ground terminal from battery. 1) Disconnect connector from fuel pump relay. <Ref. to FU(SOHCw/oOBD)-40, REMOVAL, Fuel Pump Relay.> 2) Start the engine, and run it until it stalls. 3) After the engine stalls, crank it for five more seconds. 4) Turn ignition switch OFF.
S2M0172
2. DRAINING OF FUEL
S165052A1602
7) Disconnect quick connector, and then disconnect fuel delivery hose (A). <Ref. to FU(SOHCw/ oOBD)-56, REMOVAL, Fuel Delivery, Return and Evaporation Lines.> 8) Move clips, and then disconnect fuel return hose (B) and jet pump hose (C).
WARNING: Place No fire signs near the working area. Be careful not to spill fuel on the floor. 1) Release fuel pressure. <Ref. to FU(SOHCw/ oOBD)-41, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.> 2) Open fuel flap lid, and remove fuel filler cap. 3) Disconnect battery ground cable.
S2M0060A
G6M0095
S2M0061
S2M0246
S2M0062
FU(SOHCw/oOBD)-41
FUEL
S2M0153
17) Drain fuel from there.

S2M0163
WARNING: Do not use a motor pump when draining fuel.
S2M0247 G2M0863
18) After draining fuel, reinstall fuel pump and fuel sub meter unit. Tighten nuts of fuel pump in alphabetical sequence shown in figure to specified torque. Tightening torque: 4.4 Nm (0.45 kgf-m, 3.3 ft-lb)
S2M0151
S2M0063A
S2M0152
FU(SOHCw/oOBD)-42
FUEL
S2M0152A
FU(SOHCw/oOBD)-43
FUEL TANK
8) Remove rear exhaust pipe. <Ref. to EX(SOHCw/oOBD)-10, REMOVAL Rear Exhaust Pipe.> NOTE: To facilitate the removal of parts, apply a coat of SUBARU CRC to matching area of rubber cushions in advance. SUBARU CRC (Part No. 004301003) 9) Remove heat sealed cover.
17. Fuel Tank

A: REMOVAL
S165053
S165053A18
1) Set vehicle on the lift. 2) Release fuel pressure. <Ref. to FU(SOHCw/ oOBD)-41, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.> 3) Drain fuel from fuel tank. <Ref. to FU(SOHCw/ oOBD)-41, DRAINING OF FUEL, OPERATION, Fuel.> 4) Remove rear seat cushion, and turn up cover.
S2M0166 S2M0064
5) Disconnect connector of fuel tank cord from rear harness.
10) Remove muffler assembly. <Ref. to EX(SOHCw/oOBD)-12, REMOVAL Muffler.> NOTE: To facilitate the removal of parts, apply a coat of SUBARU CRC to matching area of rubber cushions in advance. SUBARU CRC (Part No. 004301003) 11) Remove bolts which hold parking brake cable holding bracket.
S2M0164
S2M0191
S2M0165
12) Remove rear differential assembly. <Ref. to DI-25, REMOVAL, Rear Differential for T-type.> and <Ref. to DI-42, REMOVAL, Rear Differential for VA-type.> 13) Remove rear crossmember. <Ref. to RS-20, REMOVAL, Rear Crossmember.>
FU(SOHCw/oOBD)-44
FUEL TANK
14) Loosen clamp, and disconnect fuel filler hose (A) and air vent hose (B) from fuel filler pipe.
2) Set fuel tank, and temporary tighten bolts for installing fuel tank bands.
S2M0193A
S2M0169
15) Move clips, and disconnect fuel return hose (B) and evaporation hose (C). 16) Disconnect quick connector, and then disconnect fuel delivery hose (A). <Ref. to FU(SOHCw/ oOBD)-56, REMOVAL, Fuel Delivery, Return and Evaporation Lines.>
3) Connect fuel filler hose (A) and air vent hose (B).
S2M0193A
S2M0168A
17) While holding fuel tank, remove bolts from bands and dismount fuel tank. WARNING: A helper is required to perform this work.
4) Connect fuel hoses, and hold them with clips and quick connector. <Ref. to FU(SOHCw/oOBD)57, INSTALLATION, Fuel Delivery, Return and Evaporation Lines.> 5) Tighten band mounting bolts. Tightening torque: 33 Nm (3.4 kgf-m, 25 ft-lb)
S2M0169 S2M0169
B: INSTALLATION
S165053A11
1) While a helper holds fuel tank, push fuel tank harness into access hole with grommet.
6) Install rear crossmember. <Ref. to RS-20, INSTALLATION, Rear Crossmember.> 7) Install rear differential assembly. <Ref. to DI-27, INSTALLATION, Rear Differential for T-type.> and <Ref. to DI-43, INSTALLATION Rear Differential for VA-type.>
FU(SOHCw/oOBD)-45
FUEL TANK
8) Install bolts which hold parking brake holding bracket.
G6M0095 S2M0191
9) Install muffler assembly. <Ref. to EX(SOHCw/ oOBD)-12, INSTALLATION, Muffler.> 10) Install heat sealed cover.
C: INSPECTION
S165053A10
S2M0166
11) Install rear exhaust pipe. <Ref. to EX(SOHCw/ oOBD)-10, INSTALLATION, Rear Exhaust Pipe.> 12) Lower the vehicle. 13) Connect connectors to fuel tank harness, and plug access hole with grommet.
S2M0164
14) Install rear seat cushion. 15) Install fuel filler cap. 16) Connect connector to fuel pump relay. <Ref. to FU(SOHCw/oOBD)-40, INSTALLATION, Fuel Pump Relay.>
FU(SOHCw/oOBD)-46
FUEL FILLER PIPE

A: REMOVAL
S165022A18
S165022
9) Move clip, and disconnect air vent hose from air vent pipe.
WARNING: Place No fire signs near the working area. Be careful not to spill fuel on the floor. 1) Set the vehicle on the lift. 2) Drain fuel from fuel tank. <Ref. to FU(SOHCw/ oOBD)-41, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.> 3) Remove screws holding packing in place. 4) Remove wheel nuts of rear right side. 5) Lift-up the vehicle. 6) Remove rear right side wheel.
B2M1896
10) Loosen clamp, and separate fuel filler hose (A) from fuel filler pipe. 11) Move clip, and separate air vent hose (B).
B2M1748
S2M0193A
12) Remove fuel filler pipe to under side of the vehicle.
B2M1894
B2M1756
B2M1895
FU(SOHCw/oOBD)-47
FUEL FILLER PIPE

S165022A11
B: INSTALLATION
1) Hold fuel filler flap open. 2) Set fuel saucer (A) with rubber packing (C), and insert fuel filler pipe into hole from the inner side of apron.
B2M1195A B2M1196A
(1) (2) (3)
Hose Clip Pipe
B2M1196A
B2M1895
7) Connect air vent hose to air vent pipe.
B2M1896
S2M0193A
FU(SOHCw/oOBD)-48
FUEL FILLER PIPE

S2M0171
B2M1748
10) Lower the vehicle. 11) Tighten wheel nuts. 12) Connect connector to fuel pump relay. <Ref. to FU(SOHCw/oOBD)-40, INSTALLATION, Fuel Pump Relay.> 13) Connect battery ground terminal.
G6M0095
FU(SOHCw/oOBD)-49
FUEL PUMP
7) Move clips, and then disconnect fuel delivery hose (A), return hose (B) and jet pump hose (C). 8) Disconnect quick connector, and then disconnect fuel delivery hose (A). <Ref. to FU(SOHCw/ oOBD)-56, REMOVAL, Fuel Delivery, Return and Evaporation Lines.>
19. Fuel Pump

A: REMOVAL
S165025
S165025A18
WARNING: Place No fire signs near the working area. Be careful not to spill fuel on the floor. 1) Release fuel pressure. <Ref. to FU(SOHCw/ oOBD)-41, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.> 2) Open fuel filler flap lid, and remove fuel filler cap. 3) Disconnect battery ground cable.
S2M0060A
G6M0095
S2M0061
S2M0246
S2M0062
S2M0172
FU(SOHCw/oOBD)-50

S165025A11
Install in the reverse order of removal. Do the following: (1) Always use new gaskets. (2) Ensure sealing portion is free from fuel or foreign particles before installation. (3) Tighten nuts in alphabetical sequence shown in Figure to specified torque. Tightening torque: 4.4 Nm (0.45 kgf-m, 3.3 ft-lb)
S2M0063A
C: INSPECTION
S165025A10
G2M0366
FU(SOHCw/oOBD)-51
FUEL LEVEL SENSOR

S165026

A: REMOVAL
S165026A18
B: INSTALLATION
S165026A11
WARNING: Place NO FIRE signs near the working area. Be careful not to spill fuel on the floor. NOTE: Fuel level sensor is built in fuel pump assembly. 1) Remove fuel pump assembly. <Ref. to FU(SOHCw/oOBD)-50, REMOVAL, Fuel Pump.> 2) Disconnect connector from fuel pump bracket.
S2M0145
S2M0855
FU(SOHCw/oOBD)-52

A: REMOVAL
S165023A18
S165023
S2M0152
G6M0095
S2M0153
B: INSTALLATION
S165023A11
Install in the reverse order of removal. Tightening torque: T: 4.4 Nm (0.45 kgf-m, 3.3 ft-lb)
G2M0863
S2M0152A
S2M0151
FU(SOHCw/oOBD)-53
FUEL FILTER B: INSTALLATION

S165027A11
22. Fuel Filter

A: REMOVAL
S165027
S165027A18
WARNING: Place No fire signs near the working area. Be careful not to spill fuel on the floor. 1) Release fuel pressure. <Ref. to FU(SOHCw/ oOBD)-41, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.> 2) Open fuel flap lid, and remove fuel filler cap. 3) Disconnect battery ground cable.
CAUTION: If fuel hoses are damaged at the connecting portion, replace it with a new one. If clamps are badly damaged, replace with new ones. 1) Install in the reverse order of removal. 2) Tighten hose clamp screws. Tightening torque: 1 Nm (0.1 kgf-m, 0.7 ft-lb)
G6M0095
S2M0195
4) Disconnect fuel hoses from fuel filter.
C: INSPECTION
S165027A10
S2M0195
FU(SOHCw/oOBD)-54
FUEL CUT VALVE
23. Fuel Cut Valve

A: REMOVAL
S165021A18
S165021
1) Remove fuel tank. <Ref. to FU(SOHCw/oOBD)44, REMOVAL, Fuel Tank.> 2) Move clip and disconnect evaporation hose from fuel cut valve.
S2M0176
B: INSTALLATION
S165021A11
S2M0177
FU(SOHCw/oOBD)-55

2) Open fuel filler flap lid and remove fuel filler cap. 3) Remove inner trim, insulator and rear seat. 4) Remove fuel delivery pipes and hoses, fuel return pipes and hoses, evaporation pipes and hoses.

S165019
A: REMOVAL
S165019A18
1) Release fuel pressure. <Ref. to FU(SOHCw/ oOBD)-41, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.>
S2M0635
7) Separate quick connector on fuel delivery and return line. (1) Clean pipe and connector, if they are covered with dust. (2) Hold connector (A) and push retainer (B) down. (3) Pull out connector (A) from retainer (B). CAUTION: Replace retainer with new ones.
S2M0500
6) In the engine compartment, detach canister hose from canister.
S2M0228A
(A) (B) (C)
S2M0574
FU(SOHCw/oOBD)-56
FUEL DELIVERY, RETURN AND EVAPORATION LINES B: INSTALLATION

S165019A11
1) Connect quick connector on fuel delivery and return line. CAUTION: Always use a new retainer. Make sure that the connected portion is not damaged or has dust. If necessary, clean seal surface of pipe (A).
S2M0231A
S2M0229B
(A) (B) (C)
S2M0230A
(A) (B) (C)
Connector Retainer Pipe (1) (2) (3) Fitting Clamp Hose
B2M1194B
FU(SOHCw/oOBD)-57
B2M1195A
(1) (2) (3)
Hose Clip Pipe

S165019A10
C: INSPECTION
FU(SOHCw/oOBD)-58

S165571
A: INSPECTION
S165571A10
Trouble and possible cause 1. Insufficient fuel supply to the injector 1) Fuel pump will not operate. k k Defective terminal contact.
Corrective action
Trouble in electromagnetic or electronic circuit parts. 2) Lowering of fuel pump function. 3) Clogged dust or water in the fuel filter. 4) Clogged or bent fuel pipe or hose. 5) Air is mixed in the fuel system. 6) Clogged or bent breather tube or pipe. 7) Damaged diaphragm of pressure regulator. 2. Leakage or blow out fuel 1) Loosened joints of the fuel pipe. 2) Cracked fuel pipe, hose and fuel tank. 3) Defective welding part on the fuel tank. 4) Defective drain packing of the fuel tank. 5) Clogged or bent air breather tube or air vent tube.
NOTE: When the vehicle is left unattended for an extended period of time, water may accumulate in the fuel tank. To prevent water condensation. (1) Top off the fuel tank or drain the fuel completely. (2) Drain water condensation from the fuel filter. Refilling the fuel tank. Refill the fuel tank while there is still some fuel left in the tank. Protecting the fuel system against freezing and water condensation. (1) Cold areas In snow-covered areas, mountainous areas, skiing areas, etc. where ambient temperatures drop below 0C (32F) throughout the winter season, use an anti-freeze solution in the cool-
ing system. Refueling will also complement the effect of anti-freeze solution each time the fuel level drops to about one-half. After the winter season, drain water which may have accumulated in the fuel filter and fuel tank in the manner same as that described under Affected areas below. (2) Affected areas When water condensation is notched in the fuel filter, drain water from both the fuel filter and fuel tank or use a water removing agent (or antifreeze solution) in the fuel tank. Observe the instructions, notes, etc., indicated on the label affixed to the anti-freeze solution (water removing agent) container before use.
FU(SOHCw/oOBD)-59
MEMO:
FU(SOHCw/oOBD)-60
EC(SOHCw/oOBD)
1. 2. 3. 4. 5. Page General Description.....................................................................................2 Front Catalytic Converter ............................................................................3 Canister .......................................................................................................6 Purge Control Solenoid Valve .....................................................................7 Two-way Valve ............................................................................................8
GENERAL DESCRIPTION
S160001
A: CAUTION
S160001A03
EC(SOHCw/oOBD)-2

A: REMOVAL
S160017A18
S160017
7) Remove bolts which hold front exhaust pipe onto cylinder heads.
B2M3200
8) Remove front exhaust pipe and center exhaust pipe from hanger bracket.
G6M0095
3) Disconnect front oxygen sensor connector.
CAUTION: Be careful not to pull down front exhaust pipe and center exhaust pipe.
B2M1979
4) Lift-up the vehicle. 5) Remove under cover. 6) Separate center exhaust pipe from rear exhaust pipe. CAUTION: Be careful, exhaust pipe is hot.
B2M3111
9) Separate front catalytic converter from front exhaust pipe.
S2M0923
S2M0558
EC(SOHCw/oOBD)-3

4) Install center exhaust pipe to rear exhaust pipe. Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft-lb)
B: INSTALLATION
S160017A11
CAUTION: Replace gaskets with new ones. 1) Install front catalytic converter to front exhaust pipe. Tightening torque: 30 Nm (3.1 kgf-m, 22.4 ft-lb)
S2M0558
5) Tighten bolt which holds center exhaust pipe to hanger bracket.

S2M0923
2) Install front exhaust pipe and center exhaust pipe. And temporarily tighten bolt which installs center exhaust pipe to hanger bracket.
B2M3111
B2M3111
6) Install under cover. 7) Lower the vehicle. 8) Connect front oxygen sensor connector.
B2M1979
B2M3200
EC(SOHCw/oOBD)-4

G6M0095
C: INSPECTION
S160017A10
EC(SOHCw/oOBD)-5
CANISTER
3. Canister
S160037
A: REMOVAL
S160037A18
1) Remove air intake duct as a unit.
S6M0353
2) Disconnect canister hoses from evaporation pipes. 3) Remove canister with bracket.
S2M0574
B: INSTALLATION
S160037A11
Install in the reverse order of removal. CAUTION: Insert air vent hose of canister into the hole on body.
C: INSPECTION
S160037A10
EC(SOHCw/oOBD)-6
PURGE CONTROL SOLENOID VALVE

S160035A11

S160035
B: INSTALLATION
A: REMOVAL
S160035A18
S2M1198 G6M0095
2) Remove bolt which installs purge control solenoid valve onto intake manifold.
S2M1198
B2M1893B
3) Take out purge control solenoid valve through the bottom of the intake manifold. 4) Disconnect connector and hoses from purge control solenoid valve.
(A) (B)
To fuel pipe To intake manifold

S160035A10
C: INSPECTION
H2M2986
EC(SOHCw/oOBD)-7
TWO-WAY VALVE
5. Two-way Valve
A: REMOVAL
S160707A18
S160707
Disconnect hoses from two-way valve, and remove it.
S2M0578
S160707A11

S160707A10
EC(SOHCw/oOBD)-8
EXHAUST
EX(SOHCw/oOBD)
1. 2. 3. 4. 5. Page General Description.....................................................................................2 Front Exhaust Pipe......................................................................................6 Center Exhaust Pipe ...................................................................................9 Rear Exhaust Pipe ....................................................................................10 Muffler........................................................................................................12
Exhaust
GENERAL DESCRIPTION
S162001
A: COMPONENT
S162001A05
1. WITH CATALYTIC CONVERTER
S162001A0504
S2M1837A
EX(SOHCw/oOBD)-2
GENERAL DESCRIPTION
(1) Upper front exhaust CTR (2) Lower front exhaust CTR (3) Clamp (4) Upper front exhaust LH (5) Lower front exhaust LH (6) Front exhaust pipe (7) Lower front exhaust RH (8) Upper front exhaust RH (9) Gasket pipe cover pipe cover (10) (11) (12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) Spring Chamber Rear exhaust pipe cover Gasket Self-locking nut Muffler Cushion rubber Upper clamp Lower clamp Upper center exhaust pipe cover Lower center exhaust pipe cover Protector Gasket Oxygen sensor Front catalytic converter
Exhaust
(25) Center exhaust pipe (26) Lower front catalytic converter cover (27) Upper front catalytic converter cover (28) Rear exhaust pipe
Tightening torque: Nm (kgf-m, ft-lb) T1: 13 (1.3, 9.4) T2: 18 (1.8, 13.0) T3: 30 (3.1, 22.4) T4: 35 (3.6, 26.0) T5: 48 (4.9, 35.4)
pipe cover pipe cover
EX(SOHCw/oOBD)-3
Exhaust
GENERAL DESCRIPTION
2. WITHOUT CATALYTIC CONVERTER

S162001A0503
S2M1836A
(1) Upper front exhaust CTR (2) Lower front exhaust CTR (3) Clamp (4) Upper front exhaust LH (5) Lower front exhaust LH (6) Front exhaust pipe (7) Lower front exhaust RH (8) Upper front exhaust RH
(9) (10) (11) (12) (13) (14) (15) (16) (17) (18) (19) (20) (21)
Gasket Spring Chamber Rear exhaust pipe cover Gasket Self-locking nut Muffler Cushion rubber Upper clamp Lower clamp Protector Gasket Center exhaust pipe
(22) Lower front catalytic converter cover (23) Upper front catalytic converter cover (24) Rear exhaust pipe
EX(SOHCw/oOBD)-4

S162001A03
Exhaust
EX(SOHCw/oOBD)-5
Exhaust
FRONT EXHAUST PIPE

S162065

A: REMOVAL
S162065A18
6) Remove bolts which hold front exhaust pipe onto cylinder heads. CAUTION: Be careful not to pull down front and center exhaust pipe assembly.
G6M0095
2) Disconnect front oxygen sensor connector. (With catalytic converter)
B2M3200
7) Remove bolt which installs front and center exhaust pipe assembly to hanger bracket.
B2M1979
3) Lift-up the vehicle. 4) Remove under cover. <Ref. to EI-11, REMOVAL, Front Under Cover.> 5) Separate front and center exhaust pipe assembly from rear exhaust pipe. WARNING: Be careful, exhaust pipe is hot.
B2M3111
8) Remove front and center exhaust pipe assembly from the vehicle. CAUTION: Be careful not to let front and center exhaust pipe assembly fall off when removing as it is quite heavy. After removing front and center exhaust assembly, do not apply excessive pulling force on rear exhaust pipe. 9) Separate front exhaust pipe from center exhaust pipe.
B2M0055
S2M0923
EX(SOHCw/oOBD)-6
FRONT EXHAUST PIPE B: INSTALLATION

S162065A11
Exhaust
1) Install front exhaust pipe to center exhaust pipe. CAUTION: Replace gaskets with new ones. Tightening torque: 30 Nm (3.1 kgf-m, 22.4 ft-lb)
5) Tighten bolts which install front and center exhaust pipe assembly to rear exhaust pipe. Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft-lb)
B2M0055
6) Tighten bolt which holds front and center exhaust pipe assembly to hanger bracket.
S2M0923
2) Install front and center exhaust pipe assembly to the vehicle. 3) Temporarily tighten bolt which installs front and center exhaust pipe assembly to hanger bracket.
B2M3111
B2M3111
7) Install under cover. <Ref. to EI-11, INSTALLATION, Front Under Cover.> 8) Lower the vehicle. 9) Connect front oxygen sensor connector. (With catalytic converter)
B2M1979
B2M3200
EX(SOHCw/oOBD)-7
Exhaust
FRONT EXHAUST PIPE
G6M0095
C: INSPECTION
S162065A10
EX(SOHCw/oOBD)-8
CENTER EXHAUST PIPE
Exhaust

A: REMOVAL
S162067A18
S162067
After removing the center and front exhaust pipes as one unit, separate them. Refer to the procedure for removing the front exhaust pipe. <Ref. to EX(SOHCw/oOBD)-6 REMOVAL, Front Exhaust Pipe.>
B: INSTALLATION
S162067A11
Install the center exhaust pipe and front exhaust pipe as one unit. Refer to the procedure for installing the front exhaust pipe. <Ref. to EX(SOHCw/ oOBD)-7 INSTALLATION, Front Exhaust Pipe.>
C: INSPECTION
S162067A10
EX(SOHCw/oOBD)-9
Exhaust
REAR EXHAUST PIPE

S162068

A: REMOVAL
S162068A18
B: INSTALLATION
S162068A11
CAUTION: Replace gaskets with new ones. 1) Install rear exhaust pipe bracket to rubber cushion. NOTE: To facilitate removal, apply a coat of SUBARU CRC to mating area of rubber cushion in advance. SUBARU CRC (Part No. 004301003)
1) Separate rear exhaust pipe from center exhaust pipe. CAUTION: Be careful, exhaust pipe is hot.
S2M0558
S2M0560
2) Install rear exhaust pipe to muffler. Tightening torque: 48 Nm (4.9 kgf-m, 35.4 ft-lb)
S2M0559
3) Remove rear exhaust pipe bracket from rubber cushion. NOTE: To facilitate removal, apply a coat of SUBARU CRC to pipe bracket in advance. SUBARU CRC (Part No. 004301003) Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft-lb)
S2M0559
3) Install rear exhaust pipe to center exhaust pipe.
S2M0558 S2M0560
EX(SOHCw/oOBD)-10
REAR EXHAUST PIPE C: INSPECTION

S162068A10
Exhaust
EX(SOHCw/oOBD)-11
Exhaust
MUFFLER
S162066
5. Muffler
3) Remove front rubber cushion, and detach muffler assembly. NOTE: To facilitate removal, apply a coat of SUBARU CRC to mating area of rubber cushion in advance. SUBARU CRC (Part No. 004301003)
A: REMOVAL
S162066A18
S2M0559
S2M0609
2) Remove left and right rubber cushions. CAUTION: Be careful not to drop the muffler during removal. NOTE: To facilitate removal, apply a coat of SUBARU CRC to mating area of rubber cushions in advance. SUBARU CRC (Part No. 004301003)
B: INSTALLATION
S162066A11
S2M0559
S2M0608
C: INSPECTION
S162066A10
EX(SOHCw/oOBD)-12
IGNITION
IG(SOHCw/oOBD)
1. 2. 3. 4. Page General Description.....................................................................................2 Spark Plug...................................................................................................5 Ignition Coil and Ignitor Assembly...............................................................9 Spark Plug Cord ........................................................................................11
Ignition
GENERAL DESCRIPTION
S161001
A: SPECIFICATIONS
S161001E49
Ignition coil and ignitor assembly
Item Model Manufacturer Primary coil resistance Secondary coil resistance Insulation resistance between primary terminal and case Type and manufacturer
Designation CM12100B HITACHI 0.7 10% 13.0 k20% More than 10 M
Spark plug
Thread size Spark gap
BKR6E* .......... NGK RC10YC4** .......... CHAMPION BKR5E-11** .......... NGK (Alternate) mm 14, P = 1.25 0.7 0.8 mm (0.028 0.031 in)* mm (in) 1.0 1.1 mm (0.039 0.043 in)**
*: Without catalytic converter **: With catalytic converter
IG(SOHCw/oOBD)-2

S161001A05
Ignition
S6M0139B
(1) Spark plug (2) Spark plug cord (#1, #3) (3) Ignition coil and ignitor ASSY
(4) Spark plug cord (#2, #4)
C: CAUTION
S161001A03
IG(SOHCw/oOBD)-3
Ignition
GENERAL DESCRIPTION
S161001A17
D: PREPARATION TOOL
ILLUSTRATION
DESCRIPTION REMARKS CHECK BOARD KIT Troubleshooting for engine electrical systems (1) CHECK BOARD: 498307610 (2) CHECK BOARD ADAPTER: 498307620
S2M2137A
IG(SOHCw/oOBD)-4
SPARK PLUG
Ignition
2. Spark Plug
A: REMOVAL
S161003
(3) Remove air intake duct as a unit.
S161003A18
CAUTION: All spark plugs installed on an engine, must be of the same heat range. Spark plug: With catalyst model: CHAMPION RC10YC4 Without catalyst model: NGK BKR6E
1. RH SIDE
S161003A1805
B2M2012
(4) Remove resonator chamber.
G6M0095
B2M2306
2) Remove air intake duct and resonator chamber. (1) Remove bolt which installs air intake duct on the front side of body.
3) Remove spark plug cords by pulling boot, not cord itself.
S2M2135 S6M0708
(2) Remove bolt which installs air intake duct on body.
B6M0923
B6M1302
IG(SOHCw/oOBD)-5
Ignition
SPARK PLUG
S161003A1806
2. LH SIDE
5) Remove spark plugs cord by pulling boot, not cord itself.
G6M0095
S2M2136
2) Disconnect washer motor connector.
6) Remove spark plug with the spark plug socket.
S2M0546
B6M0926
3) Disconnect rear from washer motor, suitable cap. 4) Remove the two tank, then take the area.
window glass washer hose then plug connection with a bolts which hold the washer tank away from the working
B: INSTALLATION
1. RH SIDE
S161003A1105
S161003A11
Install in the reverse order of removal. Tightening torque (Spark plug): 21 Nm (2.1 kgf-m, 15 ft-lb) CAUTION: The above torque should be only applied to new spark plugs without oil on their threads. In case their threads are lubricated, the torque should be reduced by approximately 1/3 of the specified torque in order to avoid over-stressing. Tightening torque (Resonator chamber): 32 Nm (3.3 kgf-m, 24 ft-lb)
B2M2023
2. LH SIDE
S161003A1106
Install in the reverse order of removal. Tightening torque (Spark plug): 21 Nm (2.1 kgf-m, 15 ft-lb) CAUTION: The above torque should be only applied to new spark plugs without oil on their threads. In case their threads are lubricated, the torque should be reduced by approximately 1/3 of the specified torque in order to avoid over-stressing.
IG(SOHCw/oOBD)-6
SPARK PLUG C: INSPECTION

S161003A10
Ignition
S6M0420A
(A) (B) (C) (D) (E)
G6M0089
G6M0087
G6M0090
D: CLEANING
S161003E56
Clean spark plugs in a sand blast type cleaner. Avoid excessive blasting. Clean and remove carbon or oxide deposits, but do not wear away porcelain. If deposits are too stubborn, replace plugs.
G6M0088
IG(SOHCw/oOBD)-7
Ignition
SPARK PLUG
S161003A01
E: ADJUSTMENT
Correct it if the spark plug gap is measured with a gap gauge, and it is necessary. Spark plug gap: L With catalyst: 1.0 1.1 mm (0.039 0.043 in) Without catalyst: 0.7 0.8 mm (0.028 0.031 in)
S6M0412A
IG(SOHCw/oOBD)-8
Ignition

S161015
A: REMOVAL
S161015A18
S6M0371
B: INSTALLATION
G6M0095
S161015A11
Install in the reverse order of removal. 2) Disconnect spark plug cords from ignition coil and ignitor assembly. Tightening torque: 6.4 Nm (0.65 kgf-m, 4.7 ft-lb) CAUTION: Be sure to connect wires to their proper positions. Failure to do so will damage unit.
S6M0372
S6M0371
S6M0366
IG(SOHCw/oOBD)-9
Ignition

S161015A10
C: INSPECTION
Using oscilloscope and accurate tester, inspect the following items, and replace if defective. Ignitor input signal Secondary coil resistance Poor contact in ignition coil and ignitor assembly connector 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM, then connect ST. <Ref. to EN(SOHCw/oOBD)-23, HOW TO CHECK I/O SIGNAL FOR ECM, Engine Control Module (ECM) I/O Signal.> ST 498307600 CHECK BOARD KIT 3) Turn ignition switch to ON. 4) Measure voltage between ignition coil and ignition assembly and body. Connector & terminal: (A) No. 5 Engine ground (A) No. 12 Engine ground
CAUTION: If the resistance is extremely low, this indicates the presence of a ground short circuit.
B6M0810B
9) Check poor contact in ignition coil and ignitor assembly connector.
S6M0378A
Specified voltage: 3 4 V
B2M0224B
5) Turn ignition switch to OFF. 6) Disconnect connector from ignition coil and ignitor assembly. 7) Remove spark plug cords. 8) Measure resistance between spark plug cord contact portions to check secondary coil. Terminals / Specified resistance: (A) (B) / 13.0 2.6 k (C) (D) / 13.0 2.6 k
IG(SOHCw/oOBD)-10
SPARK PLUG CORD
Ignition
4. Spark Plug Cord

A: INSPECTION
S161014A10
S161014
Check for: 1) Damage to cords, deformation, burning or rust formation of terminals 2) Resistance values of cords Resistance value: 5.24 12.23 k
S6M0145
IG(SOHCw/oOBD)-11
Ignition
SPARK PLUG CORD
IG(SOHCw/oOBD)-12
Ignition
SPARK PLUG CORD
MEMO:
IG(SOHCw/oOBD)-13
Ignition
SPARK PLUG CORD
IG(SOHCw/oOBD)-14
EN(SOHCw/oOBD)
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Page Basic Diagnostic Procedure ........................................................................2 Check List for Interview...............................................................................4 General Description.....................................................................................6 Electrical Components Location................................................................10 Engine Control Module (ECM) I/O Signal.................................................20 Subaru Select Monitor...............................................................................24 Read Diagnostic Trouble Code .................................................................27 Inspection Mode ........................................................................................29 Clear Memory Mode..................................................................................31 Compulsory Valve Operation Check Mode...............................................32 Engine Malfunction Indicator Lamp (MIL) .................................................33 Diagnostics for Engine Starting Failure ....................................................47 List of Diagnostic Trouble Code (DTC).....................................................65 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ....................68 General Diagnostic Table ........................................................................113

S068501
A: PROCEDURE
No. 1
S068501E45
1. WITH SUBARU SELECT MONITOR
S068501E4501
Step Check Does the engine start? CHECK ENGINE START FAILURE. 1) Ask the customer when and how the trouble occurred using the interview check list. <Ref. to EN(SOHCw/oOBD)-4 CHECK, Check List for Interview.> 2) Start the engine.
CHECK ILLUMINATION OF CHECK ENGINE Does MIL illuminate? MALFUNCTION INDICATOR LAMP (MIL). <Ref. to EN(SOHCw/oOBD)-33 ACTIVATION OF CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL), Engine Malfunction Indicator Lamp (MIL).>
CHECK INDICATION OF DTC ON DISPLAY. 1) Turn ignition switch to OFF. 2) Connect the Subaru Select Monitor to data link connector. 3) Turn ignition switch to ON and the Subaru Select Monitor switch to ON. 4) Read DTC on the Subaru Select Monitor. <Ref. to EN(SOHCw/oOBD)-27 WITH SUBARU SELECT MONITOR, OPERATION, Read Diagnostic Trouble Code.>
Does the Subaru Select Monitor indicate DTC? <Ref. to EN(SOHCw/ oOBD)-65 LIST, List of Diagnostic Trouble Code (DTC).>
PERFORM THE DIAGNOSIS. 1) Perform the clear memory mode. <Ref. to EN(SOHCw/oOBD)-31 OPERATION, Clear Memory Mode.> 2) Perform the inspection mode. <Ref. to EN(SOHCw/oOBD)-29 OPERATION, Inspection Mode.>
Does the Subaru Select Monitor indicate DTC? <Ref. to EN(SOHCw/ oOBD)-65 LIST, List of Diagnostic Trouble Code (DTC).>
No Inspection using Diagnostics for Engine Starting Failure. <Ref. to EN(SOHCw/ oOBD)-47 Diagnostics for Engine Starting Failure.> Go to step 3. Inspection using General Diagnostic Table. <Ref. to EN(SOHCw/ oOBD)-113 INSPECTION, General Diagnostic Table.> Record diagnostic Repair the related parts. trouble code. Repair the trouble NOTE: If DTC is not cause. <Ref. to shown on display EN(SOHCw/ although the MIL oOBD)-68 Diagnostic Procedure illuminates, perform diagnostics with Diagnostic of MIL (CHECK Trouble Code ENGINE malfunc(DTC).> Go to tion indicator step 4. lamp) circuit or combination meter. <Ref. to EN(SOHCw/ oOBD)-33 Engine Malfunction Indicator Lamp (MIL).> Record diagnostic Complete the diagnosis. trouble code. Repair the trouble cause. <Ref. to EN(SOHCw/ oOBD)-68 Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Go to step 4.
Yes Go to step 2.
EN(SOHCw/oOBD)-2

2. WITHOUT SUBARU SELECT MONITOR
S068501E4502
CAUTION: Check the connector while it is connected unless specified otherwise.

No. 1
Be sure to check again from the beginning in order to prevent secondary trouble caused by repair work.
Step Check Does the engine start? CHECK ENGINE START FAILURE. 1) Ask the customer when and how the trouble occurred using the interview check list. <Ref. to EN(SOHCw/oOBD)-4 CHECK, Check List for Interview.> 2) Start the engine.
Yes Go to step 2.
CHECK ILLUMINATION OF CHECK ENGINE Does MIL illuminate? MALFUNCTION INDICATOR LAMP (MIL). <Ref. to EN(SOHCw/oOBD)-33 ACTIVATION OF CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL), Engine Malfunction Indicator Lamp (MIL).>
Go to step 3.
CHECK INDICATION OF DTC ON MIL. 1) Perform the read diagnostic trouble code (read memory mode). <Ref. to EN(SOHCw/ oOBD)-27 WITHOUT SUBARU SELECT MONITOR, OPERATION, Read Diagnostic Trouble Code.> 2) Read DTC on MIL.
Repair the trouble Does the MIL indicate DTC? <Ref. to EN(SOHCw/ cause. Go to step 4. oOBD)-65 LIST, List of Diagnostic Trouble Code (DTC).>
PERFORM THE DIAGNOSIS. 1) Perform the clear memory mode. <Ref. to EN(SOHCw/oOBD)-31 OPERATION, Clear Memory Mode.> 2) Perform the inspection mode. <Ref. to EN(SOHCw/oOBD)-29 OPERATION, Inspection Mode.>
Repair the trouble Does the MIL indicate DTC? <Ref. to EN(SOHCw/ cause. Go to step 4. oOBD)-65 LIST, List of Diagnostic Trouble Code (DTC).>
No Inspection using Diagnostics for Engine Starting Failure. <Ref. to EN(SOHCw/ oOBD)-47 Diagnostics for Engine Starting Failure.> Inspection using 9. General Diagnostic Table. <Ref. to EN(SOHCw/oOBD)-113 INSPECTION, General Diagnostic Table.> Repair the related parts. NOTE: If DTC is not shown on MIL although the MIL illuminates, perform diagnostics of MIL (CHECK ENGINE malfunction indicator lamp) circuit or combination meter. <Ref. to EN(SOHCw/ oOBD)-33 Engine Malfunction Indicator Lamp (MIL).> Complete the diagnosis.
EN(SOHCw/oOBD)-3

S068502

A: CHECK
S068502A04
1. CHECK LIST NO. 1
S068502A0401
Customer s name Date of sale Date of repair Vin no. Weather Engine no. Fuel brand Odometer reading Fine Cloudy Rainy Snowy Various/Others: F (C) Hot Warm Cool Cold Highway Suburbs Inner city Uphill Downhill Rough road Others: Cold Warming-up After warming-up Any temperature Others: rpm MPH Not affected At starting While idling At racing While accelerating While cruising While decelerating While turning (RH/LH) ON/ OFF ON/ OFF ON/ OFF ON/ OFF ON/ OFF ON/ OFF
km miles
Outdoor temperature
Place
Engine temperature
ON/ ON/ ON/ ON/ ON/
OFF OFF OFF OFF OFF
EN(SOHCw/oOBD)-4

2. CHECK LIST NO. 2
S068502A0402
Check the following items about the vehicles state when MIL turns on. NOTE: Use copies of this page for interviewing customers.
a) Other warning lights or indicators turn on. Yes/ No Low fuel warning light Charge indicator light AT diagnostics indicator light ABS warning light Engine oil pressure warning light b) Fuel level Lack of gasoline: Yes/ No Indicator position of fuel gauge: c) Intentional connecting or disconnecting of harness connectors or spark plug cords: Yes/ No What: d) Intentional connecting or disconnecting of hoses: Yes/ No What: e) Installing of parts other than genuine parts: Yes/ No What: Where: f) Occurrence of noise: Yes/ No From where: What kind: g) Occurrence of smell: Yes/ No From where: What kind: h) Intrusion of water into engine compartment or passenger compartment: Yes/ No i) Troubles occurred Engine does not start. Engine stalls during idling. Engine stalls while driving. Engine speed decreases. Engine speed does not decrease. Rough idling Poor acceleration Back fire After fire No shift Excessive shift shock
EN(SOHCw/oOBD)-5
GENERAL DESCRIPTION
S068001
A: CAUTION
S068001A03
S2M1246
B3M1666E
10) Every MFI-related part is a precision part. Do not drop them. 11) Observe the following cautions when installing a radio in MFI equipped models. CAUTION: The antenna must be kept as far apart as possible from the control unit. (The ECM is located in the engine compartment.) The antenna feeder must be placed as far apart as possible from the ECM and MFI harness. Carefully adjust the antenna for correct matching. When mounting a large power type radio, pay special attention to the three items above mentioned. Incorrect installation of the radio may affect the operation of the ECM. 12) Before disconnecting the fuel hose, disconnect the fuel pump connector and crank the engine for more than five seconds to release pressure in the fuel system. If engine starts during this operation, run it until it stops. 13) Problems in the electronic-controlled automatic transmission may be caused by failure of the
EN(SOHCw/oOBD)-6
GENERAL DESCRIPTION
engine, the electronic control system, the transmission proper, or by a combination of these. These three causes must be distinguished clearly when performing diagnostics. 14) Diagnostics should be conducted by rotating with simple, easy operations and proceeding to complicated, difficult operations. The most important thing in diagnostics is to understand the customer s complaint, and distinguish between the three causes. 15) In AT vehicles, do not continue the stall for more than five seconds at a time (from closed throttle, fully open throttle to stall engine speed). 16) On ABS vehicle, when performing driving test in jacked-up or lifted-up position, sometimes the warning light may be lit, but this is not a malfunction of the system. The reason for this is the speed difference between the front and rear wheels. After diagnosis of engine control system, perform the ABS memory clearance procedure of self-diagnosis system.
S068001A1002
2. ENGINE GROUNDING
S2M1246
C: NOTE
S068001A15

The Multipoint Fuel Injection (MFI) system is a system that supplies the optimum air-fuel mixture to the engine for all the various operating conditions through the use of the latest electronic technology. With this system fuel, which is pressurized at a constant pressure, is injected into the intake air passage of the cylinder head. The injection quantity of fuel is controlled by an intermittent injection system where the electro-magnetic injection valve (fuel injector) opens only for a short period of time, depending on 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 simple, yet highly precise metering of the fuel. Further, all the operating conditions of the engine are converted into electric signals, and this results in additional features of the system, such as large improved adaptability, easier addition of compensating element, etc. The MFI system also has the following features: Reduced emission of harmful exhaust gases. Reduced in fuel consumption. Increased engine output. Superior acceleration and deceleration. Superior startability and warm-up performance in cold weather since compensation is made for coolant and intake air temperature.
B: INSPECTION
S068001A10
1. BATTERY
S068001A1001
EN(SOHCw/oOBD)-7
GENERAL DESCRIPTION
S068001A17
D: PREPARATION TOOL
ILLUSTRATION
B2M3876
22771AA030
SELECT MONITOR KIT
B2M3877
EN(SOHCw/oOBD)-8
GENERAL DESCRIPTION
MEMO:
EN(SOHCw/oOBD)-9

S068507

A: LOCATION
1. MODULE
S068507A13 S068507A1301
S2M2105A
S2M2106A
(3) Read memory connector (4) Test mode connector (5) Data link connector
(6) Transmission control module (TCM)
EN(SOHCw/oOBD)-10
S2M0533D
S2M2107A
S2M2108A
S2M2157C
B3M1666H
B3M1652C
EN(SOHCw/oOBD)-11
2. SENSOR
S068507A1302
S2M1247A
(1) Engine coolant temperature sensor (2) Intake air temperature sensor
(3) Throttle position sensor (4) Pressure sensor (5) Knock sensor
(6) Crankshaft position sensor
EN(SOHCw/oOBD)-12
S2M1248A
S2M1249A
S2M1250A
S2M1250B
S2M0515B S2M0213K
EN(SOHCw/oOBD)-13
S2M2257A
(1) Front exhaust pipe RH (2) Front exhaust pipe LH (3) Front catalytic converter
(4) Oxygen sensor (5) Center exhaust pipe (6) Resonance chamber
(7) Rear catalytic converter (8) Rear exhaust pipe (9) Muffler
EN(SOHCw/oOBD)-14
S2M0264C
S2M0267C
S2M0654C
EN(SOHCw/oOBD)-15
3. SOLENOID VALVE, EMISSION CONTROL SYSTEM PARTS AND IGNITION SYSTEM PARTS S068507A1303
S2M1782A
(1) CO resistor (General spec. vehicles)
(2) Purge control solenoid valve (3) Idle air control solenoid valve
(4) Ignition coil and ignitor ASSY
EN(SOHCw/oOBD)-16
S2M1764A
S2M1252A
S2M1250C
S2M1253A
EN(SOHCw/oOBD)-17
S2M2105B
S2M2106B
(1) Fuel pump
(2) Main relay
(3) Fuel pump relay
EN(SOHCw/oOBD)-18
S2M0277B
S2M0278C
EN(SOHCw/oOBD)-19

S068526

S068526A08
S2M0669A
S2M0861A
EN(SOHCw/oOBD)-20

ECM Connec- Terminal tor No. No. E22 E22 E22 E22 E22 E22 E22 E22 E22 B84 B84 E22 20 14 21 18 25 22 23 25 22 22 15 24 CHECK BOARD Connec- Terminal tor No. No. B B B A B B B B B D C B 26 19 25 15 21 24 23 21 24 47 38 22 Signal (V) Ignition SW ON Engine ON (Engine OFF) (Idling) 0 0 0 3.4 3.6 5 7 to +7 0 0 1.2 1.8 5
Content Signal Crankshaft (+) position Signal sensor () Shield Signal Power Pressure supply sensor GND Throttle position sensor Signal
Note Sensor output waveform After warm-up 5 and 0 are repeatedly displayed when vehicle is driven. After warm-up On MT vehicles; switch is ON when gear is in neutral position. On AT vehicles; switch is ON when shift is in N or P position When connected: 0 When connected: 0 Ignition switch OFF: 10 13 Waveform Waveform
0 0 Fully closed: 0.2 1.0 Fully open: 4.2 4.7 5 0 0.6, or less 0 0.4 2.4 5 0 0 0.9 0 0.4 2.4
Power supply GND Signal Oxygen sensor Shield Engine coolant temperature sensor Vehicle speed sensor Intake air temperature sensor A/C switch Ignition switch Neutral position switch (MT)
B84
33
53
0 or 5
0 or 5
E22 B84 B84 28*
17 27 19
B D D 58*
16 59 50
2.3 2.5 ON: 10 13 OFF: 0 10 13
1.4 1.6 ON: 13 14 OFF: 0 13 14
ON: 10 13 OFF: 0 B84 26 D 60 ST: 10 13 ON: 0 OFF: 13 14 E22 E22 B84 B84 B84 B84 2 4 2 4 E22 E22 E22 E22 19* 20 34 9 17 3 9 7 6 16 21 28 B B D D D B C A A A A 50* 49 52 27 36 5 12 1 2 17 25 58 2.5 0 10 13 10 13 10 13 10 13 0 0 10 13 10 13 2.5 0 13 14 13 14 13 14 13 14 1 3.4 1 3.4 1 14 1 14
Neutral position switch (AT) Signal Shield Test mode connector Read memory connector Back-up power supply Knock sensor Control unit power supply # # Fuel injec- # tor # Ignition control 1, 3, 1, 3, # # # #
EN(SOHCw/oOBD)-21

ECM Connec- Terminal tor No. No. E22 B84 B84 B84 B84 B84 B84 B84 B84 B84 B84 E22 E22 B84 B84 E22 E22 E22 B84 4 3 11 2 10 5 13 6 18 1 29 5 26 16 24 32 10 11 12 21 23 31 CHECK BOARD Connec- Terminal tor No. No. A C C C C C C B D C D A B C C D A A B D 4 33 42 34 43 31 40 30 51 35 57 3 20 37 45 54 11 10 9 25 46 55 Signal (V) Ignition SW ON Engine ON (Engine OFF) (Idling) ON: 0.5, or less OFF: 10 13 ON: 0.5, or less OFF: 10 13 ON: 0.5, or less OFF: 10 13 ON: 0.5, or less OFF: 10 13 10 13 8 5 3.4 3.6 ON: 1, or less OFF: 10 13 10 13 MT: 0 AT: 5 0 0 0 1 13 0.5, or less ON: 0.5, or less OFF: 13 14 ON: 0.5, or less OFF: 13 14 ON: 0.5, or less OFF: 13 14 13 14
Content Idle air control solenoid valve Fuel pump relay control A/C relay control Radiator fan relay 1 Radiator fan relay 2 Self-shutoff control Malfunction indicator lamp Engine speed output Torque control signal VCC signal AT load signal Purge control solenoid valve Power steering pressure switch MT/AT identification Select monitor signal GND (ignition system) GND (power supply) GND (control systems) Immobilizer serial line *: RHD
Note Waveform
With A/C vehicles only Light ON: 1, or less Light OFF: 10 14 0 13, or more Waveform 89 AT and without cata5 lyst vehicles only 1.2 1.8 Waveform 13 14 When connecting test mode connector ON: 0 OFF: 13 14 MT: 0 AT: 5 0 0 0
EN(SOHCw/oOBD)-22
ENGINE CONTROL MODULE (ECM) I/O SIGNAL B: HOW TO CHECK I/O SIGNAL FOR ECM
S068526H57
When checking I/O signal, connect ST between ECM and ECM connector. 1) Prepare the ST. ST 498307600 CHECK BOARD KIT
S2M0859A
(1) (2)
CHECK BOARD CHECK BOARD ADAPTER
2) Turn ignition switch to OFF. 3) Disconnect connectors from ECM. 4) Connect connectors of CHECK BOARD ADAPTER to ECM and CHECK BOARD. 5) Connect engine harness and bulkhead harness connectors to CHECK BOARD.
EN(SOHCw/oOBD)-23

S068503

A: OPERATION
S068503A16
5) Turn ignition switch to ON (engine OFF) and Subaru Select Monitor switch to ON.

1) Prepare Subaru Select Monitor kit.
S2M0288A
S2M0285
2) Connect diagnosis cable to Subaru Select Monitor. 3) Insert cartridge into Subaru Select Monitor.
2. READ DIAGNOSTIC TROUBLE CODE (DTC) FOR ENGINE. S068503A1602

Refer to Read Diagnostic Trouble Code for information about how to indicate DTC. <Ref. to EN(SOHCw/oOBD)-27 Read Diagnostic Trouble Code.>
S2M0286A
4) Connect Subaru Select Monitor to data link connector. (1) Data link connector located in the lower portion of the instrument panel (on the driver s side).
S2M2157
(2) Connect diagnosis cable to data link connector. CAUTION: Do not connect scan tools except for Subaru Select Monitor.
EN(SOHCw/oOBD)-24

3. READ CURRENT DATA SHOWN ON DISPLAY.
S068503A1603
1) On the Main Menu display screen, select the {2. Each System Check} and press the [YES] key. 2) On the System Selection Menu display screen, select the {Engine Control System} and press the [YES] key. 3) Press the [YES] key after displayed the information of engine type. 4) On the Engine Diagnosis display screen, select the {1. Current Data Display & Save} and press the [YES] key. 5) On the Data Display Menu display screen, select the {1. 12 Data Display} and press the [YES] key. 6) Using the scroll key, move the display screen up or down until the desired data is shown. A list of the support data is shown in the following table.
Contents Battery voltage Vehicle speed signal Engine speed signal Engine coolant temperature signal Ignition timing signal Throttle position signal Throttle position signal Injection pulse width Idle air control signal Engine load data Front oxygen sensor output signal A/F correction coefficient Knock sensor signal CO resistor Intake manifold absolute/relative pressure signal Intake air temperature signal Canister purge control solenoid valve duty ratio Idle air control solenoid valve current Ignition switch signal Test mode connector signal Neutral position switch signal Air conditioning switch signal Air conditioning relay signal Radiator main fan relay signal Fuel pump relay signal Knocking signal Radiator sub fan relay signal Engine torque control signal Front oxygen sensor rich signal Crankshaft position sensor signal Electrical load signal Read memory connector signal Power steering pressure signal AT vehicle ID signal Idle switch Canister purge control solenoid valve Torque permission signal Unit of measure V km/h or MPH rpm C or F deg % V ms % % V % deg V mmHg or kPa or inHg C or F % mA ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF
EN(SOHCw/oOBD)-25

S068503A1604

Contents Ignition switch signal Test mode connector signal Neutral position switch signal Air conditioning switch signal Air conditioning relay signal Radiator main fan relay signal Fuel pump relay signal Knocking signal Radiator sub fan relay signal Engine torque control signal Front oxygen sensor rich signal Crankshaft position sensor signal Electrical load signal Read memory connector signal Power steering pressure signal AT vehicle ID signal Idle switch Canister purge control solenoid valve Torque permission signal
Message ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF
LED ON requirements When ignition switch is turned ON. When test mode connector is connected. When neutral position signal is entered. When air conditioning switch is turned ON. When air conditioning relay is in function. When radiator main fan relay is in function. When fuel pump relay is in function. When knocking signal is entered. When radiator sub fan relay is in function. When engine torque control signal is entered. When front oxygen sensor mixture ratio is rich. When crankshaft position sensor signal is entered. When the lighting switch, blower fan switch or rear defogger switch is turned ON. When read memory connector is connected. When steering wheel is turned. When AT identification signal is entered. When throttle sensor sends signal that throttle opening angle is in idle position. When canister purge control solenoid valve is in function. When torque permission signal is entered.
EN(SOHCw/oOBD)-26

A: OPERATION
S068508A16
S068508
S068508A1601
1) On the Main Menu display screen, select the {Each System Check} and press the [YES] key. 2) On the System Selection Menu display screen, select the {Engine Control System} and press the [YES] key. 3) Press the [YES] key after displayed the information of engine type. 4) On the Engine Diagnosis display screen, select the {Diagnostic Code(s) Display} and press the [YES] key. 5) On the Diagnostic Code(s) Display display screen, select the {Current Diagnostic Code(s)} or {History Diagnostic Code(s)} and press the [YES] key. NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. For detailed concerning diagnostic trouble codes, refer to the List of Diagnostic Trouble Code (DTC). <Ref. to EN(SOHCw/oOBD)-65 LIST, LIST of Diagnostic Trouble Code (DTC).>

No. 1 Step CHECK STATUS OF CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL). 1) Turn ignition switch to OFF. 2) Connect read memory connector. <Ref. to EN(SOHCw/oOBD)-10 LOCATION, Electrical Components Location.> 3) Turn ignition switch to ON.
S068508A1602
CHECK DIAGNOSTIC TROUBLE CODE (DTC).
No Check the following and repair if necessary. NOTE: Open or short circuit in engine control module power supply or ground line Open or short circuit in CHECK ENGINE malfunction indicator lamp Does the MIL indicate diag- Record diagnostic Complete read diagnostic trouble nostic trouble code (DTC)? trouble code (DTC). Then turn code. Turn ignition switch to OFF and ignition switch to disconnect read OFF, disconnect read memory con- memory connector. nector.
Yes Go to step 2.
EN(SOHCw/oOBD)-27
The CHECK ENGINE malfunction indicator lamp (MIL) flashes the code corresponding to the faulty parts. The long segment (1.3 seconds ON) indicates a ten, and the short segment (0.2 seconds ON) signifies one. And middle segment (0.5 seconds ON) means OK code. NOTE: For detailed concerning diagnostic trouble codes, refer to the List of Diagnostic Trouble Code (DTC). <Ref. to EN(SOHCw/oOBD)-65 LIST, LIST of Diagnostic Trouble Code (DTC).>
S2M1768A
EN(SOHCw/oOBD)-28
INSPECTION MODE
8. Inspection Mode
A: OPERATION
S068510A16
S068510

S068510A1602
1. PREPARATIONS FOR THE INSPECTION MODE S068510A1601

After performing diagnostics and clearing the memory, check for any remaining unresolved trouble data. 1) Connect test mode connector (green).
S2M2146
2) Connect Subaru select monitor to data link connector. <Ref. to EN(SOHCw/oOBD)-10 LOCATION, Electrical Components Location.> 3) Turn ignition switch to ON (engine OFF) and Subaru select monitor switch to ON.
S2M0288A
B2M2969A
4) On the Main Menu display screen, select the {2. Each System Check} and press the [YES] key. 5) On the System Selection Menu display screen, select the {Engine Control System} and press the [YES] key. 6) Press the [YES] key after displayed the information of engine type. 7) On the Engine Diagnosis display screen, select the {6. Dealer Check Mode Procedure} and press the [YES] key. 8) When the Perform Inspection (Dealer Check) Mode? is shown on the display screen, press the [YES] key. 9) Perform subsequent procedures as instructed on the display screen. If trouble still remains in the memory, the corresponding diagnostic trouble code (DTC) appears on the display screen.
EN(SOHCw/oOBD)-29
INSPECTION MODE
On AWD vehicles, release the parking brake. The speed difference between front and rear wheels may light either the ABS warning light, but this indicates no malfunctions. When engine control diagnosis is finished, perform the ABS memory clearance procedure of self-diagnosis system.
NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. For detailed concerning diagnostic trouble codes, refer to the DIAGNOSTIC TROUBLE CODE (DTC) LIST. <Ref. to EN(SOHCw/ oOBD)-65 LIST, List of Diagnostic Trouble Code (DTC).>

No. 1 Step CHECK STATUS OF CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL). 1) Start and warm-up the engine. 2) Turn ignition switch to OFF. 3) Set shift lever to neutral position (MT vehicles), or set selector lever to P position (AT vehicles). 4) Connect test mode connector (green). 5) Turn ignition switch to ON.
S068510A1603
CHECK DIAGNOSTIC TROUBLE CODE (DTC). 1) Set selector lever to N position, and then set selector lever to P position again (AT vehicles only). 2) Start the engine.
CHECK DIAGNOSTIC TROUBLE CODE (DTC). 1) Drive vehicle at speed greater than 11 km/h (7 MPH) for at least one minute. 2) Warm-up engine above 2,000 rpm.
No Check the following and repair if necessary. NOTE: Open or short circuit in engine control module power supply or ground line Open or short circuit in CHECK ENGINE malfunction indicator lamp Does the MIL indicate diag- Record diagnostic Go to step 3. nostic trouble code (DTC)? trouble code (DTC) and inspect using DTC. <Ref. to EN(SOHCw/ oOBD)-68 Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Does the MIL indicate diag- Record diagnostic Turn ignition switch to OFF. nostic trouble code (DTC)? trouble code (DTC) and inspect Disconnect test using DTC. <Ref. mode connector. Complete inspecto EN(SOHCw/ tion mode. oOBD)-68 Diagnostic Procedure NOTE: When on-board with Diagnostic diagnosis system Trouble Code indicates no (DTC).> trouble, the trouble is in a different symptom.
Yes Go to step 2.
EN(SOHCw/oOBD)-30
CLEAR MEMORY MODE

A: OPERATION
S068513A16
S068513
S068513A1601
1) On the Main Menu display screen, select the {2. Each System Check} and press the [YES] key. 2) On the System Selection Menu display screen, select the {Engine Control System} and press the [YES] key. 3) Press the [YES] key after displayed the information of engine type. 4) On the Engine Diagnosis display screen, select the {Clear Memory} and press the [YES] key. 5) When the Done and Turn Ignition Switch OFF are shown on the display screen, turn the Subaru Select Monitor and ignition switch to OFF. NOTE: After the memory has been cleared, the ISC must be initialized. To do this, turn the ignition switch to the ON position. Wait 3 seconds before starting the engine. For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.

No. 1 Step CHECK STATUS OF CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL). 1) Turn ignition switch to OFF. 2) Set shift lever to neutral position (MT vehicles), or set selector lever to P position (AT vehicles). 3) Connect test mode connector and read memory connector. 4) Turn ignition switch to ON.
S068513A1602
CHECK DIAGNOSTIC TROUBLE CODE (DTC). 1) Set selector lever to N position, and then set selector lever to P position again (AT vehicles only). 2) Start the engine. 3) Drive vehicle at speed greater than 11 km/h (7 MPH) for at least one minute. 4) Warm-up engine above 2,000 rpm.
No Check the following and repair if necessary. NOTE: Open or short circuit in engine control module power supply or ground line Open or short circuit in CHECK ENGINE malfunction indicator lamp Does the MIL indicate diag- Record diagnostic Turn ignition switch to OFF. nostic trouble code (DTC)? trouble code. Repair the trouble Disconnect read <Ref. to EN(SOHCw/ memory conneccause. <Ref. to oOBD)-65 LIST, List of tor and test mode EN(SOHCw/ Diagnostic Trouble Code connector. ComoOBD)-68 Diag(DTC).> nostic Procedure plete clear memory mode. with Diagnostic Trouble Code (DTC).>
Yes Go to step 2.
EN(SOHCw/oOBD)-31

A: OPERATION
S068528A16
S068528
1) Connect test mode connector at the lower portion of instrument panel (on the driver s side), to the side of the center console box.
S2M2146
2) Each valve functions when ignition switch is turned to ON (engine OFF). A list of the support portion is shown in the following table.
Compulsory Compulsory Compulsory Compulsory Contents fuel pump relay operation check purge control solenoid valve operation check radiator fan relay operation check air conditioning relay operation check
EN(SOHCw/oOBD)-32

A: PROCEDURE
S068653E45
S068653
1. Activation of check engine malfunction indicator lamp (MIL). <Ref. to EN(SOHCw/oOBD)-33 ACTIVATION OF CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL), Engine Malfunction Indicator Lamp (MIL).> 2. Check engine malfunction indicator lamp (MIL) does not come on. <Ref. to EN(SOHCw/oOBD)-34 CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT COME ON., Engine Malfunction Indicator Lamp (MIL).> 3. Check engine malfunction indicator lamp (MIL) does not go off. <Ref. to EN(SOHCw/oOBD)-38 CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT GO OFF., Engine Malfunction Indicator Lamp (MIL).> 4. Check engine malfunction indicator lamp (MIL) does not blink at a cycle of 3 Hz. <Ref. to EN(SOHCw/oOBD)-40 CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT BLINK AT A CYCLE OF 3 HZ., Engine Malfunction Indicator Lamp (MIL).> 5. Check engine malfunction indicator lamp (MIL) remains blinking at a cycle of 3 Hz. <Ref. to EN(SOHCw/oOBD)-44 CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) REMAINS BLINKING AT A CYCLE OF 3 HZ., Engine Malfunction Indicator Lamp (MIL).>
B: ACTIVATION OF CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL)

S068653E89
1) When ignition switch is turned to ON (engine off), the CHECK ENGINE malfunction indicator lamp (MIL) in the combination meter illuminates. NOTE: If the MIL does not illuminate, perform diagnostics of the CHECK ENGINE light circuit or the combination meter circuit. <Ref. to IDI-15 Combination Meter Assembly.>
2) After starting the engine, the MIL goes out. If it does not, either the engine or the emission control system is malfunctioning. <Ref. to EN(SOHCw/ oOBD)-2 PROCEDURE, Basic Diagnostic Procedure.>
OBD0053A
S2M2107
OBD0055A
EN(SOHCw/oOBD)-33
S068653E90
S2M2109
EN(SOHCw/oOBD)-34

No. 1 Step Check Is the voltage less than 1 CHECK OUTPUT SIGNAL FROM ECM. 1) Disconnect connector from ECM, then con- V? nect check board. <Ref. to EN(SOHCw/ oOBD)-23, HOW TO CHECK I/O SIGNAL FOR ECM, Engine Control Module (ECM) I/O Signal.> 2) Turn ignition switch to ON. 3) Measure voltage between ECM connector and engine ground. Connector & terminal (C) No. 40 (+) Engine ground (): CHECK POOR CONTACT. Does the MIL come on when shaking or pulling ECM connector and harness? CHECK ECM CONNECTOR. Is ECM connector correctly connected? Yes Go to step 4.
No Go to step 2.
Repair poor contact in ECM connector. Replace ECM. <Ref. to FU(SOHCw/ oOBD)-38, Engine Control Module.> Go to step 5.
Go to step 3.
Is there poor contact in CHECK POOR CONTACT. Check poor contact in combination meter con- combination meter connector? nector. <Ref. to IDI-15, Combination Meter Assembly.>
Repair poor contact in combination meter connector.
Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ECM and combination meter connector Poor contact in coupling connector (i2) Go to step 6.
EN(SOHCw/oOBD)-35
No. 6

No Check the following and repair if necessary. NOTE: Broken down ignition relay. Blown out fuse (No. 5). If replaced fuse (No. 5) blows easily, check the harness for short circuit of harness between fuse (No. 5) and ignition relay connector. Open or short circuit in harness between fuse (No. 5) and battery terminal Open circuit in harness between fuse (No. 5) and ignition relay connector Poor contact in coupling connector (i1) Poor contact in ignition relay connector Poor contact in ignition switch connector Replace bulb or combination meter.
Step Check Yes Is voltage more than 10 V? Go to step 7. CHECK HARNESS BETWEEN COMBINATION METER AND IGNITION SWITCH CONNECTOR. 1) Turn ignition switch to ON. 2) Measure voltage between combination meter connector and chassis ground. Connector & terminal (i10) No. 2 (+) Chassis ground ():
Is there poor contact in CHECK POOR CONTACT. Check poor contact in combination meter con- combination meter connector? nector. <Ref. to IDI-15, Combination Meter Assembly.>
Repair poor contact in combination meter connector.
EN(SOHCw/oOBD)-36

MEMO:
EN(SOHCw/oOBD)-37

S068653E91
S2M2109
No. 1
No Replace ECM. <Ref. to FU(SOHCw/ oOBD)-38, Engine Control Module.>
EN(SOHCw/oOBD)-38

MEMO:
EN(SOHCw/oOBD)-39
S068653E92
DIAGNOSIS: The CHECK ENGINE malfunction indicator lamp (MIL) circuit is open or shorted. Test mode connector circuit is in open. TROUBLE SYMPTOM: When inspection mode, MIL does not blink at a cycle of 3 Hz.
EN(SOHCw/oOBD)-40

WIRING DIAGRAM:
S2M2110
No. 1
Step CHECK STATUS OF CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL). 1) Turn ignition switch to OFF. 2) Disconnect test mode connector. 3) Turn ignition switch to ON.
Yes Go to step 2.
No Repair the MIL circuit. <Ref. to EN(SOHCw/ oOBD)-34, CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT COME ON., Engine Malfunction Indicator Lamp (MIL).>
EN(SOHCw/oOBD)-41
No. 2

Check Is voltage less than 1 V? Yes Go to step 3. No Go to step 5.
Step CHECK OUTPUT SIGNAL FROM ECM. Measure voltage between test mode connector and chassis ground. Connector & terminal (B75) No. 1 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND TEST MODE CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM. 3) Measure resistance of harness between ECM and test mode connector. Connector & terminal (B84) No. 19 (B75) No. 1:
Go to step 4.
CHECK POOR CONTACT. Check poor contact in ECM connector.
CHECK HARNESS BETWEEN ECM AND TEST MODE CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM. 3) Measure resistance of harness between ECM and test mode connector. Connector & terminal (B84) No. 15 (B76) No. 1:
Go to step 6.
CHECK POOR CONTACT. Check poor contact in ECM connector.
Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ECM and test mode connector Poor contact in coupling connector (B180) Replace ECM. <Ref. to FU(SOHCw/ oOBD)-38, Engine Control Module.> Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ECM and test mode connector Poor contact in coupling connector (B138) Replace ECM. <Ref. to FU(SOHCw/ oOBD)-38, Engine Control Module.>
EN(SOHCw/oOBD)-42

MEMO:
EN(SOHCw/oOBD)-43
S068653E93
DIAGNOSIS: Test mode connector circuit is shorted. TROUBLE SYMPTOM: Even though test mode connector is disconnected, MIL blinks at a cycle of 3 Hz when ignition switch is turned to ON. WIRING DIAGRAM:
S2M2110
EN(SOHCw/oOBD)-44

No. 1 Step CHECK HARNESS BETWEEN ECM CONNECTOR AND ENGINE GROUNDING TERMINAL. 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM. 3) Measure resistance of harness between ECM connector and engine ground. Connector & terminal (B84) No. 19 Engine ground: Check Is resistance less than 5 ? Yes Repair short circuit in harness between ECM and test mode connector.
No Replace ECM. <Ref. to FU(SOHCw/ oOBD)-38, Engine Control Module.>
EN(SOHCw/oOBD)-45
MEMO:
EN(SOHCw/oOBD)-46

A: PROCEDURE
S068533E45
S068533
1. Inspection of starter motor circuit. <Ref. to EN(SOHCw/oOBD)-48 STARTER MOTOR CIRCUIT, Diagnostics for Engine Starting Failure.> 2. Inspection of ECM power supply and ground line. <Ref. to EN(SOHCw/oOBD)-52 CONTROL MODULE POWER SUPPLY AND GROUND LINE, Diagnostics for Engine Starting Failure.> 3. Inspection of ignition control system. <Ref. to EN(SOHCw/oOBD)-54 IGNITION CONTROL SYSTEM, Diagnostics for Engine Starting Failure.> 4. Inspection of fuel pump circuit. <Ref. to EN(SOHCw/oOBD)-58 FUEL PUMP CIRCUIT, Diagnostics for Engine Starting Failure.> 5. Inspection of fuel injector circuit. <Ref. to EN(SOHCw/oOBD)-62 FUEL INJECTOR CIRCUIT, Diagnostics for Engine Starting Failure.>
EN(SOHCw/oOBD)-47

S068533E94
CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY and INSPECTION MODES. <Ref. to EN(SOHCw/oOBD)-31 OPERATION, Clear Memory Mode.> and <Ref. to EN(SOHCw/ oOBD)-29 OPERATION, Inspection Mode.> WIRING DIAGRAM:
S2M2111
EN(SOHCw/oOBD)-48

No. 1 Step CHECK INPUT SIGNAL FOR STARTER MOTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from starter motor. 3) Turn ignition switch to ST. 4) Measure power supply voltage between starter motor connector terminal and engine ground. Connector & terminal (B14) No. 1 (+) Engine ground (): NOTE: On AT vehicles, place the select lever in the P or N position. CHECK GROUND CIRCUIT OF STARTER MOTOR. 1) Turn ignition switch to OFF. 2) Disconnect terminal from starter motor. 3) Measure resistance of ground cable between ground cable terminal and engine ground. CHECK HARNESS BETWEEN ECM AND STARTER MOTOR CIRCUIT. 1) Turn ignition switch to OFF. 2) Measure resistance between starter motor and ECM. Connector & terminal (B14) No. 1 Engine ground: CHECK HARNESS BETWEEN BATTERY AND IGNITION SWITCH CONNECTOR. 1) Ignition switch to OFF. 2) Disconnect connector from ignition switch. 3) Measure power supply voltage between ignition switch connector and chassis ground. Connector & terminal (B72) No. 1 (+) Chassis ground (): Check Yes Is the voltage more than 10 Go to step 2. V?
No Go to step 3.
Check starter motor. <Ref. to SC-8, INSPECTION, Starter.>
Go to step 4.
CHECK HARNESS BETWEEN BATTERY AND IGNITION SWITCH CONNECTOR. 1) Connect connector to ignition switch. 2) Turn ignition switch to START. 3) Measure voltage between ignition switch and chassis ground. Connector & terminal (B72) No. 3 (+) Chassis ground (): CHECK TRANSMISSION TYPE.
NOTE: Check the following and repair if necessary. Blown out fuse (SBF-1, SBF-4) If replaced fuse (SBF-1, SBF-4) blows easily, check the harness for short circuit of harness between fuse and ignition switch connector. Open circuit in harness between ignition switch and battery Replace ignition switch.
Is the vehicle AT?
Go to step 7.
Repair open circuit between ignition switch and starter motor circuit.
EN(SOHCw/oOBD)-49
No. 7

Check Is the resistance less than 1 ? Yes No Go to step 8. Repair open circuit in harness between starter motor and ignition switch connector.
Step CHECK INHIBITOR SWITCH CIRCUIT. 1) Turn ignition switch to OFF. 2) Place the select lever in the P or N position. 3) Separate transmission harness connector. 4) Measure resistance between transmission harness connector receptacles terminals. Connector & terminal (T3) No. 11 No. 12: CHECK TRANSMISSION HARNESS. 1) Disconnect connector from inhibitor switch. 2) Measure resistance of harness between transmission harness and inhibitor switch connector. Connector & terminal (T3) No. 11 (T7) No. 7: (T3) No. 12 (T7) No. 12: CHECK POOR CONTACT. Check poor contact in inhibitor switch connector.
Go to step 9.
Repair open circuit in harness between transmission harness and inhibitor switch connector.
Replace inhibitor switch.
EN(SOHCw/oOBD)-50

MEMO:
EN(SOHCw/oOBD)-51

S068533E37
S2M2112
No. 1
Step Check Is the resistance less than CHECK MAIN RELAY. 10 ? 1) Turn ignition switch to OFF. 2) Remove main relay. 3) Connect battery to main relay terminals No. 1 and No. 2. 4) Measure resistance between main relay terminals. Terminals No. 3 No. 5:
Yes Go to step 2.
EN(SOHCw/oOBD)-52

No. 2 Step CHECK MAIN RELAY. Measure resistance between main relay terminals. Terminals No. 4 No. 6: CHECK GROUND CIRCUIT OF ECM. 1) Disconnect connectors from ECM. 2) Measure resistance of harness between ECM and engine ground. Connector & terminal (E22) No. 10 Engine ground: (E22) No. 11 Engine ground: (E22) No. 12 Engine ground: (E22) No. 21 Engine ground: CHECK INPUT VOLTAGE OF ECM. 1) Turn ignition switch to ON. 2) Measure voltage between ECM connector and engine ground. Connector & terminal (B84) No. 28 (+) Engine ground (): CHECK INPUT VOLTAGE OF MAIN RELAY. Measure voltage between main relay connector and chassis ground. Connector & terminal (B47) No. 1 (+) Chassis ground (): (B47) No. 5 (+) Chassis ground (): (B47) No. 6 (+) Chassis ground (): CHECK INPUT VOLTAGE OF ECM. Measure voltage between ECM connector and engine ground. Connector & terminal (B84) No. 34 (+) Engine ground (): CHECK INPUT VOLTAGE OF ECM. 1) Turn ignition switch to OFF. 2) Connect main relay connector. 3) Measure voltage between ECM connector and engine ground. Connector & terminal (B84) No. 5 (+) Engine ground (): CHECK INPUT VOLTAGE OF ECM. 1) Connect ST. <Ref. to EN(SOHCw/oOBD)23, HOW TO CHECK I/O SIGNAL FOR ECM, Engine Control Module (ECM) I/O Signal.> ST 498307600 CHECK BOARD KIT 2) Measure voltage between ECM connector and engine ground. Connector & terminal (B) No. 27 (+) Engine ground (): (C) No. 36 (+) Engine ground (): Check Is the resistance less than 10 ? Yes Go to step 3.
Go to step 4.
Repair open circuit in harness between ECM connector and engine grounding terminal.
Repair open or ground short circuit of power supply circuit.
Repair open or ground short circuit of power supply circuit. Repair open or ground short circuit between ECM connector and main relay connector. Repair open or ground short circuit between ECM connector and main relay connector.
Is the voltage more than 10 Check ignition V? control system. <Ref. to EN(SOHCw/ oOBD)-54, IGNITION CONTROL SYSTEM, Diagnostics for Engine Starting Failure.>
EN(SOHCw/oOBD)-53

S068533E95
S2M2113
EN(SOHCw/oOBD)-54

No. 1 Step CHECK IGNITION SYSTEM FOR SPARKS. 1) Remove plug cord cap from each spark plug. 2) Install new spark plug on plug cord cap. CAUTION: Do not remove spark plug from engine. 3) Contact spark plugs thread portion on engine. 4) While opening throttle valve fully, crank engine to check that spark occurs at each cylinder. CHECK POWER SUPPLY CIRCUIT FOR IGNITION COIL & IGNITOR ASSEMBLY. 1) Turn ignition switch to OFF. 2) Disconnect connector from ignition coil & ignitor assembly. 3) Turn ignition switch to ON. 4) Measure power supply voltage between ignition coil & ignitor assembly connector and engine ground. Connector & terminal (E12) No. 1 (+) Engine ground (): Check Does spark occur at each cylinder?
No Go to step 2.
Yes Check fuel pump system. <Ref. to EN(SOHCw/ oOBD)-58, FUEL PUMP CIRCUIT, Diagnostics for Engine Starting Failure.>
CHECK HARNESS OF IGNITION COIL & IGNITOR ASSEMBLY GROUND CIRCUIT. 1) Turn ignition switch to OFF. 2) Measure resistance between ignition coil & ignitor assembly connector and engine ground. Connector & terminal (E12) No. 3 Engine ground:
Go to step 4.
CHECK IGNITION COIL & IGNITOR ASSEMBLY. 1) Remove spark plug cords. 2) Measure resistance between spark plug cord contact portions to check secondary coil. Terminals No. 1 No. 2: No. 3 No. 4: CHECK INPUT SIGNAL FOR IGNITION COIL & IGNITOR ASSEMBLY. Check if voltage varies synchronously with engine speed when cranking, while monitoring voltage between ignition coil & ignitor assembly connector and engine ground. Connector & terminal (E12) No. 2 (+) Engine ground (): (E12) No. 4 (+) Engine ground ():
Go to step 5.
Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ignition coil & ignitor assembly, and ignition switch connector Poor contact in coupling connector (B20) Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ignition coil & ignitor assembly connector and engine grounding terminal Replace ignition coil & ignitor assembly. <Ref. to IG(SOHCw/ oOBD)-9, Ignition Coil and Ignitor Assembly.> Replace ignition coil & ignitor assembly.
EN(SOHCw/oOBD)-55
No. 6

Check Is the resistance less than 1 ? Yes Go to step 7. No Repair open circuit in harness between ECM and ignition coil & ignitor assembly connector.
Step CHECK HARNESS BETWEEN ECM AND IGNITION COIL & IGNITOR ASSEMBLY CONNECTOR. 1) Disconnect connector from ECM. 2) Measure resistance of harness between ECM and ignition coil & ignitor assembly connector. Connector & terminal (E22) No. 9 (E12) No. 4: (E22) No. 3 (E12) No. 2: (E22) No. 10 (E12) No. 3: CHECK HARNESS BETWEEN ECM AND IGNITION COIL & IGNITOR ASSEMBLY CONNECTOR. Measure resistance of harness between ECM and engine ground. Connector & terminal: (E22) No. 3 Engine ground: (E22) No. 9 Engine ground: CHECK POOR CONTACT. Check poor contact in ECM connector.
Repair ground short circuit in harness between ECM and ignition coil & ignitor assembly connector. Check fuel pump circuit. <Ref. to EN(SOHCw/ oOBD)-58, FUEL PUMP CIRCUIT, Diagnostics for Engine Starting Failure.>
EN(SOHCw/oOBD)-56

MEMO:
EN(SOHCw/oOBD)-57

S068533E96
S2M2114
EN(SOHCw/oOBD)-58

No. 1 Step CHECK OPERATING SOUND OF FUEL PUMP. 1) Connect test mode connector. 2) Turn ignition switch to ON. 3) Make sure that fuel pump is in operation. NOTE: For the procedure, refer to the COMPULSORY VALVE OPERATION CHECK MODE. <Ref. to EN(SOHCw/oOBD)-32, Compulsory Valve Operation Check Mode.> CHECK GROUND CIRCUIT OF FUEL PUMP. 1) Turn ignition switch to OFF. 2) Remove fuel pump access hole lid located on the luggage compartment floor. 3) Disconnect connector from fuel pump. 4) Measure resistance of harness connector between fuel pump and chassis ground. Connector & terminal (R58) No. 4 Chassis ground: Check Does fuel pump produce operating sound?
Yes No Check fuel injec- Go to step 2. tor circuit. <Ref. to EN(SOHCw/ oOBD)-62, FUEL INJECTOR CIRCUIT, Diagnostics for Engine Starting Failure.>
Go to step 3.
CHECK POWER SUPPLY TO FUEL PUMP. 1) Turn ignition switch to ON. 2) Measure voltage of power supply circuit between fuel pump connector and chassis ground. Connector & terminal (R58) No. 1 (+) Chassis ground (): CHECK HARNESS BETWEEN FUEL PUMP AND FUEL PUMP RELAY CONNECTOR. 1) Turn ignition switch to OFF. 2) Measure resistance of harness between fuel pump and fuel pump relay connector. Connector & terminal (R58) No. 1 (B46) No. 4:
Is the voltage more than 10 Replace fuel V? pump. <Ref. to FU(SOHCw/ oOBD)-50, Fuel Pump.>
Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between fuel pump connector and chassis grounding terminal Poor contact in coupling connector (R15) Go to step 4.
Go to step 5.
CHECK HARNESS BETWEEN FUEL PUMP AND FUEL PUMP RELAY CONNECTOR. Measure resistance of harness between fuel pump and fuel pump relay connector. Connector & terminal (R58) No. 1 Chassis ground:
Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between fuel pump and fuel pump relay connector Poor contact in coupling connectors (R15) and (B97) Repair ground short circuit in harness between fuel pump and fuel pump relay connector.
EN(SOHCw/oOBD)-59
No. 6

Check Is the resistance less than 10 ? Yes Go to step 7. No Replace fuel pump relay. <Ref. to FU(SOHCw/ oOBD)-40, Fuel Pump Relay.>
Step CHECK FUEL PUMP RELAY. 1) Disconnect connector from fuel pump relay. 2) Remove fuel pump relay from bracket. 3) Connect battery to fuel pump relay connector terminals No. 1 and No. 3. 4) Measure resistance between connector terminals of fuel pump relay. Terminals No. 2 No. 4: CHECK HARNESS BETWEEN ECM AND FUEL PUMP RELAY CONNECTOR. 1) Disconnect connectors from ECM. 2) Measure resistance of harness between ECM and fuel pump relay connector. Connector & terminal (B84) No. 3 (B46) No. 3: CHECK POOR CONTACT. Check poor contact in ECM connector.
Go to step 8.
Repair open circuit in harness between ECM and fuel pump relay connector.
Check fuel injector circuit. <Ref. to EN(SOHCw/ oOBD)-62, FUEL INJECTOR CIRCUIT, Diagnostics for Engine Starting Failure.>
EN(SOHCw/oOBD)-60

MEMO:
EN(SOHCw/oOBD)-61

S068533E97
CAUTION: Check or repair only faulty parts. After repair or replacement of faulty parts, conduct CLEAR MEMORY and INSPECTION MODES. <Ref. to EN(SOHCw/oOBD)-31 OPERATION, Clear Memory Mode.> and <Ref. to EN(SOHCw/ oOBD)-29 OPERATION, Inspection Mode.> WIRING DIAGRAM:
S2M2115
No. 1
Yes Check fuel pressure. <Ref. to ME(SOHC)-28, Fuel Pressure.>
No Go to step 2.
EN(SOHCw/oOBD)-62

No. 2 Step Check Yes Is the voltage more than 10 Go to step 3. CHECK POWER SUPPLY TO EACH FUEL V? INJECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from fuel injector. 3) Turn ignition switch to ON. 4) Measure power supply voltage between the fuel injector terminal and engine ground. Connector & terminal #1 (E5) No. 2 (+) Engine ground (): #2 (E16) No. 2 (+) Engine ground (): #3 (E6) No. 2 (+) Engine ground (): #4 (E17) No. 2 (+) Engine ground ():
No Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between main relay and fuel injector connector Poor contact in main relay connector Poor contact in coupling connector (B20) Poor contact in fuel injector connector Replace faulty fuel injector. <Ref. to FU(SOHCw/ oOBD)-32, Fuel Injector.> Repair open circuit in harness between ECM and fuel injector connector.
CHECK EACH FUEL INJECTOR. 1) Turn ignition switch to OFF. 2) Measure resistance between each fuel injector terminals. Terminals No. 1 No. 2: CHECK HARNESS BETWEEN ECM AND FUEL INJECTOR CONNECTOR. 1) Disconnect connector from ECM. 2) Measure resistance of harness between ECM and fuel injector connector. Connector & terminal (E22) No. 7 #1 (E5) No. 1: (E22) No. 7 #2 (E16) No. 1: (E22) No. 6 #3 (E6) No. 1: (E22) No. 6 #4 (E17) No. 1: CHECK HARNESS BETWEEN ECM AND FUEL INJECTOR CONNECTOR. Measure resistance of harness between ECM and fuel injector connector. Connector & terminal (E22) No. 6 Engine ground: (E22) No. 7 Engine ground: CHECK POOR CONTACT. Check poor contact in ECM connector.
Go to step 4.
Go to step 5.
Repair ground short in harness between ECM and fuel injector connector.
Check crankshaft position sensor circuit. <Ref. to EN(SOHCw/ oOBD)-64, CRANKSHAFT POSITION SENSOR CIRCUIT, Diagnostics for Engine Starting Failure.>
EN(SOHCw/oOBD)-63

S068533E98
G: CRANKSHAFT POSITION SENSOR CIRCUIT
CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY and INSPECTION MODES. <Ref. to EN(SOHCw/oOBD)-31, Clear Memory Mode.>, <Ref. to EN(SOHCw/oOBD)-29, Inspection Mode.> NOTE: Check crankshaft position sensor circuit. <Ref. to EN(SOHCw/oOBD)-68, DTC 11 CRANKSHAFT POSITION SENSOR, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(SOHCw/oOBD)-64

A: LIST
S068525A12
S068525
DTC No. Item Contents of diagnosis 11 Crankshaft position sensor No signal entered from crankshaft position sensor when ignition switch is ON. The harness connector between ECM and crankshaft position sensor is in short or open.
21
22
45
24
26
31
32
Index <Ref. to EN(SOHCw/ oOBD)-68, DTC 11 CRANKSHAFT POSITION SENSOR, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(SOHCw/ Engine coolant tempera The engine coolant temperature sensor signal is abnoroOBD)-70, DTC 21 ture sensor mal. The harness connector between ECM and engine coolant ENGINE COOLANT TEMPERATURE temperature sensor is in short or open. SENSOR, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Knock sensor The knock sensor signal is abnormal. <Ref. to EN(SOHCw/ The harness connector between ECM and knock sensor oOBD)-74, DTC 22 is in short or open. KNOCK SENSOR, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Pressure sensor The pressure sensor signal is abnormal. <Ref. to EN(SOHCw/ The harness connector between ECM and pressure sen- oOBD)-78, DTC 45 sor is in short or open. PRESSURE SENSOR, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Idle air control solenoid The idle air control solenoid valve is not in function. <Ref. to EN(SOHCw/ valve The harness connector between ECM and idle air control oOBD)-80, DTC 24 solenoid valve is in short or open. IDLE AIR CONTROL SOLENOID VALVE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Intake air temperature The intake air temperature sensor signal is abnormal. <Ref. to EN(SOHCw/ sensor The harness connector between ECM and intake air tem- oOBD)-84, DTC 26 perature sensor is in short or open. INTAKE AIR TEMPERATURE SENSOR, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(SOHCw/ Throttle position sensor The throttle position sensor signal is abnormal. oOBD)-86, DTC 31 The throttle position sensor is installed abnormally. The harness connector between ECM and throttle position THROTTLE POSITION SENSOR, Diagnostic sensor is in short or open. Procedure with Diagnostic Trouble Code (DTC).> Oxygen sensor (With cata- The oxygen sensor is not in function. <Ref. to EN(SOHCw/ lyst vehicles) The harness connector between ECM and oxygen sensor oOBD)-90, DTC 32 is in short or open. OXYGEN SENSOR, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(SOHCw/oOBD)-65

Index <Ref. to EN(SOHCw/ oOBD)-94, DTC 33 VEHICLE SPEED SIGNAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(SOHCw/ The purge control solenoid valve is not in function. oOBD)-96, DTC 35 The harness connector between ECM and purge control PURGE CONTROL solenoid valve is in short or open. SOLENOID VALVE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Abnormal signal entered from TCM. <Ref. to EN(SOHCw/ The harness connector between ECM and TCM is in oOBD)-100, DTC 38 short. TORQUE CONTROL SIGNAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(SOHCw/ The CO resistor signal is abnormal. The harness connector between ECM and CO resistor is oOBD)-102, DTC 46 CO RESISTOR (GENin short or open. ERAL SPEC. The CO value is not adjusted to specifications. VEHICLES), Diagnostic Procedure with Diagnostic Trouble Code (DTC).> The neutral position switch signal is abnormal. <Ref. to EN(SOHCw/ The harness connector between ECM and neutral position oOBD)-104, DTC 51 switch is in short or open. NEUTRAL POSITION SWITCH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Faulty immobiliser system. <Ref. to IM-2, Basic Diagnostic Procedure.> Because the ducts and hoses on air intake line are loosened <Ref. to EN(SOHCw/ or damaged, the pressure sensor signal is abnormal. oOBD)-108, DTC 54 AIR INTAKE SYSTEM , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Charge system is abnormal. <Ref. to EN(SOHCw/ oOBD)-111, DTC 85 CHARGE SYSTEM, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Contents of diagnosis The vehicle speed signal is abnormal. The harness connector between ECM and combination meter is in short or open.
DTC No. Item 33 Vehicle speed signal
35
Purge control solenoid valve
38
Torque control signal
46
CO resistor (General spec. vehicles)
51
Neutral position switch
53 54
Immobiliser system Air intake system
85
Charge system
EN(SOHCw/oOBD)-66

MEMO:
EN(SOHCw/oOBD)-67

S068521

A: DTC 11 CRANKSHAFT POSITION SENSOR
S068521G55
DIAGNOSIS: No signal entered from crankshaft position sensor when ignition switch is ON. The harness connector between ECM and crankshaft position sensor is in short or open. TROUBLE SYMPTOM: Engine stalls. Restarting impossible CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY and INSPECTION MODES. <Ref. to EN(SOHCw/oOBD)-31 OPERATION, Clear Memory Mode.> and <Ref. to EN(SOHCw/ oOBD)-29 OPERATION, Inspection Mode.> WIRING DIAGRAM:
S2M2116
EN(SOHCw/oOBD)-68

No. 1 Step CHECK CONDITION OF CRANKSHAFT POSITION SENSOR INSTALLATION. Check Yes Are the crankshaft position Go to step 2. sensor installing bolts tightened securely? Is the resistance between 1 Go to step 3. and 4 k?
No Tighten crankshaft position sensor installing bolts securely. Replace crankshaft position sensor.
CHECK CRANKSHAFT POSITION SENSOR. 1) Remove crankshaft position sensor. 2) Measure resistance between connector terminals of crankshaft position sensor. Terminals No. 1 No. 2: CHECK HARNESS BETWEEN ECM AND CRANKSHAFT POSITION SENSOR CONNECTOR. 1) Connect connector to crankshaft position sensor. 2) Disconnect connector from ECM. 3) Measure resistance of harness between crankshaft position sensor connector and ECM. Connector & terminal (E22) No. 14 (E22) No. 20: CHECK HARNESS BETWEEN ECM AND CRANKSHAFT POSITION SENSOR CONNECTOR. Measure resistance of harness between ECM connector and chassis ground. Connector & terminal (E22) No. 20 Engine ground: CHECK INPUT SIGNAL FOR ECM. 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM, then connect ST. <Ref. to EN(SOHCw/oOBD)-23, HOW TO CHECK I/O SIGNAL FOR ECM, Engine Control Module (ECM) I/O Signal.> ST 498307600 CHECK BOARD KIT 3) Set the positive (+) probe and ground lead of oscilloscope at ECM connector terminals. 4) Measure voltage indicated on oscilloscope while cranking the engine. Connector & terminal (B) No. 26 (+) (B) No. 19 (): CHECK POOR CONTACT. Check poor contact in ECM connector. CHECK ECM. 1) Connect all connectors. 2) Erase the memory. <Ref. to EN(SOHCw/ oOBD)-31, Clear Memory Mode.> 3) Perform inspection mode. <Ref. to EN(SOHCw/oOBD)-29, Inspection Mode.> 4) Read out the trouble code. <Ref. to EN(SOHCw/oOBD)-27, Read Diagnostic Trouble Code.> CHECK ANY OTHER TROUBLE CODES APPEARANCE.
Is the resistance between 1 Go to step 4. and 5 k?
Repair ground short circuit in harness between crankshaft position sensor and ECM connector. Go to step 6.
Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between crankshaft position sensor and ECM connector Go to step 5.
Is the voltage more than 400 mV?
Replace crankshaft position sensor.
Is there poor contact in ECM connector? Is the same trouble code as in the current diagnosis still being output?
Repair poor contact in ECM connector. Replace generator.
Go to step 7.
Go to step 8.
Are other trouble codes being output?
EN(SOHCw/oOBD)-69

S068521G58
B: DTC 21 ENGINE COOLANT TEMPERATURE SENSOR
DIAGNOSIS: The engine coolant temperature sensor signal is abnormal. The harness connector between ECM and engine coolant temperature sensor is in short or open. TROUBLE SYMPTOM: Hard to start Erroneous idling Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY and INSPECTION MODES. <Ref. to EN(SOHCw/oOBD)-31 OPERATION, Clear Memory Mode.> and <Ref. to EN(SOHCw/ oOBD)-29 OPERATION, Inspection Mode.> WIRING DIAGRAM:
S2M2117
EN(SOHCw/oOBD)-70

No. 1 Step CHECK HARNESS BETWEEN ENGINE COOLANT TEMPERATURE SENSOR AND ECM CONNECTOR. 1) Turn ignition switch to OFF. 2) Remove air intake duct and air cleaner assembly. 3) Disconnect connector from engine coolant temperature sensor. 4) Measure voltage between engine coolant temperature sensor connector and engine ground. Connector & terminal (E8) No. 2 (+) Engine ground (): CHECK HARNESS BETWEEN ENGINE COOLANT TEMPERATURE SENSOR AND ECM CONNECTOR. 1) Turn ignition switch to ON. 2) Measure voltage between engine coolant temperature sensor connector and engine ground. Connector & terminal (E8) No. 2 (+) Engine ground (): CHECK HARNESS BETWEEN ENGINE COOLANT TEMPERATURE SENSOR AND ECM CONNECTOR. Measure voltage between engine coolant temperature sensor connector and engine ground. Connector & terminal (E8) No. 2 (+) Engine ground (): Check Yes Is the voltage more than 10 Repair battery V? short circuit in harness between ECM and engine coolant temperature sensor connector. No Go to step 2.
Go to step 3.
Go to step 4.
CHECK HARNESS BETWEEN ENGINE COOLANT TEMPERATURE SENSOR AND ECM CONNECTOR. 1) Turn ignition switch to OFF. 2) Measure resistance of harness between engine coolant temperature sensor connector and engine ground. Connector & terminal (E8) No. 1 Engine ground:
Go to step 5.
Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ECM and engine coolant temperature sensor connector Poor contact in engine coolant temperature sensor connector Poor contact in ECM connector Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ECM and engine coolant temperature sensor connector Poor contact in engine coolant temperature sensor connector Poor contact in ECM connector
EN(SOHCw/oOBD)-71
No. 5

Step CHECK ENGINE COOLANT TEMPERATURE SENSOR. Measure resistance between engine coolant temperature sensor terminals. Terminals No. 1 No. 2: CHECK ENGINE COOLANT TEMPERATURE SENSOR. Measure resistance between engine coolant temperature sensor terminals. Terminals No. 1 No. 2: CHECK ENGINE COOLANT TEMPERATURE SENSOR. Measure resistance between engine coolant temperature sensor terminals. Terminals No. 1 No. 2: Check Yes Is the resistance between 2 Go to step 6. and 3 k at 20C (68F)? No Replace engine coolant temperature sensor. <Ref. to FU(SOHCw/ oOBD)-23, Engine Coolant Temperature Sensor.> Go to step 7. Replace engine coolant temperature sensor. <Ref. to FU(SOHCw/ oOBD)-23, Engine Coolant Temperature Sensor.> Replace engine Replace ECM. coolant tempera<Ref. to ture sensor. <Ref. FU(SOHCw/ oOBD)-38, Engine to FU(SOHCw/ Control Module.> oOBD)-23, Engine Coolant Temperature Sensor.>
Is the resistance between 0.35 and 0.4 k at 80C (176F)?
Is the resistance between 0.2 and 0.3 k at 90C (194F)?
EN(SOHCw/oOBD)-72

MEMO:
EN(SOHCw/oOBD)-73

S068521G59
C: DTC 22 KNOCK SENSOR
DIAGNOSIS: The knock sensor signal is abnormal. The harness connector between ECM and knock sensor is in short or open. TROUBLE SYMPTOM: Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY and INSPECTION MODES. <Ref. to EN(SOHCw/oOBD)-31 OPERATION, Clear Memory Mode.> and <Ref. to EN(SOHCw/ oOBD)-29 OPERATION, Inspection Mode.> WIRING DIAGRAM:
S2M2118
EN(SOHCw/oOBD)-74

No. 1 Step CHECK HARNESS BETWEEN KNOCK SENSOR AND ECM CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM. 3) Measure resistance of harness between ECM connector and engine ground. Connector & terminal (E22) No. 16 Engine ground: CHECK HARNESS BETWEEN KNOCK SENSOR AND ECM CONNECTOR. Measure resistance of harness between ECM connector and engine ground. Connector & terminal (E22) No. 16 Engine ground: CHECK KNOCK SENSOR. 1) Disconnect connector from knock sensor. 2) Measure resistance between knock sensor connector terminal and engine ground. Terminal No. 2 Engine ground: Check Yes Is the resistance more than Go to step 3. 700 k? No Go to step 2.
Go to step 5.
Go to step 6.
Replace knock sensor. <Ref. to FU(SOHCw/ oOBD)-25, Knock Sensor.> Replace knock sensor.
Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between knock sensor and ECM connector Poor contact in knock sensor connector Tighten knock sensor installation bolt securely.
Repair ground short circuit in harness between knock sensor connector and ECM connector. NOTE: The harness between both connectors is shielded. Repair short circuit of harness together with shield.
EN(SOHCw/oOBD)-75
No. 6

Step Check Is the voltage more than 2 CHECK INPUT SIGNAL FOR ECM. V? 1) Connect ST. <Ref. to EN(SOHCw/oOBD)23, HOW TO CHECK I/O SIGNAL FOR ECM, Engine Control Module (ECM) I/O Signal.> ST 498307600 CHECK BOARD KIT 2) Turn ignition switch to ON. 3) Measure voltage between ECM and engine ground. Connector & terminal (B) No. 17 (+) Engine ground (): Yes No Even if MIL lights Repair poor conup, the circuit has tact in ECM conreturned to a nor- nector. mal condition at this time. (However, the possibility of poor contact still remains.) NOTE: In this case, repair the following: Poor contact in knock sensor connector Poor contact in ECM connector
EN(SOHCw/oOBD)-76

MEMO:
EN(SOHCw/oOBD)-77

S068521G67
D: DTC 45 PRESSURE SENSOR
DIAGNOSIS: The pressure sensor signal is abnormal. The harness connector between ECM and pressure sensor is in short or open. TROUBLE SYMPTOM: Erroneous idling Engine stalls. Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY and INSPECTION MODES. <Ref. to EN(SOHCw/oOBD)-31 OPERATION, Clear Memory Mode.> and <Ref. to EN(SOHCw/ oOBD)-29 OPERATION, Inspection Mode.> WIRING DIAGRAM:
S2M2126
EN(SOHCw/oOBD)-78

No. 1 Step CHECK HARNESS BETWEEN ECM AND PRESSURE SENSOR CONNECTOR. 1) Disconnect connector from pressure sensor. 2) Turn ignition switch to ON. 3) Measure voltage between pressure sensor connector and engine ground. Connector & terminal (E21) No. 3 (+) Engine ground (): CHECK HARNESS BETWEEN ECM AND PRESSURE SENSOR CONNECTOR. 1) Disconnect connector from ECM. 2) Measure resistance of harness between ECM and pressure sensor connector. Connector & terminal (E22) No. 22 (E21) No. 2: (E22) No. 25 (E21) No. 3: (E22) No. 18 (E21) No. 1: CHECK HARNESS BETWEEN ECM AND PRESSURE SENSOR CONNECTOR. Measure resistance of harness between ECM connector and engine ground. Connector & terminal (E22) No. 25 Engine ground: (E22) No. 18 Engine ground: (E22) No. 22 Engine ground: CHECK INPUT SIGNAL FOR ECM. 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM, then connect ST. <Ref. to EN(SOHCw/oOBD)-23, HOW TO CHECK I/O SIGNAL FOR ECM, Engine Control Module (ECM) I/O Signal.> ST 498307600 CHECK BOARD KIT 3) Turn ignition switch to ON. 4) Measure voltage between ECM and engine ground. Connector & terminal (A) No. 15 (+) Engine ground (): CHECK INPUT SIGNAL FOR ECM. 1) Start engine, and idle it. 2) Measure voltage between ECM and engine ground. Connector & terminal (A) No. 15 (+) Engine ground (): CHECK POOR CONTACT. Check poor contact in pressure sensor connector. Check Is the voltage between 4.5 V and 5.5 V? Yes Go to step 2.
No Repair open circuit in harness between ECM and pressure sensor.
Go to step 3.
Repair open circuit in harness between ECM and pressure sensor connector.
Repair ground short circuit in harness between ECM and pressure sensor connector.
Is the voltage between 2.3 V and 2.5 V?
Go to step 5.
Replace pressure sensor. <Ref. to FU(SOHCw/ oOBD)-29, Pressure Sensor.>
Go to step 6.
Replace pressure sensor. <Ref. to FU(SOHCw/ oOBD)-29, Pressure Sensor.> Replace pressure sensor. <Ref. to FU(SOHCw/ oOBD)-29, Pressure Sensor.>
Repair poor contact in pressure sensor connector.
EN(SOHCw/oOBD)-79

S068521G60
E: DTC 24 IDLE AIR CONTROL SOLENOID VALVE
DIAGNOSIS: The idle air control solenoid valve is not in function. The harness connector between ECM and idle air control solenoid valve is in short or open. TROUBLE SYMPTOM: Erroneous idling Hard to start Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY and INSPECTION MODES. <Ref. to EN(SOHCw/oOBD)-31 OPERATION, Clear Memory Mode.> and <Ref. to EN(SOHCw/ oOBD)-29 OPERATION, Inspection Mode.> WIRING DIAGRAM:
S2M2119
EN(SOHCw/oOBD)-80

No. 1 Step CHECK AIR INTAKE SYSTEM. 1) Turn ignition switch to ON. 2) Start engine and idle it. 3) Check the following item. Loose installation of intake manifold, idle air control solenoid valve and throttle body Cracks of intake manifold gasket, idle air control solenoid valve gasket and throttle body gasket Loose control connection and cracks of idle air control solenoid valve by-pass hose Disconnection of vacuum hoses CHECK HARNESS BETWEEN ECM AND IDLE AIR CONTROL SOLENOID VALVE CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM and idle air control solenoid valve. 3) Measure resistance of harness between ECM and idle air control solenoid valve connector. Connector & terminal (E22) No. 4 (E7) No. 1: CHECK HARNESS BETWEEN ECM AND IDLE AIR CONTROL SOLENOID VALVE CONNECTOR. Measure resistance of harness between ECM and idle air control solenoid valve connector. Connector & terminal (E22) No. 11 (E7) No. 3: CHECK HARNESS BETWEEN ECM AND IDLE AIR CONTROL SOLENOID VALVE CONNECTOR. Measure resistance of harness between ECM connector and engine ground. Connector & terminal (E22) No. 11 Engine ground: CHECK HARNESS BETWEEN ECM AND IDLE AIR CONTROL SOLENOID VALVE CONNECTOR. Measure resistance of harness between ECM connector and engine ground. Connector & terminal (E22) No. 4 Engine ground: CHECK POOR CONTACT. Check poor contact in ECM connector. Check Is there a fault in air intake system? Yes Repair or replace air intake system. No Go to step 2.
Go to step 3.
Repair open circuit in harness between ECM and idle air control solenoid valve connector.
Go to step 4.
Repair open circuit in harness between ECM and idle air control solenoid valve connector. Go to step 5.
Is the resistance more than Repair ground 1 M? short in harness between ECM and idle air control solenoid valve. Is the resistance more than Repair ground 1 M? short circuit in harness between ECM and idle air control solenoid valve connector. Is there poor contact in ECM connector? Repair poor contact in ECM connector. Go to step 8.
Go to step 6.
Go to step 7.
Is the resistance less than CHECK MAIN RELAY. 10 ? 1) Turn ignition switch to OFF. 2) Remove main relay. 3) Connect battery to main relay terminals No. 1 and No. 2. 4) Measure resistance between main relay terminals. Terminals No. 4 No. 6:
Replace main relay.
EN(SOHCw/oOBD)-81
No. 8

Step CHECK POWER SUPPLY TO IDLE AIR CONTROL SOLENOID VALVE. 1) Disconnect connector from idle air control solenoid valve. 2) Turn ignition switch to ON. 3) Measure voltage between idle air control solenoid valve connector and engine ground. Connector & terminal (E7) No. 2 (+) Engine ground (): Check Yes Is the voltage more than 10 Go to step 9. V? No Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between idle air control solenoid valve and battery Poor contact in coupling connector (B20) Contact your Subaru distributor. NOTE: Inspection by your Subaru distributor is required, because probable cause is deterioration of multiple parts.
CHECK POOR CONTACT. Is there poor contact in idle Repair poor conCheck poor contact in idle air control solenoid air control solenoid valve tact in idle air valve connector. connector? control solenoid valve connector.
EN(SOHCw/oOBD)-82

MEMO:
EN(SOHCw/oOBD)-83

S068521G61
F: DTC 26 INTAKE AIR TEMPERATURE SENSOR
DIAGNOSIS: The intake air temperature sensor signal is abnormal. The harness connector between ECM and intake air temperature sensor is in short or open. TROUBLE SYMPTOM: Hard to start Erroneous idling Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY and INSPECTION MODES. <Ref. to EN(SOHCw/oOBD)-31 OPERATION, Clear Memory Mode.> and <Ref. to EN(SOHCw/ oOBD)-29 OPERATION, Inspection Mode.> WIRING DIAGRAM:
S2M2120
EN(SOHCw/oOBD)-84

No. 1 Step CHECK INTAKE AIR TEMPERATURE SENSOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from intake air temperature sensor. 3) Measure resistance between intake air temperature sensor terminals. Terminals No. 1 No. 2: CHECK INTAKE AIR TEMPERATURE SENSOR. Measure resistance between intake air temperature sensor terminals. Terminals No. 1 No. 2: CHECK HARNESS BETWEEN ECM AND INTAKE AIR TEMPERATURE SENSOR CONNECTOR. 1) Disconnect connector from ECM. 2) Measure resistance of harness connector between ECM and intake air temperature sensor connector. Connector & terminal (E22) No. 17 (E20) No. 1: (E22) No. 22 (E20) No. 2: CHECK HARNESS BETWEEN ECM AND INTAKE AIR TEMPERATURE SENSOR CONNECTOR. Measure resistance of harness between ECM connector and engine ground. Connector & terminal (E22) No. 17 Engine ground: (E22) No. 22 Engine ground: CHECK POOR CONTACT. Check poor contact in ECM connector. Check Yes Is the resistance between 2 Go to step 2. and 3 k at 20C (68F)?
No Replace intake air temperature sensor. <Ref. to FU(SOHCw/ oOBD)-30, Intake Air Temperature Sensor.>
Is the resistance between 2 Go to step 3. and 3 k at 50C (122F)?
Go to step 4.
Replace intake air temperature sensor. <Ref. to FU(SOHCw/ oOBD)-30, Intake Air Temperature Sensor.> Repair open circuit in harness between ECM and intake air temperature sensor connector.
Repair ground short circuit in harness between ECM and idle air control solenoid valve connector.
Contact your Subaru distributor. NOTE: Inspection by your Subaru distributor is required, because probable cause is deterioration of multiple parts.
EN(SOHCw/oOBD)-85

S068521G62
G: DTC 31 THROTTLE POSITION SENSOR
DIAGNOSIS: The throttle position sensor signal is abnormal. The throttle position sensor is installed abnormally. The harness connector between ECM and throttle position sensor is in short or open. TROUBLE SYMPTOM: Erroneous idling Engine stalls Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY and INSPECTION MODES. <Ref. to EN(SOHCw/oOBD)-31 OPERATION, Clear Memory Mode.> and <Ref. to EN(SOHCw/ oOBD)-29 OPERATION, Inspection Mode.> WIRING DIAGRAM:
S2M2121
EN(SOHCw/oOBD)-86

No. 1 Step CHECK INPUT SIGNAL FOR ECM. 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM, then connect ST. <Ref. to EN(SOHCw/oOBD)-23, HOW TO CHECK I/O SIGNAL FOR ECM, Engine Control Module (ECM) I/O Signal.> ST 498307600 CHECK BOARD KIT 3) Turn ignition switch to ON. 4) Measure voltage between ECM and engine ground while throttle valve is fully closed. Connector & terminal (B) No. 23 (+) Engine ground (): CHECK INPUT SIGNAL FOR ECM. Measure voltage between ECM and engine ground. Connector & terminal (B) No. 23 (+) Engine ground (): Check Is the voltage more than 4.5 V? Yes Go to step 3. No Go to step 2.
CHECK INPUT SIGNAL FOR ECM. Measure voltage between ECM connector and engine ground. Connector & terminal (B) No. 24 (+) Engine ground (): CHECK HARNESS BETWEEN ECM AND THROTTLE POSITION SENSOR CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connectors from throttle position sensor. 3) Turn ignition switch to ON. 4) Measure voltage between throttle position sensor connector and engine ground. Connector & terminal (E13) No. 3 (+) Engine ground ():
Contact your Subaru distributor. NOTE: Inspection by your Subaru distributor is required, because probable cause is deterioration of multiple parts. Repair poor contact in ECM connector.
Go to step 5.
CHECK HARNESS BETWEEN ECM AND THROTTLE POSITION SENSOR CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect ECM connector from CHECK BOARD. 3) Measure resistance of harness between ECM and throttle position sensor connector. Connector & terminal (E22) No. 22 (E13) No. 2:
Go to step 6.
Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between throttle position sensor and ECM connector Poor contact in throttle position sensor connector Poor contact in ECM connector Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between throttle position sensor and ECM connector Poor contact in ECM connector Poor contact in throttle position sensor connector
EN(SOHCw/oOBD)-87
No. 6

Step CHECK HARNESS BETWEEN ECM AND THROTTLE POSITION SENSOR CONNECTOR. Measure resistance of harness between throttle position sensor connector and engine ground. Connector & terminal (E13) No. 2 Engine ground: CHECK POOR CONTACT. Check poor contact in throttle position sensor connector. CHECK CONDITION OF THROTTLE POSITION SENSOR INSTALLATION. Check Is the resistance less than 10 ? Yes Repair ground short circuit in harness between throttle position sensor and ECM connector. No Go to step 7.
Is there poor contact in Repair poor conthrottle position sensor contact in throttle nector? position sensor connector. Are the throttle position Replace throttle sensor installing screws position sensor. tightened securely?
Go to step 8.
Adjust throttle position sensor and tighten throttle position sensor installing screws securely.
EN(SOHCw/oOBD)-88

MEMO:
EN(SOHCw/oOBD)-89

S068521G63
H: DTC 32 OXYGEN SENSOR
DIAGNOSIS: The oxygen sensor is not in function. The harness connector between ECM and oxygen sensor is in short or open. TROUBLE SYMPTOM: Failure of engine to start Erroneous idling Poor driving performance Engine stalls. Idle mixture is out of specifications. CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY and INSPECTION MODES. <Ref. to EN(SOHCw/oOBD)-31 OPERATION, Clear Memory Mode.> and <Ref. to EN(SOHCw/ oOBD)-29 OPERATION, Inspection Mode.> WIRING DIAGRAM:
S2M2122
EN(SOHCw/oOBD)-90

No. 1 Step CHECK FOR OTHER CAUSES AFFECTING EXHAUST GAS. NOTE: Check for use of improper fuel. Check if engine oil or coolant level is extremely low. CHECK EXHAUST SYSTEM. Check Is CO% more than 2% after engine warm-up? Yes Check fuel system. No Go to step 2.
Is the voltage more than CHECK HARNESS BETWEEN OXYGEN 0.2 V? SENSOR AND ECM CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from oxygen sensor. 3) Turn ignition switch to ON. 4) Measure voltage between front oxygen sensor harness connector and engine ground. Connector & terminal (B18) No. 4 (+) Engine ground ():
CHECK POOR CONTACT. Check poor contact in oxygen sensor connector. CHECK MAIN RELAY. 1) Turn ignition switch to OFF. 2) Remove main relay. 3) Connect battery to main relay terminals No. 1 and No. 2. 4) Measure resistance between main relay terminals. Terminals No. 4 No. 6:
Is there poor contact in oxygen sensor connector? Is the resistance less than 10 ?
Go to step 3. Repair exhaust system. NOTE: Loose installation of front portion of exhaust pipe onto cylinder heads Loose connection between front exhaust pipe and front catalytic converter Damage of exhaust pipe resulting in hole Go to step 4. Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ECM and oxygen sensor connector Poor contact in the ECM connector Repair poor con- Go to step 5. tact in oxygen sensor connector. Go to step 6. Replace main relay.
EN(SOHCw/oOBD)-91
No. 6

Step CHECK POWER SUPPLY TO OXYGEN SENSOR. 1) Turn ignition switch to ON. 2) Measure voltage between oxygen sensor connector. Connector & terminal (B18) No. 2 (+) Engine ground (): Check Yes Is the voltage more than 10 Go to step 7. V? No Repair power supply line. NOTE: In this case, repair the following: Open circuit in harness between battery and oxygen sensor connector Poor contact in oxygen sensor connector Poor contact in main relay connector Replace oxygen sensor. <Ref. to FU(SOHCw/ oOBD)-36, Oxygen Sensor.>
CHECK OXYGEN SENSOR. 1) Turn ignition switch to OFF. 2) Measure resistance between oxygen sensor terminals. Terminals No. 1 No. 2:
Repair poor contact. NOTE: In this case, repair the following: Poor contact in ECM connector Poor contact in oxygen sensor connector
EN(SOHCw/oOBD)-92

MEMO:
EN(SOHCw/oOBD)-93

S068521G64
I: DTC 33 VEHICLE SPEED SIGNAL
DIAGNOSIS: The vehicle speed signal is abnormal. The harness connector between ECM and vehicle speed sensor is in short or open. TROUBLE SYMPTOM: Erroneous idling Engine stalls. Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY and INSPECTION MODES. <Ref. to EN(SOHCw/oOBD)-31 OPERATION, Clear Memory Mode.> and <Ref. to EN(SOHCw/ oOBD)-29 OPERATION, Inspection Mode.> WIRING DIAGRAM:
S2M2123
EN(SOHCw/oOBD)-94

No. 1 Step CHECK SPEEDOMETER OPERATION IN COMBINATION METER. Check Yes Does speedometer operate Go to step 2. normally?
No Check speedometer and vehicle speed sensor. <Ref. to IDI-7, INSPECTION, Combination Meter System.> Go to step 4.
CHECK INPUT SIGNAL FOR ECM. 1) Disconnect connector from ECM, then connect ST. <Ref. to EN(SOHCw/oOBD)-23, HOW TO CHECK I/O SIGNAL FOR ECM, Engine Control Module (ECM) I/O Signal.> ST 498307600 CHECK BOARD KIT 2) Lift-up the vehicle. 3) Set the positive (+) terminal and earth lead of the oscilloscope at ECM connector terminals. Connector & terminal (D) No. 53 Engine ground: 4) Start the engine. 5) Shift the gear position, and travel at a constant speed. 6) Measure the signal voltage indicated on the oscilloscope. CHECK POOR CONTACT. Check for poor contact at ECM connector.
Go to step 3.
Is there poor contact at the Repair poor conECM connector? tact at ECM.
CHECK HARNESS BETWEEN ECM AND COMBINATION METER CONNECTOR. Measure voltage between ECM and engine ground. Connector & terminal (D) No. 53 (+) Engine ground ():
CHECK HARNESS BETWEEN ECM AND COMBINATION METER CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect check board. 3) Measure resistance of harness between ECM connector and engine ground. Connector & terminal (B84) No. 33 Engine ground: CHECK POOR CONTACT. Check poor contact in ECM connector.
Repair harness and connector. NOTE: In this case, repair the following: Battery short circuit in harness between ECM and combination meter connector Repair ground short circuit in harness between ECM and combination meter connector.
Replace ECM. <Ref. to FU(SOHCw/ oOBD)-38, Engine Control Module.> Go to step 5.
Go to step 6.
Repair poor contact in ECM.
Replace ECM. <Ref. to FU(SOHCw/ oOBD)-38, Engine Control Module.>
EN(SOHCw/oOBD)-95

S068521G65
J: DTC 35 PURGE CONTROL SOLENOID VALVE
DIAGNOSIS: The purge control solenoid valve is not in function. The harness connector between ECM and purge control solenoid valve is in short or open. TROUBLE SYMPTOM: Erroneous idling CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY and INSPECTION MODES. <Ref. to EN(SOHCw/oOBD)-31 OPERATION, Clear Memory Mode.> and <Ref. to EN(SOHCw/ oOBD)-29 OPERATION, Inspection Mode.> WIRING DIAGRAM:
S2M2124
EN(SOHCw/oOBD)-96

No. 1 Step CHECK OPERATION SOUND OF PURGE CONTROL SOLENOID VALVE. 1) Turn ignition switch to OFF. 2) Connect test mode connector. 3) Turn ignition switch to ON. 4) Make sure that the ON/OFF operating sound of purge control solenoid valve occurs at about 10 Hz. CHECK POOR CONTACT. Check poor contact in ECM connector. Check Does purge control solenoid valve produce operating sound? Yes Go to step 2. No Go to step 3.
Repair poor contact in ECM.
CHECK HARNESS BETWEEN PURGE CONTROL SOLENOID VALVE AND ECM CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect test mode connector. 3) Disconnect connector from ECM, then connect ST. <Ref. to EN(SOHCw/oOBD)-23, HOW TO CHECK I/O SIGNAL FOR ECM, Engine Control Module (ECM) I/O Signal.> ST 498307600 CHECK BOARD KIT 4) Disconnect connector from purge control solenoid valve. 5) Turn ignition switch to ON. 6) Measure voltage between ECM and engine ground. Connector & terminal (A) No. 3 (+) Engine ground (): CHECK HARNESS BETWEEN PURGE CONTROL SOLENOID VALVE AND ECM CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect ECM connector from CHECK BOARD. 3) Measure resistance of harness between ECM and purge control solenoid valve of harness connector. Connector & terminal (E22) No. 5 (E4) No. 2: CHECK PURGE CONTROL SOLENOID VALVE. 1) Remove purge control solenoid valve. 2) Measure resistance between purge control solenoid valve terminals. Terminal No. 1 No. 2: CHECK MAIN RELAY. 1) Turn ignition switch to OFF. 2) Remove main relay. 3) Connect battery to main relay terminals No. 1 and No. 2. 4) Measure resistance between main relay terminals. Terminals No. 4 No. 6:
Is the voltage more than 10 Repair battery V? short circuit in harness between ECM and purge control solenoid valve connector. After repair, replace ECM.
Replace ECM. <Ref. to FU(SOHCw/ oOBD)-38, Engine Control Module.> Go to step 4.
Go to step 5.
Repair open circuit in harness between ECM and purge control solenoid valve connector.
Go to step 6.
Go to step 7.
Replace purge control solenoid valve. <Ref. to EC(SOHCw/ oOBD)-7, Purge Control Solenoid Valve.> Replace main relay.
EN(SOHCw/oOBD)-97
No. 7

Step CHECK POWER SUPPLY TO PURGE CONTROL SOLENOID VALVE. 1) Turn ignition switch to ON. 2) Measure voltage between purge control solenoid valve and engine ground. Connector & terminal (E4) No. 1 (+) Engine ground (): Check Yes Is the voltage more than 10 Go to step 8. V? No Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between battery and purge control solenoid valve connector Poor contact in main relay connector Poor contact in coupling connector (B20) Repair poor con- Contact your tact in purge con- Subaru distributor. trol solenoid valve NOTE: Inspection by your connector. Subaru distributor is required, because probable cause is deterioration of multiple parts.
CHECK POOR CONTACT. Check poor contact in purge control solenoid valve connector.
Is there poor contact in purge control solenoid valve connector?
EN(SOHCw/oOBD)-98

MEMO:
EN(SOHCw/oOBD)-99

S068521G66
K: DTC 38 TORQUE CONTROL SIGNAL
DIAGNOSIS: Abnormal signal entered from TCM The harness connector between ECM and TCM is in short. CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY and INSPECTION MODES. <Ref. to EN(SOHCw/oOBD)-31 OPERATION, Clear Memory Mode.> and <Ref. to EN(SOHCw/ oOBD)-29 OPERATION, Inspection Mode.> WIRING DIAGRAM:
S2M2125
EN(SOHCw/oOBD)-100

No. 1 Step CHECK HARNESS BETWEEN ECM AND TCM CONNECTOR. 1) Disconnect connectors from ECM and TCM. 2) Measure resistance of harness between ECM and engine ground. Connector & terminal (B84) No. 7 Engine ground: CHECK HARNESS BETWEEN ECM AND TCM CONNECTOR. Measure resistance of harness between ECM and engine ground. Connector & terminal (B84) No. 18 Engine ground: Check Is the resistance less than 10 ? Yes Repair ground short circuit in harness between ECM and TCM connector. No Go to step 2.
Is there resistance less than 10 ?
Replace TCM. <Ref. to AT-48 Transmission Control Module (TCM).>
EN(SOHCw/oOBD)-101

S068521G68
L: DTC 46 CO RESISTOR (GENERAL SPEC. VEHICLES)
DIAGNOSIS: The CO resistor signal is abnormal. The harness connector between ECM and CO resistor is in short or open. The CO value is not adjusted to specifications. TROUBLE SYMPTOM: Erroneous idling Mixture ratio is too rich or too lean. CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY and INSPECTION MODES. <Ref. to EN(SOHCw/oOBD)-31 OPERATION, Clear Memory Mode.> and <Ref. to EN(SOHCw/ oOBD)-29 OPERATION, Inspection Mode.> WIRING DIAGRAM:
S2M2127
EN(SOHCw/oOBD)-102

No. 1 Step Check Is the voltage between 0.5 CHECK INPUT SIGNAL FOR ECM. V and 4.5 V? 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM, then connect ST. <Ref. to EN(SOHCw/oOBD)-23, HOW TO CHECK I/O SIGNAL FOR ECM, Engine Control Module (ECM) I/O Signal.> ST 498307600 CHECK BOARD KIT 3) Turn ignition switch to ON. 4) Measure voltage between ECM and engine ground. Connector & terminal (D) No. 56 (+) Engine ground (): CHECK POOR CONTACT. Is there poor contact in ECM connector? Yes Go to step 3. No Go to step 2.
CHECK HARNESS BETWEEN CO RESISTOR AND ECM CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM and CO resistor. 3) Measure resistance of harness between ECM and CO resistor connector. Connector & terminal (B84) No. 1 (B155) No. 3: (B84) No. 30 (B155) No. 2: (B84) No. 15 (B155) No. 1: CHECK HARNESS BETWEEN CO RESISTOR AND ECM CONNECTOR. Measure resistance of harness between ECM connector and engine ground. Connector & terminal (B84) No. 1 Engine ground: (B84) No. 30 Engine ground: (B84) No. 15 Engine ground: CHECK CO RESISTOR. Measure resistance between CO resistor terminals. Terminals No. 1 No. 3: CHECK CO RESISTOR. Measure variable resistance between CO resistor terminals while rotating the screw of CO resistor. Terminals No. 1 No. 2:
Go to step 4.
Replace ECM. <Ref. to FU(SOHCw/ oOBD)-38, Engine Control Module.> Repair open circuit in harness between ECM and CO resistor connector.
Repair short circuit in harness between ECM and CO resistor connector.
Is the resistance between 4 Go to step 6. and 6 k?
Replace CO resistor.
Is the resistance between 0 Replace ECM. and 6 k?
Replace CO resistor. NOTE: Ensure resistance varies in response to screw rotation.
EN(SOHCw/oOBD)-103

S068521H58
M: DTC 51 NEUTRAL POSITION SWITCH
DIAGNOSIS: The neutral position switch signal is abnormal. The harness connector between ECM and neutral position switch is in short or open. TROUBLE SYMPTOM: Erroneous idling CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY and INSPECTION MODES. <Ref. to EN(SOHCw/oOBD)-31 OPERATION, Clear Memory Mode.> and <Ref. to EN(SOHCw/ oOBD)-29 OPERATION, Inspection Mode.> WIRING DIAGRAM:
S2M2128
EN(SOHCw/oOBD)-104

No. 1 Step CHECK INPUT SIGNAL FOR ECM. 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM, then connect ST. <Ref. to EN(SOHCw/oOBD)-23, HOW TO CHECK I/O SIGNAL FOR ECM, Engine Control Module (ECM) I/O Signal.> ST 498307600 CHECK BOARD KIT 3) Turn ignition switch to ON. 4) Measure voltage between ECM and engine ground. Connector & terminal (D) No. 60 (+) Engine ground (): CHECK INPUT SIGNAL FOR ECM. Measure voltage between ECM and engine ground. Connector & terminal (D) No. 60 (+) Engine ground (): CHECK POOR CONTACT. Check poor contact in ECM connector. CHECK NEUTRAL POSITION SWITCH. 1) Turn ignition switch to OFF. 2) Disconnect connector from transmission harness. 3) Measure resistance between transmission harness and connector terminals. Connector & terminal (T2) No. 1 No. 2: CHECK NEUTRAL POSITION SWITCH. Measure resistance between transmission harness connector terminals. Connector & terminal (T2) No. 1 No. 2: CHECK HARNESS BETWEEN ECM AND NEUTRAL POSITION SWITCH CONNECTOR. 1) Disconnect ECM connector from CHECK BOARD. 2) Measure resistance of harness between ECM and transmission harness connector. Connector & terminal (B84) No. 26 (B25) No. 1: CHECK HARNESS BETWEEN ECM AND NEUTRAL POSITION SWITCH CONNECTOR. Measure resistance between ECM connector and engine ground. Connector & terminal (B84) No. 26 Engine ground: Check Is the voltage between 4.5 and 5.5 V in neutral position? Yes Go to step 2. No Go to step 4.
Is the voltage less than 1 V Go to step 3. in other positions?
Go to step 4.
Repair poor contact in ECM connector. Is the resistance more than Go to step 5. 1 M in neutral position?
Contact your Subaru distributor. Repair short circuit in transmission harness or replace neutral position switch.
Is the resistance less than 1 in other positions?
Go to step 6.
Go to step 7.
Repair open circuit in transmission harness or replace neutral position switch. Repair open circuit in harness between ECM and transmission harness connector.
Repair ground short circuit in harness between ECM and transmission harness connector.
Go to step 8.
EN(SOHCw/oOBD)-105
No. 8

Step CHECK NEUTRAL POSITION SWITCH GROUND CIRCUIT. Measure resistance of harness between transmission harness connector and engine ground. Connector & terminal (B25) No. 2 Engine ground: Check Is the resistance less than 5 ? Yes Go to step 9. No Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between transmission harness connector and engine grounding terminal Poor contact in coupling connector (B138) Repair poor con- Contact your Subaru distributor. tact in transmission harness con- NOTE: Inspection by your nector. Subaru distributor is required, because probable cause is deterioration of multiple parts.
CHECK POOR CONTACT. Check poor contact in transmission harness connector.
Is there poor contact in transmission harness connector?
EN(SOHCw/oOBD)-106

MEMO:
EN(SOHCw/oOBD)-107

S068521H59
N: DTC 54 AIR INTAKE SYSTEM
DIAGNOSIS: Intake duct, hose, nipple, etc., looseness, displacement, detachment TROUBLE SYMPTOM: High idling revs Poor engine pick up CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY and INSPECTION MODES. <Ref. to EN(SOHCw/oOBD)-31, Clear Memory Mode.>, <Ref. to EN(SOHCw/oOBD)-29, Inspection Mode.> WIRING DIAGRAM:
S2M2129
EN(SOHCw/oOBD)-108

No. 1 Step CHECK AIR INTAKE SYSTEM. 1) Turn ignition switch to ON. 2) Start engine, and idle it. 3) Check the following items: Cracks of air intake duct Disconnections of air intake duct Check for looseness, displacement of the intake manifold. Check that the intake manifold is connected in the instructed manner. (Gasket detachment, insufficient fastening torque of nuts and bolts) Check for looseness, detachment of hose, nipple etc. CHECK INPUT SIGNAL FOR ECM. 1) Turn ignition to OFF. 2) Disconnect connector from ECM, then connect ST. <Ref. to EN(SOHCw/oOBD)-23, HOW TO CHECK I/O SIGNAL FOR ECM, Engine Control Module (ECM) I/O Signal.> ST 498307600 CHECK BOARD KIT 3) Turn ignition switch to ON. 4) Measure voltage between ECM and engine ground. Connector & terminal (D) No. 51 (+) Engine ground (): CHECK INPUT SIGNAL FOR ECM. 1) Start engine, and idle it. 2) Measure voltage between ECM and engine ground. Connector & terminal (D) No. 51 (+) Engine ground (): CHECK INPUT SIGNAL FOR ECM. 1) Stop engine, and turn ignition switch to ON. 2) Measure voltage between ECM terminals while throttle valve is fully closed. Terminal No. 23 (+) No. 21 (): CHECK INPUT SIGNAL FOR ECM. Measure voltage between ECM terminals while throttle valve is fully opened. Terminal No. 23 (+) No. 21 (): Check Is there a fault in the air intake system? Yes Repair or replace air intake system. No Go to step 2.
Go to step 3.
Replace pressure sensor. <Ref. to FU(SOHCw/ oOBD)-29, Pressure Sensor.>
Go to step 4.
Replace pressure sensor. <Ref. to FU(SOHCw/ oOBD)-29, Pressure Sensor.> Replace throttle position sensor. <Ref. to FU(SOHCw/ oOBD)-26, Throttle Position Sensor.> Replace throttle position sensor. <Ref. to FU(SOHCw/ oOBD)-26, Throttle Position Sensor.> Replace idle air control solenoid valve. <Ref. to FU(SOHCw/ oOBD)-31, Idle Air Control Solenoid Valve.>
Go to step 5.
Go to step 6.
CHECK IDLE AIR CONTROL SOLENOID VALVE. 1) Start engine, and idle it. 2) Disconnect connector from idle air control solenoid valve.
Does engine revolution change?
Go to step 7.
EN(SOHCw/oOBD)-109
No. 7

Step CHECK POOR CONTACT. Check poor contact in ECM connector. Check Is there poor contact in ECM connector? Yes Repair poor contact in ECM connector. No Contact your Subaru distributor. NOTE: Inspection by your Subaru distributor is required, because probable cause is deterioration of multiple parts.
EN(SOHCw/oOBD)-110
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) O: DTC 85 CHARGE SYSTEM
S068521G71
DIAGNOSIS: Power source voltage of the ECM is low or high. TROUBLE SYMPTOM: Charge warning light comes on. CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY and INSPECTION MODES. <Ref. to EN(SOHCw/oOBD)-31 OPERATION, Clear Memory Mode.> and <Ref. to EN(SOHCw/ oOBD)-29 OPERATION, Inspection Mode.> WIRING DIAGRAM:
S2M2130
EN(SOHCw/oOBD)-111
No. 1

Step CHECK GENERATOR. 1) Start engine. 2) Idling after warm-up. 3) Measure voltage between generator B terminal and chassis ground. Terminal Generator B terminal Chassis ground: CHECK GENERATOR. 1) Run the engine at 5,000 rpm. 2) Measure voltage between generator B terminal and chassis ground. Terminal Generator B terminal (+) Chassis ground (): CHECK BATTERY TERMINAL. Turn ignition switch to OFF. Check Yes Is the voltage between 10.8 Go to step 2. V and 16.2 V? No Repair generator. <Ref. to SC-12, Generator.>
Is the voltage between 10.8 Go to step 3. V and 16.2 V?
Are the positive and nega- Go to step 4. tive battery terminals tightly clamped? Is the voltage between 10.8 Go to step 5. CHECK INPUT VOLTAGE OF ECM. 1) Disconnect connector from ECM, then con- V and 16.2 V? nect ST. <Ref. to EN(SOHCw/oOBD)-23, HOW TO CHECK I/O SIGNAL FOR ECM, Engine Control Module (ECM) I/O Signal.> ST 4983907600 CHECK BOARD KIT 2) Run the engine at idle. 3) Measure voltage between ECM connector and chassis ground. Connector & terminal (B) No. 27 (+) Chassis ground (): (C) No. 36 (+) Chassis ground (): Repair connector. CHECK POOR CONTACT IN CONNECIs there poor contact in TORS. connectors between generator, battery and ECM? Is the same trouble code Replace generaCHECK ECM. as in the current diagnosis tor. 1) Connect all connectors. still being output? 2) Erase the memory. 3) Perform inspection mode. 4) Read out the trouble code. CHECK ANY OTHER TROUBLE CODES Are other trouble codes Proceed with the APPEARANCE. being output? diagnosis corresponding to the trouble code.
Go to step 6.
Go to step 7.
EN(SOHCw/oOBD)-112

A: INSPECTION
S068257A10
S068257
NOTE: Malfunction of parts other than those listed is also possible. The right-hand priority column indicates the inspection priority of probable causes of the symptom. Carry out the check starting from A.
Symptom Problem parts 1. Engine does not start. (internal combustion does 1) ECM power supply not occur.) 2) Engine ground terminal 3) Crankshaft position sensor 4) Fuel pump 5) Pressure regulator 6) Engine coolant temperature sensor 7) Ignition coil & ignitor 8) Spark plug 9) Fuel injector 10) Idle air control solenoid valve 2. Engine does not start. (internal combustion 1) ECM power supply occurs.) 2) Spark plug 3) Engine coolant temperature sensor 4) Pressure regulator 5) Pressure sensor 6) Fuel pump 7) Fuel injector 8) Idle air control solenoid valve 3. Engine does not start. (engine stalls after inter1) ECM power supply nal combustion.) 2) Pressure sensor 3) Engine coolant temperature sensor 4) Spark plug 5) Ignition coil 6) Fuel pump 7) Pressure regulator 8) Fuel injector 9) Idle air control solenoid valve 4. Engine stalls. 1) Pressure sensor 2) Spark plug 3) Accelerator cable is out of adjustment 4) ECM power supply 5) Throttle position sensor 6) Crankshaft position sensor 7) Vehicle speed sensor 8) Ignition coil 9) Fuel pump 10) Idle air control solenoid valve 5. Rough idling 1) Spark plug 2) Pressure sensor 3) Engine coolant temperature sensor 4) Pressure regulator 5) Idle air control solenoid valve 6) Air leak in air intake system 7) ECM power supply 8) Throttle position sensor 9) Intake air temperature sensor 10) Oxygen sensor 11) Fuel pump 12) Fuel injector 13) Test mode or read memory connectors are connected. Priority A A B B B C C C C C A A B B C C C C A A B B C C C C C B B B C C C C C C C A B B B B B C C C C C C C
EN(SOHCw/oOBD)-113
Symptom 6. Hard to drive at constant speed

Problem parts 1) Pressure regulator 2) Fuel injector 3) Pressure sensor 4) Engine coolant temperature sensor 5) Throttle position sensor 6) Fuel pump 1) Spark plug 2) Throttle position sensor 3) Ignition coil 4) Fuel pump 5) Pressure regulator 6) Fuel injector 7) Pressure sensor 8) Engine coolant temperature sensor 9) Idle air control solenoid valve 10) Knock sensor 1) Accelerator cable is out of adjustment 2) Throttle position sensor 3) Idle air control solenoid valve 4) Pressure sensor 5) Engine coolant temperature sensor 1) Spark plug 2) Fuel injector 3) Ignition coil and ignitor 4) Fuel pump 5) Pressure regulator 1) Fuel pump 2) Pressure regulator 3) Engine coolant temperature sensor 4) Knock sensor 1) Engine coolant temperature sensor 2) Pressure sensor 3) Intake air temperature sensor 4) Pressure regulator 1) Pressure regulator 2) ECM power supply 3) Throttle position sensor 1) Pressure regulator 2) Pressure sensor 3) Engine coolant temperature sensor 4) Throttle sensor 5) Intake air temperature sensor 6) Fuel pump 1) ECM power supply 2) Pressure sensor 3) Pressure regulator 4) Idle air control solenoid valve 5) Air leak in air intake system Priority A B C C C C A B B B B B C C C C A B B C C A B C C C B B C C A B B B A B B A B B B B B A* B* B* B* B*
7. Poor acceleration/deceleration
8. Poor return to idling
9. Back fire
10. Knocking
11. Excessive fuel consumption
12. Shocks while driving
13. Poor engine revving
14. Remarks
A*: Including ECM ground circuit B*: Check hoses.
EN(SOHCw/oOBD)-114
FU(DOHC TURBO)
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. Page General Description.....................................................................................2 Throttle Body .............................................................................................14 Intake Manifold ..........................................................................................15 Engine Coolant Temperature Sensor........................................................29 Crankshaft Position Sensor.......................................................................30 Camshaft Position Sensor.........................................................................31 Knock Sensor ............................................................................................32 Throttle Position Sensor............................................................................33 Mass Air Flow and Intake Air Temperature Sensor ..................................34 Pressure Sensor........................................................................................35 Idle Air Control Solenoid Valve .................................................................36 Fuel Injector...............................................................................................37 Tumble Generator Valve Assembly...........................................................40 Wastegate Control Solenoid Valve............................................................41 Front Oxygen (A/F) Sensor.......................................................................42 Rear Oxygen Sensor.................................................................................44 Exhaust Temperature Sensor....................................................................46 Engine Control Module..............................................................................47 Main Relay ................................................................................................48 Fuel Pump Relay.......................................................................................49 Fuel............................................................................................................50 Fuel Tank...................................................................................................53 Fuel Filler Pipe ..........................................................................................56 Fuel Pump .................................................................................................60 Fuel Level Sensor .....................................................................................62 Fuel Sub Level Sensor..............................................................................63 Fuel Filter ..................................................................................................64 Fuel Cut Valve...........................................................................................65 Fuel Damper Valve....................................................................................66 Fuel Delivery, Return and Evaporation Lines ...........................................67 Fuel System Trouble in General ...............................................................70
GENERAL DESCRIPTION
S185001
A: SPECIFICATIONS
Model Fuel tank
S185001E49
Fuel pump
Fuel filter
(15.9 US gal, 13.2 Imp gal) Under rear seat Impeller 450 677 kPa (4.59 6.9 kg/cm2, 65.27 98.2 psi) More than 130 (34.3 US gal, 28.6 Imp gal)/h [12 V at 300 kPa (3.06 kg/cm2, 43.5 psi)] Cartridge type
60
FU(DOHC TURBO)-2
GENERAL DESCRIPTION
MEMO:
FU(DOHC TURBO)-3
GENERAL DESCRIPTION
B: COMPONENT
S185001A05
1. INTAKE MANIFOLD
S185001A0501
S2M2173A
FU(DOHC TURBO)-4
GENERAL DESCRIPTION
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) Fuel pipe ASSY Fuel hose Clip Purge control solenoid valve Vacuum hose Vacuum control hose Purge valve Purge hose Intake manifold gasket Guide pin Tumble generator valve ASSY Tumble generator valve gasket (13) (14) (15) (16) (17) (18) (19) (20) (21) Accelerator cable bracket Fuel injector Insulator Fuel injector pipe Pressure regulator Pressure regulator hose Blow-by hose stay Intake manifold Wastegate control solenoid valve ASSY (22) Nipple (23) Fuel pipe protector

Tightening torque: Nm (kgf-m, ft-lb) T1: 5 (0.50, 3.7) T2: 6.4 (0.65, 4.7) T3: 8.25 (0.84, 6.1) T4: 16 (1.63, 11.8) T5: 17 (1.73, 12.5) T6: 19 (1.94, 14.0) T7: 25 (2.55, 18.4)
FU(DOHC TURBO)-5
GENERAL DESCRIPTION
S185001A0502
EN0779
(1) (2) (3) (4)
Gasket Throttle position sensor Idle air control solenoid valve Throttle body
(5) Pressure sensor
FU(DOHC TURBO)-6
GENERAL DESCRIPTION

S185001A0503
EN0780
(1) Crankshaft position sensor (2) Knock sensor (3) Camshaft position sensor
FU(DOHC TURBO)-7
GENERAL DESCRIPTION
4. FUEL TANK
S185001A0504
S2M2152A
FU(DOHC TURBO)-8
GENERAL DESCRIPTION
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) Heat sealed cover Fuel tank band Protector LH Protector RH Fuel tank Fuel pump gasket Fuel pump ASSY Fuel level snsor Fuel cut valve gasket Fuel cut valve Evaporation hose A Clip (13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) Evaporation hose B Joint pipe Evaporation hose C Evaporation pipe ASSY Evaporation hose D Evaporation hose E Fuel return hose A Retainer Quick connector Evaporation hose F Fuel pipe ASSY Evaporation hose G (25) (26) (27) (28) (29) (30)

Fuel return hose B Fuel sub level sensor gasket Jet pump filter Fuel sub level sensor Evaporation hose H Evaporation hose I
FU(DOHC TURBO)-9
GENERAL DESCRIPTION
5. FUEL LINE
S185001A0505
S2M2153A
FU(DOHC TURBO)-10
GENERAL DESCRIPTION
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) Clip Fuel delivery hose A Fuel filter bracket Fuel filter holder Fuel filter cup Fuel filter Evaporation hose A Fuel damper Fuel delivery hose B Fuel return hose Fuel pipe ASSY Grommet (13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) Canister hose A Canister Canister bracket plate Cushion Canister bracket spacer Rear canister bracket Two-way valve return hose Two-way valve Two-way valve drain hose A Connector Two-way valve drain hose B Clamp (25) (26) (27) (28) (29) (30) (31)

Front canister bracket Evaporation hose B Roll over valve bracket Roll over valve Evaporation hose C Evaporation pipe Canister hose B
Tightening torque: Nm (kgf-m, ft-lb) T1: 23 (2.34, 17.0)
FU(DOHC TURBO)-11
GENERAL DESCRIPTION
S185001A0506
6. FUEL FILLER PIPE
S2M2245A
(1) (2) (3) (4) (5)
Fuel filter pipe ASSY Evaporation hose holder Clamp Clamp Air vent hose
(6) (7) (8) (9) (10)
Air vent pipe Air vent pipe holder Filler pipe packing Filler ring Filler cap
(11) Fuel pipe protector

FU(DOHC TURBO)-12

S185001A03
D: PREPARATION TOOL
ILLUSTRATION
S185001A17
REMARKS Troubleshooting for electrical system.
B2M3876
22771AA030
SELECT MONITOR KIT
B2M3877
FU(DOHC TURBO)-13
THROTTLE BODY
S185010
2. Throttle Body
A: REMOVAL
S185010A18
EN0784
G6M0095
6) Remove bolts which secure throttle body to intake manifold.
2) Remove intercooler. <Ref. to IN(DOHC TURBO)-10, REMOVAL, Intercooler.> 3) Disconnect connector from throttle position sensor (A) and idle air control solenoid valve (B) and pressure sensor (C).
B: INSTALLATION
S185010A11
EN0782
4) Disconnect accelerator cable.
EN0785
H2M1890
FU(DOHC TURBO)-14
INTAKE MANIFOLD
3. Intake Manifold
A: REMOVAL
S185034A18
S185034
1) Release fuel pressure. <Ref. to FU(DOHC TURBO)-50, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.> 2) Disconnect battery ground cable.
(1) Remove front side V-belt. <Ref. to ME(DOHC TURBO)-44, REMOVAL, V-belt.> (2) Disconnect the power steering switch connector.
EN0360
(3) Remove bolts which secure power steering pipe brackets to intake manifold.
G6M0095
3) Lift up vehicle. 4) Remove under cover. 5) Drain coolant about 3.0 qt).
NOTE: Do not disconnect power steering hose.
(3.2 US qt, 2.6 Imp
S2M2248
EN0073
(4) Remove bolts which secure power steering pump.
6) Remove air cleaner upper cover and air intake boot. <Ref. to IN(DOHC TURBO)-7, REMOVAL, Air Cleaner.> 7) Remove air cleaner element. 8) Remove intercooler. <Ref. to IN(DOHC TURBO)-10, REMOVAL, Intercooler.> 9) Disconnect accelerator cable.
H2M1954
H2M1890
10) Remove coolant filler tank. <Ref. to CO-37, REMOVAL, Coolant Filler Tank.> 11) Remove power steering pump from bracket.
FU(DOHC TURBO)-15
INTAKE MANIFOLD
14) Disconnect brake booster hose.
(5) Remove power steering tank from the bracket by pulling it upward.
EN0204 EN0361
15) Disconnect Pressure hose from intake duct.
EN0787
EN0208
16) Disconnect engine harness connectors from bulkhead harness connectors.
12) Disconnect emission hose from PCV valve.
EN0788 EN0789
S2M2260
EN0784
FU(DOHC TURBO)-16
INTAKE MANIFOLD
17) Disconnect connectors from engine coolant temperature sensor (A), oil pressure switch (B) and crankshaft position sensor (C).
21) Remove harness secured by clip (A) from the bracket.
S2M2256A EN0790
22) Disconnect fuel delivery hose, return hose and evaporation hose. WARNING: Catch fuel from hoses in a container.
S2M1613
EN0214
23) Remove bolts which secure intake manifold to cylinder heads.
B2M1251
20) Disconnect connector from ignition coil.

EN0792
B: INSTALLATION
S185034A11
EN0854
FU(DOHC TURBO)-17
INTAKE MANIFOLD
5) Connect connector to camshaft position sensor.
B2M1251 EN0792
6) Connect connector to ignition coil.
2) Connect fuel delivery hose, return hose, and evaporation hose.
EN0854
EN0214
7) Secure harness to the bracket with clip (A).
3) Connect connector to oil pressure switch (B), crankshaft position sensor (C) and engine coolant temperature sensor (A).
S2M2256A
EN0790
4) Connect connector to knock sensor.
S2M1613
FU(DOHC TURBO)-18
INTAKE MANIFOLD
8) Connect engine harness connector to bulkhead harness connectors.
11) Connect emission hose to PCV valve.
EN0789 EN0788
12) Connect pressure hose to intake duct.
S2M2260
EN0787
9) Connect brake booster vacuum hose.
13) Install power steering pump on bracket. (1) Install power steering tank on bracket.
EN0204
10) Connect engine coolant hoses to throttle body.
EN0361
(2) Connect connector to power steering pump switch.
EN0784
EN0360
FU(DOHC TURBO)-19
INTAKE MANIFOLD
19) Connect connector to fuel pump relay.
(3) Install power steering pump, and tighten bolts. Tightening torque: 20.1 Nm (2.05 kgf-m, 14.8 ft-lb)
S2M0093
H2M1954
(4) Install power steering pipe brackets on right side intake manifold.
20) Connect battery ground cable. 21) Lift up vehicle. 22) Install under cover. 23) Fill coolant. <Ref. to CO-14, FILLING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>
S2M2248
(5) Install front side V-belt. <Ref. to ME(DOHC TURBO)-44, INSTALLATION, V-belt.> 14) Install coolant filler tank. <Ref. to CO-37, INSTALLATION, Coolant Filler Tank.> 15) Connect accelerator cable.
H2M1890
16) Install intercooler. <Ref. to IN(DOHC TURBO)-10, INSTALLATION, Intercooler.> 17) Install air cleaner element. 18) Install air cleaner upper cover and air intake duct as a unit. <Ref. to IN(DOHC TURBO)-7, INSTALLATION, Air Cleaner.>
FU(DOHC TURBO)-20
INTAKE MANIFOLD C: DISASSEMBLY

S185034A06
5) Remove throttle body from intake manifold.
1) Remove fuel pipe protector.
EN0785 EN0794
2) Remove engine ground terminal from intake manifold.
EN0798
EN0795
7) Disconnect connector from tumble generator valve actuator.
EN0796
EN0799
3) Disconnect connector from throttle position sensor (A), idle air control solenoid valve (B) and pressure sensor (C). 4) Separate engine harness secured to the intake manifold by clip (D).
8) Disconnect connector from tumble generator valve sensor.
EN0800
S2M2249A
FU(DOHC TURBO)-21
INTAKE MANIFOLD
13) Remove two bolts which hold fuel pipes on the left side of intake manifold.
EN0801
EN0805
10) Remove purge control solenoid valve.
14) Remove bolt which hold fuel injector pipe onto intake manifold. LH SIDE
EN0802
11) Disconnect evaporation hose from intake manifold.
EN0806
EN0803
EN0807
12) Disconnect evaporation hoses from purge valve.
EN0804
FU(DOHC TURBO)-22
INTAKE MANIFOLD
RH SIDE
18) Loosen clamp which holds front left side fuel hose to injector pipe and remove the pipe from clamp.
EN0808
EN0812
19) Remove fuel injector pipe LH. 20) Remove bolts which installs fuel pipe on intake manifold.
EN0809
15) Remove fuel injector.
EN0813
21) Remove fuel pipe assembly and pressure regulator, from intake manifold. 22) Remove intake duct from intake manifold.
EN0810
16) Remove harness bracket which hold engine harness onto intake manifold.
EN0814
EN0811
17) Remove engine harness from intake manifold.
FU(DOHC TURBO)-23
INTAKE MANIFOLD
3) Install fuel pipe assembly regulator, to intake manifold. Tightening torque: 5 Nm (0.51 kgf-m, 3.69 ft-lb) and pressure
23) Remove tumble generator valve assembly from intake manifold.
EN0815
D: ASSEMBLY
S185034A02
EN0813
NOTE: Replace gasket with a new one. 1) Install tumble generator valve assembly to intake manifold. Tightening torque: 8.25 Nm (0.84 kgf-m, 6.08 ft-lb)
4) Install fuel injector pipe LH. 5) Connect left side fuel hose to injector pipe, and tighten clamp screw.
EN0812
EN0815
6) Install engine harness to intake manifold. 7) Install harness bracket which hold engine harness onto intake manifold. Tightening torque: 19 Nm (1.94 kgf-m, 14.0 ft-lb)
2) Install air intake duct to intake manifold. Tightening torque: 19 Nm (1.94 kgf-m, 14.0 ft-lb)
EN0811 EN0814
FU(DOHC TURBO)-24
INTAKE MANIFOLD
8) Install fuel injector. RH SIDE
EN0810
EN0808
9) Tighten bolt which install fuel injector pipe onto intake manifold. Tightening torque: 19 Nm (1.94 kgf-m, 14.0 ft-lb) LH SIDE
EN0809
10) Tighten two bolts which install fuel pipes on the left side of intake manifold. Tightening torque: 5 Nm (0.51 kgf-m, 3.69 ft-lb)
EN0806
EN0805 EN0807
FU(DOHC TURBO)-25
INTAKE MANIFOLD
13) Install purge control solenoid valve. Tightening torque: 16 Nm (0.16 kgf-m, 1.2 ft-lb)
11) Connect evaporation hoses to purge valve. CAUTION: Carefully connect the evaporation hoses.
EN0802
14) Connect hoses to purge control solenoid valve. CAUTION: Carefully connect the evaporation hoses.
EN0816
(A) (B) (C) (D)
To To To To
fuel pipe ASSY intake duct purge control solenoid valve intake manifold (A) (B) To intake manifold To purge valve
EN0817
12) Connect evaporation hose to intake manifold.
15) Connect connector to purge control solenoid valve.
EN0803
EN0801
FU(DOHC TURBO)-26
INTAKE MANIFOLD
16) Connect connector to tumble generator valve sensor.
19) Install throttle body to intake manifold. NOTE: Replace gasket with a new one. Tightening torque: 22 Nm (2.2 kgf-m, 16 ft-lb)
EN0800
17) Connect connector to tumble generator valve actuator.

EN0785
20) Connect connector to throttle position sensor (A), idle air control solenoid valve (B) and pressure sensor (C). 21) Secure engine harness to the intake manifold with clip (D).
EN0799
18) Connect connector to fuel injector.
S2M2249A
22) Install engine ground terminal to intake manifold. Tightening torque: 19 Nm (1.94 kgf-m, 14.0 ft-lb)
EN0798
EN0795
FU(DOHC TURBO)-27
INTAKE MANIFOLD
EN0796
23) Install fuel pipe protector. Tightening torque: 19 Nm (1.94 kgf-m, 14.0 ft-lb)
EN0794
E: INSPECTION
S185034A10
FU(DOHC TURBO)-28

S185047
A: REMOVAL
S185047A18
G6M0095
2) Remove the generator <Ref. to SC-12, REMOVAL, Generator.> 3) Disconnect connector from engine coolant temperature sensor.
EN0851
B: INSTALLATION
S185047A11
FU(DOHC TURBO)-29
CRANKSHAFT POSITION SENSOR B: INSTALLATION

S185043A11

S185043

S185043A18
A: REMOVAL
B2M1252B G6M0095
2) Remove bolt which install crankshaft position sensor to cylinder block.
G2M0408
G2M0409
FU(DOHC TURBO)-30
CAMSHAFT POSITION SENSOR

S185041A11
6. Camshaft Position Sensor

S185041
B: INSTALLATION

S185041A18
A: REMOVAL
G2M0417 G6M0095
G2M0416
3) Remove camshaft position sensor from camshaft support LH.
G2M0417
FU(DOHC TURBO)-31
KNOCK SENSOR
S185042
7. Knock Sensor
A: REMOVAL
S185042A18
B: INSTALLATION
S185042A11
G6M0095
2) Remove intercooler. <Ref. to IN(DOHC TURBO)-10, REMOVAL, Intercooler.> 3) Disconnect knock sensor connector. 2) Connect knock sensor connector.
H2M3511C
B2M4262
B2M4262
3) Install intercooler. <Ref. to IN(DOHC TURBO)10, INSTALLATION, Intercooler.> 4) Connect battery ground cable.
S2M1673
G6M0095
FU(DOHC TURBO)-32

S185039A11

A: REMOVAL
S185039A18
S185039
B: INSTALLATION
G6M0095
EN0820
2) Remove inter cooler. <Ref. to IN(DOHC TURBO)-10, REMOVAL, Intercooler.> 3) Disconnect connector from throttle position sensor.
EN0819
sensor
holding
EN0820
FU(DOHC TURBO)-33
MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR
9. Mass Air Flow and Intake Air Temperature Sensor

S185770
A: REMOVAL
S185770A18
G6M0095
2) Disconnect connector mass air flow and intake air temperature sensor. 3) Remove mass air flow and intake air temperature sensor.
EN1045
B: INSTALLATION
S185770A11
FU(DOHC TURBO)-34
PRESSURE SENSOR
10. Pressure Sensor

A: REMOVAL
S185765A18
S185765
G6M0095
2) Remove idle air control solenoid valve. <Ref. to FU(SOHC)-38, REMOVAL, Idle Air Control Solenoid Valve.> 3) Disconnect connectors from pressure sensor.
EN0821
4) Remove pressure sensor from throttle body.
B: INSTALLATION
S185765A11
Install in the reverse order of removal. NOTE: Replace gaskets for idle air control solenoid valve with new ones. Tightening torque: Pressure sensor 1.6 Nm (0.16 kgf-m, 1.2 ft-lb) Idler air control solenoid valve 2.8 Nm (0.29 kgf-m, 2.1 ft-lb)
FU(DOHC TURBO)-35
IDLE AIR CONTROL SOLENOID VALVE B: INSTALLATION

NOTE: Always use new gasket. Tightening torque: 2.8 Nm (0.29 kgf-m, 2.1 ft-lb)
S185056A11

S185056
A: REMOVAL
S185056A18
G6M0095
EN0823
EN0822
EN0823
FU(DOHC TURBO)-36
FUEL INJECTOR
12. Fuel Injector

A: REMOVAL
1. RH SIDE
S185051A18 S185051A1801
S185051
4) Remove bolts which hold injector pipe to intake manifold.
1) Remove intake manifold. <Ref. to FU(DOHC TURBO)-15, REMOVAL, Intake Manifold.> 2) Remove fuel pipe protector.
EN0808
EN0794
EN0809
5) Remove fuel injector while lifting up fuel injector pipe.
EN0798
EN0810
FU(DOHC TURBO)-37
FUEL INJECTOR
4) Remove fuel injector while lifting up fuel injector pipe.
2. LH SIDE
S185051A1802
1) Remove intake manifold. <Ref. to FU(DOHC TURBO)-15, REMOVAL, Intake Manifold.> 2) Disconnect connector from fuel injector.
EN0824
EN0798
B: INSTALLATION
1. RH SIDE
S185051A1101
S185051A11
3) Remove bolts which hold injector pipe to intake manifold.
Install in the reverse order of removal. NOTE: Replace O-ring and insulators with new ones.
EN0805
S2M2250A
(A) (B) (C)
O-ring Fuel injector Insulator
EN0807
EN0808
EN0806
FU(DOHC TURBO)-38
FUEL INJECTOR
EN0809
EN0805
EN0794
EN0806
2. LH SIDE
S185051A1102
Install in the reverse order of removal. NOTE: Replace O-ring and insulators with new ones.
EN0807
S2M2250A
(A) (B) (C)
O-ring Fuel injector Insulator
FU(DOHC TURBO)-39
TUMBLE GENERATOR VALVE ASSEMBLY

6) Remove tumble generator valve body from intake manifold.
13. Tumble Generator Valve Assembly

S185766
A: REMOVAL
S185766A18
EN0815
B: INSTALLATION
G6M0095
S185766A11
Install in the reverse order of removal. NOTE: Always use new gaskets. Tightening torque: 8.25 Nm (0.84 kgf-m, 6.1 ft-lb)
2) Remove intake manifold. <Ref. to FU(DOHC TURBO)-15, REMOVAL, Intake Manifold.> 3) Disconnect connector from tumble generator valve sensor.
EN0800
EN0815
4) Disconnect connector from tumble generator valve actuator.
EN0799
5) Remove fuel injector. <Ref. to FU(DOHC TURBO)-37, REMOVAL, Fuel Injector.>
FU(DOHC TURBO)-40
WASTEGATE CONTROL SOLENOID VALVE
14. Wastegate Control Solenoid Valve

S185057
A: REMOVAL
S185057A18
G6M0095
2) Disconnect connector (A) from wastegate control solenoid valve. 3) Disconnect pressure hoses (B) from wastegate control solenoid valve. 4) Remove wastegate control solenoid valve from bracket
S2M2251A
B: INSTALLATION
S185057A11
S2M2251
FU(DOHC TURBO)-41

15. Front Oxygen (A/F) Sensor

S185642
A: REMOVAL
S185642A18
EN0832
7) Apply SUBARU CRC or its equivalent to threaded portion of front oxygen (A/F) sensor, and leave it for one minute or more.
G6M0095
SUBARU CRC (Part No. 004301003) 8) Remove front oxygen (A/F) sensor. CAUTION: When removing the oxygen (A/F) sensor, wait until exhaust pipe cools, otherwise it will damage exhaust pipe.
2) Disconnect connector from front oxygen (A/F) sensor.
S2M2252
3) Remove harness secured by clip (A) from the bracket (B).
EN0833
S2M2253A
4) Remove front right side wheel. 5) Lift-up the vehicle.
FU(DOHC TURBO)-42
FRONT OXYGEN (A/F) SENSOR B: INSTALLATION

S185642A11
1) Before installing front oxygen (A/F) sensor, apply anti-seize compound only to threaded portion of front oxygen (A/F) sensor to make the next removal easier. Anti-seize compound: SS-30 by JET LUBE CAUTION: Never apply anti-seize compound to protector of front oxygen (A/F) sensor. 2) Install front oxygen (A/F) sensor. Tightening torque: 30Nm (3.1 kgf-m, 22 ft-lb)
7) Connect connector of front oxygen (A/F) sensor.
S2M2252
G6M0095 EN0833
3) Install service hole cover.
EN0832
4) Lower the vehicle. 5) Install front right side wheel. 6) Secure a harness to bracket (B) by clip (A).
S2M2253A
FU(DOHC TURBO)-43
REAR OXYGEN SENSOR

S185657
16. Rear Oxygen Sensor

A: REMOVAL
S185657A18
6) Remove rear oxygen sensor. CAUTION: When removing the oxygen sensor, wait until exhaust pipe cools, otherwise it will damage exhaust pipe.
G6M0095 EN0835
2) Lift-up the vehicle. 3) Disconnect connector from rear oxygen sensor.
EN0834
4) Vertically draw out clip (A) from crossmember (B).
S2M2254
5) Apply SUBARU CRC or its equivalent to threaded portion of rear oxygen sensor, and leave it for one minute or more. SUBARU CRC (Part No. 004301003)
FU(DOHC TURBO)-44
REAR OXYGEN SENSOR B: INSTALLATION

S185657A11
1) Before installing rear oxygen sensor, apply antiseize compound only to threaded portion of rear oxygen sensor to make the next removal easier. CAUTION: Never apply anti-seize compound to protector of rear oxygen sensor. Anti-seize compound: SS-30 by JET LUBE 2) Install rear oxygen sensor. Tightening torque: 21 Nm (2.1 kgf-m, 15.2 ft-lb)
G6M0095
EN0835
3) Connect connector to rear oxygen sensor.
EN0834
4) Secure clip (A) on the crossmember.
S2M2254
FU(DOHC TURBO)-45
EXHAUST TEMPERATURE SENSOR B: INSTALLATION

S185763A11
17. Exhaust Temperature Sensor

S185763
A: REMOVAL
S185763A18
1) Before installing exhaust temperature sensor, apply anti-seize compound only to threaded portion of rear oxygen sensor to make the next removal easier. CAUTION: Never apply anti-seize compound to protector of exhaust temperature sensor. Anti-seize compound: SS-30 by JET LUBE 2) Install exhaust temperature sensor. NOTE: Align mark (A) on the exhaust temperature sensor side with the joint pipe side mark (B) and tighten.
G6M0095
2) Remove joint pipe. <Ref. to EX(DOHC TURBO)-13, REMOVAL, Joint Pipe.> 3) Apply SUBARU CRC or its equivalent to threaded portion of exhaust temperature sensor, and leave it for one minute or more. SUBARU CRC (Part No. 004301003) 4) Remove exhaust temperature sensor. CAUTION: When removing the oxygen sensor, wait until exhaust pipe cools, otherwise it will damage exhaust pipe.
S2M2255A
3) Install joint pipe <Ref. to EX(DOHC TURBO)13, INSTALLATION, Joint Pipe.>. 4) Connect battery ground cable.
EN0836
G6M0095
FU(DOHC TURBO)-46

A: REMOVAL
S185049A18
S185049
G6M0095
2) Remove lower inner trim of passenger side. <Ref. to EI-38, REMOVAL, Lower Inner Trim.> 3) Detach floor mat of front passenger seat. 4) Remove protect cover.
EN0532
5) Remove nuts (A) which hold ECM to bracket. 6) Remove clip (B) from bracket.
EN0533
7) Disconnect ECM connectors and take out ECM.
B: INSTALLATION
S185049A11
Install in the reverse order of removal. CAUTION: When replacing ECM, be careful not to use the wrong spec. ECM to avoid any damage to the fuel injection system.
FU(DOHC TURBO)-47
MAIN RELAY
19. Main Relay

A: REMOVAL
S185050
S185050A18
S2M0137
B: INSTALLATION
G6M0095
S185050A11
S2M0107
S2M0108A
(A) (B) (C)
FU(DOHC TURBO)-48
FUEL PUMP RELAY
20. Fuel Pump Relay

A: REMOVAL
S185048A18
S185048
G6M0095
S2M0093
S2M0138
B: INSTALLATION
S185048A11
FU(DOHC TURBO)-49
FUEL
21. Fuel
S185052
A: OPERATION
S185052A1601
S185052A16

WARNING: Place NO FIRE signs near the working area. Disconnect ground terminal from battery. 1) Disconnect connector from fuel pump relay.
G6M0095
S2M0093
2) Start the engine, and run it until it stalls. 3) After the engine stalls, crank it for five more seconds. 4) Turn ignition switch to OFF.
S2M0246
2. DRAINING OF FUEL
S185052A1603
WARNING: Place NO FIRE signs near the working area. Be careful not to spill fuel on the floor. 1) Release fuel pressure. <Ref. to FU(DOHC TURBO)-50, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.> 2) Open fuel flap lid, and remove fuel filler cap.
S2M0172
7) Disconnect quick connector, and then disconnect fuel delivery hose (A). <Ref. to FU(DOHC TURBO)-67, REMOVAL, Fuel Delivery, Return and Evaporation Lines.>
B2M3197
FU(DOHC TURBO)-50
FUEL
8) Move clips, and then disconnect fuel return hose (B) and jet pump hose (C).
G2M0863 S2M0060A
13) Disconnect connector from fuel sub level sensor. 14) Disconnect fuel jet pump hose.
S2M0061
S2M0151
15) Remove bolts which install fuel sub level sensor on fuel tank.
S2M0062
S2M0152
16) Remove fuel sub level sensor.
S2M0153
S2M0163
FU(DOHC TURBO)-51
FUEL
17) Drain fuel from there. WARNING: Do not use a motor pump when draining fuel.
S2M0247
FU(DOHC TURBO)-52
FUEL TANK
22. Fuel Tank

A: REMOVAL
S185053
S185053A18
WARNING: Place NO FIRE signs near the working area. Be careful not to spill fuel on the floor. 1) Set vehicle on the lift. 2) Release fuel pressure. <Ref. to FU(DOHC TURBO)-52, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.> 3) Drain fuel from fuel tank. <Ref. to FU(DOHC TURBO)-50, DRAINING FUEL, OPERATION, Fuel.> 4) Remove rear seat. 5) Disconnect connector of fuel tank cord to rear harness.
EN0840
9) Loosen clamp and disconnect fuel filler hose (A) and air vent hose (B) from fuel filler pipe.
EN0539 S2M0164
10) Move clips, and disconnect quick connector. <Ref. to FU(DOHC TURBO)-67, REMOVAL, Fuel Delivery, Return and Evaporation Lines.> 11) Disconnect fuel hoses.
S2M0165 EN0540
7) Remove rear crossmember. <Ref. to RS-20, REMOVAL, Rear Crossmember.>
FU(DOHC TURBO)-53
FUEL TANK
4) Connect fuel filler hose (A) and air vent hose (B).
12) Support fuel tank with transmission jack, remove bolts from bands and dismount fuel tank from the vehicle. WARNING: A helper is required to perform this work.
EN0539
S2M2246
5) Connect fuel hoses, and hold then with clips and quick connector. <Ref. to FU(DOHC TURBO)68, INSTALLATION, Fuel Delivery, Return and Evaporation Lines.>
B: INSTALLATION
S185053A11
1) Support fuel tank with transmission jack and push fuel tank harness into access hole with grommet. 2) Set fuel tank and temporarily tighten bolts of fuel tank bands. WARNING: A helper is required to perform this work.
EN0540
6) Tighten band mounting bolts. Tightening torque: 33 Nm (3.4 kgf-m, 25 ft-lb)
S2M2246
3) Connect two-way valve hose (A) to two-way valve and connect canister hose (B) to canister.
S2M2246
7) Install rear crossmember. <Ref. to RS-20, INSTALLATION, Rear Crossmember.>
EN0840
FU(DOHC TURBO)-54
FUEL TANK
8) Connect connectors to fuel tank cord and plug service hole with grommet.
S2M0164
9) Set rear seat and floor mat. 10) Connect connector to fuel pump relay.
S2M0093
C: INSPECTION
S185053A10
FU(DOHC TURBO)-55
FUEL FILLER PIPE

S185022

A: REMOVAL
S185022A18
WARNING: Place NO FIRE signs near the working area. Be careful not to spill fuel on the floor. 1) Release fuel pressure. <Ref. to FU(DOHC TURBO)-50, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.> 2) Open fuel filler flap lid and remove filler cap. 3) Disconnect battery ground cable.
B2M1894
9) Separate evaporation hoses from clip of fuel filler pipe.
G6M0095
4) Remove screws holding packing in place.
EN0545
10) Disconnect air vent hose from fuel filler pipe.
EN0542
5) Lift-up the vehicle. 6) Remove rear right side wheel nuts. 7) Remove rear right side wheel.
B2M1896
B2M1748 B2M1895
FU(DOHC TURBO)-56
FUEL FILLER PIPE

12) Loosen clamp and separate fuel filler hose (A) from fuel filler pipe. 13) Move clip and separate air vent hose (B).
EN0548
14) Remove fuel filler pipe to under side of the vehicle. 15) Remove air vent pipe together with clip from body.
B2M1196A
4) Install air vent pipe.
EN0549 EN0549
5) Connect air vent hose to fuel filler pipe.
B: INSTALLATION
S185022A11
1) Hold fuel filler flap open. 2) Set fuel saucer (A) with rubber packing (C) and insert fuel filler pipe into hole from the inner side of apron.
B2M1896
B2M1196A
FU(DOHC TURBO)-57
FUEL FILLER PIPE

9) Tighten bolts which hold evaporation hoses onto clip of fuel filler pipe.
EN0545

EN0548
B2M1894
B2M1195A
(1) (2) (3)
Hose Clip Pipe

B2M1748
12) Lower the vehicle. 13) Tighten wheel nuts. 14) Connect connector to fuel pump relay.
B2M1895
S2M0093
FU(DOHC TURBO)-58
FUEL FILLER PIPE

15) Connect battery ground terminal.
G6M0095
FU(DOHC TURBO)-59
FUEL PUMP
24. Fuel Pump

A: REMOVAL
S185025
S185025A18
WARNING: Place No fire signs near the working area. Be careful not to spill fuel on the floor. 1) Release fuel pressure. <Ref. to FU(DOHC TURBO)-50, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.> 2) Open fuel filler flap lid, and remove fuel filler cap.
S2M0172
7) Move clips, and then disconnect fuel delivery hose (A), return hose (B) and jet pump hose (C). 8) Disconnect quick connector, and then disconnect fuel delivery hose (A). <Ref. to FU(DOHC TURBO)-67, REMOVAL, Fuel Delivery, Return and Evaporation Lines.>
B2M3197
S2M0060A
G6M0095
S2M0061
S2M0246
S2M0062
FU(DOHC TURBO)-60

S185025A11
Install in the reverse order of removal. Do the following: (1) Always use new gaskets. (2) Ensure sealing portion is free from fuel or foreign particles before installation. (3) Tighten nuts in alphabetical sequence shown in the figure to specified torque. Tightening torque: 4.4 Nm (0.45 kgf-m, 3.3 ft-lb)
S2M0063A
C: INSPECTION
S185025A10
G2M0366
FU(DOHC TURBO)-61
FUEL LEVEL SENSOR

S185026

A: REMOVAL
S185026A18
WARNING: Place NO FIRE signs near the working area. Be careful not to spill fuel on the floor. NOTE: Fuel level sensor is built in fuel pump assembly. 1) Remove fuel pump assembly. <Ref. to FU(DOHC TURBO)-60, REMOVAL , Fuel Pump.> 2) Disconnect connector from fuel pump bracket.
S2M0145
S2M0855
B: INSTALLATION
S185026A11
FU(DOHC TURBO)-62

A: REMOVAL
S185023A18
S185023
6) Remove bolts which install fuel sub level sensor on fuel tank.
S2M0152
7) Remove fuel sub level sensor.
G6M0095
S2M0153
B: INSTALLATION
S185023A11
G2M0863
4) Disconnect connector from fuel sub level sensor. 5) Disconnect fuel jet pump hose.
S2M0152
S2M0151
FU(DOHC TURBO)-63
FUEL FILTER
27. Fuel Filter

A: REMOVAL
S185027
S185027A18
WARNING: Place NO FIRE signs near the working area. Be careful not to spill fuel on the floor. 1) Release fuel pressure. <Ref. to FU(DOHC TURBO)-50, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.> 2) Disconnect fuel delivery hoses from fuel filter.
S2M0195
B: INSTALLATION
S185027A11
CAUTION: If fuel hoses are damaged at the connecting portion, replace it with a new one. If clamps are badly damaged, replace with new ones. 1) Install in the reverse order of removal. 2) Tighten hose clamp screws. Tightening torque: 12.5 Nm (1.27 kgf-m, 9.22 ft-lb)
S2M0195
C: INSPECTION
S185027A10
FU(DOHC TURBO)-64
FUEL CUT VALVE
28. Fuel Cut Valve

A: REMOVAL
S185021A18
S185021
WARNING: Place NO FIRE signs near the working area. Be careful not to spill fuel on the floor. 1) Remove fuel tank. <Ref. to FU(DOHC TURBO)-53, REMOVAL, Fuel Tank.> 2) Move clip and disconnect evaporation hose from fuel cut valve.
S2M0176
B: INSTALLATION
S185021A11
S2M0177
FU(DOHC TURBO)-65
FUEL DAMPER VALVE

S185708
29. Fuel Damper Valve

A: REMOVAL
S185708A18
1) Release fuel pressure. <Ref. to FU(DOHC TURBO)-50, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.> 2) Remove fuel damper valve from fuel return line.
EN0852
B: INSTALLATION
S185708A11
FU(DOHC TURBO)-66

S185019
A: REMOVAL
S185019A18
1) Set vehicle on the lift. 2) Release fuel pressure. <Ref. to FU(DOHC TURBO)-50, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.>
3) Open fuel filler flap lid and remove fuel filler cap. 4) Remove floor mat. <Ref. to EI-43, REMOVAL, Floor Mat.> 5) Remove fuel delivery pipes and hoses, fuel return pipes and hoses, evaporation pipes and hoses.
S2M2247
S2M0500F
(A) (B) (C)
EN0840
FU(DOHC TURBO)-67
9) Separate quick connector on fuel delivery and return line. (1) Clean pipe and connector, if they are covered with dust. (2) Hold connector (A) and push retainer (B) down. (3) Pull out connector (A) from retainer (B). CAUTION: Replace retainers with new ones.
S2M0230A
(A) (B) (C)
S2M0228A
(A) (B) (C)

S185019A11
B: INSTALLATION
1) Connect quick connector on fuel delivery line. CAUTION: Always use a new retainer. Make sure that the connected portion is not damaged or has dust. If necessary, clean seal surface of pipe.
(A) (B) (C) Connector Retainer Pipe
S2M0231A
S2M0229A
FU(DOHC TURBO)-68

B2M1194B
(1) (2) (3)
Fitting Clamp Hose
B2M1195A
(1) (2) (3)
Hose Clip Pipe

S185019A10
C: INSPECTION
FU(DOHC TURBO)-69

S185571
A: INSPECTION
S185571A10
Trouble and possible cause 1. Insufficient fuel supply to the injector 1) Fuel pump will not operate. k k Defective terminal contact.
Corrective action
Trouble in electromagnetic or electronic circuit parts. 2) Lowering of fuel pump function. 3) Clogged dust or water in the fuel filter. 4) Clogged or bent fuel pipe or hose. 5) Air is mixed in the fuel system. 6) Clogged or bent breather tube or pipe. 7) Damaged diaphragm of pressure regulator. 2. Leakage or blow out fuel 1) Loosened joints of the fuel pipe. 2) Cracked fuel pipe, hose and fuel tank. 3) Defective welding part on the fuel tank. 4) Defective drain packing of the fuel tank. 5) Clogged or bent air breather tube or air vent tube.
NOTE: When the vehicle is left unattended for an extended period of time, water may accumulate in the fuel tank. To prevent water condensation: (1) Top off the fuel tank or drain the fuel completely. (2) Drain water condensation from the fuel filter. Refilling the fuel tank. Refill the fuel tank while there is still some fuel left in the tank. Protecting the fuel system against freezing and water condensation. (1) Cold areas In snow-covered areas, mountainous areas, skiing areas, etc. where ambient temperatures drop below 0C (32F) throughout the winter season, use an anti-freeze solution in the cool-
ing system. Refueling will also complement the effect of anti-freeze solution each time the fuel level drops to about one-half. After the winter season, drain water which may have accumulated in the fuel filter and fuel tank in the manner same as that described under Affected areas below. (2) Affected areas When water condensation is notched in the fuel filter, drain water from both the fuel filter and fuel tank or use a water removing agent (or antifreeze solution) in the fuel tank. Observe the instructions, notes, etc., indicated on the label affixed to the anti-freeze solution (water removing agent) container before use.
FU(DOHC TURBO)-70
EC(DOHC TURBO)
1. 2. 3. 4. 5. 6. 7. Page General Description.....................................................................................2 Front Catalytic Converter ............................................................................3 Rear Catalytic Converter.............................................................................4 Precatalytic Converter .................................................................................5 Canister .......................................................................................................6 Purge Control Solenoid Valve .....................................................................7 Two-way Valve ............................................................................................8
GENERAL DESCRIPTION
S180001
A: CAUTION
S180001A03
EC(DOHC TURBO)-2

A: REMOVAL
S180017A18
S180017
1) Remove center exhaust pipe. <Ref. to EX(DOHC TURBO)-9, REMOVAL, Center Exhaust Pipe.> 2) Separate front catalytic converter (A) from rear catalytic converter (B).
EN0993
B: INSTALLATION
S180017A11
NOTE: Replace gaskets with new ones. Install in the reverse order of removal.
C: INSPECTION
S180017A10
EC(DOHC TURBO)-3
REAR CATALYTIC CONVERTER

S180036
3. Rear Catalytic Converter

A: REMOVAL
S180036A18
1) Remove center exhaust pipe. <Ref. to EX(DOHC TURBO)-9, REMOVAL, Center Exhaust Pipe.> 2) Separate rear catalytic converter (B) from front catalytic converter (A).
EN0993
B: INSTALLATION
S180036A11
NOTE: Replace gaskets with new ones. Install in the reverse order of removal.
C: INSPECTION
S180036A10
EC(DOHC TURBO)-4
PRECATALYTIC CONVERTER
4. Precatalytic Converter
A: REMOVAL
S180767A18
S180767
Precatalytic converter (A) is built in joint pipe. Refer to removal of joint pipe for removal procedure. <Ref. to EX(DOHC TURBO)-13, REMOVAL, Joint Pipe.>
EN0994
B: INSTALLATION
S180767A11
Precatalytic converter is built in joint pipe. Refer to installation of joint pipe for installation procedure. <Ref. to EX(DOHC TURBO)-13, INSTALLATION, Joint Pipe.>
C: INSPECTION
S180767A10
EC(DOHC TURBO)-5
CANISTER
5. Canister
S180037
A: REMOVAL
S180037A18
1) Lift-up the vehicle. 2) Loosen two clamps which hold two canister hoses, and disconnect evaporation three hoses from canister.
EN0898
3) Remove canister from body.
B2M4166
B: INSTALLATION
S180037A11
1) Install in the reverse order of removal. Tightening torque: 23 Nm (2.3 kgf-m, 17 ft-lb)
B2M4166
C: INSPECTION
S180037A10
EC(DOHC TURBO)-6
PURGE CONTROL SOLENOID VALVE

S180035A11

S180035
B: INSTALLATION
A: REMOVAL
S180035A18
EN0899 G6M0095
2) Disconnect connector and hoses from purge control solenoid valve. 3) Remove bolt which installs purge control solenoid valve onto intake manifold.
EN0817
EN0899
(A) (B)
To intake manifold To purge value

S180035A10
C: INSPECTION
EC(DOHC TURBO)-7
TWO-WAY VALVE
7. Two-way Valve
A: REMOVAL
S180707A18
S180707
1) Lift-up the vehicle. 2) Remove canister from body. <Ref. to EC(DOHC TURBO)-6, REMOVAL, Canister.> 3) Remove two-way valve with bracket as a single unit from body.
EN0901
4) Remove two-way valve from bracket.
S180707A11

S180707A10
EC(DOHC TURBO)-8
INTAKE (INDUCTION)
IN(DOHC TURBO)
1. 2. 3. 4. 5. 6. 7. Page General Description.....................................................................................2 Air Cleaner ..................................................................................................7 Air Intake Duct.............................................................................................8 Intake Duct ..................................................................................................9 Intercooler..................................................................................................10 Turbocharger .............................................................................................12 Air By-pass Valve ......................................................................................14
Intake (Induction)
GENERAL DESCRIPTION
S184001
A: COMPONENT
1. AIR CLEANER
S184001A05 S184001A0501
S2M2164A
(1) (2) (3) (4) (5) (6) (7)
Mass air flow sensor Air cleaner upper cover Air cleaner element Spacer Bushing Clip Air cleaner lower case
(8) (9) (10) (11) (12) (13) (14)
Cushion rubber Air intake duct Resonator chamber ASSY Cushion rubber Clamp Air intake boot Cushion
Tightening torque: Nm (kgf-m, ft-lb) T1: 7.5 (0.76, 5.5) T2: 33 (3.4, 25) T3: 2.5 (0.25, 1.8) T4: 1.7 (0.17, 1.2)
IN(DOHC TURBO)-2
GENERAL DESCRIPTION
2. INTAKE DUCT
S184001A0502
Intake (Induction)
EN0903
(1) Clamp (2) Air by-pass hose A (3) Air by-pass hose B
(4) Air by-pass hose C (5) Air by-pass hose D (6) Intake duct
Tightening torque: Nm (kgf-m, ft-lb) T1: 15.7 (1.6, 11.6)
IN(DOHC TURBO)-3
Intake (Induction)
GENERAL DESCRIPTION
S184001A0503
3. INTER COOLER
S2M2165A
(1) (2) (3) (4) (5) (6) (7) (8)
PVC pipe Air by-pass hose C Stay Clamp Air intake hose Intercooler Intercooler bracket Air by-pass valve
(9) (10) (11) (12) (13) (14) (15) (16)
Gasket Intercooler duct A Intercooler duct B Intercooler duct C Air by-pass hose A Clamp Air by-pass pipe Air by-pass hose B
Tightening torque: Nm (kgf-m, ft-lb) T1: 3 (0.22, 1.6) T2: 6.4 (0.65, 4.7) T3: 16 (1.6, 11.7)
IN(DOHC TURBO)-4
GENERAL DESCRIPTION
4. TURBOCHARGER
S184001A0504
Intake (Induction)
H2M1608C
(1) (2) (3) (4) (5) (6) (7)
Oil inlet pipe Metal gasket Turbocharger Water pipe Clamp Engine coolant hose Gasket
(8) (9) (10) (11) (12)
Oil outlet pipe Clip Oil outlet hose Turbocharger bracket RH Turbocharger bracket LH
Tightening torque: Nm (kgf-m, ft-lb) T1: 4.4 (0.45, 3.3) T2: 4.9 (0.50, 3.6) T3: 29 (3.0, 21.7) T4: 30 (3.1, 22.4) T5: 33 (3.4, 24.6)
IN(DOHC TURBO)-5
Intake (Induction)
GENERAL DESCRIPTION
S184001A03
B: CAUTION
Wear working clothing, including a cap, protective goggles, and protective shoes during operation. Remove contamination including dirt and corrosion before removal, installation or disassembly. Keep the disassembled parts in order and protect them from dust or dirt. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly, and replacement. Be careful not to burn your hands, because each part on the vehicle is hot after running. Be sure to tighten fasteners including bolts and nuts to the specified torque. Place shop jacks or safety stands at the specified points. Before disconnecting electrical connectors of sensor or units, be sure to disconnect negative terminal from battery.
IN(DOHC TURBO)-6
AIR CLEANER
Intake (Induction)
2. Air Cleaner
A: REMOVAL
S184087
7) Remove air cleaner lower case.
S184087A18
1) Disconnect connector battery ground cable.
EN0905
B: INSTALLATION
G6M0095
S184087A11
2) Disconnect connector from mass air flow sensor.
EN0031
EN0905
3) Loosen clamp (A) which connects air intake boot to intake duct. 4) Remove the two clips (B) from air cleaner upper cover.
CAUTION: Before installing air cleaner upper cover, align holes with protruding portions of air cleaner lower case, then secure upper cover to lower case.
EN0992
5) Remove air cleaner upper cover. 6) Remove air cleaner element.
EN0906
C: INSPECTION
S184087A10
Replace if excessively damaged or dirty.
IN(DOHC TURBO)-7
Intake (Induction)
AIR INTAKE DUCT

S184566
3. Air Intake Duct

A: REMOVAL
S184566A18
Remove bolts which install air intake duct on the front side of body.
S2M2166
S184566A11

S184566A10
1) Inspect for cracks and loose connections. 2) Inspect that no foreign objects are mixed in the air intake duct.
IN(DOHC TURBO)-8
INTAKE DUCT
Intake (Induction)
4. Intake Duct
A: REMOVAL
S184760
S184760A18
G6M0095
2) Remove intake manifold. <Ref. to FU(DOHC TURBO)-15, REMOVAL, Intake Manifold.> 3) Remove sensor, engine harness, and fuel pipe attached to the intake manifold. <Ref. to FU(DOHC TURBO)-21, DISASSEMBLY, Intake Manifold.> 4) Remove intake duct from intake manifold.
EN0814
B: INSTALLATION
S184760A11
IN(DOHC TURBO)-9
Intake (Induction)
INTERCOOLER
S184761
5. Intercooler
A: REMOVAL
5) Separate intercooler from throttle body.
S184761A18
1) Remove air by-pass hoses from intercooler.
S2M2230
B: INSTALLATION
S2M2226
S184761A11
2) Loosen clamp, and remove hoses from air bypass valve.
S2M2227
S2M2228
3) Remove bolts which secure intercooler to bracket.
S2M2229 S2M2228
S2M2229
4) Separate intercooler air duct from turbocharger.
IN(DOHC TURBO)-10
INTERCOOLER C: DISASSEMBLY
S184761A06
Intake (Induction)
S184761A02
D: ASSEMBLY
1) Loosen clamps, then remove intercooler duct.
Assemble in the reverse order of disassembly. Tightening torque: 16 Nm (1.6 kgf-m, 11.7 ft-lb)
H2M1884
2) Remove intercooler ducts from intercooler.

H2M1886
H2M1885
3) Remove air by-pass valve.
S2M2231
S2M2231
IN(DOHC TURBO)-11
Intake (Induction)
TURBOCHARGER
S184762
6. Turbocharger
A: REMOVAL
S184762A18
7) Loosen clamp which secures turbocharger to air inlet duct.
H2M1936
G6M0095
8) Remove bolt which secures bracket of oil pipe to turbocharger. 9) Remove oil pipe from turbocharger.
3) Remove center exhaust pipe. <Ref. to EX(DOHC TURBO)-9, REMOVAL, Center Exhaust Pipe.> 4) Lower the vehicle. 5) Separate turbocharger joint pipe from turbocharger.
EN0913
10) Remove turbocharger bracket.
EN0911
6) Disconnect engine coolant hose which is connected to coolant filler tank.
H2M1940
11) Disconnect oil outlet hose from pipe.
EN0912
H2M1941
12) Take out turbocharger from engine compartment.
IN(DOHC TURBO)-12
TURBOCHARGER B: INSTALLATION
S184762A11
Intake (Induction)
4) Install joint pipe to turbocharger. CAUTION: Replace gasket with a new one. Tightening torque: 30 Nm (3.1 kgf-m, 22.4 ft-lb)
1) Connect oil outlet hose to outlet pipe.
H2M1941
2) Install turbocharger to air intake duct.

EN0911
5) Install turbocharger bracket.
H2M1936
3) Install oil pipe to turbocharger.

H2M1940
6) Connect engine coolant hose which is connected to coolant filler tank.
EN0913
EN0912
7) Lift-up the vehicle. 8) Install center exhaust pipe. <Ref. to EX(DOHC TURBO)-10, INSTALLATION, Center Exhaust Pipe.>
IN(DOHC TURBO)-13
Intake (Induction)
AIR BY-PASS VALVE

S184016
7. Air By-pass Valve

A: REMOVAL
S184016A18
1) Disconnect air by-pass hoses from air by-pass valve.
S2M2232
2) Remove air by-pass valve from intercooler.
S2M2231
B: INSTALLATION
S184016A11
S2M2231
IN(DOHC TURBO)-14
MECHANICAL
ME(DOHC TURBO)
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. Page General Description.....................................................................................2 Compression .............................................................................................22 Idle Speed .................................................................................................23 Ignition Timing ...........................................................................................24 Intake Manifold Vacuum............................................................................25 Engine Oil Pressure ..................................................................................26 Fuel Pressure ............................................................................................27 Valve Clearance ........................................................................................28 Engine Assembly.......................................................................................33 Engine Mounting .......................................................................................42 Preparation for Overhaul...........................................................................43 V-belt .........................................................................................................44 Crankshaft Pulley ......................................................................................46 Belt Cover..................................................................................................47 Timing Belt Assembly ................................................................................48 Camshaft Sprocket....................................................................................56 Crankshaft Sprocket..................................................................................57 Camshaft ...................................................................................................58 Cylinder Head Assembly ...........................................................................63 Cylinder Block ...........................................................................................70 Engine Trouble in General ........................................................................91 Engine Noise .............................................................................................97
Mechanical
GENERAL DESCRIPTION
S183001
A: SPECIFICATIONS
Type Valve arrangement
S183001E49
Engine
Bore x Stroke Piston displacement Compression ratio Compression pressure (at 200 300 rpm) Number of piston rings Opening Intake valve timing Closing Opening Exhaust valve timing Closing Intake Valve clearance Exhaust Idling speed [At neutral position on MT; P or N position on AT] Firing order Ignition timing
mm (in) cm3 (cu in)
Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine Belt driven, double overhead camshaft, 4-valve/ cylinder 92 x 75 (3.62 x 2.95) 1,994 (121.67) 8.0 981 1,177 (10 12, 142 171) Pressure ring: 2, Oil ring: 1 3 BTDC 33 ABDC 33 BBDC 3 ATDC 0.200.02 (0.00790.0008) 0.250.02 (0.00980.0008) 700100 (No load) 800150 (A/C switch ON) 1324 1210/700 rpm
kPa (kg/cm2, psi)
mm (in) mm (in) rpm
BTDC/rpm
NOTE: STD: Standard
I.D.: Inner Diameter
O.D.: Outer Diameter
OS: Oversize
US: Undersize
ME(DOHC TURBO)-2
GENERAL DESCRIPTION
Belt tension adjuster Protrusion of adjuster rod Spacer O.D. Tensioner bush I.D. Belt tensioner Clearance between spacer and bush Side clearance of spacer Bend limit Thrust clearance Intake Camshaft Cam lobe height Exhaust Jounal O.D. STD STD Limit STD Limit STD Limit Front Center rear STD Limit STD Limit STD Limit 5.2 6.2 mm (0.205 0.244 in)
Mechanical
Oil clearance Cylinder head Surface warpage limit Surface grinding limit Standard height Refacing angle Intake Contacting width Exhaust Valve guide Inner diameter Protrusion above head Intake Head edge thickness Exhaust Stem diameter STD Limit Overall length Free length Squareness Valve spring Tension/spring height
Valve seat
STD Limit STD Limit
Valve
Stem oil clearance
STD Limit STD Limit Intake Exhaust Intake Exhaust Intake Exhaust
17.955 17.975 mm (0.7069 0.7077 in) 18.0 18.08 mm (0.7087 0.7118 in) 0.025 0.125 mm (0.0010 0.0049 in) 0.175 mm (0.0069 in) 0.2 0.55 mm (0.0079 0.0217 in) 0.81 mm (0.0319 in) 0.020 mm (0.0079 in) 0.015 0.070 mm (0.0006 0.0028 in) 0.10 mm (0.0039 in) 44.75 44.85 mm (1.7618 1.7657 in) 44.65 mm (1.759 in) 44.60 44.70 mm (1.7559 1.7598 in) 44.50 mm (1.7520 in) 37.946 37.963 mm (1.4939 1.4946 in) 29.946 29.963 mm (1.1790 1.1796 in) 0.037 0.072 mm (0.0015 0.0028 in) 0.10 mm (0.0039 in) 0.05 mm (0.0020 in) 0.3 mm (0.012 in) 127.5 mm (5.02 in) 90 1.0 mm (0.039 in) 1.7 mm (0.067 in) 1.5 mm (0.059 in) 2.2 mm (0.087 in) 6.000 6.015 mm (0.2362 0.2368 in) 12.0 12.4 mm (0.472 0.488 in) 1.2 mm (0.047 in) 0.8 mm (0.031 in) 1.5 mm (0.059 in) 0.8 mm (0.031 in) 5.950 5.965 mm (0.2343 0.2348 in) 5.950 5.965 mm(0.2343 0.2348 in) 0.035 0.062 mm (0.0014 0.0024 in) 0.040 0.067 mm (0.0016 0.0026 in) 0.15 mm (0.0059 in) 104.4 mm (4.110 in) 104.7 mm (4.122 in) 44.67 mm (1.7587 in) 2.5, 2.0 mm (0.079 in) 220.715.7 N (22.51.6 kgf, 49.63.5 lb)/36.0 mm (1.417 in) 510.925.5 N (52.12.6 kgf, 114.95.7 lb)/26.6 mm (1.0.47 in)
ME(DOHC TURBO)-3
Mechanical
GENERAL DESCRIPTION
Surface warpage limit (mating with cylinder head) Surface grinding limit A Cylinder bore STD B STD Taper Limit STD Out-of-roundness Limit STD Piston clearance Limit Enlarging (boring) limit A STD B Outer diameter 0.25 mm (0.0098 in) OS 0.50 mm (0.0197 in) OS STD Standard clearance between piston pin and hole in piston Limit Degree of fit Top ring Piston ring gap Second ring Oil ring Clearance between piston Top ring ring and piston ring Second groove ring STD Limit STD Limit STD Limit STD Limit STD Limit Limit STD Limit STD Limit STD 0.03 mm (0.0012 in) US 0.05 mm (0.0020 in) US 0.25 mm (0.0098 in) US STD Limit 0.05 mm (0.0020 in) 0.1 mm (0.004 in) 92.005 92.015 mm (3.6222 3.6226 in) 91.995 92.005 mm (3.6218 3.6222 in) 0.015 mm (0.0006 in) 0.050 mm (0.0020 in) 0.010 mm (0.0004 in) 0.050 mm (0.0020 in) 0.010 0.030 mm (0.0004 0.0012 in) 0.050 mm (0.0020 in) 0.5 mm (0.020 in) 91.985 91.995 mm (3.6214 3.6218 in) 91.975 91.985 mm (3.6211 3.6214 in) 92.225 92.235 mm (3.6309 3.6313 in) 92.475 92.485 mm (3.6407 3.6411 in) 0.004 0.008 mm (0.0002 0.0003 in) 0.020 mm (0.0008 in) Piston pin must be fitted into position with thumb at 20C (68F). 0.20 0.26 mm (0.0079 0.0102 in) 1.0 mm (0.039 in) 0.35 0.50 mm (0.0138 0.0197 in) 1.0 mm (0.039 in) 0.20 0.70 mm (0.0079 0.0276 in) 1.5 mm (0.059 in) 0.040 0.080 mm (0.0016 0.0031 in) 0.15 mm (0.0059 in) 0.030 0.070 mm (0.0012 0.0028 in) 0.15 mm (0.0059 in) 0.10 mm (0.0039 in) 0.070 0.330 0.4 0.020 0.046 0.05 1.492 1.501 mm mm mm mm mm (0.0028 0.0130 in) (0.016 in) (0.0008 0.0018 in) (0.0020 in) (0.0587 0.0591 in)
Cylinder block
Piston
Piston pin
Piston ring
Connecting rod
Bend twist per 100 mm (3.94 in) in length Side clearance Oil clearance
1.510 1.513 mm (0.0594 0.0596 in)
Connecting rod bearing
Thickness at center portion
1.520 1.523 mm (0.0598 0.0600 in)
1.620 1.623 mm (0.0638 0.0639 in) 0 0.022 mm (0 0.0009 in) 0.030 mm (0.0012 in)
Connecting rod bushing
Clearance between piston pin and bushing
ME(DOHC TURBO)-4
GENERAL DESCRIPTION
Bend limit Crank pin and crank jour- Out-of-roundness nal Grinding limit STD 0.03 mm (0.0012 in) US 0.05 mm Crank pin outer diameter (0.0020 in) US 0.25 mm (0.0098 in) US STD 0.03 mm (0.0012 in) US #1, #3, #5 0.05 mm (0.0020 in) US 0.25 mm (0.0098 in) US Crank journal outer diameter STD 0.03 mm (0.0012 in) US 0.05 mm #2, #4 (0.0020 in) US 0.25 mm (0.0098 in) US STD Thrust clearance Limit STD Oil clearance Limit STD 0.03 mm (0.0012 in) US 0.05 mm #1, #3 (0.0020 in) US 0.25 mm (0.0098 in) US Crankshaft bearing thickness STD 0.03 mm (0.0012 in) US 0.05 mm #2, #4, #5 (0.0020 in) US 0.25 mm (0.0098 in) US
Mechanical
0.035 mm (0.0014 in) 0.020 mm (0.0008 in) or less 0.25 mm (0.0098 in) 51.984 52.000 mm (2.0466 2.0472 in) 51.954 51.970 mm (2.0454 2.0461 in)
51.934 51.950 mm (2.0466 2.0453 in)
51.734 51.750 mm (2.0368 2.0374 in) 59.992 60.008 mm (2.3619 2.3625 in) 59.962 59.978 mm (2.3607 2.3613 in)
Crankshaft
59.942 59.958 mm (2.3599 2.3605 in)
59.742 59.758 mm (2.3520 2.3527 in) 59.992 60.008 mm (2.3619 2.3625 in) 59.962 59.978 mm (2.3607 2.3613 in)
59.942 59.958 mm (2.3599 2.3605 in)
59.742 59.758 mm (2.3520 2.3527 in) 0.030 0.115 mm (0.0012 0.0045 in) 0.25 mm (0.0098 in) 0.010 0.030 mm (0.0004 0.0012 in) 0.040 mm (0.0016 in) 1.998 2.011 mm (0.0787 0.0792 in) 2.017 2.020 mm (0.0794 0.0795 in)
2.027 2.030 mm (0.0798 0.0799 in)
2.127 2.130 mm (0.0837 0.0839 in) 2.000 2.013 mm (0.0787 0.0793 in) 2.019 2.022 mm (0.0795 0.0796 in)
Crankshaft bearing
2.029 2.032 mm (0.0799 0.0800 in)
2.129 2.132 mm (0.0838 0.0839 in)
ME(DOHC TURBO)-5
Mechanical
GENERAL DESCRIPTION
MEMO:
ME(DOHC TURBO)-6

1. TIMING BELT
S183001A05
Mechanical
S183001A0501
S2M2241A
(1) Right-hand belt cover No. 2 (2) Timing belt guide (MT vehicles only) (3) Crankshaft sprocket (4) Left-hand belt cover No. 2 (5) Tensioner bracket (6) Automatic belt tension adjuster ASSY (7) Belt idler (8) Right-hand exhaust camshaft sprocket
(9) Right-hand intake camshaft sprocket (10) Left-hand intake camshaft sprocket (11) Left-hand exhaust camshaft sprocket (12) Timing belt (13) Belt idler No. 2 (14) Belt idler (15) Left-hand belt cover (16) Front belt cover
(17) Right-hand belt cover (18) Crankshaft pulley

Tightening torque: Nm (kgf-m, ft-lb) T1: 5 (0.5, 3.6) T2: 10 (1.0, 7) T3: 25 (2.5, 18.1) T4: 39 (4.0, 28.9) T5: 98 (10, 72.4) T6: 127 (13, 94.0)
ME(DOHC TURBO)-7
Mechanical
GENERAL DESCRIPTION
S183001A0502
2. CYLINDER HEAD AND CAMSHAFT
S2M1188A
ME(DOHC TURBO)-8
GENERAL DESCRIPTION
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) Rocker cover (RH) Rocker cover gasket (RH) Oil separator cover Gasket Intake camshaft cap (Front RH) Intake camshaft cap (Center RH) Intake camshaft cap (Rear RH) Intake camshaft (RH) Exhaust camshaft cap (Front RH) Exhaust camshaft cap (Center RH) Exhaust camshaft cap (Rear RH) Exhaust camshaft (RH) Cylinder head bolt (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) Oil seal Cylinder head (RH) Cylinder head gasket (RH) Cylinder head gasket (LH) Cylinder head (LH) Intake camshaft (LH) Exhaust camshaft (LH) Intake camshaft cap (Front LH) Intake camshaft cap (Center LH) Intake camshaft cap (Rear LH) Exhaust camshaft (Front LH) Exhaust camshaft cap (Center LH) (26) Exhaust camshaft cap (Rear LH) (27) Rocker cover gasket (LH) (28) (29) (30) (31) (32) (33) Rocker cover (LH) Oil filler cap Gasket Oil filler duct O-ring Stud bolt
Mechanical
Tightening torque: Nm (kgf-m, ft-lb) T1: <Ref. to ME(DOHC TURBO)-
63, INSTALLATION, Cylinder Head Assembly.> T2: 5 (0.5, 3.6) T3: 10 (1.0, 7) T4: 6.4 (0.65, 4.7)
ME(DOHC TURBO)-9
Mechanical
GENERAL DESCRIPTION
S183001A0503
3. CYLINDER HEAD AND VALVE ASSEMBLY
S2M1197A
(1) (2) (3) (4) (5)
Exhaust valve Intake valve Cylinder head Valve spring seat Intake valve oil seal
(6) (7) (8) (9) (10)
Valve spring Retainer Retainer key Valve lifter Shim
(11) Exhaust valve oil seal (12) Intake valve guide (13) Exhaust valve guide
ME(DOHC TURBO)-10
GENERAL DESCRIPTION
4. CYLINDER BLOCK
S183001A0504
Mechanical
EN0144
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14)
Oil pressure switch Cylinder block (RH) Service hole plug Gasket Oil separator cover Water by-pass pipe Oil pump Front oil seal Rear oil seal O-ring Service hole cover Cylinder block (LH) Water pump Baffle plate
(15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27)
Oil cooler Waster by-pass pipe Connector Oil strainer Gasket Oil pan Drain plug Metal gasket Oil level gauge guide Oil filter Gasket Water pump hose Plug
Tightening torque: Nm (kgf-m, ft-lb) T1: 5 (0.5, 3.6) T2: 6.4 (0.65, 4.7) T3: 10 (1.0, 7) T4: 25 (2.5, 18.1) T5: 47 (4.8, 34.7) T6: 69 (7.0, 50.6) T7: First 12 (1.2, 8.7) T8: T9: T10: T11:
Second 12 (1.2, 8.7) 16 (1.6, 11.6) 44 (4.5, 33) 25 (2.5, 18.1) 55 (5.5, 40)
ME(DOHC TURBO)-11
Mechanical
GENERAL DESCRIPTION
S183001A0505
5. CRANKSHAFT AND PISTON
EN0415
(1) (2) (3) (4) (5) (6) (7) (8)
Flywheel (MT vehicles only) Ball bearing (MT vehicles only) Reinforcement (AT vehicles only) Drive plate (AT vehicles only) Top ring Second ring Oil ring Piston
(9) (10) (11) (12) (13) (14) (15) (16)
Piston pin Circlip Connecting rod bolt Connecting rod Connecting rod bearing Connecting rod cap Crankshaft Woodruff key
(17) Crankshaft bearing #1, #3 (18) Crankshaft bearing #2, #4 (19) Crankshaft bearing #5
ME(DOHC TURBO)-12
GENERAL DESCRIPTION
6. ENGINE MOUNTING
S183001A0506
Mechanical
S2M1783A
(1) Hear shield cover (2) Front cushion rubber (3) Front engine mounting bracket
ME(DOHC TURBO)-13
Mechanical
GENERAL DESCRIPTION
S183001A03
C: CAUTION
Wear working clothing, including a cap, protective goggles, and protective shoes during operation. Remove contamination including dirt and corrosion before removal, installation or disassembly. Keep the disassembled parts in order and protect them from dust or dirt. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly, and replacement. Be careful not to burn your hands, because each part in the vehicle is hot after running. Be sure to tighten fasteners including bolts and nuts to the specified torque. Place shop jacks or safety stands at the specified points. Before disconnecting electrical connectors of sensors or units, be sure to disconnect negative terminal from battery. All parts should be thoroughly cleaned, paying special attention to the engine oil passages, pistons and bearings. Rotating parts and sliding parts such as piston, bearing and gear should be coated with oil prior to assembly.
Be careful not to let oil, grease or coolant contact the timing belt, clutch disc and flywheel. All removed parts, if to be reused, should be reinstalled in the original positions and directions. Bolts, nuts and washers should be replaced with new ones as required. Even if necessary inspections have been made in advance, proceed with assembly work while making rechecks. Remove or install engine in an area where chain hoists, lifting devices, etc. are available for ready use. Be sure not 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. Prior to starting work, prepare the following: Service tools, clean cloth, containers to catch coolant and oil, wire ropes, chain hoist, transmission jacks, etc. Lift-up or lower the vehicle when necessary. Make sure to support the correct positions.
D: PREPARATION TOOL
1. SPECIAL TOOLS
ILLUSTRATION
S183001A1701
S183001A17
DESCRIPTION CYLINDER HEAD TABLE
REMARKS Used for replacing valve guides. Used for removing and installing valve springs.
EN0147
498457000
ENGINE STAND ADAPTER RH
B2M3851
ME(DOHC TURBO)-14
GENERAL DESCRIPTION
ILLUSTRATION TOOL NUMBER 498457100 DESCRIPTION ENGINE STAND ADAPTER LH
Mechanical
REMARKS Used with ENGINE STAND (499817000).
B2M3852
498497100
CRANKSHAFT STOPPER
Used for stopping rotation of flywheel when loosening and tightening crankshaft pulley bolt, etc.
B2M3853
498277200
STOPPER SET
Used for removing and installing automatic transmission assembly to engine
B3M2043
398744300
PISTON GUIDE
Used for installing piston in cylinder.
B2M3854
ME(DOHC TURBO)-15
Mechanical
ILLUSTRATION
GENERAL DESCRIPTION
TOOL NUMBER 498857100 DESCRIPTION VALVE OIL SEAL GUIDE REMARKS Used for press-fitting of intake and exhaust valve guide oil seals.
B2M3855
499017100
PISTON PIN GUIDE Used for installing piston pin, piston and connecting rod.
B2M3856
499037100
CONNECTING ROD Used for removing and installing connecting rod bushing. BUSHING REMOVER & INSTALLER
B2M3857
499097700
PISTON PIN REMOVER ASSY
Used for removing piston pin.
B2M3858
ME(DOHC TURBO)-16
GENERAL DESCRIPTION
ILLUSTRATION TOOL NUMBER 499207400 DESCRIPTION CAMSHAFT SPROCKET WRENCH
Mechanical
REMARKS Used for removing and installing camshaft sprocket.
B2M4158
499587700
CAMSHAFT OIL SEAL INSTALLER
Used for installing cylinder head plug.
B2M3860
499587200
CRANKSHAFT OIL SEAL INSTALLER
Used for installing crankshaft oil seal. Used with CRANKSHAFT OIL SEAL GUIDE (499597100).
B2M3861
499597100
CRANKSHAFT OIL SEAL GUIDE
Used for installing crankshaft oil seal. Used with CRANKSHAFT OIL SEAL INSTALLER (499587200).
B2M3863
ME(DOHC TURBO)-17
Mechanical
ILLUSTRATION
GENERAL DESCRIPTION
TOOL NUMBER 499718000 DESCRIPTION VALVE SPRING REMOVER REMARKS Used for removing and installing valve spring.
B2M3864
498267700
VALVE GUIDE ADJUSTER
Used for installing intake and exhaust valve guides.
B2M3865
499767200
VALVE GUIDE REMOVER
Used for removing valve guides.
B2M3867
499767400
VALVE GUIDE REAMER
Used for reaming valve guides.
B2M3868
ME(DOHC TURBO)-18
GENERAL DESCRIPTION
ILLUSTRATION TOOL NUMBER 499817000 DESCRIPTION ENGINE STAND
Mechanical
REMARKS Stand used for engine disassembly and assembly. Used with ENGINE STAND ADAPTER RH (498457000) & LH (498457100).
B2M3869
499977300
CRANK PULLEY WRENCH
Used for stopping rotation of crankshaft pulley when loosening and tightening crankshaft pulley bolts.
B2M4157
499987500
CRANKSHAFT SOCKET
Used for rotating crankshaft.
B2M3871
498547000
OIL FILTER WRENCH
B2M3872
ME(DOHC TURBO)-19
Mechanical
ILLUSTRATION
GENERAL DESCRIPTION
TOOL NUMBER 499587100 DESCRIPTION OIL SEAL INSTALLER REMARKS Used for installing oil pump oil seal.
B2M3875
499587600
OIL SEAL GUIDE
Used for installing camshaft oil seal.
S1H0136
499597200
OIL SEAL GUIDE
Used for installing camshaft oil seal. Used with OIL SEAL GUIDE (499587600).
EN0168
49818200
SHIM REPLACER
Used for correct valve clearance.
EN0169
ME(DOHC TURBO)-20
GENERAL DESCRIPTION
ILLUSTRATION TOOL NUMBER DESCRIPTION 24082AA150 CARTRIDGE (Newly adopted tool)
Mechanical
B2M3876
22771AA030
SELECT MONITOR KIT
B2M3877

TOOL NAME Compression Gauge Timing Light
S183001A1702
REMARKS Used for measuring compression. Used for measuring ignition timing.
E: PROCEDURE
S183001E45
It is possible to conduct the following service procedures with engine on the vehicle, however, the procedures described in this section are based on the condition that the engine is removed from the vehicle. V-belt Timing Belt Camshaft Cylinder Head
ME(DOHC TURBO)-21
Mechanical
COMPRESSION
S183081
2. Compression
A: INSPECTION
S183081A10
CAUTION: After warming-up, engine becomes very hot. Be careful not to burn yourself during measurement. 1) After warming-up the engine, turn ignition switch to OFF. 2) Make sure that the battery is fully charged. 3) Release fuel pressure. <Ref. to FU(DOHC TURBO)-50, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.> 4) Remove all the spark plugs. <Ref. to IG(DOHC TURBO)-4, REMOVAL, Spark Plug.> 5) Fully open throttle valve. 6) Check the starter motor for satisfactory performance and operation. 7) Hold the compression gauge tight against the spark plug hole. CAUTION: When using a screw-in type compression gauge, the screw (put into cylinder head spark plug hole) should be less than 18 mm (0.71 in) long. 8) Crank the engine by means of the starter motor, and read the maximum value on the gauge when the pointer is steady.
EN0172
9) Perform at least two measurements per cylinder, and make sure that the values are correct. Compression (350 rpm and fully open throttle): Standard; 981 1,177 kPa (10.0 12.0 kg/cm2, 142 171 psi) Limit; 981 kPa (10.0 kg/cm2, 142 psi) Difference between cylinders; 49 kPa (0.5 kg/cm2, 7 psi)
ME(DOHC TURBO)-22
IDLE SPEED
Mechanical
3. Idle Speed
A: INSPECTION
S183082
S183082A10
1) Before checking idle speed, check the following: (1) Ensure that air cleaner element is free from clogging, ignition timing is correct, spark plugs are in good condition, and that hoses are connected properly. (2) Ensure that malfunction indicator light (CHECK ENGINE light) does not illuminate. 2) Warm-up the engine. 3) Stop the engine, and turn ignition switch to OFF. 4) Insert the cartridge to SUBARU SELECT MONITOR. 5) Connect SUBARU SELECT MONITOR to the data link connector. 6) Turn ignition switch to ON, and SUBARU SELECT MONITOR switch to ON. 7) Select {2. Each System Check} in Main Menu. 8) Select {Engine Control System} in Selection Menu. 9) Select {1. Current Data Display & Save} in Engine Control System Diagnosis. 10) Select {1.12 Data Display} in Data Display Menu. 11) Start the engine, and read engine idle speed. 12) Check idle speed when unloaded. (With headlights, heater fan, rear defroster, radiator fan, air conditioning, etc. OFF) Idle speed [No load and gears in neutral (MT), or N or P position (AT)]: 700100 rpm 13) Check idle speed when loaded. (Turn air conditioning switch to ON and operate compressor for at least one minute before measurement.) Idle speed [A/C ON, no load and gears in neutral]: 800150 rpm CAUTION: Never rotate idle adjusting screw. If idle speed is out of specifications, refer to General Onboard Diagnosis Table under Engine Control System. <Ref. to EN(DOHC TURBO)-2, Basic Diagnostic Procedure.>
ME(DOHC TURBO)-23
Mechanical
IGNITION TIMING
S183086
4. Ignition Timing
A: INSPECTION
S183086A10
1) Before checking ignition timing speed, check the following: (1) Ensure that air cleaner element is free from clogging, spark plugs are in good condition, and that hoses are connected properly. (2) Ensure that malfunction indicator light (CHECK ENGINE light) does not illuminate. 2) Warm-up the engine. 3) Stop the engine, and turn ignition switch to OFF. 4) Insert the cartridge to SUBARU SELECT MONITOR. 5) Connect SUBARU SELECT MONITOR to the data link connector. 6) Turn ignition switch to ON, and SUBARU SELECT MONITOR switch to ON. 7) Select {2. Each System Check} in Main Menu. 8) Select {Engine Control System} in Selection Menu. 9) Select {1. Current Data Display & Save} in Engine Control System Diagnosis. 10) Select {1.12 Data Display} in Data Display Menu. 11) Start the engine, at idle speed and check the ignition timing. Ignition timing [BTDC/rpm]: 1210/700 If the timing is not correct, check the ignition control system. Refer to Engine Control System. <Ref. to EN(DOHC TURBO)-2, Basic Diagnostic Procedure.>
ME(DOHC TURBO)-24
INTAKE MANIFOLD VACUUM
Mechanical
5. Intake Manifold Vacuum

A: INSPECTION
S183654A10
S183654
1) Warm-up the engine. 2) Disconnect the brake vacuum hose and install the vacuum gauge to the hose fitting on the manifold.
3) Keep the engine at the idle speed and read the vacuum gauge indication. By observing the gauge needle movement, the internal condition of the engine can be diagnosed as described below.
H2M1767
Vacuum pressure (at idling, A/C OFF): Less than 60.0 kPa (450 mmHg, 17.72 inHg)
Diagnosis of engine condition by measurement of manifold vacuum Vacuum gauge indication Possible engine condition 1. Needle is steady but lower than normal position. This tenLeakage around intake manifold gasket or disconnection or dency becomes more evident as engine temperature rises. damaged vacuum hose 2. When engine speed is reduced slowly from higher speed, Back pressure too high, or exhaust system clogged needle stops temporarily when it is lowering or becomes steady above normal position. 3. Needle intermittently drops to position lower than normal Leakage around cylinder position. 4. Needle drops suddenly and intermittently from normal posi- Sticky valves tion. 5. When engine speed is gradually increased, needle begins to Weak or broken valve springs vibrate rapidly at certain speed, and then vibration increases as engine speed increases. 6. Needle vibrates above and below normal position in narrow Defective ignition system or throttle chamber idle adjustment range.
4) After measuring intake manifold vacuum, install brake vacuum hose.
ME(DOHC TURBO)-25
Mechanical
ENGINE OIL PRESSURE

S183655
6. Engine Oil Pressure

A: INSPECTION
S183655A10
1) Remove oil pressure switch from engine cylinder block. <Ref. to LU-21, REMOVAL, Oil Pressure Switch.> 2) Connect oil pressure gauge hose to cylinder block. 3) Connect battery ground cable.
G6M0095
4) Start the engine, and measure oil pressure.
S2M0242
Oil pressure: 98 kPa (1.0 kg/cm2, 14 psi) or more at 800 rpm 294 kPa (3.0 kg/cm2, 43 psi) or more at 5,000 rpm CAUTION: If oil pressure is out of specification, check oil pump, oil filter and lubrication line. <Ref. to LU-25, INSPECTION, Engine Lubrication System Trouble in General.> If oil pressure warning light is turned ON and oil pressure is in specification, replace oil pressure switch. <Ref. to LU-25, INSPECTION, Engine Lubrication System Trouble in General.> NOTE: The specified data is based on an engine oil temperature of 80C (176F). 5) After measuring oil pressure, install oil pressure switch. <Ref. to LU-21, INSTALLATION, Oil Pressure Switch.>
ME(DOHC TURBO)-26
FUEL PRESSURE
Mechanical
7. Fuel Pressure
A: INSPECTION
S183656
S183656A10
WARNING: Before removing fuel pressure gauge, release fuel pressure. NOTE: If out of specification, check or replace pressure regulator and pressure regulator vacuum hose. 1) Release fuel pressure. <Ref. to FU(DOHC TURBO)-50, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.> 2) Open fuel flap lid, and remove fuel filler cap.
5) Start the engine. 6) Measure fuel pressure while disconnecting pressure regulator vacuum hose from intake manifold. Fuel pressure: Standard; 284 314 kPa (2.9 3.2 kg/cm2, 41 46 psi)
S2M0554
7) After connecting pressure regulator vacuum hose, measure fuel pressure. Fuel pressure: Standard; 230 260 kPa (2.35 2.65 kg/cm2, 33 38 psi)
B2M3135
3) Disconnect fuel delivery hoses from fuel filter, and connect fuel pressure gauge.
S2M0554
S2M0195
NOTE: The fuel pressure gauge registers 10 to 20 kPa (0.1 to 0.2 kg/cm2, 1 to 3 psi) higher than standard values during high-altitude operations.
4) Connect connector of fuel pump relay.
S2M0093
ME(DOHC TURBO)-27
Mechanical
VALVE CLEARANCE
S183083
8. Valve Clearance
A: INSPECTION
S183083A10
10) When inspecting #2 and #4 cylinders; (1) Disconnect battery cables, and remove battery and battery carrier.
then
CAUTION: Inspection and adjustment of valve clearance should be performed while engine is cold. 1) Set the vehicle onto the lift. 2) Disconnect battery ground cable.
H6M0426
(2) Remove bolt which secures engine harness bracket onto body.
G6M0095
3) Remove air intake duct. <Ref. to IN(DOHC TURBO)-8, REMOVAL , Air Intake Duct.> 4) Remove one bolt which secures timing belt cover (RH). 5) Lift-up the vehicle. 6) Remove under cover. 7) Loosen remaining bolts which secure timing belt cover (RH), then remove belt cover. 8) Lower the vehicle. 9) When inspecting #1 and #3 cylinders: (1) Pull out engine harness connector with bracket from air cleaner upper cover.
H6M0429
(3) Remove washer tank mounting bolts.
B6M0561
(4) Disconnect washer motor connectors.

H2M1958
(2) Remove air cleaner case. <Ref. to IN(DOHC TURBO)-7, REMOVAL, Air Cleaner.> (3) Disconnect spark plug cords from spark plugs (#1 and #3 cylinders). (4) Place suitable container under the vehicle. (5) Disconnect PCV hose from rocker cover (RH). (6) Remove bolts, then remove rocker cover (RH).
H6M0430
ME(DOHC TURBO)-28
VALVE CLEARANCE
(5) Move washer tank upward.
Mechanical
NOTE: If the measured value is not within specification, take notes of the value in order to adjust the valve clearance later on.
H6M0431
(6) Disconnect spark plug cords from spark plugs (#2 and #4 cylinders). (7) Place suitable container under the vehicle. (8) Disconnect PCV hose from rocker cover (LH). (9) Remove bolts, then remove rocker cover (LH). 11) Turn crankshaft pulley clockwise until arrow mark on camshaft sprocket is set to position shown in figure. NOTE: Turn crankshaft using ST. ST 499987500 CRANKSHAFT SOCKET
B2M1234B
13) If necessary, adjust the valve clearance. <Ref. to ME(DOHC TURBO)-30, ADJUSTMENT, Valve Clearance.> 14) Further turn crankshaft pulley clockwise. Using the same procedures described previously, then measure valve clearances again. (1) Set arrow mark on camshaft sprocket to position shown in figure, and measure #2 cylinder exhaust valve and #3 cylinder intake valve clearances.
S2M1192B
S2M1194B
12) Measure #1 cylinder intake valve and #3 cylinder exhaust valve clearance by using thickness gauge (A). CAUTION: Insert the thickness gauge in as horizontal a direction as possible with respect to the shim. Measure exhaust valve clearances while lifting-up the vehicle. Valve clearance: Intake: 0.200.02 mm (0.00790.0008 in) Exhaust: 0.250.02 mm (0.00980.0008 in)
(2) Set arrow mark on camshaft sprocket to position shown in figure, and measure #2 cylinder intake valve and #4 cylinder exhaust valve clearances.
S2M1195B
ME(DOHC TURBO)-29
Mechanical
VALVE CLEARANCE
ST (1) Prepare the ST. 498187200 SHIM REPLACER
(3) Set arrow mark on camshaft sprocket to position shown in figure, and measure #1 cylinder exhaust valve and #4 cylinder intake valve clearances.
H2M3622
S2M1196B
(2) Rotate the notch of the valve lifter outward by 45.
15) After inspection, install the related parts in the reverse order of removal. Tightening torque: 32 Nm (3.3 kgf-m, 24 ft-lb)
H2M1777A
(3) Adjust SHIM REPLACER notch to valve lifter and set it.
EN0191
B: ADJUSTMENT
S183083A01
CAUTION: Adjustment of valve clearance should be performed while engine is cold. 1) Measure all valve clearances. <Ref. to ME(DOHC TURBO)-28, INSPECTION, Valve Clearance.> NOTE: Record each valve clearance after it has been measured.
H2M3628
NOTE: When setting, be careful SHIM REPLACER edge does not touch shim. (4) Tighten bolt (A) and install it to the cylinder head.
B2M1234
2) Remove shim from valve lifter.
ME(DOHC TURBO)-30
VALVE CLEARANCE
(5) Tighten bolt (B) and insert the valve lifter.
Mechanical
4) Select a shim of suitable thickness using measured valve clearance and shim thickness, by referring to the following table. 5) Set suitable shim selected in step 4) to valve lifter.
Unit: mm Intake valve:S =(V + T) - 0.20 Exhaust valve:S =(V + T) - 0.25 S: Shim thickness to be used V: Measured valve clearance T: Shim thickness required
H2M3623A
(6) Insert tweezers into the notch of the valve lifter, and take the shim out.
H2M3629
NOTE: By using a magnet (A), the shim (B) can be taken out without dropping it.
H2M3624A
3) Measure thickness of shim with micrometer.
B2M1240
Part No. 13218 AK010 13218 AK020 13218 AK030 13218 AK040 13218 AK050 13218 AK060 13218 AK070 13218 AK080 13218 AK090 13218 AK100 13218 AK110 13218 AE710 13218 AE730 13218 AE750 13218 AE770 13218 AE790 13218 AE810 13218 AE830 13218 AE850 13218 AE870 13218 AE890 13218 AE910 13218 AE920 13218 AE930 13218 AE940 13218 AE950 13218 AE960 13218 AE970 13218 AE980 13218 AE990 13218 AF000 13218 AF010 13218 AF020 13218 AF030 13218 AF040 13218 AF050 13218 AF060 13218 AF070 13218 AF090 13218 AF110
Thickness mm (in) 2.00 (0.0787) 2.02 (0.0795) 2.04 (0.0803) 2.06 (0.0811) 2.08 (0.0819) 2.10 (0.0827) 2.12 (0.0835) 2.14 (0.0843) 2.16 (0.0850) 2.18 (0.0858) 2.20 (0.0866) 2.22 (0.0874) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.30 (0.0906) 2.32 (0.0913) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.40 (0.0945) 2.42 (0.0953) 2.43 (0.0957) 2.44 (0.0961) 2.45 (0.0965) 2.46 (0.0969) 2.47 (0.0972) 2.48 (0.0976) 2.49 (0.0980) 2.50 (0.0984) 2.51 (0.0988) 2.52 (0.0992) 2.53 (0.0996) 2.54 (0.1000) 2.55 (0.1004) 2.56 (0.1008) 2.57 (0.1012) 2.58 (0.1016) 2.60 (0.1024) 2.62 (0.1031)
ME(DOHC TURBO)-31
Mechanical
13218 AF130 13218 AF150 13218 AF170 13218 AF190 2.64 2.66 2.68 2.70
VALVE CLEARANCE
(0.1039) (0.1047) (0.1055) (0.1063)
6) Inspect all valves for clearance again at this stage. If the valve clearance is not correct, repeat the procedure over again from the first step. 7) After inspection, install the related parts in the reverse order of removal.
ME(DOHC TURBO)-32
ENGINE ASSEMBLY
Mechanical
9. Engine Assembly
A: REMOVAL
1) 2) 3) 4)
S183079A18
S183079
(3) Disconnect A/C pressure hoses from A/C compressor.
Set the vehicle on lift arms. Open front hood fully and support with stay. Raise rear seat, and turn floor mat up. Release fuel pressure. (1) Disconnect fuel pump relay connector.
S2M1584
10) Remove intercooler. <Ref. to IN(DOHC TURBO)-10, REMOVAL, Intercooler.> 11) Disconnect the following connectors and cable. (1) Engine harness connector
S2M0093
(2) Start the engine, and run until stalls. (3) After the engine stalls, crank it for five seconds more. (4) Turn ignition switch to OFF. 5) Remove filler cap. 6) Disconnect battery ground terminal.
S2M1929
(2) Engine ground terminal
G6M0095
7) Remove radiator from vehicle. <Ref. to CO-25, REMOVAL, Radiator.> 8) Remove coolant filler tank. <Ref. to CO-37, REMOVAL, Coolant Filler Tank.> 9) Collect refrigerant, and remove pressure hoses. (1) Place and connect the attachment hose to the refrigerant recycle system. (2) Collect refrigerant from A/C system.
S2M0731
(3) Engine harness connector
S2M1930
ME(DOHC TURBO)-33
Mechanical
ENGINE ASSEMBLY
(2) Heater inlet outlet hose
(4) Generator connector, terminal and A/C compressor connectors
EN0205 B2M1291I
(A) (B)
A/C compressor connector Generator connector and terminal
(5) Accelerator cable
13) Remove power steering pump from bracket. (1) Loosen lock bolt and slider bolt, and remove front side V-belt. <Ref. to ME(DOHC TURBO)44, FRONT SIDE BELT, REMOVAL, V-belt.> (2) Disconnect the power steering switch connector.
S2M1931
(6) Clutch release spring
EN0360
(3) Remove pipe with bracket from intake manifold.
S2M1932
12) Disconnect the following hoses (1) Brake booster vacuum hose
S2M0903
(4) Remove power steering pump from engine.
EN0204 H2M1954
ME(DOHC TURBO)-34
ENGINE ASSEMBLY
(5) Remove power steering tank from the bracket by pulling it upward.
Mechanical
16) Remove nuts which install front cushion rubber onto front crossmember.
EN0361
S2M1927
17) Separate clutch release fork from release bearing. (MT vehicles) (1) Remove clutch operating cylinder from transmission. (2) Remove plug using 10 mm hexagon wrench.
EN0208
14) Remove center exhaust pipe. <Ref. to EX(DOHC TURBO)-9, REMOVAL, Center Exhaust Pipe.> 15) Remove nuts which hold lower side of transmission to engine.
S2M1935
B3M2047
ME(DOHC TURBO)-35
Mechanical
ENGINE ASSEMBLY
(3) Screw 6 mm dia. bolt into release fork shaft, and remove it.
S2M0126
20) Disconnect fuel delivery hose, return hose and evaporation hose. CAUTION: Catch fuel from hose into container. Disconnect hose with its end wrapped with cloth to prevent fuel from splashing.
S2M1936A
(A) (B)
Shaft Bolt
(4) Raise release fork and unfasten release bearing tabs to free release fork. CAUTION: Step (4) is required to prevent interference with engine when removing engine from transmission. 18) Select torque converter clutch from drive plate. (AT vehicles) (1) Lower the vehicle. (2) Remove service hole plug. (3) Remove bolts which hold torque converter clutch to drive plate. (4) Remove other bolts while rotating tha engine using ST. ST 499977300 CRANK PULLEY WRENCH
EN0214
21) Remove fuel filter and bracket.
G2M0818
S2M0207
ME(DOHC TURBO)-36
ENGINE ASSEMBLY
Mechanical
24) Separation of engine and transmission. (1) Remove starter. <Ref. to SC-5, REMOVAL, Starter.> (2) Install ST to torque converter clutch case. (AT vehicles) ST 498277200 STOPPER SET
G2M0297
23) Support transmission with a garage jack. CAUTION: Before moving engine away from transmission, check to be sure no work has been overlooked. Doing this is very important in order to facilitate re-installation and because transmission lowers under its own weight.
H2M1961A
(3) Remove bolt which holds right upper side of transmission to engine.
B3M2044 S2M1928
25) Remove engine from vehicle. (1) Slightly raise engine. (2) Raise transmission with garage jack. (3) Move engine horizontally until mainshaft is withdrawn from clutch cover. (4) Slowly move engine away from engine compartment. CAUTION: Be careful not to damage adjacent parts or body panels with crank pulley, oil pressure gauge, etc. 26) Remove front cushion rubbers.
B: INSTALLATION
S183079A11
1) Install clutch release fork and bearing onto transmission. (MT vehicles)
ME(DOHC TURBO)-37
Mechanical
ENGINE ASSEMBLY
(4) Apply grease to specified points. Spline FX2200 Shaft SUNLIGHT 2
(1) Remove release bearing from clutch cover with flat type screw driver.
S2M1843
(2) Install release bearing on transmission. (3) Install release fork into release bearing tab.
S2M1938A S2M1937A
(A) (B)
Release fork Release bearing
(A) (B)
Spline (FX2200) Shaft (SUNLIGHT 2)
(5) Insert release fork shaft into release fork. CAUTION: Make sure the cutout portion of release fork shaft contacts spring pin.
S2M1845A
(A) (B) (C)
Release fork Release shaft Spring pin
ME(DOHC TURBO)-38
ENGINE ASSEMBLY
(6) Tighten plug. Tightening torque: 44 Nm (4.5 kgf-m, 32.5 ft-lb) 6) Remove garage jack.
Mechanical
G2M0297
7) Install pitching stopper.

S2M1846
2) Install front cushion rubbers to engine. Tightening torque: 34 Nm (3.5 kgf-m, 25.3 ft-lb) 3) Install engine onto transmission. (1) Position engine in engine compartment and align it with transmission. CAUTION: Be careful not to damage adjacent parts or body panels with crank pulley, oil pressure gauge, etc. (2) Apply a small amount of grease to splines of mainshaft. (MT vehicles) 4) Tighten bolt which hold right upper side of transmission to engine. Tightening torque: 50 Nm (5.1 kgf-m, 36.9 ft-lb)
Tightening torque: T1: 49 Nm (5.0 kgf-m, 36.2 ft-lb) T2: 57 Nm (5.8 kgf-m, 42 ft-lb)
S2M0126E
8) Remove ST from torque converter clutch case. (AT vehicles) NOTE: Be careful not to drop the ST into the torque converter clutch case when removing ST. ST 498277200 STOPPER SET 9) Install starter. <Ref. to SC-6, INSTALLATION, Starter.> 10) Install torque converter clutch onto drive plate. (AT vehicles) (1) Tighten bolts which hold torque converter clutch to drive plate.
B2M2791
5) Remove lifting device and wire ropes.
ME(DOHC TURBO)-39
Mechanical
ENGINE ASSEMBLY
(1) Install the power steering tank on bracket.
(2) Tighten other bolts while rotating the engine by using ST. CAUTION: Be careful not to drop bolts into torque converter clutch housing. ST 499977300 CRANK PULLEY WRENCH Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
EN0361
(2) Install power steering pump on bracket, and tighten bolts. Tightening torque: 20.1 Nm (2.05 kgf-m, 14.8 ft-lb)
S2M0207
(3) Clog plug onto service hole. 11) Push clutch release lever to fit bearing into clutch cover.
H2M1954
(3) Install power steering pipe bracket on right side intake manifold, and install spark plug codes.
H2M1818
12) Install fuel filter and bracket.
S2M0903
(4) Connect power steering switch connector.
G2M0818
13) Install power steering pump on bracket.
EN0360
ME(DOHC TURBO)-40
ENGINE ASSEMBLY
(5) Install front side V-belt, and adjust it. <Ref. to ME(SOHC)-42, FRONT SIDE BELT, INSTALLATION, V-belt.> 14) Tighten nuts which hold lower side of transmission to engine. Tightening torque: 50 Nm (5.1 kgf-m, 36.9 ft-lb)
Mechanical
CAUTION: After connecting each cable, adjust them. 20) Install air intake system. (1) Install intercooler. <Ref. to IN(DOHC TURBO)-10, INSTALLATION, Intercooler.> (2) Install air cleaner element and air cleaner upper cover. (3) Install engine harness connector bracket. (4) Install filler hose to air cleaner case.
B2M2790
15) Tighten nuts which install front cushion rubber onto crossmember. Tightening torque: 83 Nm (8.5 kgf-m, 61 ft-lb) CAUTION: Make sure the front cushion rubber mounting bolts (A) and locator (B) are securely installed.
H2M1962B
(A) (B)
Filler hose Connector bracket
21) Install A/C pressure hoses. (With A/C) CAUTION: Use new O-rings. Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
B2M3880A
16) Install center exhaust pipe. <Ref. to EX(DOHC TURBO)-7, INSTALLATION, Front Exhaust Pipe.> 17) Connect the following hoses. (1) Fuel delivery hose, return hose and evaporation hose (2) Heater inlet and outlet hoses (3) Brake booster vacuum hose 18) Connect the following connectors and terminals. (1) Engine ground terminal (2) Engine harness connectors (3) Generator connector and terminal (4) A/C compressor connectors (With A/C) 19) Connect the following cables. (1) Accelerator cable (2) Clutch release spring
S2M1584
22) Install radiator. <Ref. to CO-27, INSTALLATION, Radiator.> 23) Install coolant filler tank. <Ref. to CO-27, INSTALLATION, Radiator.> 24) Install window washer tank. 25) Install battery in the vehicle, and connect cables. 26) Fill coolant. <Ref. to CO-27, INSTALLATION, Radiator.> 27) Charge A/C system with refrigerant. <Ref. to AC-20, OPERATION, Refrigerant Charging Procedure.> 28) Remove front hood stay, and close front hood. 29) Take off the vehicle from lift arms.
ME(DOHC TURBO)-41
Mechanical
ENGINE MOUNTING
S183085
10. Engine Mounting

A: REMOVAL
S183085A18
1) Remove engine assembly. <Ref. to ME(DOHC TURBO)-33, REMOVAL, Engine Assembly.> 2) Remove engine mounting from engine assembly.
B: INSTALLATION
S183085A11
Install in the reverse order of removal. Tightening torque: Engine mounting; 35 Nm (3.6 kgf-m, 25.8 ft-lb)
C: INSPECTION
S183085A10
Make sure there are no cracks or other damage.
ME(DOHC TURBO)-42
Mechanical

A: PROCEDURE
S183091E45
S183091
1) After removing the engine from the body, secure it in the ST shown below. ST1 498457000 ENGINE STAND ADAPTER RH ST2 498457100 ENGINE STAND ADAPTER LH ST3 499817000 ENGINE STAND
S2M1876A
2) In this section the procedures described under each index are all connected and stated in order. It will be the complete procedure for overhauling of the engine itself when you go through all steps in the process. Therefore, in this section, to conduct the particular procedure within the flow of a section, you need to go back and conduct the procedure described previously in order to do that particular procedure.
ME(DOHC TURBO)-43
Mechanical
V-BELT
S183080
12. V-belt
3) Remove the A/C belt. 4) Remove the A/C belt tensioner.

S183080A1801
A: REMOVAL
S183080A18
1. FRONT SIDE BELT
NOTE: Perform the following procedures 1) to 4) with the engine installed to the body. 1) Remove V-belt cover.
S2M0113
B: INSTALLATION
1. FRONT SIDE BELT
S183080A11
S183080A1101
CAUTION: Wipe off any oil or water on the belt and pulley.
S2M2235
2) Loosen the lock bolt (A). 3) Loosen the slider bolt (B). 4) Remove the front side belt (C).
1) Install a belt, and tighten the slider bolt so as to obtain the specified belt tension <Ref. to ME(DOHC TURBO)-45, INSPECTION, V-belt.> 2) Tighten the lock bolt (A) 3) Tighten slider bolt (B). Tightening torque: Lock bolt through bolt: 25 Nm (2.5 kgf-m, 18 ft-lb) Slider bolt: 8 Nm (0.8 kgf-m, 5.5 ft-lb)
EN0225
2. REAR SIDE BELT
S183080A1802
1) Loosen the lock nut (A). 2) Loosen the slider bolt (B).
EN0225
EN0226
ME(DOHC TURBO)-44
V-BELT
2. REAR SIDE BELT
S183080A1102
Mechanical
S183080A10
C: INSPECTION
1) Install a belt, and tighten the slider bolt (B) so as to obtain the specified belt tension. <Ref. to ME(DOHC TURBO)-45, INSPECTION, V-belt.> 2) Tighten the lock nut (A). Tightening torque: Lock nut (A); 22.6 Nm (2.3 kgf-m, 16.6 ft-lb)
1) Replace belts, if cracks, fraying or wear is found. 2) Check drive belt tension and adjust it if necessary by changing generator installing position and/or idler pulley installing position. Belt tension (A) replaced: 7 9 mm (0.276 0.354 in) reused: 9 11 mm (0.354 0.433 in) (B)* replaced: 7.5 8.5 mm (0.295 0.335 in) reused: 9.0 10.0 mm (0.354 0.394 in) *: With Air conditioner
EN0226
B2M4123A
ME(DOHC TURBO)-45
Mechanical
CRANKSHAFT PULLEY
S183098
13. Crankshaft Pulley

A: REMOVAL
S183098A18
1) Remove V-belt. <Ref. to ME(DOHC TURBO)44, REMOVAL, V-belt.> 2) Remove crankshaft pulley bolt. To lock crankshaft, use ST. ST 499977300 CRANKSHAFT PULLEY WRENCH
CAUTION: If the tightening angle of crankshaft pulley bolt is less than 45 degrees, the bolt should be damaged. In this case, the bolt must be replaced. (1) Replace the crankshaft pulley bolts and clean them. Crankshaft pulley bolt: 12369AA011 (2) Clean the crankshaft thread using an air gun. (3) Tighten the bolts temporarily with tightening torque of 44 Nm (4.5 kgf-m, 33 ft-lb). (4) Tighten the crankshaft pulley bolts keeping them in an angle between 65 degrees and 75 degrees. CAUTION: Conduct the tightening procedures by confirming the turning angle of the crankshaft pulley bolt referring to the gauge indicated on the belt cover. 4) Install A/C belt tensioner.
H2M2393C
3) Remove crankshaft pulley.
B: INSTALLATION
S183098A11
1) Install crankshaft pulley. 2) Install pulley bolt. To lock crankshaft, use ST. ST 499977300 CRANKSHAFT PULLEY WRENCH (1) Clean the crankshaft pulley thread using an air gun. (2) Apply engine oil to the crankshaft pulley bolt seat and thread. (3) Tighten the bolts temporarily with tightening torque of 44 Nm (4.5 kgf-m, 33 ft-lb). (4) Tighten the crankshaft pulley bolts. Tightening torque: 127 Nm (13.0 kgf-m, 94.0 ft-lb)
S2M0113
5) Install A/C belt.
EN0226
C: INSPECTION
H2M2393A
S183098A10
3) Confirm that the tightening angle of the crankshaft pulley bolt is 45 degrees or more. If not, conduct the following procedures (1) through (4).
1) Make sure the V-belt is not worn or otherwise damaged. 2) Check the tension of the belt. <Ref. to ME(DOHC TURBO)-45, INSPECTION, V-belt.>
ME(DOHC TURBO)-46
BELT COVER
Mechanical
14. Belt Cover

A: REMOVAL
S183582
S183582A18
1) Remove V-belt. <Ref. to ME(DOHC TURBO)44, REMOVAL, V-belt.> 2) Remove crankshaft pulley. <Ref. to ME(DOHC TURBO)-46, REMOVAL, Crankshaft Pulley.> 3) Remove left-hand belt cover (A). 4) Remove right-hand belt cover (B). 5) Remove front belt cover (C).
S2M1221A
B: INSTALLATION
S183582A11
1) Install front belt cover (C). Tightening torque: 5 Nm (0.5 kgf-m, 3.6 ft-lb) 2) Install right-hand belt cover (B). Tightening torque: 5 Nm (0.5 kgf-m, 3.6 ft-lb) 3) Install left-hand belt cover (A). Tightening torque: 5 Nm (0.5 kgf-m, 3.6 ft-lb)
S2M1221A
4) Install crankshaft pulley. <Ref. to ME(DOHC TURBO)-46, INSTALLATION, Crankshaft Pulley.> 5) Install V-belt. <Ref. to ME(DOHC TURBO)-44, INSTALLATION, V-belt.>
C: INSPECTION
S183582A10
Make sure the cover is not damaged.
ME(DOHC TURBO)-47
Mechanical

S183099
15. Timing Belt Assembly

A: REMOVAL
1. TIMING BELT
S183099A18 S183099A1801
1) Remove V-belt. <Ref. to ME(DOHC TURBO)44, REMOVAL, V-belt.> 2) Remove crankshaft pulley. <Ref. to ME(DOHC TURBO)-46, REMOVAL, Crankshaft Pulley.> 3) Remove belt cover. <Ref. to ME(DOHC TURBO)-47, REMOVAL, Belt Cover.> 4) Remove timing belt guides. (MT vehicle only)
EN0259
S2M0294
5) If alignment mark and/or arrow mark (which indicates rotation direction) on timing belt fade away, put new marks before removing timing belt as follows: (1) Turn crankshaft using ST, and align alignment marks on crankshaft sprocket, left-hand intake camshaft sprocket, left-hand exhaust camshaft sprocket, right-hand intake camshaft sprocket and right hand exhaust camshaft sprocket with notches of belt cover and cylinder block. ST 499987500 CRANKSHAFT SOCKET
EN0257
S2M1878A
(2) Using white paint, put alignment and/or arrow marks on timing belts in relation to the sprockets.
EN0258
EN0233
ME(DOHC TURBO)-48
Mechanical
2. BELT IDLER AND AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY S183099A1802

1) Remove belt idler (B) and (C).
S2M1225
Z1: 54.5 tooth length Z2: 51 tooth length Z3: 28 tooth length 2) Remove belt idler No. 2.
S2M1226A
S2M1223A
6) Remove belt idler (A).
S2M0411
3) Remove automatic belt tension adjuster assembly.
S2M1226A
7) Remove timing belt. CAUTION: After timing belt has been removed, never rotate intake and exhaust, camshaft sprocket. If camshaft sprocket is rotated, the intake and exhaust valve heads strike together and valve stems are bent.
S2M0412
B: INSTALLATION
S183099A11
1. AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER

S183099A1101
1) Preparation for installation of automatic belt tension adjuster assembly: CAUTION: Always use a vertical type pressing tool to move the adjuster rod down. Do not use a lateral type vise. Push adjuster rod vertically.
ME(DOHC TURBO)-49
Mechanical

2) Install automatic belt tension adjuster assembly. Tightening torque: 39 Nm (4.0 kgf-m, 28.9 ft-lb)
Be sure to slowly move the adjuster rod down applying a pressure of 294 N (30 kgf, 66 lb). Press-in the push adjuster rod gradually taking more than three minutes. Do not allow press pressure to exceed 9,807 N (1,000 kgf, 2,205 lb). Press the adjuster rod as far as the end surface of the cylinder. Do not press the adjuster rod into the cylinder. Doing so may damage the cylinder. Do not release press pressure until stopper pin is completely inserted. (1) Attach the automatic belt tension adjuster assembly to the vertical pressing tool. (2) Slowly move the adjuster rod down with a pressure of 294 N (30 kgf, 66 lb) until the adjuster rod is aligned with the stopper pin hole in the cylinder.
S2M0416
3) Install belt idler No. 2. Tightening torque: 39 Nm (4.0 kgf-m, 28.9 ft-lb)
H2M2382
S2M0411
(3) With a 2 mm (0.08 in) dia. stopper pin or a 2 mm (0.08 in) (nominal) dia. hex bar wrench inserted into the stopper pin hole in the cylinder, secure the adjuster rod.
4) Install belt idler. Tightening torque: 39 Nm (4.0 kgf-m, 28.9 ft-lb)
H2M2383
S2M0410
2. TIMING BELT
S183099A1102
1) Preparation for installation of automatic belt tension adjuster assembly. <Ref. to ME(DOHC TURBO)-49, AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER, INSTALLATION, Timing Belt Assembly.> 2) Crankshaft and camshaft sprocket alignment.
ME(DOHC TURBO)-50

(1) Align mark (A) on crankshaft sprocket with mark on the oil pump cover at cylinder block.
Mechanical
(4) Align single line mark (A) on left-hand exhaust camshaft sprocket with notch (B) on belt cover by turning sprocket counterclockwise (as viewed from front of engine).
EN0243
(2) Align single line mark (A) on right-hand exhaust camshaft sprocket with notch (B) on belt cover.
S2M1229B
(5) Align single line mark (A) on left-hand intake camshaft sprocket with notch (B) on belt cover by turning sprocket clockwise (as viewed from front of engine). Ensure double lines (C) on intake and exhaust camshaft sprockets are aligned.
S2M1227B
(3) Align single line mark (A) on right-hand intake camshaft sprocket with notch (B) on belt cover. (Make sure double lines (C) on intake camshaft and exhaust camshaft sprockets are aligned.)
S2M1230B
(6) Ensure camshaft and crankshaft sprockets are positioned properly.
S2M1228B
ME(DOHC TURBO)-51
Mechanical

timing belt is to be installed at as small an angle as possible, in order to prevent mutual interference of intake and exhaust valve heads. Do not allow camshafts to rotate in the direction shown in the figure as this causes both intake and exhaust valves to lift simultaneously, resulting in interference with their heads.
CAUTION: Intake and exhaust camshafts for this DOHC engine can be independently rotated with timing belts removed. As can be seen from the figure, if intake and exhaust valves are lifted simultaneously, their heads will interfere with each other, resulting in bent valves.
B2M1392B
(A) (B)
Intake camshaft Exhaust camshaft
S2M1231A
3) Installation of timing belt When timing belts are not installed, four camshafts are held at the zero-lift position, where all cams on camshafts do not push intake and exhaust valves down. (Under this condition, all valves remain unlifted.) When camshafts are rotated to install timing belts, #2 intake and #4 exhaust cam of left-hand camshafts are held to push their corresponding valves down. (Under this condition, these valves are held lifted.) Right-side camshafts are held so that their cams do not push valves down. Left-hand camshafts must be rotated from the zero-lift position to the position where
S2M0418
ME(DOHC TURBO)-52
Mechanical
Align alignment mark on timing belt with marks on sprockets in the alphabetical order shown in figure. While aligning marks, position timing belt properly. CAUTION: Disengagement of more than three timing belt teeth may result in interference between the valve and piston. Ensure belts rotating direction is correct.
S2M1232A
4) Install belt idlers. Tightening torque: 39 Nm (4.0 kgf-m, 28.9 ft-lb) CAUTION: Make sure that the marks on timing belt and sprockets are aligned.
Clearance: 1.00.5 mm (0.0390.020 in)
S2M0297
H2M2398
5) After ensuring that the marks on timing belt and sprockets are aligned, remove stopper pin from tensioner adjuster. 6) Install timing belt guide. (MT vehicle only) (1) Temporarily tighten remaining bolts. (2) Check and adjust clearance between timing belt and timing belt guide.
EN0254
ME(DOHC TURBO)-53
Mechanical
EN0255
EN0258
EN0256
EN0259
(3) Tighten remaining bolts. Tightening torque: 9.8 Nm (1.0 kgf-m, 7.2 ft-lb)
7) Install belt cover. <Ref. to ME(DOHC TURBO)47, INSTALLATION, Belt Cover.> 8) Install crankshaft pulley. <Ref. to ME(DOHC TURBO)-46, REMOVAL, Crankshaft Pulley.> 9) Install V-belt. <Ref. to ME(DOHC TURBO)-44, INSTALLATION, V-belt.>
C: INSPECTION
1. TIMING BELT
S183099A10
S183099A1001
1) Check timing belt teeth for breaks, cracks, and wear. If any fault is found, replace belt. 2) Check the condition of back side of belt; if any crack is found, replace belt.
S2M0294
CAUTION: Be careful not to let oil, grease or coolant contact the belt. Remove quickly and thoroughly if this happens. Do not bend the belt sharply. Bending radius: h 60 mm (2.36 in) or more
EN0257
G2M0115
ME(DOHC TURBO)-54

2. AUTOMATIC BELT TENSION ADJUSTER S183099A1002
1) Visually check oil seals for leaks, and rod ends for abnormal wear or scratches. If necessary, replace automatic belt tension adjuster assembly. CAUTION: Slight traces of oil at rods oil seal does not indicate a problem. 2) Check that the adjuster rod does not move when a pressure of 294 N (30 kgf, 66 lb) is applied to it. This is to check adjuster rod stiffness. 3) If the adjuster rod is not stiff and moves freely when applying 294 N (30 kgf, 66 lb), check it using the following procedures: (1) Slowly press the adjuster rod down to the end surface of the cylinder. Repeat this motion 2 or 3 times. (2) With the adjuster rod moved all the way up, apply a pressure of 294 N (30 kgf, 66 lb) to it. Check adjuster rod stiffness. (3) If the adjuster rod is not stiff and moves down, replace the automatic belt tension adjuster assembly with a new one. CAUTION: Always use a vertical type pressing tool to move the adjuster rod down. Do not use a lateral type vise. Push adjuster rod vertically. Press-in the push adjuster rod gradually taking more than three minutes. Do not allow press pressure to exceed 9,807 N (1,000 kgf, 2,205 lb). Press the adjuster rod as far as the end surface of the cylinder. Do not press the adjuster rod into the cylinder. Doing so may damage the cylinder. 4) Measure the extension of rod beyond the body. If it is not within specifications, replace with a new one. Rod extension: H 5.70.5 mm (0.2240.020 in)
Mechanical
S183099A1003
3. BELT TENSION PULLEY
1) Check mating surfaces of timing belt and contact point of adjuster rod for abnormal wear or scratches. Replace belt tension pulley if faulty. 2) Check belt tension pulley for smooth rotation. Replace if noise or excessive play is noted. 3) Check belt tension pulley for grease leakage.
4. BELT IDLER
S183099A1004
1) Check idler for smooth rotation. Replace if noise or excessive play is noted. 2) Check outer contacting surfaces of idler pulley for abnormal wear and scratches. 3) Check idler for grease leakage.
H2M2381A
ME(DOHC TURBO)-55
Mechanical
CAMSHAFT SPROCKET
S183097
16. Camshaft Sprocket

A: REMOVAL
S183097A18
B: INSTALLATION
S183097A11
1) Remove V-belt. <Ref. to ME(DOHC TURBO)44, REMOVAL, V-belt.> 2) Remove crankshaft pulley. <Ref. to ME(DOHC TURBO)-46, REMOVAL, Crankshaft Pulley.> 3) Remove belt cover. <Ref. to ME(DOHC TURBO)-47, REMOVAL, Belt Cover.> 4) Remove timing belt assembly. <Ref. to ME(DOHC TURBO)-48, REMOVAL, Timing Belt Assembly.> 5) Remove camshaft position sensor. <Ref. to FU(DOHC TURBO)-31, REMOVAL, Camshaft Position Sensor.> 6) Remove camshaft sprockets. To lock camshaft, use ST. ST 499207400 CAMSHAFT SPROCKET WRENCH
1) Install camshaft sprocket No. 1. and No. 2. To lock camshaft, use ST. ST 499207100 CAMSHAFT SPROCKET WRENCH Tightening torque: 98 Nm (10 kgf-m, 72.4 ft-lb) CAUTION: Do not confuse left and right side camshaft sprockets during installation. The camshaft sprocket No. 2 is identified by a projection used to monitor camshaft position sensor.
S2M1879A
S2M1879A
2) Install camshaft position sensor. <Ref. to FU(DOHC TURBO)-31, INSTALLATION, Camshaft Position Sensor.> 3) Install timing belt assembly. <Ref. to ME(DOHC TURBO)-49, INSTALLATION, Timing Belt Assembly.> 4) Install belt cover. <Ref. to ME(DOHC TURBO)47, INSTALLATION, Belt Cover.> 5) Install crankshaft pulley. <Ref. to ME(DOHC TURBO)-46, INSTALLATION, Crankshaft Pulley.> 6) Install V-belt. <Ref. to ME(DOHC TURBO)-44, INSTALLATION, V-belt.>
C: INSPECTION
S183097A10
ME(DOHC TURBO)-56
CRANKSHAFT SPROCKET
Mechanical
S183101A11
17. Crankshaft Sprocket

A: REMOVAL
S183101A18
S183101
B: INSTALLATION
1) Install crankshaft sprocket.
1) Remove V-belt. <Ref. to ME(DOHC TURBO)44, REMOVAL, V-belt.> 2) Remove crankshaft pulley. <Ref. to ME(DOHC TURBO)-46, REMOVAL, Crankshaft Pulley.> 3) Remove belt cover. <Ref. to ME(DOHC TURBO)-47, REMOVAL, Belt Cover.> 4) Remove timing belt assembly. <Ref. to ME(DOHC TURBO)-48, REMOVAL, Timing Belt Assembly.> 5) Remove camshaft sprocket. <Ref. to ME(DOHC TURBO)-56, REMOVAL, Camshaft Sprocket.> 6) Remove crankshaft sprocket.
EN0263
2) Install camshaft sprocket. <Ref. to ME(DOHC TURBO)-56, INSTALLATION, Camshaft Sprocket.> 3) Install timing belt assembly. <Ref. to ME(DOHC TURBO)-49, INSTALLATION, Timing Belt Assembly.> 4) Install belt cover. <Ref. to ME(DOHC TURBO)47, INSTALLATION, Belt Cover.> 5) Install crankshaft pulley. <Ref. to ME(DOHC TURBO)-46, INSTALLATION, Crankshaft Pulley.> 6) Install V-belt. <Ref. to ME(DOHC TURBO)-44, INSTALLATION, V-belt.>
EN0263
C: INSPECTION
S183101A10
ME(DOHC TURBO)-57
Mechanical
CAMSHAFT
S183092
18. Camshaft
A: REMOVAL
S183092A18
1) Remove V-belt. <Ref. to ME(DOHC TURBO)44, INSTALLATION, V-belt.> 2) Remove crankshaft pulley. <Ref. to ME(DOHC TURBO)-46, REMOVAL, Crankshaft Pulley.> 3) Remove belt cover. <Ref. to ME(DOHC TURBO)-47, REMOVAL, Belt Cover.> 4) Remove timing belt assembly. <Ref. to ME(DOHC TURBO)-48, REMOVAL, Timing Belt Assembly.> 5) Remove camshaft sprocket. <Ref. to ME(DOHC TURBO)-56, REMOVAL, Camshaft Sprocket.> 6) Remove crankshaft sprocket. <Ref. to ME(DOHC TURBO)-57, REMOVAL, Crankshaft Sprocket.> 7) Remove left-hand belt cover No. 2.
10) Remove oil level gauge guide. (LH side only) 11) Remove spark plug cord. 12) Remove rocker cover and gasket. 13) Loosen intake camshaft cap bolts equally, a little at a time in alphabetical sequence shown in figure.
S2M1233A
14) Remove camshaft caps and intake camshaft. 15) Loosen exhaust camshaft cap bolts equally, a little at a time in alphabetical sequence shown in figure.
S2M1162
8) Remove right-hand belt cover No.2.
S2M1234A
16) Remove camshaft caps and exhaust camshaft. CAUTION: Arrange camshaft caps in order so that they can be installed in their original positions. 17) Similarly, remove right-hand camshafts and related parts.
B2M0738
S2M1163
ME(DOHC TURBO)-58
CAMSHAFT B: INSTALLATION
S183092A11
Mechanical
1) Camshaft installation Apply engine oil to cylinder head at camshaft bear-ing location before installing camshaft. Install cam-shaft so that each valves is close to or in contact with base circle of cam lobe. CAUTION: When camshafts are positioned as shown in figure, camshafts need to be rotated at a minimum to align with timing belt during installation. Right-hand camshaft need not be rotated when set at position shown in figure. Left-hand intake camshaft: Rotate 80 clock-wise. Left-hand exhaust camshaft: Rotate 45 counterclockwise.
Fluid packing: THREE BOND 1215 or equivalent
S2M1839A
(2) Apply engine oil to cap bearing surface and install cap on camshaft as shown by identification mark (A). (3) Gradually tighten cap in at least two stages in alphabetical sequence shown in figure, and then tighten to specified torque. Tightening torque: 20 Nm (2.0 kgf-m, 14.5 ft-lb)
S2M1233A
(4) Similarly, tighten cap on exhaust side. After tightening cap, ensure camshaft rotates only slightly while holding it at base circle.
B2M1200B
A B (a) (b)
Left side cylinder head Right side cylinder head Intake camshaft Exhaust camshaft
2) Camshaft cap installation (1) Apply fluid packing sparingly to cap mating surface. CAUTION: Do not apply fluid packing excessively. Failure to do so may cause excess packing to come out and flow toward oil seal, resulting in oil leaks.
ME(DOHC TURBO)-59
Mechanical
CAMSHAFT
7) Install right-hand belt cover No. 2. Tightening torque: 5 Nm (0.5 kgf-m, 3.6 ft-lb)
3) Camshaft oil seal installation Apply grease to new oil seal lips and press onto front end of camshaft by using ST1 and ST2. CAUTION: Use a new oil seal. ST1 ST2 499587600 499597200 OIL SEAL INSTALLER OIL SEAL GUIDE
B2M0738
8) Install left-hand belt cover No. 2.

S2M1880A
4) Rocker cover installation (1) Install gasket on rocker cover. Install peripheral gasket and ignition coil gasket. (2) Apply fluid packing to four front open edges of peripheral gasket. Fluid packing: THREE BOND 1215 or equivalent
S2M1162
9) Install tensioner bracket. Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
S2M0300B
(3) Install rocker cover on cylinder head. Ensure gasket is properly positioned during installation. 5) Install spark plug cord. 6) Similarly, install parts on right-hand side.
S2M1163
10) Install crankshaft sprocket. <Ref. to ME(DOHC TURBO)-56, INSTALLATION, Camshaft Sprocket.> 11) Install camshaft sprockets. <Ref. to ME(DOHC TURBO)-56, INSTALLATION, Camshaft Sprocket.> 12) Install timing belt assembly. <Ref. to ME(DOHC TURBO)-49, INSTALLATION, Timing Belt Assembly.> 13) Install belt cover. <Ref. to ME(DOHC TURBO)-47, INSTALLATION, Belt Cover.>
ME(DOHC TURBO)-60
CAMSHAFT
14) Install crankshaft pulley. <Ref. to ME(DOHC TURBO)-46, INSTALLATION, Crankshaft Pulley.> 15) Install V-belt. <Ref. to ME(DOHC TURBO)-44, INSTALLATION, V-belt.> Tightening torque: 20 Nm (2.0 kgf-m, 14.5 ft-lb)
Mechanical
C: INSPECTION
S183092A10
1) Measure the bend, and repair or replace if necessary. Limit: 0.020 mm (0.0008 in)
S2M1233A
CAUTION: Do not turn the camshaft. (5) Remove the bearing caps. (6) Measure the widest point of the plastigauge on 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: 0.037 0.072 mm (0.0015 0.0028 in) Limit: 0.10 mm (0.0039 in)
G2M0746
2) Check journal for damage and wear. Replace if faulty. 3) Measure outside diameter of camshaft journal. If the journal diameter is not as specified, check the oil clearance.
Camshaft journal Front Center, rear 37.946 37.963 29.946 29.963 (1.4939 1.4946 in) (1.1790 1.1796 in)
Standard
4) Measurement of the camshaft journal oil clearance (1) Clean the bearing caps and camshaft journals. (2) Place the camshafts on the cylinder head. (Without installing valve rocker.) (3) Place plastigauge across each of the camshaft journals. (4) Gradually tighten cap in at least two stages in alphabetical sequence shown in figure, and then tighten to specified torque.
B2M1216
(7) Completely remove the plastigauge. 5) Check cam face condition; remove minor faults by grinding with oil stone. Measure the cam height H; replace if the limit has been exceeded.
ME(DOHC TURBO)-61
Mechanical
CAMSHAFT
Cam height: H Standard: Intake: 44.75 44.85 mm (1.7618 1.7657 in) Exhaust: 44.60 44.70 mm (1.7559 1.7598 in) Limit: Intake: 44.65 mm (1.7579 in) Exhaust: 44.50 mm (1.7520 in) Cam base circle diameter A: 37.0 mm (1.457 in)
B2M1209A
6) Measure the thrust clearance of camshaft with dial gauge. If the clearance exceeds the limit, replace caps and cylinder head as a set. If necessary replace camshaft. Standard: 0.015 0.070 mm (0.0006 0.0028 in) Limit: 0.1 mm (0.004 in)
B2M1217
ME(DOHC TURBO)-62
Mechanical
19. Cylinder Head Assembly

A: REMOVAL
S183093A18
S183093
CAUTION: Do not scratch the mating surface of cylinder head and cylinder block. 12) Similarly, remove right side cylinder head.
1) Remove V-belt. <Ref. to ME(DOHC TURBO)44, REMOVAL, V-belt.> 2) Remove crankshaft pulley. <Ref. to ME(DOHC TURBO)-46, REMOVAL, Crankshaft Pulley.> 3) Remove belt cover. <Ref. to ME(DOHC TURBO)-47, REMOVAL, Belt Cover.> 4) Remove timing belt assembly. <Ref. to ME(DOHC TURBO)-48, REMOVAL, Timing Belt Assembly.> 5) Remove camshaft sprocket. <Ref. to ME(DOHC TURBO)-56, REMOVAL, Camshaft Sprocket.> 6) Remove intake manifold. <Ref. to FU(DOHC TURBO)-15, REMOVAL, Intake Manifold.> 7) Remove bolt which installs A/C compressor bracket on cylinder head. 8) Remove camshaft. <Ref. to ME(DOHC TURBO)-58, REMOVAL, Camshaft.> 9) Remove cylinder head bolts in alphabetical sequence shown in figure. CAUTION: Leave bolts (A) and (D) engaged by three or four threads to prevent cylinder head from falling.
B: INSTALLATION
S183093A11
1) Install cylinder head and gaskets on cylinder block. CAUTION: Use new cylinder head gaskets. Be careful not to scratch the mating surface of cylinder head and cylinder block. 2) Tighten cylinder head bolts. (1) Apply a coat of engine oil to washers and bolt threads. (2) Tighten all bolts to 29 Nm (3.0 kgf-m, 22 ft-lb) in alphabetical sequence. Then tighten all bolts to 69 Nm (7.0 kgf-m, 51 ft-lb) in alphabetical sequence. (3) Back off all bolts by 180 first; back them off by 180 again. (4) Tighten bolts (A) and (B) to 34 Nm (3.5 kgf-m, 25 ft-lb).
B2M1397D
(5) Tighten bolts (C), (D), (E) and (F) to 15 Nm (1.5 kgf-m, 11 ft-lb).
B2M1397C
10) While tapping cylinder head with a plastic hammer, separate it from cylinder block. Remove bolts (A) and (D) to remove cylinder head.
B2M1397D
(6) Tighten all bolts by 80 to 90 in alphabetical sequence.

B2M1397C
CAUTION: Do not tighten bolts more than 90. (7) Further tighten all bolts by 80 to 90 in alphabetical sequence.
11) Remove cylinder head gasket.
ME(DOHC TURBO)-63
Mechanical
CAUTION: Ensure that the total re-tightening angle [in the two previous steps] do not exceed 180. 3) Install camshaft. <Ref. to ME(DOHC TURBO)59, INSTALLATION, Camshaft.> 4) Install A/C compressor bracket on cylinder head. 5) Install intake manifold. <Ref. to ME(DOHC TURBO)-59, INSTALLATION, Camshaft.> 6) Install camshaft sprocket. <Ref. to ME(DOHC TURBO)-56, INSTALLATION, Camshaft Sprocket.> 7) Install timing belt assembly. <Ref. to ME(DOHC TURBO)-49, INSTALLATION, Timing Belt Assembly.> 8) Install belt cover. <Ref. to ME(DOHC TURBO)47, INSTALLATION, Belt Cover.> 9) Install crankshaft pulley. <Ref. to ME(DOHC TURBO)-46, INSTALLATION, Crankshaft Pulley.> 10) Install V-belt. <Ref. to ME(DOHC TURBO)-44, INSTALLATION, V-belt.>
C: DISASSEMBLY
S183093A06
1) Remove valve shims and valve lifters. 2) Compress the valve spring and remove the valve spring retainer key. Remove each valve and valve spring. ST 498267600 CYLINDER HEAD TABLE ST 499718000 VALVE SPRING REMOVER CAUTION: Keep removed parts in order for re-installing in their original positions. Mark each valve to prevent confusion. Use extreme care not to damage the lips of the intake valve oil seals and exhaust valve oil seals.
S2M1881A
ME(DOHC TURBO)-64
CYLINDER HEAD ASSEMBLY D: ASSEMBLY

S183093A02
Mechanical
S2M1197A
(1) (2) (3) (4) (5)
Exhaust valve Intake valve Cylinder head Valve spring seat Intake valve oil seal
(6) (7) (8) (9) (10)
Valve spring Retainer Retainer key Valve lifter Shim
(11) Exhaust valve oil seal (12) Intake valve guide (13) Exhaust valve guide
1) Installation of valve spring and valve (1) Coat stem of each valve with engine oil and insert valve into valve guide. CAUTION: When inserting valve into valve guide, use special care not to damage the oil seal lip. (2) Set cylinder head on ST1. (3) Install valve spring and retainer using ST2. ST 498267600 CYLINDER HEAD TABLE ST 499718000 VALVE SPRING REMOVER
ME(DOHC TURBO)-65
Mechanical

CAUTION: Uneven torque for the cylinder head nuts can cause warping. When reassembling, pay special attention to the torque so as to tighten evenly.
CAUTION: Be sure to install the valve springs with their close-coiled end facing the seat on the cylinder head.
S2M1881A
(4) Compress valve spring and fit valve spring retainer key. (5) After installing, tap valve spring retainers lightly with wooden hammer for better seating. 2) Apply oil to the surface of the valve lifter and valve shim. 3) Install valve lifter and valve shim.
S2M1840A
2. VALVE SEAT
S183093A1002
Inspect intake and exhaust valve seats, and correct the contact surfaces with valve seat cutter if they are defective or when valve guides are replaced. Valve seat width: W Intake Standard 1.0 mm (0.039 in) Limit 1.7 mm (0.067 in) Exhaust Standard 1.5 mm (0.059 in) Limit 2.2 mm (0.087 in)
E: INSPECTION
S183093A10
1. CYLINDER HEAD
S183093A1001
1) Make sure that no crack or other damage exists. In addition to visual inspection, inspect important areas by means of red check. 2) Measure the warping of the cylinder head surface that mates with crankcase by using a straight edge (A) and thickness gauge (B). If the warping exceeds 0.05 mm (0.0020 in), regrind the surface with a surface grinder. Warping limit: 0.05 mm (0.0020 in) Grinding limit: 0.3 mm (0.012 in) Standard height of cylinder head: 127.5 mm (5.02 in)
G2M0761
3. VALVE GUIDE
S183093A1003
1) Check the clearance between valve guide and stem. The clearance can be checked by measuring the outside diameter of valve stem and the inside diameter of valve guide with outside and inside micrometers respectively.
ME(DOHC TURBO)-66

Clearance between the valve guide and valve stem: Standard Intake 0.035 0.062 mm (0.0014 0.0024 in) Exhaust 0.040 0.067 mm (0.0016 0.0026 in) Limit 0.15 mm (0.0059 in) 2) If the clearance between valve guide and stem exceeds the limit, replace valve guide or valve itself whichever shows greater amount of wear. See following procedure for valve guide replacement. Valve guide inner diameter: 6.000 6.012 mm (0.2362 0.2367 in) Valve stem outer diameters: Intake 5.950 5.965 mm (0.2343 0.2348 in) Exhaust 5.945 5.960 mm (0.2341 0.2346 in) (1) Place cylinder head on ST1 with the combustion chamber upward so that valve guides enter the holes in ST1. (2) Insert ST2 into valve guide and press it down to remove valve guide. ST1 498267600 CYLINDER HEAD TABLE ST2 499767200 VALVE GUIDE REMOVER
Mechanical
(4) Before installing new valve guide, make sure that neither scratches nor damages exist on the inside surface of the valve guide holes in cylinder head. (5) Put new valve guide, coated with sufficient oil, in cylinder, and insert ST1 into valve guide. Press in until the valve guide upper end is flush with the upper surface of ST2. ST1 499767200 VALVE GUIDE REMOVER ST2 498267700 VALVE GUIDE ADJUSTER
S2M1883A
(6) Check the valve guide protrusion. Valve guide protrusion: L 12.0 12.4 mm (0.472 0.488 in) (7) Ream the inside of valve guide with ST. Gently rotate the reamer clockwise while pressing it lightly into valve guide, and return it also rotating clockwise. After reaming, clean valve guide to remove chips. ST 499767400 VALVE GUIDE REAMER CAUTION: Apply engine oil to the reamer when reaming. If the inner surface of the valve guide is torn, the edge of the reamer should be slightly ground with an oil stone. If the inner surface of the valve guide becomes lustrous and the reamer does not chips, use a new reamer or remedy the reamer. (8) Recheck the contact condition between valve and valve seat after replacing valve guide.
S2M1882A
(3) Turn cylinder head upside down and place ST as shown in the figure. ST 498767700 VALVE GUIDE ADJUSTER
G2M0763
ME(DOHC TURBO)-67
Mechanical

S183093A1004
4. INTAKE AND EXHAUST VALVE
5. VALVE SPRINGS
S183093A1005
1) Inspect the flange and stem of valve, and replace if damaged, worn, or deformed, or if H is less than the specified limit. H: Intake Standard 1.2 mm (0.047 in) Limit 0.8 mm (0.031 in) Exhaust Standard 1.5 mm (0.059 in) Limit 0.8 mm (0.031 in) Valve overall length: Intake 104.4 mm (4.110 in) Exhaust 104.7 mm (4.122 in)
1) Check valve springs for damage, free length, and tension. Replace valve spring if it is not to the specifications presented in the table. 2) To measure the squareness of the valve spring, stand the spring on a surface plate and measure its deflection at the top using a try square.
Free length Valve spring 44.67 mm (1.7587 in) 220.715.7 N (22.51.6 kgf, 49.63.5 lb)/36.0 mm (1.417 in) 510.925.5 N (52.12.6 kgf, 114.95.7 lb)/26.6 mm (1.047 in) 2.5, 2.0 mm (0.079 in)
Tension/spring height
Squareness
G2M0154
G2M0153
2) Put a small amount of grinding compound on the seat surface and lap the valve and seat surface. Install a new intake valve oil seal after lapping.
ME(DOHC TURBO)-68

6. INTAKE AND EXHAUST VALVE OIL SEAL S183093A1006
Replace oil seal with new one, if lip is damaged or spring out of place, or when the surfaces of intake valve and valve seat are reconditioned or intake valve guide is replaced. 1) Place cylinder head on ST1. 2) Press in oil seal to the specified dimension indicated in the figure by using ST2. ST1 498267600 CYLINDER HEAD TABLE ST2 498857100 VALVE GUIDE REMOVER CAUTION: Apply engine oil to oil seal before force-fitting. Differentiate between intake valve oil seal and exhaust valve oil seal by noting their difference in color. Color of rubber part: Intake [Black] Exhaust [Brown] Color of spring part: Intake [Silver] Exhaust [Silver]
Mechanical
S183093A1007
7. VALVE LIFTER
1) Check valve lifter visually. 2) Measure outer diameter of valve lifter. Outer diameter: 34.959 34.975 mm (1.3763 1.3770 in)
B2M1222
3) Measure inner diameter of valve lifter mating part on cylinder head. Inner diameter: 34.994 35.016 mm (1.3777 1.3786 in)
B2M1400
S2M1924A
CAUTION: If difference between outer diameter of valve lifter and inner diameter of valve lifter mating part is over the limit, replace cylinder head. Standard: 0.019 0.057 mm (0.0007 0.0022 in) Limit: 0.100 mm (0.0039 in)
ME(DOHC TURBO)-69
Mechanical
CYLINDER BLOCK
S183090
20. Cylinder Block

A: REMOVAL
S183090A18
NOTE: Before conducting this procedure, drain engine oil completely if applicable. 1) Remove intake manifold. <Ref. to FU(DOHC TURBO)-15, REMOVAL, Intake Manifold.> 2) Remove V-belt. <Ref. to ME(DOHC TURBO)44, REMOVAL, V-belt.> 3) Remove crankshaft pulley. <Ref. to ME(DOHC TURBO)-46, REMOVAL, Crankshaft Pulley.> 4) Remove belt cover. <Ref. to ME(DOHC TURBO)-47, REMOVAL, Belt Cover.> 5) Remove timing belt assembly. <Ref. to ME(DOHC TURBO)-48, REMOVAL, Timing Belt Assembly.> 6) Remove camshaft sprocket. <Ref. to ME(DOHC TURBO)-56, REMOVAL, Camshaft Sprocket.> 7) Remove crankshaft sprocket. <Ref. to ME(DOHC TURBO)-57, REMOVAL, Crankshaft Sprocket.> 8) Remove generator and A/C compressor with their brackets. 9) Remove cylinder head assembly. <Ref. to ME(DOHC TURBO)-63, REMOVAL, Cylinder Head Assembly.> 10) Remove clutch housing cover. (MT vehicles only)
11) Remove flywheel (MT vehicle) or drive plate (AT vehicle). Using ST, lock crankshaft. ST 498497100 CRANKSHAFT STOPPER MT VEHICLES
S2M1818B
AT VEHICLES
S2M1870B
12) Remove oil separator cover. 13) Remove water by-pass pipe for heater. 14) Remove oil filter.
ME(DOHC TURBO)-70
CYLINDER BLOCK
15) Remove oil cooler.
Mechanical
17) Remove oil strainer stay. 18) Remove oil strainer. 19) Remove baffle plate. 20) Remove water pips. 21) Remove water pump. 22) Remove oil pump from cylinder block. Use a flat-bladed screwdriver as shown in figure when removing oil pump. CAUTION: Be careful not to scratch the mating surface of cylinder block and oil pump.
S2M1819 S2M1835B
(A) (B) (C)
Gasket Oil cooler Connector
16) Removal of oil pan (1) Turn cylinder block with #2 and #4 piston sides facing upward. (2) Remove bolts which secure oil pan to cylinder block. (3) Insert a oil pan cutter blade between cylinder block-to-oil pan clearance and remove oil pan. CAUTION: Do not use a screwdriver or similar tool in place of oil pan cutter.
S2M1820
ME(DOHC TURBO)-71
Mechanical
CYLINDER BLOCK
EN0294
(1) Service hole plug (2) Gasket
(3) Circlip (4) Piston pin
(5) Service hole cover (6) O-ring
23) Remove service hole cover and service hole plugs using hexagon wrench [14 mm (0.55 in)].
24) Rotate crankshaft to bring #1 and #2 pistons to bottom dead center position, then remove piston circlip through service hole of #1 and #2 cylinders.
B2M2620 G2M0165
ME(DOHC TURBO)-72
CYLINDER BLOCK
25) Draw out piston pin from #1 and #2 pistons using ST. ST 499097700 PISTON PIN REMOVER CAUTION: Be careful not to confuse original combination of piston, piston pin and cylinder.
Mechanical
26) Similarly remove piston pins from #3 and #4 pistons. 27) Remove bolts which connect cylinder block on the side of #2 and #4 cylinders. 28) Back off bolts which connect cylinder block on the side of #1 and #3 cylinders two or three turns. 29) Set up cylinder block so that #1 and #3 cylinders are on the upper side, then remove cylinder block connecting bolts. 30) Separate left-hand and right-hand cylinder blocks. CAUTION: When separating cylinder block, do not allow the connecting rod to fall and damage the cylinder block.
G2M0166
B2M2408A
(1) Cylinder block (2) Rear oil seal
(3) Crankshaft (4) Crankshaft bearing
(5) Piston
31) Remove rear oil seal. 32) Remove crankshaft together with connecting rod. 33) Remove crankshaft bearings from cylinder block using hammer handle.
CAUTION: Do not confuse combination of crankshaft bearings. Press bearing at the end opposite to locking lip. 34) Draw out each piston from cylinder block using wooden bar or hammer handle.
ME(DOHC TURBO)-73
Mechanical
CYLINDER BLOCK
CAUTION: Do not confuse combination of piston and cylinder.
B: INSTALLATION
S183090A11
B2M2407A
(1) Crankshaft bearing (2) Crankshaft (3) Cylinder block
(4) Rear oil seal
CAUTION: Remove oil in the mating surface of bearing and cylinder block before installation. Also apply a coat of engine oil to crankshaft pins. 1) Position crankshaft on the #2 and #4 cylinder block. 2) Apply fluid packing to the mating surface of #1 and #3 cylinder block, and position it on #2 and #4 cylinder block. Fluid packing: THREE BOND 1215 or equivalent
CAUTION: Do not allow fluid packing to jut into O-ring grooves, oil passages, bearing grooves, etc.
S2M1826A
ME(DOHC TURBO)-74
CYLINDER BLOCK
3) Temporarily tighten 10 mm cylinder block connecting bolts in alphabetical sequence shown in figure.
Mechanical
6) Install rear oil seal using ST1 and ST2. ST1 499597100 OIL SEAL GUIDE ST2 499587200 OIL SEAL INSTALLER
B2M0088D
G2M0186
4) Tighten 10 mm cylinder block connecting bolts in alphabetical sequence. Tightening torque: 47 Nm (4.8 kgf-m, 34.7 ft-lb)
7) Position the top ring gap at (A) or (B) in the figure.
EN0304
B2M0088D
5) Tighten 8 mm and 6 mm cylinder block connecting bolts in alphabetical sequence shown in figure. Tightening torque: (A) (G): 25 Nm (2.5 kgf-m, 18.1 ft-lb) (H): 6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
8) Position the second ring gap at 180 on the reverse side for the top ring gap. 9) Position the upper rail gap at (C) or (D) in the figure.
EN0305
10) Position the expander gap at 180 of the reverse side for the upper rail gap.
B2M0089F
ME(DOHC TURBO)-75
Mechanical
CYLINDER BLOCK
11) Position the lower rail gap at (E) or (F) in the figure. CAUTION: Ensure ring gaps do not face the same direction. Ensure ring gaps are not within the piston skirt area.
EN0305
12) Install circlip. Install circlips in piston holes located opposite service holes in cylinder block, when positioning all pistons in the corresponding cylinders. CAUTION: Use new circlips.
B2M1403A
CAUTION: Piston front mark faces towards the front of the engine.
EN0307
(A)
Front mark
ME(DOHC TURBO)-76
CYLINDER BLOCK
Mechanical
B2M1322J
(1) Piston (2) Piston pin (3) Circlip
(4) Gasket (5) Service hole plug
13) Installing piston (1) Turn cylinder block so that #1 and #2 cylinders face upward. (2) Using ST1, turn crankshaft so that #1 and #2 connecting rods are set at bottom dead center. ST1 499987500 CRANKSHAFT SOCKET (3) Apply a coat of engine oil to pistons and cylinders and insert pistons in their cylinders using ST2. ST2 498744300 PISTON GUIDE
(1) Insert ST3 into service hole to align piston pin hole with connecting rod small end. CAUTION: Apply a coat of engine oil to ST3 before insertion. ST3 499017100 PISTON PIN GUIDE
G2M0189
S2M0306A
(2) Apply a coat of engine oil to piston pin and insert piston pin into piston and connecting rod through service hole.
14) Installing piston pin
ME(DOHC TURBO)-77
Mechanical
CYLINDER BLOCK
(3) Install circlip. CAUTION: Use new circlips.
G2M0190
(4) Apply fluid packing around the service hole plug. Fluid packing: THREE BOND 1215 or equivalent
B2M2625
(5) Install service hole plug and gasket. CAUTION: Use a new gasket.
B2M2620
ME(DOHC TURBO)-78
CYLINDER BLOCK
Mechanical
B2M1323K
(1) (2) (3) (4)
Piston Piston pin Circlip Gasket
(5) Service hole plug (6) Service hole cover (7) O-ring
(6) Turn cylinder block so that #3 and #4 cylinders face upward. Using the same procedures as used for #1 and #2 cylinders, install pistons and piston pins. 15) Install water pipe. 16) Install baffle plate. Tightening torque: 6.4 Nm (0.65 kgf-m, 4.7 ft-lb) 17) Install oil strainer and O-ring Tightening torque: 10 Nm (1.0 kgf-m, 7 ft-lb) 18) Install oil strainer stay.
19) Apply fluid packing to matching surfaces and install oil pan. Fluid packing: THREE BOND 1215 or equivalent
S2M1833A
ME(DOHC TURBO)-79
Mechanical
CYLINDER BLOCK
ST 499587100 OIL SEAL INSTALLER
20) Apply fluid packing to matching surfaces and install oil separator cover. Fluid packing: THREE BOND 1215 or equivalent
S2M0235
(2) Apply fluid packing to matching surface of oil pump.

S2M1834A
21) Install flywheel (MT vehicles) or drive plate (AT vehicles). To lock crankshaft, use ST. ST 498497100 CRANKSHAFT STOPPER Tightening torque: 72 Nm (7.3 kgf-m, 52.8 ft-lb) MT VEHICLES
Fluid packing: THREE BOND 1215 or equivalent
B2M0390B
(A)
O-ring
(3) Apply a coat of engine oil to the inside of the oil seal.
S2M1818B
AT VEHICLES
S2M0118B
(4) Install oil pump on cylinder block. Be careful not to damage oil seal during installation.
S2M1870B
22) Install clutch housing cover. 23) Installation of oil pump (1) Discard front oil seal after removal. Replace with a new one using ST.
Tightening torque: 6.4 Nm (0.65 kgf-m, 4.7 ft-lb) CAUTION: Do not forget to install O-ring and seal when installing oil pump. Align flat surface of oil pumps inner rotor with crankshaft before installation. 24) Install water pump and gasket.
ME(DOHC TURBO)-80
CYLINDER BLOCK
Tightening torque: First; 12 Nm (1.2 kgf-m, 8.7 ft-lb) Second; 12 Nm (1.2 kgf-m, 8.7 ft-lb) CAUTION: Be sure to use a new gasket. When installing water pump, tighten bolts in two stages in alphabetical sequence as shown in figure.
Mechanical
28) Install water by-pass pipe between oil cooler and water pump.
EN0321
29) Install water pipe. CAUTION: Always use a new O-ring.

H2M1846D
25) Install water by-pass pipe for heater. 26) Install oil cooler. Tightening torque: T1: 55 Nm (5.5 kgf-m, 40 ft-lb) T2: 69 Nm (7.0 kgf-m, 50.6 ft-lb)
30) Install cylinder head assembly. <Ref. to ME(DOHC TURBO)-63, INSTALLATION, Cylinder Head Assembly.> 31) Install oil level gauge guide and tighten attaching bolt (left side only). 32) Install rocker cover. 33) Install crankshaft sprocket. <Ref. to ME(DOHC TURBO)-57, INSTALLATION, Crankshaft Sprocket.> 34) Install camshaft sprocket. <Ref. to ME(DOHC TURBO)-56, INSTALLATION, Camshaft Sprocket.> 35) Install timing belt assembly. <Ref. to ME(DOHC TURBO)-49, INSTALLATION, Timing Belt Assembly.> 36) Install belt cover. <Ref. to ME(DOHC TURBO)-47, INSTALLATION, Belt Cover.> 37) Install crankshaft pulley. <Ref. to ME(DOHC TURBO)-46, INSTALLATION, Crankshaft Pulley.> 38) Install generator and A/C compressor brackets on cylinder head. 39) Install V-belt. <Ref. to ME(DOHC TURBO)-44, INSTALLATION, V-belt.> 40) Install intake manifold. <Ref. to FU(DOHC TURBO)-15, REMOVAL, Intake Manifold.>
EN0320
(A) (B) (C)
O-ring Oil cooler Connector
27) Install oil filter using ST. ST 498547000 OIL FILTER WRENCH
ME(DOHC TURBO)-81
Mechanical
CYLINDER BLOCK
S183090A06
C: DISASSEMBLY
B2M1320I
(1) Connecting rod cap (2) Connecting rod bearing
(3) Top ring (4) Second ring
(5) Oil ring (6) Circlip
1) Remove connecting rod cap. 2) Remove connecting rod bearing. CAUTION: Arrange removed connecting rod, connecting rod cap and bearing in order to prevent confusion. 3) Remove piston rings using the piston ring expander. 4) Remove the oil ring by hand. CAUTION: Arrange the removed piston rings in good order to prevent confusion. 5) Remove circlip.
ME(DOHC TURBO)-82
CYLINDER BLOCK D: ASSEMBLY

S183090A02
Mechanical
B2M1320J
(1) (2) (3) (4)
Connecting rod bearing Connecting rod Connecting rod cap Oil ring
(5) Second ring (6) Top ring (7) Circlip
1) Install connecting rod bearings on connecting rods and connecting rod caps. CAUTION: Apply oil to the surfaces of the connecting rod bearings. 2) Install connecting rod on crankshaft. CAUTION: Position each connecting rod with the side marked facing forward. 3) Install connecting rod cap with connecting rod nut. Ensure the arrow on connecting rod cap faces the front during installation. CAUTION: Each connecting rod has its own mating cap. Make sure that they are assembled correctly by checking their matching number. When tightening the connecting rod nuts, apply oil on the threads. 4) Install oil ring spacer, upper rail and lower rail in this order by hand. Then install second ring and top ring with a piston ring expander.
E: INSPECTION
S183090A10
1. CYLINDER BLOCK
S183090A1001
1) Visually check for cracks and damage. Especially, inspect important parts by means of red lead check. 2) Check the oil passages for clogging. 3) Inspect crankcase surface that mates with cylinder head for warping by using a straight edge, and correct by grinding if necessary. Warping limit: 0.05 mm (0.0020 in) Grinding limit: 0.1 mm (0.004 in) Standard height of cylinder block: 201.0 mm (7.91 in)
ME(DOHC TURBO)-83
Mechanical
CYLINDER BLOCK
S183090A1002
2. CYLINDER AND PISTON
1) The cylinder bore size is stamped on the cylinder blocks front upper surface. CAUTION: Measurement should be performed at a temperature 20C (68F). NOTE: Standard sized pistons are classified into two grades, A and B. These grades should be used as a guide line in selecting a standard piston. Standard diameter: A: 92.005 92.015 mm (3.6222 3.6226 in) B: 91.995 92.005 mm (3.6218 3.6222 in)
2) How to measure the inner diameter of each cylinder Measure the inner diameter of each cylinder in both the thrust and piston pin directions at the heights shown in the figure, using a cylinder bore gauge. CAUTION: Measurement should be performed at a temperature 20C (68F). Taper: Standard 0.015 mm (0.0006 in) Limit 0.050 mm (0.0020 in) Out-of-roundness: Standard 0.010 mm (0.0004 in) Limit 0.050 mm (0.0020 in)
H2M1732C
(A) (B) (C) (D) (E) (F)
Main jourual size mark Cylinder block RH-LH combination mark #1 cylinder bore size mark #2 cylinder bore size mark #3 cylinder bore size mark #4 cylinder bore size mark
S2M1821A
(A) (B)
Piston pin direction Thrust direction
3) When piston is to be replaced due to general or cylinder wear, determine a suitable sized piston by measuring the piston clearance. 4) How to measure the outer diameter of each piston Measure the outer diameter of each piston at the height shown in the figure. (Thrust direction) CAUTION: Measurement should be performed at a temperature of 20C (68F).
ME(DOHC TURBO)-84
CYLINDER BLOCK
Piston grade point H: 37.0 mm (1.457 in) Piston outer diameter: Standard A: 91.985 91.995 mm (3.6214 3.6218 in) B: 91.975 91.985 mm (3.6211 3.6214 in) 0.25 mm (0.0098 in) oversize 92.225 92.235 mm (3.6309 3.6313 in) 0.50 mm (0.0197 in) oversize 92.475 92.485 mm (3.6407 3.6411 in)
Mechanical
CAUTION: Immediately after reboring, the cylinder diameter may differ from its real diameter due to temperature rise. Thus, pay attention to this when measuring the cylinder diameter. Limit of cylinder enlarging (boring): 0.5 mm (0.020 in)
3. PISTON AND PISTON PIN
S183090A1003
1) Check pistons and piston pins for damage, cracks, and wear and the piston ring grooves for wear and damage. Replace if defective. 2) Measure the piston-to-cylinder clearance at each cylinder. <Ref. to ME(DOHC TURBO)-84, CYLINDER AND PISTON, INSPECTION, Cylinder Block.> If any of the clearances is not to specification, replace the piston or bore the cylinder to use an oversize piston. 3) Make sure that piston pin can be inserted into the piston pin hole with a thumb at 20C (68F). Replace if defective. Standard clearance between piston pin and hole in piston: Standard 0.004 0.008 mm (0.0002 0.0003 in) Limit 0.020 mm (0.0008 in)
B2M1305A
5) Calculate the clearance between cylinder and piston. CAUTION: Measurement should be performed at a temperature of 20C (68F). Cylinder to piston clearance at 20C (68F): Standard 0.010 0.030 mm (0.0004 0.0012 in) Limit 0.050 mm (0.0020 in) 6) Boring and honing (1) If the value of taper, out-of-roundness, or cylinder-to-piston clearance measured exceeds the specified limit or if there is any damage on the cylinder wall, rebore it to use an oversize piston. CAUTION: When any of the cylinders needs reboring, all other cylinders must be bored at the same time, and use oversize pistons. Do not perform boring on one cylinder only, nor use an oversize piston for one cylinder only. (2) If the cylinder inner diameter exceeds the limit after boring and honing, replace the crankcase.
B2M1401
B2M0084A
ME(DOHC TURBO)-85
Mechanical
CYLINDER BLOCK
The oil ring is a combined ring consisting of two rails and a spacer in between. When installing, be careful to assemble correctly.
4) Check circlip installation groove on the piston for burr (A). If necessary, remove burr from the groove so that piston pin can lightly move.
B2M0420B
EN0331
5) Check piston pin circlip for distortion, cracks and wear.
4. PISTON RING
S183090A1004
1) If piston ring is broken, damaged, or worn, or if its tension is insufficient, or when the piston is replaced, replace piston ring with a new one of the same size as the piston. CAUTION: N is marked on the end of the top and second rings. When installing the rings to the piston, face this mark upward.
(A) (B) (C) (a) (b) (c)
Top ring Second ring Oil ring Upper rail Spacer Lower rail
2) Squarely place piston ring and oil ring in cylinder, and measure the piston ring gap with a thickness gauge.
Standard 0.20 0.35 (0.0079 0.0138) 0.35 0.50 (0.0138 0.0197) 0.20 0.70 (0.0079 0.0276) Unit: mm (in) Limit 1.0 (0.039) 1.0 (0.039) 1.5 (0.059)
Top ring Piston ring gap Second ring Oil ring rail
EN0330
G2M0174
ME(DOHC TURBO)-86
CYLINDER BLOCK
3) Measure the clearance between piston ring and piston ring groove with a thickness gauge. CAUTION: Before measuring the clearance, clean the piston ring groove and piston ring.
Standard 0.040 0.080 (0.0016 0.0031) 0.030 0.070 (0.0012 0.0028) Unit: mm (in) Limit 0.15 (0.0059)
Mechanical
S183090A1005
5. CONNECTING ROD
1) Replace connecting rod, if 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 mm (3.94 in) in length: 0.10 mm (0.0039 in)
Clearance between piston ring and piston ring groove
Top ring Second ring
0.15 (0.0059)
B2M1402A
B2M1184B
(A) (B)
Thickness gauge Connecting rod
3) Install connecting rod fitted with bearing to crankshaft and measure the side clearance (thrust clearance). Replace connecting rod if the side clearance exceeds the specified limit. Connecting rod side clearance: Standard 0.070 0.330 mm (0.0028 0.0130 in) Limit 0.4 mm (0.016 in)
EN0335
ME(DOHC TURBO)-87
Mechanical
CYLINDER BLOCK
6) Inspect bushing at connecting rod small end, and replace if worn or damaged. Also measure the piston pin clearance at the connecting rod small end. Clearance between piston pin and bushing: Standard 0 0.022 mm (0 0.0009 in) Limit 0.030 mm (0.0012 in)
4) Inspect connecting rod bearing for scar, peeling, seizure, melting, wear, etc. 5) Measure the oil clearance on individual connecting rod bearings by means of plastigauge. If any oil clearance is not within specification, replace the defective bearing with a new one of standard size or undersize as necessary. (See the table below.) Connecting rod oil clearance: Standard 0.020 0.046 mm (0.0008 0.0018 in) Limit 0.05 mm (0.0020 in)
Unit: mm (in) Bearing Standard 0.03 (0.0012) undersize 0.05 (0.0020) undersize 0.25 (0.0098) undersize Bearing size (Thickness at center) 1.492 1.501 (0.0587 0.0591) 1.510 1.513 (0.0594 0.0596) 1.520 1.523 (0.0598 0.0600) 1.620 1.623 (0.0638 0.0639) Outer diameter of crank pin 51.984 (2.0466 51.954 (2.0454 51.934 (2.0446 51.734 (2.0368 52.000 2.0472) 51.970 2.0461) 51.950 2.0453) 51.750 2.0374)
B2M0085
B2M0084
7) Replacement procedure is as follows. (1) Remove bushing from connecting rod with ST and press. (2) Press bushing with ST after applying oil on the periphery of bushing. ST 499037100 CONNECTING ROD BUSHING REMOVER AND INSTALLER
G2M0177
(3) Make two 3 mm (0.12 in) holes in bushing. Ream the inside of bushing. (4) After completion of reaming, clean bushing to remove chips.
ME(DOHC TURBO)-88
CYLINDER BLOCK
6. CRANKSHAFT AND CRANKSHAFT BEARING S183090A1006
1) Clean crankshaft completely and check for cracks by means of red lead check etc., and replace if defective. 2) Measure the crankshaft bend, and correct or replace if it exceeds the limit. CAUTION: If a suitable V-block is not available, install #1 and #5 crankshaft bearing on cylinder block, position crankshaft on these bearings and measure crankshaft bend using a dial gauge. Crankshaft bend limit: 0.035 mm (0.0014 in)
Mechanical
3) Inspect the crank journal and crank pin for wear. If they are not within the specifications, replace bearing with a suitable (undersize) one, and replace or recondition crankshaft as necessary. When grinding crank journal or crank pin, finish them to the specified dimensions according to the undersize bearing to be used. Crank pin and crank journal: Out-of-roundness 0.020 mm (0.0008 in) or less Taper limit 0.07 mm (0.0028 in) Grinding limit 0.250 mm (0.0098 in)
EN0339
G2M0179
Unit: mm (in) Crank journal diameter #1, #3, #5 #2, #4 59.992 60.008 59.992 60.008 (2.3619 2.3625) (2.3619 2.3625) 1.998 2.011 (0.0787 0.0792) 59.962 59.978 (2.3607 2.3613) 2.017 2.020 (0.0794 0.0795) 59.942 59.958 (2.3599 2.3605) 2.027 2.030 (0.0798 0.0799) 59.742 59.758 (2.3520 2.3527) 2.127 2.130 (0.0837 0.0839) 2.000 2.013 (0.0787 0.0793) 59.962 59.978 (2.3607 2.3613) 2.019 2.022 (0.0795 0.0796) 59.942 59.958 (2.3599 2.3605) 2.029 2.032 (0.0799 0.0800) 59.742 59.758 (2.3520 2.3527) 2.129 2.132 (0.0838 0.0839) Crank pin diameter 51.984 52.000 (2.0466 2.0472) 1.492 1.510 (0.0587 0.0591) 51.954 51.970 (2.0454 2.0461) 1.510 1.513 (0.0594 0.0596) 51.934 51.950 (2.0446 2.0453) 1.520 1.523 (0.0598 0.0600) 51.734 51.750 (20368 2.0374) 1.620 1.623 (0.0638 0.0639)
Journal O.D. Standard Bearing size (Thickness at center) Journal O.D. 0.03 (0.0012) undersize Bearing size (Thickness at center) Journal O.D. 0.05 (0.0020) undersize Bearing size (Thickness at center) Journal O.D. 0.25 (0.0098) undersize Bearing size (Thickness at center)
O.D. ... Outer Diameter
ME(DOHC TURBO)-89
Mechanical
CYLINDER BLOCK
5) Inspect individual crankshaft bearings for signs of flaking, seizure, melting, and wear. 6) Measure the oil clearance on each crankshaft bearing by means of plastigauge. If the measurement is not within the specification, replace defective bearing with an undersize one, and replace or recondition crankshaft as necessary.
Unit: mm (in) Crankshaft oil clearance 0.010 0.030 (0.0004 Standard 0.0012) Limit 0.040 (0.0016)
4) Measure the thrust clearance of crankshaft at center bearing. If the clearance exceeds the limit, replace bearing. Crankshaft thrust clearance: Standard 0.030 0.115 mm (0.0012 0.0045 in) Limit 0.25 mm (0.0098 in)
EN0341
ME(DOHC TURBO)-90
Mechanical
21. Engine Trouble in General

A: INSPECTION
S183095A10
S183095
NOTE: RANK shown in the chart refer to the possibility of reason for the trouble in order (Very often to Rarely) A Very often B Sometimes C Rarely
TROUBLE 1. Engine will not start. 1) Starter does not turn. PROBLEM PARTS, ETC. Starter POSSIBLE CAUSE RANK B C C B A A B C C C C A A B B B C C C C C B C B B
2) Initial combustion does not occur.
Defective battery-to-starter harness Defective starter switch Defective inhibitor switch or neutral switch Defective starter Battery Poor terminal connection Run-down battery Defective charging system Friction Seizure of crankshaft and connecting rod bearing Seized camshaft Seized or stuck piston and cylinder Starter Defective starter Engine control system <Ref. to EN(DOHC TURBO)-2, Basic Diagnostic Procedure.> Fuel line Defective fuel pump and relay Lack of or insufficient fuel Belt Defective Defective timing Compression Incorrect valve clearance Loosened spark plugs or defective gasket Loosened cylinder head bolts or defective gasket Improper valve seating Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity)
ME(DOHC TURBO)-91
Mechanical
TROUBLE 3) Initial combustion occur.

PROBLEM PARTS, ETC. POSSIBLE CAUSE Engine control system <Ref. to EN(DOHC TURBO)-2, Basic Diagnostic Procedure.> Intake system Defective intake manifold gasket Defective throttle body gasket Fuel line Defective fuel pump and relay Clogged fuel line Lack of or insufficient fuel Belt Defective Defective timing Compression Incorrect valve clearance Loosened spark plugs or defective gasket Loosened cylinder head bolts or defective gasket Improper valve seating Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity) Engine control system <Ref. to EN(DOHC TURBO)-2, Basic Diagnostic Procedure.> Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective intake manifold gasket Defective throttle body gasket Dirty air cleaner element Fuel line Clogged fuel line Lack of or insufficient fuel Belt Defective Defective timing Compression Incorrect valve clearance Loosened spark plugs or defective gasket Loosened cylinder head bolts or defective gasket Improper valve seating Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity) RANK A B B C C B B B C C C C C B C B B A B C C B B C C B B B C C C C C B C B B
4) Engine stalls after initial combustion.
ME(DOHC TURBO)-92

TROUBLE 2. Rough idle and engine stall
Mechanical
RANK A A A A B B C B C C C B C B B B B C B B A B B C C A B C
PROBLEM PARTS, ETC. POSSIBLE CAUSE Engine control system <Ref. to EN(DOHC TURBO)-2, Basic Diagnostic Procedure.> Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective intake manifold gasket Defective throttle body gasket Defective PCV valve Loosened oil filler cap Dirty air cleaner element Fuel line Defective fuel pump and relay Clogged fuel line Lack of or insufficient fuel Belt Defective timing Compression Incorrect valve clearance Loosened spark plugs or defective gasket Loosened cylinder head bolts or defective gasket Improper valve seating Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity) Lubrication system Incorrect oil pressure Defective rocker cover gasket Cooling system Overheating Others Malfunction of evaporative emission control system Stuck or damaged throttle valve Accelerator cable out of adjustment
ME(DOHC TURBO)-93
Mechanical

RANK A A A B B B B B A B B C B B B B B C B C A B B C C A A A A A B B B B B B B C B B C C C C C C A B B C
TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE 3. Low output, hesitation and Engine control system <Ref. to EN(DOHC TURBO)-2, Basic Diagnostic Procepoor acceleration dure.> Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective intake manifold gasket Defective throttle body gasket Defective PCV valve Loosened oil filler cap Dirty air cleaner element Fuel line Defective fuel pump and relay Clogged fuel line Lack of or insufficient fuel Belt Defective timing Compression Incorrect valve clearance Loosened spark plugs or defective gasket Loosened cylinder head bolts or defective gasket Improper valve seating Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity) Lubrication system Incorrect oil pressure Cooling system Overheating Over cooling Others Malfunction of evaporative emission control system 4. Surging Engine control system <Ref. to EN(DOHC TURBO)-2, Basic Diagnostic Procedure.> Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective intake manifold gasket Defective throttle body gasket Defective PCV valve Loosened oil filler cap Dirty air cleaner element Fuel line Defective fuel pump and relay Clogged fuel line Lack of or insufficient fuel Belt Defective timing Compression Incorrect valve clearance Loosened spark plugs or defective gasket Loosened cylinder head bolts or defective gasket Improper valve seating Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Improper engine oil (low viscosity) Cooling system Overheating Others Malfunction of evaporative emission control system
ME(DOHC TURBO)-94

TROUBLE 5. Engine does not return to idle.
Mechanical
RANK A A A B A B B A C C B B C B B C C B C C C A C C C A B B C B A A B C A A B B B B B B
6. Dieseling (Run-on)
8. Knocking
9. Excessive engine oil consumption
PROBLEM PARTS, ETC. POSSIBLE CAUSE Engine control system <Ref. to EN(DOHC TURBO)-2, Basic Diagnostic Procedure.> Intake system Loosened or cracked vacuum hose Others Stuck or damaged throttle valve Accelerator cable out of adjustment Engine control system <Ref. to EN(DOHC TURBO)-2, Basic Diagnostic Procedure.> Cooling system Overheating Others Malfunction of evaporative emission control system Engine control system <Ref. to EN(DOHC TURBO)-2, Basic Diagnostic Procedure.> Intake system Loosened or cracked intake duct Loosened or cracked PCV hose Loosened or cracked vacuum hose Defective PCV valve Loosened oil filler cap Belt Defective timing Compression Incorrect valve clearance Loosened spark plugs or defective gasket Loosened cylinder head bolts or defective gasket Improper valve seating Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Lubrication system Incorrect oil pressure Cooling system Over cooling Others Malfunction of evaporative emission control system Engine control system <Ref. to EN(DOHC TURBO)-2, Basic Diagnostic Procedure.> Intake system Loosened oil filler cap Belt Defective timing Compression Incorrect valve clearance Incorrect valve timing Cooling system Overheating Intake system Loosened or cracked PCV hose Defective PCV valve Loosened oil filler cap Compression Defective valve stem Worn or stuck piston rings, cylinder and piston Lubrication system Loosened oil pump attaching bolts and defective gasket Defective oil filter seal Defective crankshaft oil seal Defective rocker cover gasket Loosened oil drain plug or defective gasket Loosened oil pan fitting bolts or defective oil pan
ME(DOHC TURBO)-95
Mechanical

POSSIBLE CAUSE to EN(DOHC TURBO)-2, Basic Diagnostic Proce Dirty air cleaner element Defective timing Incorrect valve clearance Loosened spark plugs or defective gasket Loosened cylinder head bolts or defective gasket Improper valve seating Defective valve stem Worn or broken valve spring Worn or stuck piston rings, cylinder and piston Incorrect valve timing Incorrect oil pressure Over cooling Accelerator cable out of adjustment RANK A A B B C C B C C B B C C B
TROUBLE PROBLEM PARTS, ETC. 10. Excessive fuel consump- Engine control system <Ref. tion dure.> Intake system Belt Compression
Lubrication system Cooling system Others
ME(DOHC TURBO)-96
ENGINE NOISE
Mechanical
22. Engine Noise

A: INSPECTION
Type of sound
S183096
S183096A10
Condition Sound increases as engine speed increases.
Regular clicking sound
Oil pressure is low. Heavy and dull clank Oil pressure is normal. High-pitched clank (Spark knock) Sound is noticeable when accelerating with an overload.
Possible cause Valve mechanism is defective. Incorrect valve clearance Worn valve rocker Worn camshaft Broken valve spring Worn crankshaft main bearing Worn connecting rod bearing (big end) Loose flywheel mounting bolts Damaged engine mounting Ignition timing advanced Accumulation of carbon inside combustion chamber Wrong spark plug Improper gasoline
Sound is reduced when fuel injector connector of noisy cylinder is disconnected. (NOTE*) Sound is reduced when fuel injector connector of noisy cylKnocking sound when engine inder is disconnected. is operating under idling speed (NOTE*) and engine is warm Sound is not reduced if each fuel injector connector is disconnected in turn. (NOTE*) Squeaky sound Rubbing sound Gear scream when starting engine Sound like polishing glass with a dry cloth Clank when engine speed is medium (1,000 to 2,000 rpm). Hissing sound Timing belt noise Valve tappet noise
Worn crankshaft main bearing Worn bearing at crankshaft end of connecting rod Worn cylinder liner and piston ring Broken or stuck piston ring Worn piston pin and hole at piston end of connecting rod Unusually worn valve lifter Worn cam gear Worn camshaft journal bore in crankcase Insufficient generator lubrication Defective generator brush and rotor contact Defective ignition starter switch Worn gear and starter pinion Loose drive belt Defective water pump shaft Loss of compression Air leakage in air intake system, hoses, connections or manifolds Loose timing belt Belt contacting case/adjacent part Incorrect valve clearance
NOTE*: When disconnecting fuel injector connector, Malfunction Indicator Light (CHECK ENGINE light) illuminates and trouble code is stored in ECM memory. Therefore, carry out the CLEAR MEMORY MODE <Ref. to EN(DOHC TURBO)-47, OPERATION, Clear Memory Mode.> and INSPECTION MODE <Ref. to EN(DOHC TURBO)-44, OPERATION, Inspection Mode.> after connecting fuel injector connector.
ME(DOHC TURBO)-97
Mechanical
ENGINE NOISE
MEMO:
ME(DOHC TURBO)-98
EXHAUST
EX(DOHC TURBO)
1. 2. 3. 4. 5. 6. Page General Description.....................................................................................2 Front Exhaust Pipe......................................................................................7 Center Exhaust Pipe ...................................................................................9 Joint Pipe...................................................................................................13 Rear Exhaust Pipe ....................................................................................14 Muffler........................................................................................................15
Exhaust
GENERAL DESCRIPTION
S182001
A: COMPONENT
S182001A05
1. FRONT EXHAUST PIPE
S182001A0501
S2M2237A
EX(DOHC TURBO)-2
GENERAL DESCRIPTION
(1) Gasket (2) Upper exhaust manifold cover (RH) (3) Exhaust manifold (RH) (4) Lower exhaust manifold cover (RH) (5) Front exhaust pipe upper clamp (6) Front exhaust pipe upper cover (7) Front exhaust pipe upper insulator (RH) (8) Front exhaust pipe upper insulator (LH) (9) Gasket (10) Front exhaust pipe (11) Front exhaust pipe lower insulator (RH) (12) Front exhaust pipe lower insulator (LH) (13) Front exhaust pipe lower cover (14) Front exhaust pipe lower clamp (15) Gasket (16) Gasket (17) Upper exhaust manifold cover (LH) (18) Exhaust manifold (LH) (19) Lower exhaust manifold cover (LH) (20) Gasket (21) (22) (23) (24) (25)
Exhaust
Turbocharger joint pipe Gasket Front oxygen (A/F) sensor Precatalytic converter Exhaust temperature sensor
Tightening torque: Nm (kgf-m, ft-lb) T1: 18.6 (1.9, 13.7) T2: 25 (2.5, 18.1) T3: 35 (3.6, 26.0) T4: 39 (4, 28.9)
EX(DOHC TURBO)-3
Exhaust
GENERAL DESCRIPTION
S182001A0502
2. CENTER AND REAR EXHAUST PIPE, AND MUFFLER AUSTRALIA SPEC. VEHICLES
S2M2239A
(1) (2) (3) (4) (5) (6) (7) (8) (9)
Gasket Rear oxygen converter Upper center pipe cover Center exhaust pipe Lower center pipe cover Bracket (MT) Gasket Rear exhaust pipe Upper cover
(10) (11) (12) (13) (14) (15) (16) (17) (18)
Lower cover Upper cover A Lower cover A Spring Bolt Cushion Gasket Cushion Muffler
(19) Muffler cutter

Tightening torque: Nm (kgf-m, ft-lb) T1: 18 (1.8, 13.0) T2: 30 (3.1, 22.4) T3: 35 (3.6, 26.0) T4: 48 (4.9, 35.4)
EX(DOHC TURBO)-4
GENERAL DESCRIPTION
EXCEPT AUSTRALIA SPEC. VEHICLES
Exhaust
S2M2176B
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
Gasket Front catalytic converter Upper center pipe cover (Front) Center exhaust pipe (Front) Lower center pipe cover (Front) Bracket Gasket Upper center pipe cover (Rear) Lower center pipe cover (Rear) Upper rear catalytic converter cover (11) Lower clamp (12) Lower rear catalytic converter cover (13) Rear oxygen sensor
(14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24)
Rear catalytic converter Upper clamp Gasket Rear exhaust pipe Lower rear exhaust pipe cover (Front) Chamber Lower rear exhaust pipe cover (Rear) Cushion Spring Bolt Upper rear exhaust pipe cover (Front)
(25) Upper rear exhaust pipe cover (Rear) (26) Gasket (27) Muffler (28) Cushion (29) Muffler cutter (30) Center exhaust pipe (Rear)
EX(DOHC TURBO)-5
Exhaust
GENERAL DESCRIPTION
S182001A03
B: CAUTION
EX(DOHC TURBO)-6
FRONT EXHAUST PIPE
Exhaust

A: REMOVAL
S182065A18
S182065
10) Separate front exhaust pipe from exhaust mani-folds.
G2M0854
G6M0095
B: INSTALLATION
S182065A11
2) Remove front oxygen (A/F) sensor. <Ref. to FU(DOHC TURBO)-42, REMOVAL, Front Oxygen (A/F) Sensor.> 3) Remove under cover. 4) Remove lower exhaust manifold cover (RH). 5) Remove lower and upper exhaust manifold covers (LH).
CAUTION: Replace gaskets with new ones. 1) Assemble front exhaust pipe and exhaust manifolds. Tightening torque: 39 Nm (4 kgf-m, 28.9 ft-lb)
G2M0852
G2M0854
6) Remove bolts and nuts which hold front exhaust pipe assembly to turbocharger joint pipe. 7) While holding front exhaust pipe assembly with one hand, remove nuts which hold front exhaust pipe assembly to cylinder head exhaust port.
2) Install front exhaust pipe covers. Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft-lb) 3) Install upper exhaust manifold cover (RH). Tightening torque: 18.6 Nm (1.9 kgf-m, 13.7 ft-lb) 4) Install front exhaust pipe assembly. Tightening torque: 35 Nm (3.6 kgf-m, 26.0 ft-lb)
G2M0853
8) Remove front exhaust pipe assembly. 9) Remove covers from exhaust manifold and front exhaust pipe.
EX(DOHC TURBO)-7
Exhaust
FRONT EXHAUST PIPE
5) Connect exhaust manifold (RH) to turbocharger joint pipe. Tightening torque: 35 Nm (3.6 kgf-m, 26.0 ft-lb)
G2M0853
6) Install upper and lower exhaust manifold covers (LH). Tightening torque: 18.6 Nm (1.9 kgf-m, 13.7 ft-lb) 7) Install lower exhaust manifold cover (RH). Tightening torque: 18.6 Nm (1.9 kgf-m, 13.7 ft-lb)
G2M0852
8) Install front oxygen (A/F) sensor. <Ref. to FU(DOHC TURBO)-43, INSTALLATION, Front Oxygen (A/F) Sensor.> 9) Install under cover. 10) Connect battery ground cable.
G6M0095
EX(DOHC TURBO)-8
CENTER EXHAUST PIPE
Exhaust

A: REMOVAL
S182067A18
S182067
8) Remove bolts which install the lower side of turbocharger upper cover. CAUTION: Be careful, turbocharger and exhaust pipe are hot.
1) Set the vehicle on the lift. 2) Disconnect battery ground cable. 3) Remove intercooler. <Ref. to TURBO)-10, REMOVAL, Intercooler.> 4) Remove intercooler bracket.
IN(DOHC
H2M1929
H2M1928
9) Lower the vehicle. 10) Remove turbocharger upper cover.
5) Lift-up the vehicle. 6) Remove under cover. 7) Remove universal joint bolts and then remove universal joint (RHD model only). CAUTION: Scribe alignment marks on universal joint so that it can be reassembled at the original serration.
H2M1733
11) Remove bolts which install the upper side of turbocharger lower cover, and remove it.
H2M1950
H2M1931
EX(DOHC TURBO)-9
Exhaust
CENTER EXHAUST PIPE

17) Remove intercooler bracket. 18) Remove bolt which holds center exhaust pipe to hanger bracket. CAUTION: Be careful not to pull down center exhaust pipe.
12) Separate center exhaust pipe from turbocharger.
H2M1745
13) Lift-up the vehicle. 14) Disconnect connector from rear oxygen sensor.
S2M1723
19) Remove center exhaust pipe.
EN0834
15) Separate center exhaust pipe from rear exhaust pipe.
H2M1762
B: INSTALLATION
S182067A11
CAUTION: Replace gaskets with new ones. 1) Install center exhaust pipe and temporarily tighten bolt which holds center exhaust pipe to hanger bracket. 2) Temporarily tighten bolt which holds center pipe to transmission. 3) Connect center exhaust pipe to turbocharger. Tightening torque: 35 Nm (3.6 kgf-m, 26.0 ft-lb)
G2M0855
16) Remove bolt which holds center exhaust pipe bracket to transmission.
H2M1746
H2M1745
EX(DOHC TURBO)-10
CENTER EXHAUST PIPE

4) Install center exhaust pipe to rear exhaust pipe. Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft-lb)
Exhaust
7) Tighten bolt which holds center exhaust pipe to hanger bracket. Tightening torque: 35 Nm (3.6 kgf-m, 26 ft-lb)
G2M0855
5) Connect connector to rear oxygen sensor. Tightening torque: 35 Nm (3.6 kgf-m, 26.0 ft-lb)
S2M1723
8) Tighten bolts which hold intercooler bracket.
9) Lower the vehicle. 10) Place turbocharger lower cover, and tighten bolts which install the upper side of lower cover. Tightening torque: 7.4 Nm (0.75 kgf-m, 5.4 ft-lb)
EN0834
6) Tighten bolt which holds center exhaust pipe bracket to transmission. Tightening torque: 30 Nm (3.1 kgf-m, 22.4 ft-lb)
H2M1931
11) Place turbocharger upper cover, and tighten bolts which install the upper side of upper cover. Tightening torque: 7.4 Nm (0.75 kgf-m, 5.4 ft-lb)
H2M1746
H2M1930
EX(DOHC TURBO)-11
Exhaust
CENTER EXHAUST PIPE

17) Install intercooler bracket.
13) Tighten bolts which install the under side of turbocharger upper cover. Tightening torque: 7.4 Nm (0.75 kgf-m, 5.4 ft-lb)
S2M1928
H2M1929
14) Install universal joint (RHD model only). (1) Align bolt hole on the long yoke side of universal joint with the cutout at the serrated section of shaft end, and insert universal joint. (2) Align bolt hole on the short yoke side of universal joint with the cutout at the serrated section of gearbox assembly. Lower universal joint completely. (3) Temporarily tighten bolt on the short yoke side. Raise universal joint to make sure the bolt is properly passing through the cutout at the serrated section. (4) Tighten bolt on the long yoke side, then that on the short yoke side. Tightening torque: 24 Nm (2.4 kgf-m, 17.4 ft-lb) CAUTION: Make sure that universal joint bolts are tightened through notches in shaft serration. Excessively large tightening torque of universal joint bolts may lead to heavy steering wheel operation. Standard clearance between gearbox to DOJ: Over 15 mm (0.59 in)
18) Install intercooler. <Ref. to IN(DOHC TURBO)-10, INSTALLATION, Intercooler.> 19) Align center of roll connector. (With airbag model) <Ref. to AB-11, ROLL CONNECTOR, INSPECTION, Inspection Locations After a Collision.>
H2M1950
15) Install under cover. 16) Lower the vehicle.
EX(DOHC TURBO)-12
JOINT PIPE
Exhaust
4. Joint Pipe
A: REMOVAL
S182771
6) Remove lower exhaust manifold cover (RH).
S182771A18
G2M0852
7) Remove nuts. Which hold front exhaust manifold to joint pipe.

G6M0095
2) Remove solenoid valve cover.
EN0917
EN0828
3) Disconnect from exhaust temperature sensor connector.
8) Remove center exhaust pipe. <Ref. to EX(DOHC TURBO)-9, REMOVAL, Center Exhaust Pipe.> 9) Remove turbocharger. <Ref. to IN(DOHC TURBO)-12, REMOVAL, Turbocharger.> 10) Take off joint pipe in the upward direction.
B: INSTALLATION
S182771A11
EN0896
4) Remove front oxygen (A/F) sensor. <Ref. to FU(DOHC TURBO)-42, REMOVAL, Front Oxygen (A/F) Sensor.> 5) Remove under cover.
H2M1747A
EX(DOHC TURBO)-13
Exhaust
REAR EXHAUST PIPE

S182068

A: REMOVAL
S182068A18
B: INSTALLATION
S182068A11
CAUTION: Replace gaskets with new ones. 1) Install rear exhaust pipe to muffler. Tightening torque: 48 Nm (4.9 kgf-m, 35.4 ft-lb)
G6M0095
2) Lift up the vehicle. 3) Separate rear exhaust pipe from center exhaust pipe. CAUTION: Be careful, exhaust pipe is hot.
S2M0559
2) Install rear exhaust pipe to center exhaust pipe. Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft-lb)
S2M0558
S2M0558
3) Lower the vehicle. 4) Connect battery ground cable.
G6M0095 S2M0559
5) Remove rear exhaust pipe.
C: INSPECTION
S182068A10
EX(DOHC TURBO)-14
MUFFLER
Exhaust
S182066A11
6. Muffler
S182066
B: INSTALLATION
A: REMOVAL
S182066A18
S2M0559 S2M0559
2) Remove rubber cushions, and detach muffler. CAUTION: Be careful not to drop the muffler during removal. NOTE: To facilitate removal, apply a coat of SUBARU CRC to mating area of rubber cushions in advance. SUBARU CRC (Part No. 004301003)
C: INSPECTION
S182066A10
S2M2177
EX(DOHC TURBO)-15
Exhaust
MUFFLER
MEMO:
EX(DOHC TURBO)-16
IGNITION
IG(DOHC TURBO)
1. 2. 3. Page General Description.....................................................................................2 Spark Plug...................................................................................................4 Ignition Coil and Ignitor Assembly...............................................................8
Ignition
GENERAL DESCRIPTION
S181001
A: SPECIFICATIONS
Item Ignition coil and ignitor assembly Spark plug Model Manufacturer Type and manufacturer Thread size Spark gap
S181001E49
Designation FK0140 DIAMOND mm mm (in) PFR6G .......... NGK 14, P = 1.25 0.7 0.8 (0.028 0.031)
IG(DOHC TURBO)-2

S181001A05
Ignition
EN0853
(1) Spark plug (2) Ignition coil and ignitor ASSY
Tightening torque: Nm (kgf-m, ft-lb) T1: 21 (2.1, 15) T2: 16 (1.6, 11.7)
C: CAUTION
S181001A03
IG(DOHC TURBO)-3
Ignition
SPARK PLUG
S181003
2. Spark Plug
A: REMOVAL
S181003A18
CAUTION: All spark plugs installed on an engine, must be of the same heat range. Spark plug: NGK: PFR6G
1. RH SIDE
S181003A1801
EN0856
2. LH SIDE
S181003A1802
1) Disconnect battery cables, and then remove battery and battery carrier.
G6M0095
2) Remove air cleaner lower case. <Ref. to IN(DOHC TURBO)-7, REMOVAL, Air Cleaner.> 3) Disconnect connector from ignition coil.
G6M0095
2) Disconnect washer motor connector (A).
EN0854
4) Remove ignition coil.

B6M0562D
3) Disconnect rear window glass washer hose from washer motor, then plug connection with a suitable cap.
EN0855
IG(DOHC TURBO)-4
SPARK PLUG
4) Remove the two bolts which hold the washer tank, then take the tank away from the working area.
Ignition
S181003A11
B: INSTALLATION
1. RH SIDE
S181003A1101
1) Install in the reverse order of removal. Tightening torque (Spark plug): 21 Nm (2.1 kgf-m, 15 ft-lb) Tightening torque (Ignition coil): 16 Nm (1.63 kgf-m, 11.8 ft-lb) CAUTION: The above torque should be only applied to new spark plugs without oil on their threads. In case their threads are lubricated, the torque should be reduced by approximately 1/3 of the specified torque in order to avoid over-stressing.
B2M2023
5) Disconnect connector from ignition coil.
2. LH SIDE
S181003A1102
1) Install in the reverse order of removal. Tightening torque (Spark plug): 21 Nm (2.1 kgf-m, 15 ft-lb) Tightening torque (Ignition coil): 16 Nm (1.63 kgf-m, 11.8 ft-lb) CAUTION: The above torque should be only applied to new spark plugs without oil on their threads. In case their threads are lubricated, the torque should be reduced by approximately 1/3 of the specified torque in order to avoid over-stressing.
EN0857
6) Remove ignition coil.
EN0858
7) Remove spark plug with the spark plugs socket.
EN0859
IG(DOHC TURBO)-5
Ignition
SPARK PLUG
S181003A10
C: INSPECTION
S6M0420A
(A) (B) (C) (D) (E)
G6M0089
G6M0087
G6M0090
G6M0088
IG(DOHC TURBO)-6
SPARK PLUG D: ADJUSTMENT

S181003A01
Ignition
Clean spark plugs in a sand blast type cleaner. Avoid excessive blasting. Clean and remove carbon or oxide deposits, but do not wear away porcelain. If deposits are too stubborn, replace plugs. After cleaning spark plugs, recondition firing surface of electrodes with file. Then correct the spark plug gap using a gap gauge. Spark plug gap: L 0.7 0.8 mm (0.028 0.031 in)
S6M0412A
IG(DOHC TURBO)-7
Ignition

S181015
A: REMOVAL
S181015A18
Direct ignition type has been adopted. Refer to the Spark Plug Removal for removal procedure. <Ref. to IG(DOHC TURBO)-4, REMOVAL, Spark Plug.>
B: INSTALLATION
S181015A11
C: INSPECTION
S181015A10
Because ignition coil is a direct ignition type, the resistance cannot be measured in a single unit. For inspection procedure of ignition system, refer to the following. <Ref. to EN(DOHC TURBO)-72, IGNITION CONTROL SYSTEM, Diagnostics for Engine Starting Failure.>
IG(DOHC TURBO)-8
EN(DOHC TURBO)
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. Page Basic Diagnostic Procedure ........................................................................2 Check List for Interview...............................................................................4 General Description.....................................................................................6 Electrical Components Location................................................................10 Engine Control Module (ECM) I/O Signal.................................................26 Engine Condition Data ..............................................................................29 Engine Condition Data ..............................................................................30 Data Link Connector .................................................................................33 OBD-II General Scan Tool ........................................................................34 Subaru Select Monitor...............................................................................36 Read Diagnostic Trouble Code .................................................................43 Inspection Mode ........................................................................................44 Clear Memory Mode..................................................................................47 Compulsory Valve Operation Check Mode...............................................48 Engine Malfunction Indicator Lamp (MIL) .................................................50 Diagnostics for Engine Starting Failure ....................................................63 List of Diagnostic Trouble Code (DTC).....................................................82 Diagnostic Procedure with Diagnostic Trouble Code (DTC) ....................90 General Diagnostic Table ........................................................................344

S088501
A: PROCEDURE
1. ENGINE
No. 1
S088501E4501
S088501E45
Step Check Does the engine start? CHECK ENGINE START FAILURE. 1) Ask the customer when and how the trouble occurred using the interview check list. <Ref. to EN(DOHC TURBO)-4, CHECK, Check List for Interview.> 2) Start the engine.
CHECK ILLUMINATION OF CHECK ENGINE Does CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL). malfunction indicator lamp illuminate?
CHECK INDICATION OF DTC ON DISPLAY. Does the Subaru Select Monitor or OBD-II general 1) Turn ignition switch to OFF. scan tool indicate DTC? 2) Connect the Subaru Select Monitor or the OBD-II general scan tool to data link connector. 3) Turn ignition switch to ON and the Subaru Select Monitor or OBD-II general scan tool switch to ON. 4) Read DTC on the Subaru Select Monitor or OBD-II general scan tool.
PERFORM THE DIAGNOSIS. 1) Perform the clear memory mode. <Ref. to EN(DOHC TURBO)-47, Clear Memory Mode.> 2) Perform the inspection mode. <Ref. to EN(DOHC TURBO)-44, Inspection Mode.>
Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC?
No Inspection using Diagnostics for Engine Start Failure. <Ref. to EN(DOHC TURBO)-63, Diagnostics for Engine Starting Failure.> Go to step 3. Inspection using General Diagnostics Table. <Ref. to EN(DOHC TURBO)-344, General Diagnostic Table.> Record diagnostic Repair the related parts. trouble code. Repair the trouble NOTE: If DTC is not cause. <Ref. to shown on display EN(DOHC although the MIL TURBO)-82, List illuminates, perof Diagnostic form diagnostics Trouble Code of MIL (CHECK (DTC).> Go to ENGINE malfuncstep 4. tion indicator lamp) circuit or combination meter. <Ref. to EN(DOHC TURBO)-50, Engine Malfunction Indicator Lamp (MIL).> Complete the Inspect using Diagnostics Pro- diagnosis. cedure with Diagnostic Trouble Code (DTC). <Ref. to EN(DOHC TURBO)-90, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Yes Go to step 2.
EN(DOHC TURBO)-2

S088501E4502
When trouble code about automatic transmission is shown on display, carry out the following basic check. After that, carry out the replacement or repair work. 1) ATF level check <Ref. to AT-9, Automatic Transmission Fluid.> 2) Differential gear oil level check <Ref. to AT-11, Differential Gear Oil.> 3) ATF leak check <Ref. to AT-9, Automatic Transmission Fluid.> 4) Differential gear oil leak check <Ref. to AT-11, Differential Gear Oil.> 5) Stall test <Ref. to AT-11, Differential Gear Oil.> 6) Line pressure test <Ref. to AT-16, Line Pressure Test.> 7) Transfer clutch pressure test <Ref. to AT-18, Transfer Clutch Pressure Test.> 8) Time lag test <Ref. to AT-15, Time Lag Test.> 9) Road test <Ref. to AT-12, Road Test.> 10) Shift characteristics <Ref. to AT-18, Transfer Clutch Pressure Test.>
EN(DOHC TURBO)-3

S088502

A: CHECK
S088502A04
1. CHECK LIST NO. 1
S088502A0401
Customer s name Date of sale Date of repair Vin no. Weather Engine no. Fuel brand Odometer reading Fine Cloudy Rainy Snowy Various/Others: C (F) Hot Warm Cool Cold Highway Suburbs Inner city Uphill Downhill Rough road Others: Cold Warming-up After warming-up Any temperature Others: rpm MPH Not affected At starting While idling At racing While accelerating While cruising While decelerating While turning (RH/LH) ON/ OFF ON/ OFF ON/ OFF ON/ OFF ON/ OFF ON/ OFF
km miles
Outdoor temperature
Place
Engine temperature
ON/ ON/ ON/ ON/ ON/
OFF OFF OFF OFF OFF
EN(DOHC TURBO)-4

2. CHECK LIST NO. 2
S088502A0402
Check the following items about the vehicles state when MIL turns on.
NOTE: Use copies of this page for interviewing customers.
a) Other warning lights or indicators turn on. Yes/ No Low fuel warning light Charge indicator light AT diagnostics indicator light ABS warning light Engine oil pressure warning light b) Fuel level Lack of gasoline: Yes/ No Indicator position of fuel gauge: c) Intentional connecting or disconnecting of harness connectors or spark plug cords: Yes/ No What: d) Intentional connecting or disconnecting of hoses: Yes/ No What: e) Installing of parts other than genuine parts: Yes/ No What: Where: f) Occurrence of noise: Yes/ No From where: What kind: g) Occurrence of smell: Yes/ No From where: What kind: h) Intrusion of water into engine compartment or passenger compartment: Yes/ No i) Troubles occurred Engine does not start. Engine stalls during idling. Engine stalls while driving. Engine speed decreases. Engine speed does not decrease. Rough idling Poor acceleration Back fire After fire No shift Excessive shift shock
EN(DOHC TURBO)-5
GENERAL DESCRIPTION
S088001
A: CAUTION
S088001A03
8) Use ECM mounting stud bolts at the body head grounding point when measuring voltage and resistance inside the passenger compartment.
H2M1154A
EN0945
B3M1666E
11) Every MFI-related part is a precision part. Do not drop them. 12) Observe the following cautions when installing a radio in MFI equipped models. CAUTION: The antenna must be kept as far apart as possible from the control unit. (The ECM is located under the steering column, inside of the instrument panel lower trim panel.)
EN(DOHC TURBO)-6
GENERAL DESCRIPTION
The antenna feeder must be placed as far apart as possible from the ECM and MFI harness. Carefully adjust the antenna for correct matching. When mounting a large power type radio, pay special attention to the three items above mentioned. Incorrect installation of the radio may affect the operation of the ECM. 13) Before disconnecting the fuel hose, disconnect the fuel pump connector and crank the engine for more than five seconds to release pressure in the fuel system. If engine starts during this operation, run it until it stops. 14) Problems in the electronic-controlled automatic transmission may be caused by failure of the engine, the electronic control system, the transmission proper, or by a combination of these. These three causes must be distinguished clearly when performing diagnostics. 15) Diagnostics should be conducted by rotating with simple, easy operations and proceeding to complicated, difficult operations. The most important thing in diagnostics is to understand the customer s complaint, and distinguish between the three causes. 16) On ABS vehicle, when performing driving test in jacked-up or lifted-up position, sometimes the warning light may be lit, but this is not a malfunction of the system. The reason for this is the speed difference between the front and rear wheels. After diagnosis of engine control system, perform the ABS memory clearance procedure of self-diagnosis system.
S088001A1002
2. ENGINE GROUNDING
EN0945
C: NOTE
S088001A15
1. DESCRIPTION
S088001A1501
B: INSPECTION
S088001A10
1. BATTERY
S088001A1001
The on-board diagnostics (OBD) system detects and indicates a fault in various inputs and outputs of the complex electronic control. CHECK ENGINE malfunction indicator lamp (MIL) in the combination meter indicates occurrence of a fault or trouble. Further, against such a failure or sensors as may disable the drive, the fail-safe function is provided to ensure the minimal driveability. The OBD system incorporated with the vehicles within this engine family complies with Section 1968.1, California Code of Regulations (OBD-II regulation). The OBD system monitors the components and the system malfunction listed in Engine Section which affects on emissions. When the system decides that a malfunction occurs, MIL illuminates. At the same time of the MIL illumination or blinking, a diagnostic trouble code (DTC) and a freeze frame engine conditions are stored into on-board computer. The OBD system stores freeze frame engine condition data (engine load, engine coolant temperature, fuel trim, engine speed and vehicle speed, etc.) into on-board computer when it detects a malfunction first. If the OBD system detects the various malfunctions including the fault of fuel trim or misfire, the OBD system first stores freeze frame engine conditions about the fuel trim or misfire. When the malfunction does not occur again for three consecutive driving cycles, MIL is turned off, but DTC remains at on-board computer. The OBD-II system is capable of communication with a general scan tool (OBD-II general scan tool) formed by ISO 9141 CARB. The OBD-II diagnostics procedure is different from the usual diagnostics procedure. When troubleshooting OBD-II vehicles, connect Subaru
EN(DOHC TURBO)-7
GENERAL DESCRIPTION
Reduced emission of harmful exhaust gases. Reduced in fuel consumption. Increased engine output. Superior acceleration and deceleration. Superior startability and warm-up performance in cold weather since compensation is made for coolant and intake air temperature.
Select Monitor or the OBD-II general scan tool to the vehicle.

The Multipoint Fuel Injection (MFI) system is a system that supplies the optimum air-fuel mixture to the engine for all the various operating conditions through the use of the latest electronic technology. With this system fuel, which is pressurized at a constant pressure, is injected into the intake air passage of the cylinder head. The injection quantity of fuel is controlled by an intermittent injection system where the electro-magnetic injection valve (fuel injector) opens only for a short period of time, depending on 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 simple, yet highly precise metering of the fuel. Further, all the operating conditions of the engine are converted into electric signals, and this results in additional features of the system, such as large improved adaptability, easier addition of compensating element, etc. The MFI system also has the following features:
3. AUTOMATIC TRANSMISSION AND ELECTRONIC-HYDRAULIC CONTROL SYSTEM S088001A1503

The electronic-hydraulic control system consists of various sensors and switches, a transmission control module (TCM) and the hydraulic controller including solenoid valves. The system controls the transmission proper including shift control, lock-up control, overrunning clutch control, line pressure control and shift timing control. It also controls the AWD transfer clutch. In other words, the system detects various operating conditions from various input signals and sends output signals to shift solenoids 1, 2 and low clutch timing solenoid and 2-4 brake timing solenoid, line pressure duty solenoid, lock-up duty solenoid, transfer duty solenoid and 2-4 brake duty solenoid (a total of eight solenoids).
D: PREPARATION TOOL
ILLUSTRATION
S088001A17
TOOL NUMBER 24082AA150 (New adopted tool)
DESCRIPTION CARTRIDGE
B2M3876
22771AA030
SELECT MONITOR KIT
B2M3877
EN(DOHC TURBO)-8
GENERAL DESCRIPTION
MEMO:
EN(DOHC TURBO)-9

S088507
A: LOCATION
1. ENGINE MODULE
S088507A13
S088507A1301
S2M0226H
S2M1401E
(3) Data link connector (4) Test mode connector
EN(DOHC TURBO)-10
B3M1575A
S2M2215A
S2M2157A
S2M2244B
EN(DOHC TURBO)-11
SENSOR
S2M2216A
(1) Pressure sensor (2) Engine coolant temperature sensor (3) Throttle position sensor
(4) Knock sensor (5) Camshaft position sensor (6) Crankshaft position sensor
(7) Mass air flow and intake air temperature sensor (8) Tumble generator valve position sensor
EN(DOHC TURBO)-12
EN1008
EN1009
EN1010
EN1011
EN1012
EN1013
EN1014
EN1015
EN(DOHC TURBO)-13
Australia Model
S2M2258A
Except Australia Model
S2M2259A
(1) Front oxygen (A/F) sensor (2) Precatalytic converter (3) Exhaust temperature sensor
(4) Front catalytic converter (5) Rear oxygen sensor
(6) Rear catalytic converter (Except Australia model)
EN(DOHC TURBO)-14
EN1016
EN1017
EN0949
EN1018
EN0950
EN(DOHC TURBO)-15
S2M2217A
S2M2218A
(1) Fuel level sensor
(2) Fuel sub level sensor
EN1036
EN1037
EN(DOHC TURBO)-16

MEMO:
EN(DOHC TURBO)-17
SOLENOID VALVE, ACTUATOR, EMISSION CONTROL SYSTEM PARTS AND IGNITION SYSTEM PARTS
S2M2216B
(1) Wastegate control solenoid valve (2) Idle air control solenoid valve
(3) Purge control solenoid valve (4) Ignition coil
(5) Tumble generator valve actuator
EN(DOHC TURBO)-18
EN1021
EN1022
EN1023
EN1024
EN0952
EN(DOHC TURBO)-19
S2M2217B
S2M2218B
(1) Fuel pump (2) Main relay (3) Fuel pump relay
(4) Inhibitor switch (5) Radiator main fan relay (6) Radiator sub fan relay
(7) Starter
EN(DOHC TURBO)-20
EN0953
S2M0278B
S2M0663A
B2M2246G
EN0746
EN1030
EN(DOHC TURBO)-21

S088507A1302
2. TRANSMISSION MODULE
S2M2217C
S2M2218C
(1) Transmission Control Module (TCM) (for AT vehicles)
(2) AT diagnostic indicator light (for AT vehicles)
EN(DOHC TURBO)-22
B3M1592D
B3M1652B
S2M2215B
EN(DOHC TURBO)-23
SENSOR
B2M2258A
B2M2259A
B2M2260A
B2M2261A
OBD0653B
(1) Rear vehicle speed sensor (for AT vehicles) (2) Front vehicle speed sensor (for MT vehicles) (3) Front vehicle speed sensor (for AT vehicles) (4) Torque converter turbine speed sensor (5) ATF temperature sensor (for AT vehicles) (6) Brake light switch
EN(DOHC TURBO)-24

SOLENOID VALVE AND SWITCH (AT VEHICLES)
B2M2246F
B2M2263K
B2M2264F
(1) (2) (3) (4) (5) (6) (7) (8) (9)
Inhibitor switch Shift solenoid valve 1 Shift solenoid valve 2 Line pressure duty solenoid Lock-up duty solenoid Transfer duty solenoid 2-4 brake duty solenoid Low clutch timing solenoid valve 2-4 brake timing solenoid valve
SOLENOID VALVE AND SWITCH (MT VEHICLES)
B2M2265A
(1) Neutral position switch
EN(DOHC TURBO)-25

S088526

S088526A08
EN0955
Content Crankshaft Signal (+) Signal () position sensor Shield Signal (+) Camshaft Signal () position sensor Shield Signal Power supply GND (sensor) Signal Rear oxy- Shield gen sensor GND (sensor) Front oxySignal 1 gen (A/F) sensor Signal 2 heater Rear oxygen sensor heater signal Engine Signal coolant GND (sentemperature sensor sor) Vehicle speed signal Throttle position sensor
Connector No. B135 B135 B135 B135 B135 B135 B135 B135 B135 B135 B135 B135 B137 B137 B136 B135 B135 B134
Terminal No. 2 11 21 1 10 21 7 9 19 17 26 19 4 5 13 18 19 1
Signal (V) Ignition SW ON Engine ON (Idling) (Engine OFF) 0 7 +7 0 0 0 0 0 7 +7 0 0 0 0 Fully closed: 0.2 1.0 Fully opened: 4.2 4.7 5 0 0 0 0 0 1.0 0 1.0 0 1.0 1.0 1.4 0 0 or 5 5 0 0 0.9 0 0 0 1.0 0 1.0 0 1.0 1.0 1.4 0 0 or 5
Note Sensor output waveform Sensor output waveform After warm-up the engine. After warm-up the engine. 5 and 0 are repeatedly displayed when vehicle is driven.
EN(DOHC TURBO)-26

Connector No. B84 B84 B84 B135 B135 B135 B84 B135 B135 B84 B135 B135 B84 B84 B84 B84 B137 B134 B134 B134 MT AT B135 B135 B134 B135 B135 B137 B137 B137 B135 B134 B136 B136 B136 B136 Terminal No. 13 8 7 27 16 19 23 9 19 13 9 19 4 5 11 10 24 16 6 14 8 8 5 4 22 10 2 3 9 10 24 23 22 21 Signal (V) Ignition SW ON Engine ON (Idling) (Engine OFF) 0.3 4.5 0 0 0 0 0 Fully closed: 0.2 1.0 Fully opened: 4.2 4.7 5 0 Fully closed: 0.2 1.0 Fully opened: 4.2 4.7 5 0 0 or 5 0 or 5 0 or 5 0 or 5 10 13 5 0 0 or 5 0 or 5 0 or 5 0 or 5 13 14 5 0 0
Content Signal Mass air Shield flow sensor GND Intake air temperature sensor signal Exhaust Signal gas temGND perature (sensor) sensor Tumble generator valve position sensor RH Tumble generator valve position sensor LH Signal Power supply GND (sensor) Signal
Note Cranking: 8 14 Switch is ON when gear is in neutral position. Switch is ON when shift is in N or P position. When connected: 0 Ignition switch OFF: 10 13 Waveform Waveform Waveform Waveform
Power supply GND (sensor) Tumble generator valve RH (open) Tumble generator valve RH (close) Tumble generator valve LH (open) Tumble generator valve LH (close) Wastegate control solenoid valve Starter switch A/C switch Ignition switch Neutral position switch
Test mode connector Knock sen- Signal sor Shield Back-up power supply Control unit power supply Sensor power supply Line end check 1 #1 #2 Ignition control #3 #4
0 0 ON: 10 13 ON: 13 14 OFF: 0 OFF: 0 10 13 13 14 ON: 120.5 OFF: 0 ON: 0 OFF: 120.5 5 5 2.8 2.8 0 0 10 13 13 14 10 13 13 14 10 13 13 14 5 5 0 0 0 13 14 0 13 14 0 13 14 0 13 14
EN(DOHC TURBO)-27

Connector No. B137 B136 B136 B136 B136 Terminal No. 1 6 5 4 10 Signal (V) Ignition SW ON Engine ON (Idling) (Engine OFF) 10 13 1 14 10 13 1 14 10 13 1 14 10 13 1 14 0 or 13 14 ON: 0.5, or less OFF: 10 13 ON: 0.5, or less OFF: 10 13 ON: 0.5, or less OFF: 10 13 ON: 1, or less OFF: 10 13 1.7 2.4 5 0 0.12 4.75 ON: 0 OFF: 10 13 ON: 0 OFF: 10 13 ON: 0 OFF: 10 13 10 13 2.8 3.2 2.4 2.7 0 Less than 1 More than 4 0 0 0 0 0 0 0 0 0 0 or 13 14 ON: 0.5, or less OFF: 13 14 ON: 0.5, or less OFF: 13 14 ON: 0.5, or less OFF: 13 14 0 13, or more ON: 1, or less OFF: 13 14 1.1 1.6 5 0 0.12 4.75 ON: 0 OFF: 13 14 ON: 0 OFF: 13 14 ON: 0 OFF: 13 14 ON: 0 OFF: 13 14 2.8 3.2 2.4 2.7 0 Less than 1 More than 4 0 0 0 0 0 0 0 0 0
Content #1 #2 #3 #4 Signal
Note Waveform Waveform Waveform Waveform Waveform
Fuel injector Idle air control solenoid valve
A/C relay control Radiator fan relay 1 control Radiator fan relay 2 control Malfunction indicator lamp Engine speed output Purge control solenoid valve Signal Power supPressure ply sensor GND (sensor) Fuel level sensor Small light switch Blower fan switch Rear defogger switch Power steering oil pressure switch Front oxygen (A/F) sensor signal (+) Front oxygen (A/F) sensor signal () Front oxygen (A/F) sensor shield SSM/GST communication line GND (sensors) GND (injectors) GND (ignition system) GND (power supply) GND (control systems) GND (oxygen sensor heater 1) GND (oxygen sensor heater 2)
B137 B137 B137 B137 B136 B137 B135 B135 B135 B135 B134 B134 B134 B135 B137 B137 B136 B134 B135 B136 B136 B136 B134 B134 B134 B137 B137
27 17 28 15 9 16 8 9 19 25 17 9 3 24 19 29 7 21 19 8 18 17 22 7 15 9 8
With A/C vehicles only Light ON: 1, or less Light OFF: 10 14 Waveform
EN(DOHC TURBO)-28

S088530A08
S088530
Content Engine load Specified data 1.6 2.9 (%): Idling 6.4 12.8 (%): 2,500 rpm racing
Measuring condition: After warm-up the engine. Gear position is in neutral position. A/C is turned OFF. All accessory switches are turned OFF.
EN(DOHC TURBO)-29

S088506
S088506A08
TR0532
Check with ignition switch ON. Content Back-up power supply Ignition power supply Connector No. B56 B54 B54 B55 Terminal No. 1 23 24 1 Measuring conditions Ignition switch OFF Ignition switch ON (with engine OFF) Select lever in P range Select lever in any other than P range (except N range) Select lever in N range Select lever in any other than N range (except P range) Select lever in R range Select lever in any other than R range Select lever in D range Select lever in any other than D range Select lever in 3 range Select lever in any other than 3 range Select lever in 2 range Select lever in any other than 2 range Select lever in 1 range Select lever in any other than 1 range Brake pedal depressed. Brake pedal released. Voltage (V) 10 16 10 16 Less than 1 More than 8 Less than 1 More than 8 Less than 1 More than 8 Less than 1 More than 8 Less than 1 More than 8 Less than 1 More than 8 Less than 1 More than 8 More than 10.5 Less than 1 Resistance to body (ohms)
P range switch
N range switch
B55
14
R range switch Inhibitor switch D range switch 3 range switch 2 range switch 1 range switch Brake switch
B55
B55
B55
B55
B55
B55
12
EN(DOHC TURBO)-30

Check with ignition switch ON. Content Connector No. B55 B55 B55 B55 B56 B56 B54 B54 Terminal No. 21 16 23 11 11 10 3 2 Measuring conditions ABS switch ON ABS switch OFF Hold switch ON Hold switch OFF Power switch ON Power switch OFF Throttle fully opened. Throttle fully closed. Light ON Light OFF Light ON Light OFF Throttle fully closed. Throttle fully open. Ignition switch ON (With engine OFF) ATF temperature 20C (68F) ATF temperature 80C (176F) Vehicle stopped. Vehicle speed at least 20 km/h (12 MPH) Vehicle speed at least 20 km/h (12 MPH) Engine idling after warm-up. (D range) Engine idling after warm-up. (N range) Vehicle speed at most 10 km/h (6 MPH) Ignition switch ON (with engine OFF) Ignition switch ON (with engine ON) When cruise control is set (SET lamp ON) When cruise control is not set (SET lamp OFF) Ignition switch ON (with engine ON) Ignition switch ON (with engine ON) Ignition switch ON Engine idling after warm-up. 1st or 4th gear 2nd or 3rd gear 1st or 2nd gear 3rd or 4th gear Voltage (V) Less than 1 6.5 15 Less than 1 More than 8 Less than 1 More than 10 Less than 1 More than 6.5 Less than 1 More than 9 Less than 1 More than 9 0.3 0.7 4.0 4.6 4.8 5.3 1.6 2.0 0.4 0.9 0
Resistance to body (ohms) 2.1 2.9 k 275 375 450 650 450 650
ABS signal Hold switch Power switch Kick-down switch POWER indicator light AT OIL TEMP indicator light Throttle position sensor Throttle position sensor power supply ATF temperature sensor
B54
11
Rear vehicle speed sensor Front vehicle speed sensor Torque converter turbine speed sensor Vehicle speed output signal
B55 B55
24 18
More than 1 (AC range) More than 1 (AC range) 0
B55
450 650 More than 1 (AC range) Less than 1 More than 4 More than 10.5 8 11 Less than 1 More than 6.5 4 4 8 0.5 1.2 More than 9 Less than 1 More than 9 Less than 1 10 16 10 16
B56
17
Engine speed signal
B55
17
Cruise set signal
B55
22
Torque control signal 1 Torque control signal 2 Torque control cut signal Mass air flow signal Shift solenoid 1 Shift solenoid 2
B56 B56 B55 B54 B54 B54
5 14 10 1 22 5
EN(DOHC TURBO)-31

Check with ignition switch ON.
Content
Connector No.
Terminal No.
Measuring conditions Ignition switch ON (with engine OFF) Throttle fully closed after warm-up. Ignition switch ON (with engine OFF) Throttle fully open after warm-up. When lock up occurs. When lock up is released. Fuse on FWD switch Fuse removed from FWD switch (with throttle fully open and with select lever in 1st gear). Ignition switch ON (with engine OFF) Throttle fully closed after warm-up. Ignition switch ON (with engine OFF) Throttle fully open after warm-up. 1st gear 3rd gear 2nd gear 4th gear Fuse removed. Fuse installed. Fuse ONFWD switch Fuse removed from FWD switch
Voltage (V)
B54
B54
10 17
B54
10 17
1.5 4.0 2.0 4.5 Less than 0.5 Less than 1 More than 9 Less than 1 More than 9 0 0 0 0 0 6 9.1 Less than 1 Less than 1 More than 9
B54
18
2-4 brake timing solenoid Low clutch timing solenoid Sensor Sensor Sensor Sensor ground ground ground ground line line line line 1 2 3 4
B54 B54 B54 B55 B54 B54 B56 B54 B55
16 15 20 9 10 19 19 21 20
10 16 10 16 Less Less Less Less than than than than 1 1 1 1
System ground line FWD switch
Less than 1
FWD indicator light Data link signal (Subaru Select Monitor)
B56
2 15 6
B56
EN(DOHC TURBO)-32
DATA LINK CONNECTOR
8. Data Link Connector

A: NOTE
S088505A15
S088505
This connector is used both for OBD-II general scan tools and the Subaru Select Monitor. CAUTION: Do not connect any scan tools other than the OBD-II general scan tools and the Subaru Select Monitor, because the circuit for the Subaru Select Monitor may be damaged.
H2M1280
Terminal No. 1 2 3 4 5 6 7 8
Contents Power supply Blank Blank Blank Blank Line end check signal 1 Blank Line end check signal 2
Terminal No. 9 10 11 12 13 14 15 16
Contents Blank K line of ISO 9141 CARB Blank Ground Ground Blank Blank Blank
EN(DOHC TURBO)-33

S088527
9. OBD-II General Scan Tool

A: OPERATION
S088527A16
1. HOW TO USE OBD-II GENERAL SCAN TOOL S088527A1601

1) Prepare a general scan tool (OBD-II general scan tool) required by SAE J1978. 2) Open the cover and connect the OBD-II general scan tool to the data link connector (A) located in the lower portion of the instrument panel (on the driver s side).
3) Using the OBD-II general scan tool, call up diagnostic trouble code(s) and freeze frame data. OBD-II general scan tool functions consist of: (1) MODE $01: Current powertrain diagnostic data (2) MODE $02: Powertrain freeze frame data (3) MODE $03: Emission-related powertrain diagnostic trouble codes (4) MODE $04: Clear/Reset emission-related diagnostic information Read out data according to repair procedures. (For detailed operation procedures, refer to the OBD-II General Scan Tool Operation Manual.) NOTE: For details concerning diagnostic trouble codes, refer to the List of Diagnostic Trouble Code (DTC). <Ref. to EN(DOHC TURBO)-82, List of Diagnostic Trouble Code (DTC).>
S2M2157B
2. MODE $01 (CURRENT POWERTRAIN DIAGNOSTIC DATA)
S088527A1602
Refers to data denoting the current operating condition of analog input/output, digital input/output and/or the powertrain system. A list of the support data and PID (Parameter Identification) codes are shown in the following table.
PID 01 03 04 05 06 07 0B 0C 0D 0E 0F 10 11 13 15 24 1C Data Number of emission-related powertrain trouble codes and MIL status Fuel system control status Calculated engine load value Engine coolant temperature Short term fuel trim Long term fuel trim Intake manifold absolute pressure Engine revolution Vehicle speed Ignition timing advance Intake air temperature Air flow rate from pressure sensor Throttle valve opening angle Check whether oxygen sensor is installed. Oxygen sensor output voltage and short term fuel trim associated with oxygen sensorbank 2 A/F sensor 1 output voltage and short term fuel trim associated with A/F sensor 1 On-board diagnosis system Unit of measure ON/OFF % C % % kPa rpm km/h C g/sec % V and % V and %
NOTE: Refer to OBD-II general scan tool manufacturer s instruction manual to access generic OBD-II PIDs (MODE $01).
EN(DOHC TURBO)-34

3. MODE $02 (POWERTRAIN FREEZE FRAME DATA)
S088527A1603
Refers to data denoting the operating condition when trouble is sensed by the on-board diagnosis system. A list of the support data and PID (Parameter Identification) codes are shown in the following table.
PID 02 03 04 05 06 07 0B 0C 0D Data Trouble code that caused CARB required freeze frame data storage Fuel system control status Calculated engine load value Engine coolant temperature Short term fuel trim Long term fuel trim Intake manifold absolute pressure Engine revolution Vehicle speed Unit of measure % C % % kPa rpm km/h
NOTE: Refer to OBD-II general scan tool manufacturer s instruction manual to access freeze frame data (MODE $02).
4. MODE $03 (EMISSION-RELATED POWERTRAIN DIAGNOSTIC TROUBLE CODE)
S088527A1604
Refer to Read Diagnostic Trouble Code for information about data denoting emission-related powertrain diagnostic trouble codes. <Ref. to EN(DOHC TURBO)-43, Read Diagnostic Trouble Code.>
5. MODE $04 (CLEAR/RESET EMISSION-RELATED DIAGNOSTIC INFORMATION)
S088527A1605
Refers to the mode used to clear or reset emission-related diagnostic information (OBD-II trouble diagnostic information). NOTE: Refer to OBD-II general scan tool manufacturer s instruction manual to clear or reset emission-related diagnostic information (MODE $04).
EN(DOHC TURBO)-35

S088503

A: OPERATION
S088503A16

1) Prepare Subaru Select Monitor kit. <Ref. to EN(DOHC TURBO)-8, PREPARATION TOOL, General Description.>
S2M0288A
S2M0285
2) Connect diagnosis cable to Subaru Select Monitor. 3) Insert cartridge into Subaru Select Monitor. <Ref. to EN(DOHC TURBO)-8, PREPARATION TOOL, General Description.>
2. READ DIAGNOSTIC TROUBLE CODE (DTC) FOR ENGINE. (NORMAL MODE)

S088503A1602
Refer to Read Diagnostic Trouble Code for information about how to indicate DTC. <Ref. to EN(DOHC TURBO)-43, Read Diagnostic Trouble Code.>
3. READ DIAGNOSTIC TROUBLE CODE (DTC) FOR ENGINE. (OBD MODE) S088503A1603
Refer to Read Diagnostic Trouble Code for information about how to indicate DTC. <Ref. to EN(DOHC TURBO)-43, Read Diagnostic Trouble Code.>
S2M0286A
4) Connect Subaru Select Monitor to data link connector. (1) Data link connector located (A) in the lower portion of the instrument panel (on the driver s side).
S2M2157B
EN(DOHC TURBO)-36

4. READ CURRENT DATA FOR ENGINE. (NORMAL MODE)
S088503A1604
1) On the Main Menu display screen, select the {Each System Check} and press the [YES] key. 2) On the System Selection Menu display screen, select the {Engine Control System} and press the [YES] key. 3) Press the [YES] key after displayed the information of engine type. 4) On the Engine Diagnosis display screen, select the {Current Data Display & Save} and press the [YES] key. 5) On the Data Display Menu display screen, select the {Data Display} and press the [YES] key. 6) Using the scroll key, move the display screen up or down until the desired data is shown. A list of the support data is shown in the following table.
Contents Battery voltage Vehicle speed signal Engine speed signal Engine coolant temperature signal Ignition timing signal Throttle position signal Throttle position signal Injection pulse width Idle air control signal Alternator duty control signal Fuel pump duty control signal A/F sensor current A/F sensor resistance Front oxygen (A/F) sensor output signal Rear oxygen sensor output signal Short term fuel trim Knock sensor signal Atmospheric absolute pressure signal Intake manifold relative pressure signal Intake manifold absolute pressure signal A/F correction (short term fuel trim) by rear oxygen sensor Long term whole fuel trim Front oxygen (A/F) sensor heater current Rear oxygen sensor heater voltage Canister purge control solenoid valve duty ratio Primary supercharged pressure control signal Tumble generator valve position sensor signal (right side) Tumble generator valve position sensor signal (left side) Tumble generator valve drive signal Fuel level signal Intake air temperature signal Learned ignition timing Mass air flow sensor signal Mass air flow sensor signal Ignition switch signal Test mode connector signal Neutral position switch signal Air conditioning switch signal Air conditioning signal Display Battery Voltage Vehicle Speed Engine Speed Coolant Temp. Ignition Timing Throttle Opening Angle Throttle Sensor Voltage Fuel Injection #1 Pulse ISC Valve Duty Ratio ALT Duty Fuel Pump Duty A/F Sensor #1 Current A/F Sensor #1 Resistance A/F Sensor #1 Rear O2 Sensor A/F Correction #1 Knocking Correction Atmosphere Pressure Mani. Relative Pressure Mani. Absolute Pressure A/F Correction #3 A/F Learning #1 A/F Heater Current 1 Rear O2 Heater Voltage CPC Valve Duty Ratio Primary Control TGV Position Sensor R TGV Position Sensor L TGV Drive Fuel Level Intake Air Temp. Learned Ignition Timing Mass Air Flow Air Flow Sensor Voltage Ignition Switch Test Mode Signal Neutral Position Switch A/C Switch A/C Compressor Signal Unit of measure V km/h or MPH rpm C or F deg % V ms % % % mA V % deg mmHg or kPa or inHg or psi mmHg or kPa or inHg or psi mmHg or kPa or inHg or psi % % A V % % V V OPEN or CLOSE V C or F deg g/s V ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF
EN(DOHC TURBO)-37
Contents Radiator main fan relay signal Fuel pump relay signal Knocking signal Radiator sub fan relay signal Power steering switch signal Engine torque control signal #1 Engine torque control signal #2 Engine torque control permission signal Rear oxygen sensor rich signal Starter switch signal Idle switch signal Crankshaft position sensor signal Camshaft position sensor signal Rear defogger switch signal Blower fan switch signal Small light switch signal Tumble generator valve output signal

Display Radiator Fan Relay #1 Fuel Pump Relay Knocking Signal Radiator Fan Relay #2 P/S Switch Torque Control Signal #1 Torque Control Signal #2 Torque Permission Signal Rear O2 Rich Signal Starter Switch Idle Switch Crankshaft Position Sig. Camshaft Position Sig. Rear Defogger SW Blower Fan SW Light Switch TGV Output Unit of measure ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF
EN(DOHC TURBO)-38

5. READ CURRENT DATA FOR ENGINE. (OBD MODE)
S088503A1605
1) On the Main Menu display screen, select the {Each System Check} and press the [YES] key. 2) On the System Selection Menu display screen, select the {Engine Control System} and press the [YES] key. 3) Press the [YES] key after displayed the information of engine type. 4) On the Engine Diagnosis display screen, select the {OBD System} and press the [YES] key. 5) On the OBD Menu display screen, select the {Current Data Display & Save} and press the [YES] key. 6) On the Data Display Menu display screen, select the {Data Display} and press the [YES] key. 7) Using the scroll key, move the display screen up or down until the desired data is shown. A list of the support data is shown in the following table.
Contents Number of diagnosis code Malfunction indicator lamp status Monitoring test of misfire Monitoring test of fuel system Monitoring test of comprehensive component Test of catalyst Test of heated catalyst Test of evaporative emission purge control system Test of secondary air system Test of air conditioning system refrigerant Test of oxygen sensor Test of oxygen sensor heater Test of EGR system Air fuel ratio control system for bank 1 Engine load data Engine coolant temperature signal Short term fuel trim by front oxygen (A/F) sensor Long term fuel trim by front oxygen (A/F) sensor Intake manifold absolute pressure signal Engine speed signal Vehicle speed signal Ignition timing advance for #1 cylinder Intake air temperature signal Intake air amount Throttle position signal A/F sensor equipment Rear oxygen sensor output signal Air fuel ratio correction by rear oxygen sensor On-board diagnostic system Display Number of Diagnosis Code MI (MIL) Misfire monitoring Fuel system monitoring Component monitoring Catalyst Diagnosis Heated catalyst Evaporative purge system Secondary air system A/C system refrigerant Oxygen sensor O2 Heater Diagnosis EGR system Fuel System for Bank 1 Calculated load value Coolant Temp. Short term fuel trim B1 Long term fuel trim B1 Mani. Absolute Pressure Engine Speed Vehicle Speed Ignition timing adv. #1 Intake Air Temp. Mass Air Flow Throttle Opening Angle A/F sensor Oxygen Sensor #12 Short term fuel trim #12 OBD System Unit of measure Complete or incomplete Complete or incomplete Complete or incomplete Complete or incomplete No support No support No support No support No support Complete or incomplete Complete or incomplete No support % C or F % % mmHg or kPa or inHg or psi rpm km/h or MPH C or F g/s % ON or OFF V %
EN(DOHC TURBO)-39

S088503A1606
6. READ FREEZE FRAME DATA FOR ENGINE. (OBD MODE)
1) On the Main Menu display screen, select the {Each System Check} and press the [YES] key. 2) On the System Selection Menu display screen, select the {Engine Control System} and press the [YES] key. 3) Press the [YES] key after displayed the information of engine type. 4) On the Engine Diagnosis display screen, select the {OBD System} and press the [YES] key. 5) On the OBD Menu display screen, select the {Freeze Frame Data} and press the [YES] key. A list of the support data is shown in the following table.
Contents Diagnostic trouble code (DTC) for freeze frame data Air fuel ratio control system for bank 1 Engine load data Engine coolant temperature signal Short term fuel trim by front oxygen (A/F) sensor Long term fuel trim by front oxygen (A/F) sensor Intake manifold absolute pressure signal Engine speed signal Vehicle speed signal Display Freeze frame data Fuel system for Bank1 Engine Load Coolant Temp. Short term fuel trim B1 Long term fuel trim B1 Mani. Absolute Pressure Engine Speed Vehicle Speed Unit of measure DTC ON or OFF % C or F % % mmHg or kPa or inHg or psi rpm km/h or MPH
7. READ OXYGEN SENSOR MONITORING TEST RESULTS DATA FOR ENGINE. (OBD MODE) S088503A1607
1) On the Main Menu display screen, select the {Each System Check} and press the [YES] key. 2) On the System Selection Menu display screen, select the {Engine Control System} and press the [YES] key. 3) Press the [YES] key after displayed the information of engine type. 4) On the Engine Diagnosis display screen, select the {OBD System} and press the [YES] key. 5) On the OBD Menu display screen, select the {O2 Sensor Monitor} and press the [YES] key. 6) On the O2 Sensor Select display screen, select the {Bank 1-Sensor1} or {Bank 1-Sensor2} and press the [YES] key. Bank 1-Sensor1 indicates the front oxygen or A/F sensor, and Bank 1-Sensor2 indicates the rear oxygen sensor. A list of the support data is shown in the following table.
Contents Oxygen sensor for monitoring test Rich to lean oxygen sensor threshold voltage Lean to rich oxygen sensor threshold voltage Low oxygen sensor voltage for switch time calculation High oxygen sensor voltage for switch time calculation Rich to lean oxygen sensor switch time Lean to rich oxygen sensor switch time Maximum oxygen sensor voltage for test cycle Minimum oxygen sensor voltage for test cycle Display <O2 Sensor Monitor (-------)> Rich to lean sensor volt Lean to rich sensor volt Low sensor voltage High sensor voltage Rich to lean switch time Lean to rich switch time Maximum sensor Voltage Minimum sensor Voltage Unit of measure V V V V sec sec V V
EN(DOHC TURBO)-40

S088503A1608
1) On the Main Menu display screen, select the {Each System Check} and press the [YES] key. 2) On the System Selection Menu display screen, select the {Engine Control System} and press the [YES] key. 3) Press the [YES] key after displayed the information of engine type. 4) On the Engine Diagnosis display screen, select the {Current Data Display & Save} and press the [YES] key. 5) On the Data Display Menu display screen, select the {Data & LED Display} and press the [YES] key. 6) Using the scroll key, move the display screen up or down until the desired data is shown. A list of the support data is shown in the following table.
Contents Ignition switch signal Test mode connector signal Neutral position switch signal Air conditioning switch signal Air conditioning relay signal Radiator main fan relay signal Knocking signal Radiator sub fan relay signal Engine torque control signal #1 Engine torque control signal #2 Engine torque control permission signal Rear oxygen sensor rich signal Starter switch signal Idle switch signal Crankshaft position sensor signal Camshaft position sensor signal Power steering switch signal Rear defogger switch signal Blower fan switch signal Light switch signal Tumble generator valve actuator signal Tumble generator valve drive signal Display Ignition Switch Test Mode Signal Neutral SW A/C SW A/C Relay Radiator Fan Relay #1 Knocking Signal Radiator Fan Relay #2 Torque Control Signal #1 Torque Control Signal #2 Torque Control Permit Rear O2 Rich Signal Starter Switch Signal Idle Switch Signal Crankshaft Position Sig. Camshaft Position Sig. P/S SW Rear Defogger SW Blower Fan SW Light SW TGV Signal TGV Drive Message ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON ON ON ON or or or or OFF OFF OFF OFF LED ON requirements When ignition switch is turned ON. When test mode connector is connected. When neutral position signal is entered. When air conditioning switch is turned ON. When air conditioning relay is in function. When radiator main fan relay is in function. When knocking signal is entered. When radiator sub fan relay is in function. When engine torque control signal 1 is entered. When engine torque control signal 2 is entered. When engine torque control permission signal is entered. When rear oxygen sensor mixture ratio is rich. When starter switch signal is entered. When idle switch signal is entered. When crankshaft position sensor signal is entered. When camshaft position sensor signal is entered. When power steering switch is entered. When rear defogger switch is turned ON. When blower fan switch is turned ON. When small light switch is turned ON.
ON or OFF When TGV actuator signal is entered. ON or OFF When TGV moves and valve opens.
EN(DOHC TURBO)-41

S088503A1609
9. READ CURRENT DATA FOR AT.
1) On the Main Menu display screen, select the {Each System Check} and press the [YES] key. 2) On the System Selection Menu display screen, select the {Transmission Control System} and press the [YES] key. 3) Press the [YES] key after displayed the information of transmission type. 4) On the Transmission Diagnosis display screen, select the {Current Data Display & Save} and press the [YES] key. 5) On the Data Display Menu display screen, select the {Data Display} and press the [YES] key. 6) Using the scroll key, move the display screen up or down until the desired data is shown. A list of the support data is shown in the following table.
Contents Battery voltage Rear vehicle speed sensor signal Front vehicle speed sensor signal Engine speed signal Automatic transmission fluid temperature signal Throttle position signal Gear position Line pressure control duty ratio Lock up clutch control duty ratio Transfer clutch control duty ratio Power supply for throttle position sensor Torque converter turbine speed signal 2-4 brake timing pressure control duty ratio Intake manifold pressure sensor voltage 2 wheel drive switch signal Kick down switch signal Stop lamp switch signal Anti lock brake system signal Cruise control system signal Neutral/Parking range signal Reverse range signal Drive range signal 3rd range signal 2nd range signal 1st range signal Shift control solenoid A Shift control solenoid B Torque control output signal #1 Torque control output signal #2 Torque control cut signal 2-4 brake timing control solenoid valve Low clutch timing control solenoid valve Automatic transmission diagnosis indicator lamp Display Battery Voltage Vehicle Speed #1 Vehicle Speed #2 Engine Speed ATF Temp. Throttle Sensor Voltage Gear Position Line Pressure Duty Ratio Lock Up Duty Ratio Transfer Duty Ratio Throttle Sensor Power AT Turbine Speed 2-4B Duty Ratio Mani. Pressure Voltage 2WD Switch Kick Down Switch Stop Lamp Switch ABS Signal Cruise Control Signal N/P Range Signal R Range Signal D Range Signal 3rd Range Signal 2nd Range Signal 1st Range Signal Shift Solenoid #1 Shift Solenoid #2 Torque Control Signal #1 Torque Control Signal #2 Torque Control Cut Sig. 2-4 Brake Timing Sol. Low Clutch Timing Sol. AT Diagnosis Lamp Unit of measure V km/h or MPH km/h or MPH rpm C or F V % % % V rpm % V ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF
EN(DOHC TURBO)-42
S088508A1603

S088508
A: OPERATION
S088508A16

1) On the Main Menu display screen, select the {Each System Check} and press the [YES] key. 2) On the System Selection Menu display screen, select the {Engine Control System} and press the [YES] key. 3) Press the [YES] key after displayed the information of engine type. 4) On the Engine Diagnosis display screen, select the {Diagnostic Code(s) Display} and press the [YES] key. 5) On the Diagnostic Code(s) Display display screen, select the {Current Diagnostic Code(s)} or {History Diagnostic Code(s)} and press the [YES] key. NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. For detailed concerning diagnostic trouble codes, refer to the List of Diagnostic Trouble Code (DTC). <Ref. to EN(DOHC TURBO)-82, List of Diagnostic Trouble Code (DTC).>
Refers to data denoting emission-related powertrain diagnostic trouble codes. For details concerning diagnostic trouble codes, refer to the List of Diagnostic Trouble Code (DTC). <Ref. to EN(DOHC TURBO)-82, List of Diagnostic Trouble Code (DTC).> NOTE: Refer to OBD-II general scan tool manufacturer s instruction manual to access emission-related powertrain diagnostic trouble codes (MODE $03).

1) On the Main Menu display screen, select the {2. Each System Check} and press the [YES] key. 2) On the System Selection Menu display screen, select the {Engine Control System} and press the [YES] key. 3) Press the [YES] key after displayed the information of engine type. 4) On the Engine Diagnosis display screen, select the {OBD System} and press the [YES] key. 5) On the OBD Menu display screen, select the {Diagnosis Code(s) Display} and press the [YES] key. 6) Make sure that a diagnostic trouble code (DTC) is shown on the display screen. NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. For detailed concerning diagnostic trouble codes, refer to the List of Diagnostic Trouble Code (DTC). <Ref. to EN(DOHC TURBO)-82, List of Diagnostic Trouble Code (DTC).>
EN(DOHC TURBO)-43
INSPECTION MODE
S088510
12. Inspection Mode

A: OPERATION
S088510A16
1. PREPARATION FOR THE INSPECTION MODE S088510A1601

S2M0285
S2M0286A
S2M2244A
B2M2969A
2. SUBARU SELECT MONITOR
S088510A1602
After performing diagnostics and clearing the memory, check for any remaining unresolved trouble data.
EN(DOHC TURBO)-44
INSPECTION MODE
5) Connect Subaru Select Monitor to data link connector. (1) Connect Subaru Select Monitor to data link connector (A) located in the lower portion of the instrument panel (on the driver s side).
NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. For detailed concerning diagnostic trouble codes, refer to the List of Diagnostic Trouble Code (DTC). <Ref. to EN(DOHC TURBO)-82, List of Diagnostic Trouble Code (DTC).> Release the parking brake. The speed difference between front and rear wheels may light either the ABS warning light, but this indicates no malfunctions. When engine control diagnosis is finished, perform the ABS memory clearance procedure of self-diagnosis system.

S2M2157B
S088510A1603
After performing diagnostics and clearing the memory, check for any remaining unresolved trouble data: 1) Connect test mode connector (A) at the lower side of the instrument panel (on the driver s side), to the side of the center console box.
S2M2244A
S2M0288A
2) Connect the OBD-II general scan tool to its data link connector (A) in the lower portion of the instrument panel (on the driver s side). CAUTION: Do not connect the scan tools except for Subaru Select Monitor and OBD-II general scan tool.
7) On the Main Menu display screen, select the {2. Each System Check} and press the [YES] key. 8) On the System Selection Menu display screen, select the {Engine Control System} and press the [YES] key. 9) Press the [YES] key after displayed the information of engine type. 10) On the Engine Diagnosis display screen, select the {Dealer Check Mode Procedure} and press the [YES] key. 11) When the Perform Inspection (Dealer Check) Mode? is shown on the display screen, press the [YES] key. 12) Perform subsequent procedures as instructed on the display screen. If trouble still remains in the memory, the corresponding diagnostic trouble code (DTC) appears on the display screen.
S2M2157B
3) Start the engine. NOTE: Ensure the selector lever is placed in the P position before starting. (AT vehicles)
EN(DOHC TURBO)-45
INSPECTION MODE
Depress clutch pedal when starting the engine. (MT vehicles) 4) Using the selector lever or shift lever, turn the P position switch and the N position switch to ON. 5) Depress the brake pedal to turn the brake switch ON. (AT vehicles) 6) Keep engine speed in the 2,500 3,000 rpm range for 40 seconds. NOTE: On models without tachometer, use the tachometer (Secondary pickup type). 7) Place the selector lever or shift lever in the D position (AT vehicles) or 1st gear (MT vehicles) and drive the vehicle at 5 to 10 km/h (3 to 6 MPH). NOTE: On AWD vehicles, release the parking brake. The speed difference between front and rear wheels may light the ABS warning light, but this indicates no malfunctions. When engine control diagnosis is finished, perform the ABS memory clearance procedure of self-diagnosis system. 8) Using the OBD-II general scan tool, check for diagnostic trouble code(s) and record the result(s). NOTE: For detailed operation procedures, refer to the OBD-II General Scan Tool Instruction Manual. For detailed concerning diagnostic trouble codes, refer to the List of Diagnostic Trouble Code (DTC). <Ref. to EN(DOHC TURBO)-82, List of Diagnostic Trouble Code (DTC).>
EN(DOHC TURBO)-46
CLEAR MEMORY MODE
S088513A1603

A: OPERATION
S088513A16
S088513

1) On the Main Menu display screen, select the {2. Each System Check} and press the [YES] key. 2) On the System Selection Menu display screen, select the {Engine Control System} and press the [YES] key. 3) Press the [YES] key after displayed the information of engine type. 4) On the Engine Diagnosis display screen, select the {Clear Memory} and press the [YES] key. 5) When the Done and Turn Ignition Switch OFF are shown on the display screen, turn the Subaru Select Monitor and ignition switch to OFF. NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.
For clear memory procedures using the OBD-II general scan tool, refer to the OBD-II General Scan Tool Instruction Manual.

1) On the Main Menu display screen, select the {2. Each System Check} and press the [YES] key. 2) On the System Selection Menu display screen, select the {Engine Control System} and press the [YES] key. 3) Press the [YES] key after displayed the information of engine type. 4) On the Engine Diagnosis display screen, select the {OBD System} and press the [YES] key. 5) On the OBD Menu display screen, select the {4. Diagnosis Code(s) Cleared} and press the [YES] key. 6) When the Clear Diagnostic Code? is shown on the display screen, press the [YES] key. 7) Turn Subaru Select Monitor and ignition switch to OFF. NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.
EN(DOHC TURBO)-47

5) Connect Subaru Select Monitor to data link connector. (1) Connect Subaru Select Monitor to data link connector (A) located in the lower portion of the instrument panel (on the driver s side).

A: OPERATION
S088528A16
S088528
S2M2157B
S2M0285
S2M0288A S2M0286A
S2M2244A
7) On the Main Menu display screen, select the {2. Each System Check} and press the [YES] key. 8) On the System Selection Menu display screen, select the {Engine Control System} and press the [YES] key. 9) Press the [YES] key after displayed the information of engine type. 10) On the Engine Diagnosis display screen, select the {System Operation Check Mode} and press the [YES] key. 11) On the System Operation Check Mode display screen, select the {Actuator ON/OFF Operation} and press the [YES] key. 12) Select the desired compulsory actuator on the Actuator ON/OFF Operation display screen and press the [YES] key. 13) Pressing the [NO] key completes the compulsory operation check mode. The display will then return to the Actuator ON/OFF Operation screen.
EN(DOHC TURBO)-48

Compulsory Compulsory Compulsory Compulsory Contents fuel pump relay operation check radiator fan relay operation check air conditioning relay operation check purge control solenoid valve operation check
Display Fuel Pump Relay Radiator Fan Relay A/C Compressor Relay CPC Solenoid Valve
NOTE: The following parts will be displayed but not functional because they are not installed on the vehicle.
Display EGR Solenoid Valve ASV Solenoid Valve PCV Solenoid Valve Vent Control Solenoid Valve FICD Solenoid Pressure Switching Sol. 1 Pressure Switching Sol. 2 AAI Solenoid Valve Fuel Tank Sensor Control Valve
For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.
EN(DOHC TURBO)-49

S088653

A: PROCEDURE
S088653E45
1. Activation of check engine malfunction indicator lamp (MIL). <Ref. to EN(DOHC TURBO)-51, ACTIVATION OF CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL), Engine Malfunction Indicator Lamp (MIL).> 2. Check engine malfunction indicator lamp (MIL) does not come on. <Ref. to EN(DOHC TURBO)-52, CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT COME ON., Engine Malfunction Indicator Lamp (MIL).> 3. Check engine malfunction indicator lamp (MIL) does not go off. <Ref. to EN(DOHC TURBO)-55, CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT GO OFF., Engine Malfunction Indicator Lamp (MIL).> 4. Check engine malfunction indicator lamp (MIL) does not blink at a cycle of 3 Hz. <Ref. to EN(DOHC TURBO)-56, CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT BLINK AT A CYCLE OF 3 HZ., Engine Malfunction Indicator Lamp (MIL).> 5. Check engine malfunction indicator lamp (MIL) remains blinking at a cycle of 3 Hz. <Ref. to EN(DOHC TURBO)-60, CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) REMAINS BLINKING AT A CYCLE OF 3 HZ., Engine Malfunction Indicator Lamp (MIL).>
EN(DOHC TURBO)-50
ENGINE MALFUNCTION INDICATOR LAMP (MIL) B: ACTIVATION OF CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL)
S088653E89
1) When ignition switch is turned to ON (engine off), the CHECK ENGINE malfunction indicator lamp (MIL) (A) in the combination meter illuminates. NOTE: If the MIL does not illuminate, perform diagnostics of the CHECK ENGINE light circuit or the combination meter circuit. <Ref. to EN(DOHC TURBO)52, CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT COME ON., Engine Malfunction Indicator Lamp (MIL).>
OBD0055A
S2M2215C
2) After starting the engine, the MIL goes out. If it does not, either the engine or the emission control system is malfunctioning.
OBD0053A
3) If the diagnosis system senses a misfire which could damage the catalyzer, the MIL will blink at a cycle of 1 Hz.
OBD0054A
EN(DOHC TURBO)-51
S088653E90
S2M2179
EN(DOHC TURBO)-52

No. 1 Step CHECK OUTPUT SIGNAL FROM ECM. 1) Turn ignition switch to ON. 2) Measure voltage between ECM connector and chassis ground. Connector & terminal (B137) No. 15 (+) Chassis ground (): CHECK POOR CONTACT. Check Is the voltage less than 1 V? Yes Go to step 4.
No Go to step 2.
CHECK ECM CONNECTOR.
Does the MIL come on when shaking or pulling ECM connector and harness? Is ECM connector correctly connected?
Repair poor contact in ECM connector. Replace ECM. <Ref. to FU(DOHC TURBO)-47, Engine Control Module.> Go to step 5.
Go to step 3.
CHECK POOR CONTACT. Is there poor contact in Repair poor conCheck poor contact in combination meter con- combination meter connec- tact in combinanector. tor? tion meter connector.
Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ECM and combination meter connector Poor contact in coupling connector Go to step 6.
EN(DOHC TURBO)-53
No. 6

No Check the following and repair if necessary. NOTE: Broken down ignition relay. Blown out fuse (No. 5). If replaced fuse (No. 5) blows easily, check the harness for short circuit of harness between fuse (No. 5) and ignition relay connector. Open or short circuit in harness between fuse (No. 5) and battery terminal Open circuit in harness between fuse (No. 5) and ignition relay connector Poor contact in ignition relay connector Poor contact in ignition switch connector Replace lamp bulb.
Step Check Yes Is voltage more than 10 V? Go to step 7. CHECK HARNESS BETWEEN COMBINATION METER AND IGNITION SWITCH CONNECTOR. 1) Turn ignition switch to ON. 2) Measure voltage between combination meter connector and chassis ground. Connector & terminal (i10) No. 2 (+) Chassis ground ():
CHECK LAMP BULB. Remove engine malfunction indicator lamp bulb.
Is lamp bulb condition OK? Repair combination meter connector.
EN(DOHC TURBO)-54

S088653E91
S2M2179
No. 1
No Replace ECM. <Ref. to FU(DOHC TURBO)-47, Engine Control Module.>
EN(DOHC TURBO)-55
S088653E92
DIAGNOSIS: The CHECK ENGINE malfunction indicator lamp (MIL) circuit is open or shorted. Test mode connector circuit is in open. TROUBLE SYMPTOM: When inspection mode, MIL does not blink at a cycle of 3 Hz.
EN(DOHC TURBO)-56

WIRING DIAGRAM:
S2M2180
EN(DOHC TURBO)-57
No. 1

Check Does the MIL come on? Yes Go to step 2. No Repair the MIL circuit. <Ref. to EN(DOHC TURBO)-52, CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL) DOES NOT COME ON., Engine Malfunction Indicator Lamp (MIL).> Go to step 3.
Step CHECK STATUS OF CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL). 1) Turn ignition switch to OFF. 2) Disconnect test mode connector. 3) Turn ignition switch to ON. (engine OFF)
CHECK HARNESS BETWEEN COMBINATION METER AND ECM CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM. 3) Turn ignition switch to ON. CHECK HARNESS BETWEEN TEST MODE CONNECTOR AND CHASSIS GROUND. 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM. 3) Measure resistance of harness between test mode connector and chassis ground. Connector & terminal (B76) No. 1 Chassis ground:
Does the MIL come on?
CHECK POOR CONTACT. Check poor contact in ECM connector. CHECK HARNESS BETWEEN ECM AND TEST MODE CONNECTOR. 1) Connect test mode connector. 2) Measure resistance of harness between ECM and chassis ground. Connector & terminal (B134) No. 5 Chassis ground: CHECK POOR CONTACT. Check poor contact in ECM connector.
Is there poor contact in ECM connector? Is resistance less than 1 ?
Repair ground short circuit in harness between combination meter and ECM connector. Go to step 4. Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between test mode connector and chassis ground Repair poor con- Go to step 5. tact in ECM connector. Go to step 6. Repair open circuit in harness between ECM and test mode connector.
Replace ECM. <Ref. to FU(DOHC TURBO)-47, Engine Control Module.>
EN(DOHC TURBO)-58

MEMO:
EN(DOHC TURBO)-59
S088653E93
DIAGNOSIS: Test mode connector circuit is shorted. TROUBLE SYMPTOM: MIL blinks at a cycle of 3 Hz when ignition switch is turned to ON. WIRING DIAGRAM:
S2M2180
EN(DOHC TURBO)-60

No. 1 Step CHECK TEST MODE CONNECTOR. 1) Disconnect test mode connector. 2) Turn ignition switch to ON. Check Yes Does MIL flash on and off? Go to step 2.
No System is in good order. NOTE: MIL blinks at a cycle of 3 Hz when test mode connector is connected. Replace ECM. <Ref. to FU(DOHC TURBO)-47, Engine Control Module.>
CHECK HARNESS BETWEEN ECM CONNECTOR AND ENGINE GROUNDING TERMINAL. 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM. 3) Measure resistance of harness between ECM connector and chassis ground. Connector & terminal (B134) No. 5 Chassis ground:
Repair short circuit in harness between ECM and test mode connector.
EN(DOHC TURBO)-61
MEMO:
EN(DOHC TURBO)-62

A: PROCEDURE
S088533E45
S088533
1. Inspection of starter motor circuit. <Ref. to EN(DOHC TURBO)-64, STARTER MOTOR CIRCUIT, Diagnostics for Engine Starting Failure.> 2. Inspection of ECM power supply and ground line. <Ref. to EN(DOHC TURBO)-68, CONTROL MODULE POWER SUPPLY AND GROUND LINE, Diagnostics for Engine Starting Failure.> 3. Inspection of ignition control system. <Ref. to EN(DOHC TURBO)-72, IGNITION CONTROL SYSTEM, Diagnostics for Engine Starting Failure.> 4. Inspection of fuel pump circuit. <Ref. to EN(DOHC TURBO)-76, FUEL PUMP CIRCUIT, Diagnostics for Engine Starting Failure.> 5. Inspection of fuel injector circuit. <Ref. to EN(DOHC TURBO)-78, FUEL INJECTOR CIRCUIT, Diagnostics for Engine Starting Failure.>
EN(DOHC TURBO)-63

S088533E94
CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to EN(DOHC TURBO)-47, Clear Memory Mode.> and INSPECTION MODE <Ref. to EN(DOHC TURBO)-44, Inspection Mode.>. WIRING DIAGRAM:
S2M2181
EN(DOHC TURBO)-64

No. 1 2 Step Check CHECK OPERATION OF STARTER MOTOR. Does starter motor operate when the switch starts? Is the trouble code stored CHECK DTC. in memory? <Ref. to <Ref. to EN(DOHC TURBO)-43, EN(DOHC TURBO)-82, OPERATION, Read Diagnostic Trouble LIST, List of Diagnostic Code.> Trouble Code (DTC).> Yes Go to step 2.
No Go to step 3.
CHECK INPUT SIGNAL FOR STARTER MOTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from starter motor. 3) Turn ignition switch to ST. 4) Measure power supply voltage between starter motor connector terminal and engine ground. Connector & terminal (B14) No. 1 (+) Engine ground (): NOTE: On AT vehicles, place the selector lever in the P or N position. CHECK GROUND CIRCUIT OF STARTER MOTOR. 1) Turn ignition switch to OFF. 2) Disconnect terminal from starter motor. 3) Measure resistance of ground cable between ground cable terminal and engine ground. CHECK HARNESS BETWEEN ECM AND STARTER MOTOR CIRCUIT. 1) Turn ignition switch to OFF. 2) Measure resistance between starter motor and ECM. Connector & terminal (B14) No. 1 Engine ground: CHECK HARNESS BETWEEN ECM AND STARTER MOTOR CIRCUIT. 1) Turn ignition switch to START. 2) Measure resistance of fuse. Connector & terminal (B14) No. 1 Engine ground: CHECK HARNESS BETWEEN BATTERY AND IGNITION SWITCH CONNECTOR. 1) Ignition switch to OFF. 2) Disconnect connector from ignition switch. 3) Measure power supply voltage between ignition switch connector and chassis ground. Connector & terminal (B72) No. 1 (+) Chassis ground (): CHECK HARNESS BETWEEN BATTERY AND IGNITION SWITCH CONNECTOR. 1) Connect connector to ignition switch. 2) Turn ignition switch to START. 3) Measure voltage between ignition switch and chassis ground. Connector & terminal (B72) No. 3 (+) Chassis ground ():
Go to step 3. Record DTC. Repair the trouble case. <Ref. to EN(DOHC TURBO)-90, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Go to step 5. Is the voltage more than 10 Go to step 4. V?
Check starter motor. <Ref. to SC-5, Starter.>
Go to step 6.
Go to step 7.
Repair open circuit in harness between ignition switch and battery.
Replace ignition switch.
EN(DOHC TURBO)-65
No. 9

Check Is the vehicle AT? Yes Go to step 10. No Repair open circuit between ignition switch and starter motor circuit. Go to step 11.
10
11
12
CHECK INHIBITOR SWITCH CIRCUIT. 1) Turn ignition switch to OFF. 2) Place the selector lever in the P or N position. 3) Separate transmission harness connector. 4) Measure resistance between transmission harness connector receptacles terminals. Connector & terminal (T3) No. 11 No. 12: CHECK TRANSMISSION HARNESS. 1) Disconnect connector from inhibitor switch. 2) Measure resistance of harness between transmission harness and inhibitor switch connector. Connector & terminal (T3) No. 11 (T7) No. 1: CHECK POOR CONTACT. Check poor contact in inhibitor switch connector.
Repair open circuit in harness between starter motor and ignition switch connector.
Go to step 12.
Repair open circuit in harness between transmission harness and inhibitor switch connector. Replace inhibitor switch.
EN(DOHC TURBO)-66

MEMO:
EN(DOHC TURBO)-67

S088533E37
CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to EN(DOHC TURBO)-47, Clear Memory Mode.> and INSPECTION MODE. <Ref. to EN(DOHC TURBO)-44, Inspection Mode.> WIRING DIAGRAM: LHD MODEL
S2M2182
EN(DOHC TURBO)-68

RHD MODEL
S2M2183
EN(DOHC TURBO)-69
No. 1

Check Is the resistance less than 10 ? Yes Go to step 2. No Replace main relay.
Step CHECK MAIN RELAY. 1) Turn the ignition switch to OFF. 2) Remove main relay. 3) Connect battery to main relay terminals No. 1 and No. 2. 4) Measure resistance between main relay terminals. Terminals No. 3 No. 5: No. 4 No. 6: CHECK GROUND CIRCUIT OF ECM. 1) Disconnect connector from ECM. 2) Measure resistance of harness between ECM and chassis ground. Connector & terminal (B134) No. 7 Chassis ground: (B134) No. 15 Chassis ground: (B134) No. 22 Chassis ground: (B136) No. 8 Chassis ground: (B136) No. 17 Chassis ground: (B136) No. 18 Chassis ground: (B137) No. 8 Chassis ground: (B137) No. 9 Chassis ground: (B84) No. 1 Chassis ground: (MT model) CHECK INPUT VOLTAGE OF ECM. Measure voltage between ECM connector and chassis ground. Connector & terminal (B137) No. 10 (+) Chassis ground (): (B134) No. 14 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND MAIN RELAY CONNECTOR. 1) Turn ignition switch to OFF. 2) Measure resistance between ECM and chassis ground. Connector & terminal (B134) No. 2 Chassis ground: CHECK OUTPUT VOLTAGE FROM ECM. 1) Connect connector to ECM. 2) Turn ignition switch to ON. 3) Measure voltage between ECM connector and chassis ground. Connector & terminal (B134) No. 2 (+) Chassis ground (): CHECK INPUT VOLTAGE OF MAIN RELAY. Check voltage between main relay connector and chassis ground. Connector & terminal (B47) No. 2 (+) Chassis ground (): CHECK GROUND CIRCUIT OF MAIN RELAY. 1) Turn ignition switch to OFF. 2) Measure resistance between main relay connector and chassis ground. Connector & terminal (B47) No. 1 Chassis ground:
Go to step 3.
Repair open circuit in harness between ECM connector and engine grounding terminal.
Repair ground short circuit in harness between ECM connector and main relay connector, then replace ECM. Replace ECM. <Ref. to FU(DOHC TURBO)-47, Engine Control Module.> Repair open circuit in harness between ECM connector and main relay connector. Repair open circuit between main relay and chassis ground.
Go to step 8.
EN(DOHC TURBO)-70

No. 8 Step CHECK INPUT VOLTAGE OF MAIN RELAY. Measure voltage between main relay connector and chassis ground. Connector & terminal (B47) No. 5 (+) Chassis ground (): (B47) No. 6 (+) Chassis ground (): CHECK INPUT VOLTAGE OF ECM. 1) Connect main relay connector. 2) Turn ignition switch to ON. 3) Measure voltage between ECM connector and chassis ground. Connector & terminal (B137) No. 2 (+) Chassis ground (): (B137) No. 3 (+) Chassis ground (): Check Yes Is the voltage more than 10 Go to step 9. V?
No Repair open or ground short circuit in harness of power supply circuit. Repair open or ground short circuit in harness between ECM connector and main relay connector.
Is the voltage more than 10 Check ignition V? control system. <Ref. to EN(DOHC TURBO)-72, IGNITION CONTROL SYSTEM, Diagnostics for Engine Starting Failure.>
EN(DOHC TURBO)-71

S088533E95
CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to EN(DOHC TURBO)-47, Clear Memory Mode.> and INSPECTION MODE <Ref. to EN(DOHC TURBO)-44, Inspection Mode.>. WIRING DIAGRAM: LHD MODEL
S2M2184
EN(DOHC TURBO)-72

RHD MODEL
EN0962
No. 1
Step CHECK SPARK PLUG CONDITION. 1) Remove spark plug. <Ref. to IG(DOHC TURBO)-4, Spark Plug.> 2) Check spark plug condition. <Ref. to IG(DOHC TURBO)-4, Spark Plug.> CHECK IGNITION SYSTEM FOR SPARKS. 1) Connect spark plug to ignition coil. 2) Release fuel pressure. <Ref. to FU(DOHC TURBO)-50, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.> 3) Contact spark plugs thread portion on engine. 4) While opening throttle valve fully, crank engine to check that spark occurs at each cylinder.
Check Is spark plugs status OK?
Yes Go to step 2.
No Replace spark plug
Does spark occur at each cylinder?
Check fuel pump Go to step 3. system. <Ref. to EN(DOHC TURBO)-76, FUEL PUMP CIRCUIT, Diagnostics for Engine Starting Failure.>
EN(DOHC TURBO)-73
No. 3

Check Yes Is the voltage more than 10 Go to step 4. V? No Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ignition coil & ignitor assembly, and ignition switch connector Poor contact in coupling connectors Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ignition coil & ignitor assembly connector and engine grounding terminal Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ECM and ignition coil & ignitor assembly connector Poor contact in coupling connector Repair ground short circuit in harness between ECM and ignition coil & ignitor assembly connector.
Step CHECK POWER SUPPLY CIRCUIT FOR IGNITION COIL & IGNITOR ASSEMBLY. 1) Turn ignition switch to OFF. 2) Disconnect connector from ignition coil & ignitor assembly. 3) Turn ignition switch to ON. 4) Measure power supply voltage between ignition coil & ignitor assembly connector and engine ground. Connector & terminal (E31) No. 3 (+) Engine ground (): (E32) No. 3 (+) Engine ground (): (E33) No. 3 (+) Engine ground (): (E34) No. 3 (+) Engine ground (): CHECK HARNESS OF IGNITION COIL & IGNITOR ASSEMBLY GROUND CIRCUIT. 1) Turn ignition switch to OFF. 2) Measure resistance between ignition coil & ignitor assembly connector and engine ground. Connector & terminal (E31) No. 2 Engine ground: (E32) No. 2 Engine ground: (E33) No. 2 Engine ground: (E34) No. 2 Engine ground:
Go to step 5.
CHECK HARNESS BETWEEN ECM AND IGNITION COIL & IGNITOR ASSEMBLY CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM. 3) Disconnect connector from ignition coil & ignitor assembly. 4) Measure resistance of harness between ECM and ignition coil & ignitor assembly connector. Connector & terminal (B136) No. 21 (E34) No. 1: (B136) No. 22 (E33) No. 1: (B136) No. 23 (E32) No. 1: (B136) No. 24 (E31) No. 1: CHECK HARNESS BETWEEN ECM AND IGNITION COIL & IGNITOR ASSEMBLY CONNECTOR. Measure resistance of harness between ECM and engine ground. Connector & terminal: (B136) No. 21 Engine ground: (B136) No. 22 Engine ground: (B136) No. 23 Engine ground: (B136) No. 24 Engine ground: CHECK POOR CONTACT. Check poor contact in ECM connector.
Go to step 6.
Replace ignition coil and ignitor assembly.
EN(DOHC TURBO)-74

MEMO:
EN(DOHC TURBO)-75

S088533E96
CAUTION: After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to EN(DOHC TURBO)-47, Clear Memory Mode.> and INSPECTION MODE <Ref. to EN(DOHC TURBO)-44, Inspection Mode.>. WIRING DIAGRAM:
S2M2185
EN(DOHC TURBO)-76

No. 1 Step Check Does fuel pump produce CHECK OPERATING SOUND OF FUEL operating sound? PUMP. Make sure that fuel pump is in operation for two seconds when turning ignition switch to ON. NOTE: Fuel pump operation can also be executed using Subaru Select Monitor (Function mode: FD01). For the procedure, refer to Compulsory Valve Operation Check Mode. <Ref. to EN(DOHC TURBO)-48, Compulsory Valve Operation Check Mode.>
No Record DTC. Repair the trouble case. <Ref. to EN(DOHC TURBO)-90, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Yes Check fuel injector circuit. <Ref. to EN(DOHC TURBO)-78, FUEL INJECTOR CIRCUIT, Diagnostics for Engine Starting Failure.>
EN(DOHC TURBO)-77

S088533E97
CAUTION: Check or repair only faulty parts. After repair or replacement of faulty parts, conduct CLEAR MEMORY MODE <Ref. to EN(DOHC TURBO)-47, Clear Memory Mode.> and INSPECTION MODE. <Ref. to EN(DOHC TURBO)-44, Inspection Mode.>
EN(DOHC TURBO)-78

WIRING DIAGRAM: LHD MODEL
S2M2186
EN(DOHC TURBO)-79
RHD MODEL
EN0965
No. 1
Yes Check fuel pressure. <Ref. to ME(DOHC TURBO)-27, INSPECTION, Fuel Pressure.>
No Go to step 2.
EN(DOHC TURBO)-80

No. 2 Step Check Yes Is the voltage more than 10 Go to step 3. CHECK POWER SUPPLY TO EACH FUEL V? INJECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from #1 cylinder fuel injector. 3) Turn ignition switch to ON. 4) Measure power supply voltage between the fuel injector terminal and engine ground. Connector & terminal #1 (E5) No. 2 (+) Engine ground (): #2 (E16) No. 2 (+) Engine ground (): #3 (E6) No. 2 (+) Engine ground (): #4 (E17) No. 2 (+) Engine ground ():
No Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between main relay and fuel injector connector Poor contact in main relay connector Poor contact in coupling connector Poor contact in fuel injector connector Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ECM and fuel injector connector Poor contact in coupling connector Go to step 5.
CHECK HARNESS BETWEEN ECM AND FUEL INJECTOR CONNECTOR. 1) Disconnect connector from ECM. 2) Measure resistance of harness between ECM and fuel injector connector. Connector & terminal (B137) No. 1 (E5) No. 1: (B136) No. 6 (E16) No. 1: (B136) No. 5 (E6) No. 1: (B136) No. 4 (E6) No. 1:
Go to step 4.
CHECK HARNESS BETWEEN ECM AND FUEL INJECTOR CONNECTOR. Measure resistance of harness between ECM and fuel injector connector. Connector & terminal (B137) No. 1 Chassis ground: (B136) No. 6 Chassis ground: (B136) No. 5 Chassis ground: (B136) No. 4 Chassis ground: CHECK EACH FUEL INJECTOR. 1) Turn ignition switch to OFF. 2) Measure resistance between each fuel injector terminals. Terminals No. 1 No. 2: CHECK POOR CONTACT. Check poor contact in ECM connector.
Replace faulty fuel injector.
Inspection using General Diagnostic Table. <Ref. to EN(DOHC TURBO)-344, INSPECTION, General Diagnostic Table.>
EN(DOHC TURBO)-81

S088525
A: LIST
DTC No. P0031
S088525A12
Item Front oxygen (A/F) sensor heater circuit low input
Index
P0032
P0037
P0038
P0101
P0102
P0103
P0106
P0107
P0108
P0111
P0112
P0113
P0117
P0118
P0121
P0122
<Ref. to EN(DOHC TURBO)-90, DTC P0031 FRONT OXYGEN (A/F) SENSOR HEATER CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Front oxygen (A/F) sensor heater <Ref. to EN(DOHC TURBO)-94, DTC P0032 FRONT OXYGEN (A/F) circuit high input SENSOR HEATER CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Rear oxygen sensor heater circuit <Ref. to EN(DOHC TURBO)-96, DTC P0037 REAR OXYGEN SENmalfunction SOR HEATER CIRCUIT MALFUNCTION , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Rear oxygen sensor heater circuit <Ref. to EN(DOHC TURBO)-100, DTC P0038 REAR OXYGEN SENhigh input SOR HEATER CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Mass air flow sensor circuit range/ <Ref. to EN(DOHC TURBO)-102, DTC P0101 MASS AIR FLOW SENperformance problem (high input) SOR CIRCUIT RANGE/PERFORMANCE PROBLEM (HIGH INPUT) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Mass air flow sensor circuit low <Ref. to EN(DOHC TURBO)-104, DTC P0102 MASS AIR FLOW SENinput SOR CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Mass air flow sensor circuit high <Ref. to EN(DOHC TURBO)-108, DTC P0103 MASS AIR FLOW SENinput SOR CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Pressure sensor circuit range/ <Ref. to EN(DOHC TURBO)-110, DTC P0106 PRESSURE SENSOR performance problem (low input) CIRCUIT RANGE/PERFORMANCE PROBLEM (LOW INPUT) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Pressure sensor circuit low input <Ref. to EN(DOHC TURBO)-114, DTC P0107 PRESSURE SENSOR CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Pressure sensor circuit high input <Ref. to EN(DOHC TURBO)-118, DTC P0108 PRESSURE SENSOR CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Intake air temperature sensor circuit <Ref. to EN(DOHC TURBO)-122, DTC P0111 INTAKE AIR TEMPERArange/performance problem TURE SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Intake air temperature sensor circuit <Ref. to EN(DOHC TURBO)-124, DTC P0112 INTAKE AIR TEMPERAlow input TURE SENSOR CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Intake air temperature sensor circuit <Ref. to EN(DOHC TURBO)-126, DTC P0113 INTAKE AIR TEMPERAhigh input TURE SENSOR CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Engine coolant temperature sensor <Ref. to EN(DOHC TURBO)-130, DTC P0117 ENGINE COOLANT circuit low input TEMPERATURE SENSOR CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Engine coolant temperature sensor <Ref. to EN(DOHC TURBO)-132, DTC P0118 ENGINE COOLANT circuit high input TEMPERATURE SENSOR CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Throttle position sensor circuit <Ref. to EN(DOHC TURBO)-136, DTC P0121 THROTTLE POSITION range/performance problem (high SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (HIGH INPUT) input) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Throttle position sensor circuit low <Ref. to EN(DOHC TURBO)-138, DTC P0122 THROTTLE POSITION input SENSOR CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(DOHC TURBO)-82

DTC No. P0123 Item Throttle position sensor circuit high input Index
P0125
P0131
P0132
P0133
P0136
P0139
P0171
P0172
P0244
P0245
P0246
P0301
P0302
P0303
P0304
P0327
P0328
P0335
<Ref. to EN(DOHC TURBO)-142, DTC P0123 THROTTLE POSITION SENSOR CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Insufficient coolant temperature for <Ref. to EN(DOHC TURBO)-146, DTC P0125 INSUFFICIENT COOLclosed loop fuel control ANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(DOHC TURBO)-148, DTC P0131 FRONT OXYGEN (A/F) Front oxygen (A/F) sensor circuit SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (LOW INPUT) range/performance problem (low , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> input) Front oxygen (A/F) sensor circuit <Ref. to EN(DOHC TURBO)-150, DTC P0132 FRONT OXYGEN (A/F) range/performance problem (high SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (HIGH INPUT) input) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Front oxygen (A/F) sensor circuit <Ref. to EN(DOHC TURBO)-152, DTC P0133 FRONT OXYGEN (A/F) slow response SENSOR CIRCUIT SLOW RESPONSE , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Rear oxygen sensor circuit malfunc- <Ref. to EN(DOHC TURBO)-154, DTC P0136 REAR OXYGEN SENtion SOR CIRCUIT MALFUNCTION , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Rear oxygen sensor circuit slow <Ref. to EN(DOHC TURBO)-158, DTC P0139 REAR OXYGEN SENresponse SOR CIRCUIT SLOW RESPONSE , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Fuel trim malfunction (A/F too lean) <Ref. to EN(DOHC TURBO)-160, DTC P0171 FUEL TRIM MALFUNCTION (A/F TOO LEAN) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Fuel trim malfunction (A/F too rich) <Ref. to EN(DOHC TURBO)-161, DTC P0172 FUEL TRIM MALFUNCTION (A/F TOO RICH) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Wastegate control solenoid valve <Ref. to EN(DOHC TURBO)-164, DTC P0244 WASTEGATE CONmalfunction (high input) TROL SOLENOID VALVE MALFUNCTION (HIGH INPUT) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Wastegate control solenoid valve <Ref. to EN(DOHC TURBO)-166, DTC P0245 WASTEGATE CONcircuit low input TROL SOLENOID VALVE CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Wastegate control solenoid valve <Ref. to EN(DOHC TURBO)-170, DTC P0246 WASTEGATE CONcircuit high input TROL SOLENOID VALVE CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Cylinder 1 misfire detected <Ref. to EN(DOHC TURBO)-172, DTC P0301 CYLINDER 1 MISFIRE DETECTED , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Cylinder 2 misfire detected <Ref. to EN(DOHC TURBO)-172, DTC P0302 CYLINDER 2 MISFIRE DETECTED , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Cylinder 3 misfire detected <Ref. to EN(DOHC TURBO)-172, DTC P0303 CYLINDER 3 MISFIRE DETECTED , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Cylinder 4 misfire detected <Ref. to EN(DOHC TURBO)-172, DTC P0304 CYLINDER 4 MISFIRE DETECTED , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Knock sensor circuit low input <Ref. to EN(DOHC TURBO)-182, DTC P0327 KNOCK SENSOR CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Knock sensor circuit high input <Ref. to EN(DOHC TURBO)-184, DTC P0328 KNOCK SENSOR CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Crankshaft position sensor circuit <Ref. to EN(DOHC TURBO)-186, DTC P0335 CRANKSHAFT POSImalfunction TION SENSOR CIRCUIT MALFUNCTION , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(DOHC TURBO)-83
DTC No. P0336

Item Index <Ref. to EN(DOHC TURBO)-188, DTC P0336 CRANKSHAFT POSITION SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(DOHC TURBO)-190, DTC P0340 CAMSHAFT POSITION SENSOR CIRCUIT MALFUNCTION , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(DOHC TURBO)-192, DTC P0341 CAMSHAFT POSITION SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(DOHC TURBO)-196, DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(DOHC TURBO)-198, DTC P0444 EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CONTROL VALVE CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(DOHC TURBO)-202, DTC P0445 EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(DOHC TURBO)-206, DTC P0461 FUEL LEVEL SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(DOHC TURBO)-210, DTC P0462 FUEL LEVEL SENSOR CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(DOHC TURBO)-214, DTC P0463 FUEL LEVEL SENSOR CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(DOHC TURBO)-218, DTC P0464 FUEL LEVEL SENSOR INTERMITTENT INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(DOHC TURBO)-222, DTC P0480 COOLING FAN RELAY 1 CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(DOHC TURBO)-226, DTC P0483 COOLING FAN FUNCTION PROBLEM , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(DOHC TURBO)-230, DTC P0500 VEHICLE SPEED SENSOR MALFUNCTION , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(DOHC TURBO)-232, DTC P0506 IDLE CONTROL SYSTEM RPM LOWER THAN EXPECTED , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(DOHC TURBO)-234, DTC P0507 IDLE CONTROL SYSTEM RPM HIGHER THAN EXPECTED , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(DOHC TURBO)-236, DTC P0508 IDLE CONTROL SYSTEM CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(DOHC TURBO)-238, DTC P0509 IDLE CONTROL SYSTEM CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(DOHC TURBO)-240, DTC P0512 STARTER SWITCH CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to IM-34, DTC P0153 INCORRECT IMMOBILIZER KEY (USE OF UNREGISTERED KEY) , Diagnostics Chart with Trouble Code.>
Crankshaft position sensor circuit range/performance problem Camshaft position sensor circuit malfunction Camshaft position sensor circuit range/performance problem Catalyst system efficiency below threshold Evaporative emission control system purge control valve circuit low input Evaporative emission control system purge control valve circuit high input Fuel level sensor circuit range/ performance problem Fuel level sensor circuit low input
P0340
P0341
P0420
P0444
P0445
P0461
P0462
P0463
Fuel level sensor circuit high input
P0464
Fuel level sensor intermittent input
P0480
Cooling fan relay 1 circuit low input
P0483
Cooling fan function problem
P0500
Vehicle speed sensor malfunction
P0506
Idle control system RPM lower than expected Idle control system RPM higher than expected Idle control system circuit low input
P0507
P0508
P0509
Idle control system circuit high input
P0512
Starter switch circuit high input
P0153
Incorrect immobilizer key
EN(DOHC TURBO)-84

DTC No. P0545 Item Exhaust gas temperature sensor circuit low input Exhaust gas temperature sensor circuit high input Internal control module memory check sum error Brake switch input malfunction Index
P0546
P0604
P0703
P0705 P0710 P0715 P0720 P0725 P0731 P0732 P0733 P0734 P0741
Transmission range sensor circuit malfunction Transmission fluid temperature sensor circuit malfunction Torque converter turbine speed sensor circuit malfunction Output speed sensor (vehicle speed sensor 2) circuit malfunction Engine speed input circuit malfunction Gear 1 incorrect ratio Gear 2 incorrect ratio Gear 3 incorrect ratio Gear 4 incorrect ratio Torque converter clutch system malfunction Torque converter clutch system (Lock-up duty solenoid) electrical Pressure control solenoid (Line pressure duty solenoid) electrical Shift solenoid A (Shift solenoid 1) electrical Shift solenoid B (Shift solenoid 2) electrical 2-4 brake pressure control solenoid valve circuit malfunction 2-4 brake timing control solenoid valve circuit malfunction Tumble generator valve #2 (LH) position sensor circuit low input Tumble generator valve #2 (LH) position sensor circuit high input Tumble generator valve #1 (RH) position sensor circuit low input
P0743 P0748 P0753 P0758 P0778 P0785 P1086
P1087
P1088
<Ref. to EN(DOHC TURBO)-242, DTC P0545 EXHAUST GAS TEMPERATURE SENSOR CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(DOHC TURBO)-244, DTC P0546 EXHAUST GAS TEMPERATURE SENSOR CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(DOHC TURBO)-248, DTC P0604 INTERNAL CONTROL MODULE MEMORY CHECK SUM ERROR , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(DOHC TURBO)-252, DTC P0703 BRAKE SWITCH INPUT MALFUNCTION , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to AT-122, CHECK INHIBITOR SWITCH., Diagnostic Procedure for No-trouble Code.> <Ref. to AT-46, TROUBLE CODE 27 ATF TEMPERATURE SENSOR , Diagnostic Procedure with Trouble Code.> <Ref. to AT-64, TROUBLE CODE 36 TORQUE CONVERTER TURBINE SPEED SENSOR , Diagnostic Procedure with Trouble Code.> <Ref. to AT-58, TROUBLE CODE 33 FRONT VEHICLE SPEED SENSOR , Diagnostic Procedure with Trouble Code.> <Ref. to AT-42, TROUBLE CODE 11 ENGINE SPEED SIGNAL , Diagnostic Procedure with Trouble Code.> <Ref. to EN(DOHC TURBO)-254, DTC P0731 GEAR 1 INCORRECT RATIO , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(DOHC TURBO)-254, DTC P0732 GEAR 2 INCORRECT RATIO , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(DOHC TURBO)-254, DTC P0733 GEAR 3 INCORRECT RATIO , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(DOHC TURBO)-255, DTC P0734 GEAR 4 INCORRECT RATIO , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(DOHC TURBO)-256, DTC P0741 TORQUE CONVERTER CLUTCH SYSTEM MALFUNCTION , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to AT-96, TROUBLE CODE 77 LOCK-UP DUTY SOLENOID , Diagnostic Procedure with Trouble Code.> <Ref. to AT-88, TROUBLE CODE 75 LINE PRESSURE DUTY SOLENOID , Diagnostic Procedure with Trouble Code.> <Ref. to AT-72, TROUBLE CODE 71 SHIFT SOLENOID 1 , Diagnostic Procedure with Trouble Code.> <Ref. to AT-76, TROUBLE CODE 72 SHIFT SOLENOID 2 , Diagnostic Procedure with Trouble Code.> <Ref. to AT-92, TROUBLE CODE 76 2- BRAKE DUTY SOLENOID , Diagnostic Procedure with Trouble Code.> <Ref. to AT-84, TROUBLE CODE 74 2-4 BRAKE TIMING SOLENOID , Diagnostic Procedure with Trouble Code.> <Ref. to EN(DOHC TURBO)-258, DTC P1086 TUMBLE GENERATOR VALVE #2 (LH) POSITION SENSOR CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(DOHC TURBO)-262, DTC P1087 TUMBLE GENERATOR VALVE #2 (LH) POSITION SENSOR CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(DOHC TURBO)-266, DTC P1088 TUMBLE GENERATOR VALVE #1 (RH) POSITION SENSOR CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(DOHC TURBO)-85
DTC No. P1089

Item Index <Ref. to EN(DOHC TURBO)-270, DTC P1089 TUMBLE GENERATOR VALVE #1 (RH) POSITION SENSOR CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(DOHC TURBO)-273, DTC P1090 TUMBLE GENERATOR VALVE SYSTEM #1 (RH) MALFUNCTION (STUCK OPEN) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(DOHC TURBO)-274, DTC P1091 TUMBLE GENERATOR VALVE SYSTEM #1 (RH) MALFUNCTION (STUCK CLOSE) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(DOHC TURBO)-275, DTC P1092 TUMBLE GENERATOR VALVE SYSTEM #2 (LH) MALFUNCTION (STUCK OPEN) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(DOHC TURBO)-276, DTC P1093 TUMBLE GENERATOR VALVE SYSTEM #2 (LH) MALFUNCTION (STUCK CLOSE) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(DOHC TURBO)-278, DTC P1094 TUMBLE GENERATOR VALVE CIRCUIT #1 (OPEN CIRCUIT) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(DOHC TURBO)-280, DTC P1095 TUMBLE GENERATOR VALVE CIRCUIT #1 (OVERCURRENT) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(DOHC TURBO)-282, DTC P1096 TUMBLE GENERATOR VALVE CIRCUIT #2 (OPEN CIRCUIT) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(DOHC TURBO)-284, DTC P1097 TUMBLE GENERATOR VALVE CIRCUIT #2 (OVERCURRENT) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(DOHC TURBO)-286, DTC P1110 ATMOSPHERIC PRESSURE SENSOR CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(DOHC TURBO)-286, DTC P1111 ATMOSPHERIC PRESSURE SENSOR CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(DOHC TURBO)-287, DTC P1112 ATMOSPHERIC PRESSURE SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(DOHC TURBO)-288, DTC P1130 FRONT OXYGEN (A/F) SENSOR CIRCUIT MALFUNCTION (OPEN CIRCUIT) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(DOHC TURBO)-290, DTC P1131 FRONT OXYGEN (A/F) SENSOR CIRCUIT MALFUNCTION (SHORT CIRCUIT) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(DOHC TURBO)-292, DTC P1134 FRONT OXYGEN (A/F) SENSOR MICRO-COMPUTER PROBLEM , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(DOHC TURBO)-294, DTC P1139 FRONT OXYGEN (A/F) SENSOR #1 HEATER CIRCUIT RANGE/PERFORMANCE PROBLEM , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(DOHC TURBO)-296, DTC P1141 MASS AIR FLOW SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (LOW INPUT) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(DOHC TURBO)-298, DTC P1142 THROTTLE POSITION SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (LOW INPUT) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> <Ref. to EN(DOHC TURBO)-300, DTC P1146 PRESSURE SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (HIGH INPUT) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Tumble generator valve #1 (RH) position sensor circuit high input Tumble generator valve #1(RH) malfunction (stuck open) Tumble generator valve #1(RH) malfunction (stuck close) Tumble generator valve #2(LH) malfunction (stuck open) Tumble generator valve #2(LH) malfunction (stuck close) Tumble generator valve circuit #1 (opencircuit) Tumble generator valve circuit #1 (overcurrent) Tumble generator valve circuit #2 (opencircuit) Tumble generator valve circuit #2 (overcurrent) Atmospheric pressure sensor low input Atmospheric pressure sensor high input Atmospheric pressure sensor range/ performance problem Front oxygen sensor circuit malfunction (open circuit) Front oxygen sensor circuit malfunction (short circuit) Front oxygen (A/F) sensor microcomputer problem Front oxygen (A/F) sensor #1 heater circuit perfomance/range problem Mass air flow sensor circuit range/ perfomance problem (low input) Throttle position sensor circuit range/performance problem (low input) Pressure sensor circuit range/ performance problem (high input)
P1090
P1091
P1092
P1093
P1094
P1095
P1096
P1097
P1110
P1111
P1112
P1130
P1131
P1134
P1139
P1141
P1142
P1146
EN(DOHC TURBO)-86

DTC No. P1244 Item Wastegate control solenoid valve malfunction (low input) Index
P1245
P1301
P1312
P1480
P1507
P1518
P1544
P1560
P1570 P1571 P1572 P1574 P1576 P1577 P1590
P1591
P1594
P1595
P1596
P1700
<Ref. to EN(DOHC TURBO)-304, DTC P1244 WASTEGATE CONTROL SOLENOID VALVE RANGE/PERFORMANCE PROBLEM (LOW INPUT) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Wastegate control solenoid valve <Ref. to EN(DOHC TURBO)-306, DTC P1245 WASTEGATE CONmalfunction (fail-safe) TROL SOLENOID VALVE MALFUNCTION (FAIL-SAFE) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Fire due to increased exhaust tem- <Ref. to EN(DOHC TURBO)-308, DTC P1301 FIRE DUE TO perature INCREASED EXHAUST TEMPERATURE , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Exhaust temperature sensor mal<Ref. to EN(DOHC TURBO)-310, DTC P1312 EXHAUST GAS TEMfunction PERATURE CIRCUIT MALFUNCTION , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Cooling fan relay 1 circuit high input <Ref. to EN(DOHC TURBO)-312, DTC P1480 COOLING FAN RELAY 1 CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Idle control system malfunction (fail- <Ref. to EN(DOHC TURBO)-316, DTC P1507 IDLE CONTROL SYSsafe) TEM MALFUNCTION (FAIL-SAFE) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Starter switch circuit low input <Ref. to EN(DOHC TURBO)-318, DTC P1518 STARTER SWITCH CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> High exhaust temperature detected <Ref. to EN(DOHC TURBO)-320, DTC P1544 HIGH EXHAUST TEMPERATURE DETECTED , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Back-up voltage circuit malfunction <Ref. to EN(DOHC TURBO)-322, DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Antennna <Ref. to IM-35, DTC P1570 ANTENNA , Diagnostics Chart with Trouble Code.> Reference code incompatibility <Ref. to IM-26, DTC P1571 REFERENCE CODE INCOMPATIBILITY , Diagnostics Chart with Trouble Code.> IMM circuit failure except antenna <Ref. to IM-27, DTC P1572 IMM CIRCUIT FAILURE (EXCEPT circuit ANTENNA CIRCUIT) , Diagnostics Chart with Trouble Code.> Key communication failure <Ref. to IM-33, DTC P1574 KEY COMMUNICATION FAILURE , Diagnostics Chart with Trouble Code.> EGI control module EEPROM <Ref. to IM-34, DTC P1576 EGI CONTROL MODULE EEPROM , Diagnostics Chart with Trouble Code.> IMM control module EEPROM <Ref. to IM-34, DTC P1577 IMM CONTROL MODULE EEPROM , Diagnostics Chart with Trouble Code.> Neutral position switch circuit high <Ref. to EN(DOHC TURBO)-326, DTC P1590 NEUTRAL POSITION input (AT model) SWITCH CIRCUIT HIGH INPUT (AT MODEL) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Neutral position switch circuit low <Ref. to EN(DOHC TURBO)-330, DTC P1591 NEUTRAL POSITION input (AT model) SWITCH CIRCUIT LOW INPUT (AT MODEL) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Automatic transmission diagnosis <Ref. to EN(DOHC TURBO)-332, DTC P1594 AUTOMATIC TRANSinput signal circuit malfunction MISSION DIAGNOSIS INPUT SIGNAL CIRCUIT MALFUNCTION , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Automatic transmission diagnosis <Ref. to EN(DOHC TURBO)-334, DTC P1595 AUTOMATIC TRANSinput signal circuit low input MISSION DIAGNOSIS INPUT SIGNAL CIRCUIT LOW INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Automatic transmission diagnosis <Ref. to EN(DOHC TURBO)-336, DTC P1596 AUTOMATIC TRANSinput signal circuit high input MISSION DIAGNOSIS INPUT SIGNAL CIRCUIT HIGH INPUT , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Throttle position sensor circuit mal- <Ref. to AT-50, TROUBLE CODE 31 THROTTLE POSITION SENSOR function for automatic transmission , Diagnostic Procedure with Trouble Code.>
EN(DOHC TURBO)-87
DTC No. P1701

Item Index
P1703 P1711
P1712
<Ref. to EN(DOHC TURBO)-338, DTC P1701 CRUISE CONTROL SET SIGNAL CIRCUIT MALFUNCTION FOR AUTOMATIC TRANSMISSION , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Low clutch timing control solenoid <Ref. to AT-80, TROUBLE CODE 73 LOW CLUTCH TIMING SOLEvalve circuit malfunction NOID , Diagnostic Procedure with Trouble Code.> Engine torque control signal 1 circuit <Ref. to EN(DOHC TURBO)-340, DTC P1711 ENGINE TORQUE CONmalfunction TROL SIGNAL 1 CIRCUIT MALFUNCTION , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Engine torque control signal 2 circuit <Ref. to EN(DOHC TURBO)-342, DTC P1712 ENGINE TORQUE CONmalfunction TROL SIGNAL 2 CIRCUIT MALFUNCTION , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Cruise control set signal circuit malfunction for automatic transmission
EN(DOHC TURBO)-88

MEMO:
EN(DOHC TURBO)-89

S088521

S088521F83
A: DTC P0031 FRONT OXYGEN (A/F) SENSOR HEATER CIRCUIT LOW INPUT
DTC DETECTING CONDITION: Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(DOHC TURBO)47, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(DOHC TURBO)-44, Inspection Mode.>. WIRING DIAGRAM:
S2M2187
EN(DOHC TURBO)-90

No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. Check Yes Go to step 2. Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0031 and P0037 at the same time? Is the voltage more than 10 Go to step 3. V? No Go to step 5.
CHECK POWER SUPPLY TO FRONT OXYGEN (A/F) SENSOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from front oxygen (A/F) sensor. 3) Turn ignition switch to ON. 4) Measure voltage between front oxygen (A/F) sensor connector and engine ground. Connector & terminal (B18) No. 2 (+) Engine ground ():
Is the resistance less than CHECK GROUND CIRCUIT OF ECM. Measure resistance of harness between ECM 5 ? connector and chassis ground. Connector & terminal (B137) No. 8 Chassis ground: (B137) No. 9 Chassis ground:
Go to step 4.
CHECK CURRENT DATA. 1) Start engine 2) Read data of front oxygen (A/F) sensor heater current using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(DOHC TURBO)-36, Subaru Select Monitor.> OBD-II scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Instruction Manual. CHECK OUTPUT SIGNAL FROM ECM. 1) Start and idle the engine. 2) Measure voltage between ECM connector and chassis ground. Connector & terminal (B137) No. 4 (+) Chassis ground (): (B137) No. 5 (+) Chassis ground ():
Repair poor contact in connector. NOTE: In this case, repair the following: Poor contact in front oxygen (A/F) sensor connector Poor contact in ECM connector
Repair power supply line. NOTE: In this case, repair the following: Open circuit in harness between main relay and front oxygen (A/F) sensor connector Poor contact in front oxygen (A/F) sensor connector Poor contact in main relay connector Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ECM and engine ground terminal Poor contact in ECM connector Poor contact in coupling connector Go to step 5.
Go to step 6.
EN(DOHC TURBO)-91
No. 6

Step CHECK OUTPUT SIGNAL FROM ECM. Measure voltage between ECM connector and chassis ground. Connector & terminal (B137) No. 4 (+) Chassis ground (): (B137) No. 5 (+) Chassis ground (): CHECK FRONT OXYGEN (A/F) SENSOR. 1) Turn ignition switch to OFF. 2) Measure resistance between front oxygen (A/F) sensor connector terminals. Terminals No. 2 No. 1: Check Does the voltage change less than 1.0 V by shaking harness and connector of ECM while monitoring the value with voltage meter? Is the resistance less than 10 ? Yes Repair poor contact in ECM connector. No Go to step 7.
Repair harness and connector. NOTE: In this case, repair the following: Open or ground short circuit in harness between front oxygen (A/F) sensor and ECM connector Poor contact in front oxygen (A/F) sensor connector Poor contact in ECM connector
Replace front oxygen (A/F) sensor. <Ref. to FU(DOHC TURBO)-42, Front Oxygen (A/F) Sensor.>
EN(DOHC TURBO)-92

MEMO:
EN(DOHC TURBO)-93
B: DTC P0032 FRONT OXYGEN (A/F) SENSOR HEATER CIRCUIT HIGH INPUT
S088521F84
S2M2187
EN(DOHC TURBO)-94

No. 1 Step CHECK OUTPUT SIGNAL FROM ECM. 1) Turn ignition switch to ON. 2) Measure voltage between ECM connector and chassis ground. Connector & terminal (B137) No. 4 (+) Chassis ground (): (B137) No. 5 (+) Chassis ground (): CHECK FRONT OXYGEN (A/F) SENSOR HEATER CURRENT. 1) Turn ignition switch to OFF. 2) Repair battery short circuit in harness between ECM and front oxygen (A/F) sensor connector. 3) Turn ignition switch to ON. 4) Read data of front oxygen (A/F) sensor heater current using Subaru Select Monitor or the OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(DOHC TURBO)-36, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedure, refer to the OBD-II General Scan Tool Instruction Manual. CHECK OUTPUT SIGNAL FROM ECM. Measure voltage between ECM connector and chassis ground. Connector & terminal (B137) No. 4 (+) Chassis ground (): (B137) No. 5 (+) Chassis ground (): Check Is the voltage more than 8 V? Yes Go to step 3. No Go to step 2.
END
Does the voltage change more than 8 V by shaking harness and connector of ECM while monitoring the value with voltage meter?
END Repair battery short circuit in harness between ECM and front oxygen (A/F) sensor connector.
EN(DOHC TURBO)-95
C: DTC P0037 REAR OXYGEN SENSOR HEATER CIRCUIT MALFUNCTION

S088521F85
DTC DETECTING CONDITION: Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(DOHC TURBO)47, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(DOHC TURBO)-44, Inspection Mode.>. WIRING DIAGRAM:
S2M2188
EN(DOHC TURBO)-96

No. 1 Step CHECK GROUND CIRCUIT OF ECM. 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM. 3) Measure resistance of harness between ECM connector and chassis ground. Connector & terminal (B137) No. 8 Chassis ground: (B137) No. 9 Chassis ground: Check Is the resistance less than 5 ? Yes Go to step 2.
No Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ECM and engine ground terminal Poor contact in ECM connector Poor contact in coupling connector Go to step 3.
CHECK CURRENT DATA. 1) Start engine. 2) Read data of rear oxygen sensor heater current using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(DOHC TURBO)-36, Subaru Select Monitor.> OBD-II scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Instruction Manual. CHECK OUTPUT SIGNAL FROM ECM. 1) Start and idle the engine. 2) Measure voltage between ECM connector and chassis ground. Connector & terminal (B136) No. 13 (+) Chassis ground (): CHECK OUTPUT SIGNAL FROM ECM. Measure voltage between ECM connector and chassis ground. Connector & terminal (B136) No. 13 (+) Chassis ground (): CHECK OUTPUT SIGNAL FROM ECM. 1) Disconnect connector from rear oxygen sensor. 2) Measure voltage between ECM connector and chassis ground. Connector & terminal (B136) No. 13 (+) Chassis ground ():
Repair connector. NOTE: In this case, repair the following: Poor contact in rear oxygen sensor connector Poor contact in rear oxygen sensor connecting harness connector Poor contact in ECM connector Is the voltage less than 1.0 Go to step 6. Go to step 4. V?
Does the voltage change less than 1.0 V by shaking harness and connector of ECM while monitoring the value with voltage meter?
Go to step 5.
Is the voltage less than 1.0 Replace ECM. V? <Ref. to FU(DOHC TURBO)-47, Engine Control Module.>
Repair battery short circuit in harness between ECM and rear oxygen sensor connector. After repair, replace ECM. <Ref. to FU(DOHC TURBO)-47, Engine Control Module.>
EN(DOHC TURBO)-97
No. 6

Step Check Yes Is the voltage more than 10 Go to step 7. CHECK POWER SUPPLY TO REAR OXYV? GEN SENSOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from rear oxygen sensor. 3) Turn ignition switch to ON. 4) Measure voltage between rear oxygen sensor connector and engine ground or chassis ground. Connector & terminal (B19) No. 2 (+) Chassis ground (): No Repair power supply line. NOTE: In this case, repair the following: Open circuit in harness between main relay and rear oxygen sensor connector Poor contact in rear oxygen sensor connector Poor contact in coupling connector Replace rear oxygen sensor. <Ref. to FU(DOHC TURBO)-44, Rear Oxygen Sensor.>
CHECK REAR OXYGEN SENSOR. 1) Turn ignition switch to OFF. 2) Measure resistance between rear oxygen sensor connector terminals. Terminals No. 1 No. 2:
Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between rear oxygen sensor and ECM connector Poor contact in rear oxygen sensor connector Poor contact in ECM connector Poor contact in coupling connector
EN(DOHC TURBO)-98

MEMO:
EN(DOHC TURBO)-99
D: DTC P0038 REAR OXYGEN SENSOR HEATER CIRCUIT HIGH INPUT

S088521F86
S2M2188
EN(DOHC TURBO)-100

No. 1 Step CHECK INPUT SIGNAL FOR ECM. Measure voltage between ECM connector and chassis ground. Connector & terminal (B136) No. 13 (+) Chassis ground (): CHECK CURRENT DATA. 1) Turn ignition switch to OFF. 2) Repair battery short circuit in harness between ECM and rear oxygen sensor connector. 3) Turn ignition switch to ON. 4) Read data of rear oxygen sensor heater current using Subaru Select Monitor or the OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(DOHC TURBO)-36, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedure, refer to the OBD-II General Scan Tool Instruction Manual. CHECK POOR CONTACT. Check poor contact in ECM connector. Check Is the voltage more than 8 V? Yes Go to step 2. No Go to step 3.
Is the value more than 7 A?
END
END
EN(DOHC TURBO)-101
E: DTC P0101 MASS AIR FLOW SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (HIGH INPUT)
S088521B08
CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(DOHC TURBO)47, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(DOHC TURBO)-44, Inspection Mode.>. WIRING DIAGRAM:
S2M2189
EN(DOHC TURBO)-102

No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0102 or P0103 Yes Inspect DTC P0102 or P0103 using List of Diagnostic Trouble Code (DTC). <Ref. to EN(DOHC TURBO)-82, List of Diagnostic Trouble Code (DTC).> NOTE: In this case, it is not necessary to inspect DTC P0101.
No Replace mass air flow and intake air temperature sensor. <Ref. to FU(DOHC TURBO)-34, Mass Air Flow and Intake Air Temperature Sensor.>
EN(DOHC TURBO)-103

S088521B09
F: DTC P0102 MASS AIR FLOW SENSOR CIRCUIT LOW INPUT

DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: Erroneous idling Engine stalls. Poor driving performance WIRING DIAGRAM:
S2M2189
EN(DOHC TURBO)-104

No. 1 Step CONNECT SUBARU SELECT MONITOR OR THE OBD-II GENERAL SCAN TOOL, AND READ DATA. 1) Turn ignition switch to OFF. 2) Connect Subaru Select Monitor or the OBD-II general scan tool to data link connector. 3) Turn ignition switch to ON and Subaru Select Monitor or the OBD-II general scan tool switch to ON. 4) Start engine. 5) Read data of mass air flow sensor signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(DOHC TURBO)-36, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Instruction Manual. Yes No Even if MIL lights Go to step 2. up, the circuit has returned to a normal condition at this time. A temporary poor contact of the connector or harness may be the cause. Repair harness or connector in the mass air flow sensor. NOTE: In this case, repair the following: Open or ground short circuit in harness between mass air flow sensor and ECM connector Poor contact in mass air flow sensor or ECM connector Is the voltage less than 0.2 Go to step 4. Go to step 3. V? Check Is the value equal to or more than 1.3 g/sec (0.172 lb/min) or 0.3 V and equal to or less than 240 g/sec (32 lb/min) or 4.58 V?
CHECK INPUT SIGNAL FOR ECM. Measure voltage between ECM connector and chassis ground while engine is idling. Connector & terminal (B84) No. 13 (+) Chassis ground (): CHECK INPUT SIGNAL FOR ECM (USING SUBARU SELECT MONITOR). Measure voltage between ECM connector and chassis ground while engine is idling.
Repair poor conDoes the voltage change more than 0.2 V by shaking tact in ECM connector. harness and connector of ECM while monitoring the value with Subaru select monitor?
CHECK POWER SUPPLY TO MASS AIR FLOW SENSOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from mass air flow sensor. 3) Turn ignition switch to ON. 4) Measure voltage between mass air flow sensor connector and chassis ground. Connector & terminal (B3) No. 1 (+) Chassis ground ():
Is the voltage more than 10V?
Go to step 5.
Contact your Subaru distributor. NOTE: Inspection by DTM is required, because probable cause is deterioration of multiple parts. Repair open circuit between mass air flow sensor and main relay
EN(DOHC TURBO)-105
No. 5

Step CHECK HARNESS BETWEEN ECM AND MASS AIR FLOW SENSOR CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM. 3) Measure resistance of harness between ECM and mass air flow sensor connector. Connector & terminal (B84) No. 13 (B3) No. 3: (B135) No. 27 (B3) No. 4: (B135) No. 19 (B3) No. 5: CHECK HARNESS BETWEEN ECM AND MASS AIR FLOW SENSOR CONNECTOR Measure resistance of harness between ECM and chassis ground. Connector & terminal (B84) No. 13 Chassis ground: (B135) No. 27 Chassis ground: (B135) No. 19 Chassis ground: CHECK POOR CONTACT Check poor contact in mass air flow sensor connector. Check Is the resistance less than 1? Yes Go to step 6. No Repair open circuit between ECM and mass air flow sensor connector.
Is the resistance more than Go to step 7. 1M?
Repair ground short circuit between ECM and mass air flow sensor connector.
Is there poor contact in mass air flow sensor connector?
Repair poor contact in mass air flow sensor connector.
Replace mass air flow and intake air temperature sensor. <Ref. to FU(DOHC TURBO)-34, Mass Air Flow and Intake Air Temperature Sensor.>
EN(DOHC TURBO)-106

MEMO:
EN(DOHC TURBO)-107

S088521B10
G: DTC P0103 MASS AIR FLOW SENSOR CIRCUIT HIGH INPUT

S2M2189
EN(DOHC TURBO)-108

No. 1 Step CONNECT SUBARU SELECT MONITOR OR THE OBD-II GENERAL SCAN TOOL, AND READ DATA. 1) Turn ignition switch to OFF. 2) Connect Subaru Select Monitor or the OBD-II general scan tool to data link connector. 3) Turn ignition switch to ON and Subaru Select Monitor or the OBD-II general scan tool switch to ON. 4) Start engine. 5) Read data of mass air flow sensor signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(DOHC TURBO)-36, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Instruction Manual. CHECK HARNESS BETWEEN ECM AND MASS AIR FLOW SENSOR CONNECTOR. 1) Turn ignition switch to OFF and Subaru Select Monitor or the OBD-II general scan tool switch to OFF. 2) Disconnect connector from mass air flow sensor. 3) Turn ignition switch to ON and Subaru Select Monitor or the OBD-II general scan tool switch to ON. 4) Read data of mass air flow sensor signal using Subaru select monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(DOHC TURBO)-36, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Instruction Manual. Check Is the value equal to or more than 1.3 g/sec (0.172 lb/min) or 0.3 V and equal to or less than 240 g/sec (32 lb/min) or 4.58 V? Yes No Even if MIL lights Go to step 2. up, the circuit has returned to a normal condition at this time.
Is the value more than 240 g/sec (32 lb/min) or 4.58 V in function mode F06?
Replace mass air Repair battery flow sensor. short circuit in harness between mass air flow sensor and ECM connector. After repair, replace ECM.
EN(DOHC TURBO)-109
H: DTC P0106 PRESSURE SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (LOW INPUT)

S088521F90
DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: Failure of engine to start CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(DOHC TURBO)47, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(DOHC TURBO)-44, Inspection Mode.>. LHD MODEL:
S2M2190
EN(DOHC TURBO)-110

RHD MODEL:
S2M2191
EN(DOHC TURBO)-111
No. 1

Step CHECK IDLE SWITCH SIGNAL. 1) Turn ignition switch to ON. 2) Operate the LED operation mode for engine using Subaru Select Monitor. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the LED OPERATION MODE FOR ENGINE. <Ref. to EN(DOHC TURBO)-36, Subaru Select Monitor.> Check Does the LED of {Idle Switch Signal} come on? Yes Go to step 2. No Check throttle position sensor circuit. <Ref. to EN(DOHC TURBO)-136, DTC P0121 THROTTLE POSITION SENSOR CIRCUIT RANGE/ PERFORMANCE PROBLEM (HIGH INPUT) -, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> NOTE: In this case, it is not necessary to inspect DTC P0106. Go to step 3.
CHECK ANY OTHER DTC ON DISPLAY.
Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0107 or P0108?
CHECK CONDITION OF INTAKE MANIFOLD Is the pressure sensor PRESSURE SENSOR. installation bolt tightened securely? CHECK CONDITION OF THROTTLE BODY. Is the throttle body installa- Replace pressure tion bolt tightened sensor. <Ref. to securely? FU(DOHC TURBO)-35, Pressure Sensor.>
Inspect DTC P0107 or P0108 using List of Diagnostic Trouble Code (DTC). <Ref. to EN(DOHC TURBO)-82, List of Diagnostic Trouble Code (DTC).> NOTE: In this case, it is not necessary to inspect DTC P0106. Go to step 4.
Tighten pressure sensor installation bolt securely. Tighten throttle body installation bolt securely.
EN(DOHC TURBO)-112

MEMO:
EN(DOHC TURBO)-113

S088521B12
I: DTC P0107 PRESSURE SENSOR CIRCUIT LOW INPUT

CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(DOHC TURBO)47, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(DOHC TURBO)-44, Inspection Mode.>. WIRING DIAGRAM: LHD MODEL
S2M2190
EN(DOHC TURBO)-114

RHD MODEL
S2M2191
EN(DOHC TURBO)-115
No. 1

Step CHECK CURRENT DATA. 1) Start engine. 2) Read the data of intake manifold absolute pressure signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(DOHC TURBO)-36, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Instruction Manual. CHECK POOR CONTACT. Check poor contact in ECM and pressure sensor connector. Check Is the value less than 7.2 kPa (54 mmHg, 2.1 inHg)? Yes Go to step 3. No Go to step 2.
Repair poor contact in ECM or pressure sensor connector. Go to step 5.
Is the voltage less than 0.7 Go to step 6. CHECK INPUT SIGNAL FOR ECM. V? Measure voltage between ECM and chassis ground. Connector & terminal (B135) No. 8 (+) Chassis ground ():
CHECK HARNESS BETWEEN ECM AND PRESSURE SENSOR CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from pressure sensor. 3) Turn ignition switch to ON. 4) Measure voltage between pressure sensor connector and engine ground. Connector & terminal (E21) No. 3 (+) Engine ground ():
Go to step 7.
Contact your Subaru distributor. NOTE: Inspection by DTM is required, because probable cause is deterioration of multiple parts. Contact your Subaru distributor. NOTE: Inspection by DTM is required, because probable cause is deterioration of multiple parts. Repair open circuit in harness between ECM and intake manifold pressure sensor connector.
EN(DOHC TURBO)-116

No. 7 Step CHECK HARNESS BETWEEN ECM AND PRESSURE SENSOR CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM. 3) Measure resistance of harness between ECM and intake manifold pressure sensor connector. Connector & terminal (B135) No. 19 (E21) No. 2: CHECK HARNESS BETWEEN ECM AND PRESSURE SENSOR CONNECTOR. Measure resistance of harness between intake manifold pressure sensor connector and engine ground. Connector & terminal (E21) No. 1 Engine ground: CHECK POOR CONTACT. Check poor contact in pressure sensor connector. Check Is the resistance less than 1 ? Yes Go to step 8.
No Repair open circuit in harness between ECM and intake manifold pressure sensor connector.
Repair ground short circuit in harness between ECM and intake manifold pressure sensor connector. Replace pressure sensor. <Ref. to FU(DOHC TURBO)-35, Pressure Sensor.>
EN(DOHC TURBO)-117

S088521B13
J: DTC P0108 PRESSURE SENSOR CIRCUIT HIGH INPUT

S2M2190
EN(DOHC TURBO)-118

RHD MODEL
S2M2191
EN(DOHC TURBO)-119
No. 1

Step CHECK CURRENT DATA. 1) Start engine. 2) Read the data of intake manifold absolute pressure signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(DOHC TURBO)-36, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Instruction Manual. CHECK INPUT SIGNAL FOR ECM. Measure voltage between ECM connector and chassis ground. Connector & terminal (B135) No. 9 (+) Chassis ground (): CHECK INPUT SIGNAL FOR ECM. Measure voltage between ECM connector and chassis ground. Connector & terminal (B135) No. 9 (+) Chassis ground (): Check Is the value more than 282 kPa (2,121 mmHg, 83.50 inHg)? Yes Go to step 9. No Go to step 2.
Go to step 4.
Go to step 3.
Is the voltage less than 0.7 Go to step 5. CHECK INPUT SIGNAL FOR ECM. V? Measure voltage between ECM connector and chassis ground. Connector & terminal (B135) No. 8 (+) Chassis ground ():
CHECK HARNESS BETWEEN ECM AND PRESSURE SENSOR CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from pressure sensor. 3) Turn ignition switch to ON. 4) Measure voltage between pressure sensor connector and engine ground. Connector & terminal (E21) No. 3 (+) Engine ground (): CHECK HARNESS BETWEEN ECM AND PRESSURE SENSOR CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM. 3) Measure resistance of harness between ECM and pressure sensor connector. Connector & terminal (B135) No. 8 (E21) No. 1:
Go to step 6.
Contact your Subaru distributor. NOTE: Inspection by DTM is required, because probable cause is deterioration of multiple parts. Contact your Subaru distributor. NOTE: Inspection by DTM is required, because probable cause is deterioration of multiple parts. Repair open circuit in harness between ECM and pressure sensor connector.
Go to step 7.
Repair open circuit in harness between ECM and pressure sensor connector.
EN(DOHC TURBO)-120

No. 7 Step CHECK HARNESS BETWEEN ECM AND INTAKE MANIFOLD PRESSURE SENSOR CONNECTOR. Measure resistance of harness between ECM and pressure sensor connector. Connector & terminal (B135) No. 19 (E21) No. 2: CHECK POOR CONTACT. Check poor contact in pressure sensor connector. Check Is the resistance less than 1 ? Yes Go to step 8.
No Repair open circuit in harness between ECM and pressure sensor connector.
Is the value more than 282 CHECK HARNESS BETWEEN ECM AND kPa (2,121 mmHg, 83.50 PRESSURE SENSOR CONNECTOR. inHg)? 1) Turn ignition switch to OFF and Subaru Select Monitor or the OBD-II general scan tool switch to OFF. 2) Disconnect connector from pressure sensor. 3) Turn ignition switch to ON and Subaru Select Monitor or the OBD-II general scan tool switch to ON. 4) Read data of intake manifold absolute pressure signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(DOHC TURBO)-36, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Instruction Manual.
Repair battery short circuit in harness between ECM and pressure sensor connector.
Replace intake manifold pressure sensor. <Ref. to FU(DOHC TURBO)-35, Pressure Sensor.> Replace pressure sensor. <Ref. to FU(DOHC TURBO)-35, Pressure Sensor.>
EN(DOHC TURBO)-121
K: DTC P0111 INTAKE AIR TEMPERATURE SENSOR CIRCUIT RANGE/ PERFORMANCE PROBLEM
S088521B14
DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: Erroneous idling Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(DOHC TURBO)47, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(DOHC TURBO)-44, Inspection Mode.>. WIRING DIAGRAM:
S2M2189
EN(DOHC TURBO)-122

No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0112, P0113, P0117, P0118 or P0125? Yes Inspect DTC P0112, P0113, P0117, P0118 or P0125 using List of Diagnostic Trouble Code (DTC). <Ref. to EN(DOHC TURBO)-82, List of Diagnostic Trouble Code (DTC).> NOTE: In this case, it is not necessary to inspect DTC P0111. Replace mass air flow and intake air temperature sensor. <Ref. to FU(DOHC TURBO)-34, Mass Air Flow and Intake Air Temperature Sensor.> No Go to step 2.
Is the engine coolant temCHECK ENGINE COOLANT TEMPERAperature between 75C TURE. 1) Start the engine and warm it up completely. (167F) and 95C (203F)? 2) Measure engine coolant temperature using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(DOHC TURBO)-36, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Instruction Manual.
Inspect DTC P0125 using List of Diagnostic Trouble Code (DTC). <Ref. to EN(DOHC TURBO)-82, List of Diagnostic Trouble Code (DTC).>
EN(DOHC TURBO)-123
L: DTC P0112 INTAKE AIR TEMPERATURE SENSOR CIRCUIT LOW INPUT

S088521B15
DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: Erroneous idling Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(DOHC TURBO)47, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(DOHC TURBO)-44, Inspection Mode.>. WIRING DIAGRAM:
S2M2189
EN(DOHC TURBO)-124

No. 1 Step CHECK CURRENT DATA. 1) Start engine. 2) Read data of intake air temperature sensor signal using Subaru Select Monitor or the OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(DOHC TURBO)-36, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedure, refer to the OBD-II General Scan Tool Instruction Manual. CHECK HARNESS BETWEEN MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR AND ECM CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from mass air flow and intake air temperature sensor. 3) Turn ignition switch to ON. 4) Read data of intake air temperature sensor signal using Subaru Select Monitor or the OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(DOHC TURBO)-36, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedure, refer to the OBD-II General Scan Tool Instruction Manual. Check Is the value greater than 55C (131F)? Yes Go to step 2.
Is the value less than 36C (33F)?
No Repair poor contact. NOTE: In this case, repair the following: Poor contact mass air flow and intake air temperature sensor Poor contact in ECM Poor contact in joint connector Replace mass air Repair ground flow and intake air short circuit in temperature sen- harness between mass air flow and sor. <Ref. to intake air temFU(DOHC TURBO)-34, Mass perature sensor and ECM connecAir Flow and tor. Intake Air Temperature Sensor.>
EN(DOHC TURBO)-125
M: DTC P0113 INTAKE AIR TEMPERATURE SENSOR CIRCUIT HIGH INPUT

S088521B16
DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: Erroneous idling Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(DOHC TURBO)47, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(DOHC TURBO)-44, Inspection Mode.>. WIRING DIAGRAM:
S2M2189
EN(DOHC TURBO)-126

No. 1 Step CHECK CURRENT DATA. 1) Start engine. 2) Read data of intake air temperature sensor signal using Subaru Select Monitor or the OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(DOHC TURBO)-36, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedure, refer to the OBD-II General Scan Tool Instruction Manual. CHECK HARNESS BETWEEN MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR AND ECM CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from mass air flow and intake air temperature sensor. 3) Measure voltage between mass air flow and intake air temperature sensor connector and engine ground. Connector & terminal (B3) No. 2 (+) Engine ground (): CHECK HARNESS BETWEEN INTAKE AIR TEMPERATURE AND PRESSURE SENSOR AND ECM CONNECTOR. 1) Turn ignition switch to ON. 2) Measure voltage between mass air flow and intake air temperature sensor connector and engine ground. Connector & terminal (B3) No. 2 (+) Engine ground (): CHECK HARNESS BETWEEN MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR AND ECM CONNECTOR. Measure voltage between mass air flow and intake air temperature sensor and pressure sensor connector and engine ground. Connector & terminal (B3) No. 2 (+) Engine ground (): Check Is the value less than 36C (33F)? Yes Go to step 2.
No Repair poor contact. NOTE: In this case, repair the following: Poor contact in mass air flow and intake air temperature sensor Poor contact in ECM Poor contact in joint connector Go to step 3.
Is the voltage more than 10 Repair battery V? short circuit in harness between mass air flow and intake air temperature sensor and ECM connector.
Go to step 4. Is the voltage more than 10 Repair battery V? short circuit in harness between mass air flow and intake air temperature sensor and ECM connector. Is the voltage more than 3 V? Go to step 5. Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between mass air flow and intake air temperature sensor and ECM connector Poor contact in mass air flow and intake air temperature sensor Poor contact in ECM Poor contact in joint connector
EN(DOHC TURBO)-127
No. 5

Step CHECK HARNESS BETWEEN MASS AIR FLOW AND INTAKE AIR TEMPERATURE SENSOR AND ECM CONNECTOR. 1) Turn ignition switch to OFF. 2) Measure resistance of harness between mass air flow and intake air temperature sensor and engine ground. Connector & terminal (B3) No. 5 Engine ground: Check Is the resistance less than 5 ? Yes Replace mass air flow and intake air temperature sensor. <Ref. to FU(DOHC TURBO)-34, Mass Air Flow and Intake Air Temperature Sensor.> No Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between mass air flow and intake air temperature sensor and ECM connector Poor contact in mass air flow and intake air temperature sensor Poor contact in ECM Poor contact in joint connector
EN(DOHC TURBO)-128

MEMO:
EN(DOHC TURBO)-129
N: DTC P0117 ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT LOW INPUT

S088521F91
DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: Hard to start Erroneous idling Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(DOHC TURBO)47, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(DOHC TURBO)-44, Inspection Mode.>. WIRING DIAGRAM:
S2M2192
EN(DOHC TURBO)-130

No. 1 Step Check Is the value greater than CHECK CURRENT DATA. 150C (302F)? 1) Start engine. 2) Read data of engine coolant temperature sensor signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(DOHC TURBO)-36, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Instruction Manual. Yes Go to step 2.
Is the value less than CHECK HARNESS BETWEEN ENGINE 40C (40F)? COOLANT TEMPERATURE SENSOR AND ECM CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from engine coolant temperature sensor. 3) Turn ignition switch to ON. 4) Read data of engine coolant temperature sensor signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(DOHC TURBO)-36, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Instruction Manual.
No Repair poor contact. NOTE: In this case, repair the following: Poor contact in engine coolant temperature sensor Poor contact in ECM Poor contact in coupling connector Poor contact in joint connector Repair ground Replace engine coolant tempera- short circuit in ture sensor. <Ref. harness between engine coolant to FU(DOHC temperature senTURBO)-29, sor and ECM conEngine Coolant Temperature Sen- nector. sor.>
EN(DOHC TURBO)-131
O: DTC P0118 ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT HIGH INPUT

S088521F92
S2M2192
EN(DOHC TURBO)-132

No. 1 Step Check Is the value less than CHECK CURRENT DATA. 40C (40F)? 1) Start engine. 2) Read data of engine coolant temperature sensor signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(DOHC TURBO)-36, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Instruction Manual. Yes Go to step 2.
No Repair poor contact. NOTE: In this case, repair the following: Poor contact in engine coolant temperature sensor Poor contact in ECM Poor contact in coupling connector Poor contact in joint connector Go to step 3.
CHECK HARNESS BETWEEN ENGINE COOLANT TEMPERATURE SENSOR AND ECM CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from engine coolant temperature sensor. 3) Measure voltage between engine coolant temperature sensor connector and engine ground. Connector & terminal (E8) No. 2 (+) Engine ground (): CHECK HARNESS BETWEEN ENGINE COOLANT TEMPERATURE SENSOR AND ECM CONNECTOR. 1) Turn ignition switch to ON. 2) Measure voltage between engine coolant temperature sensor connector and engine ground. Connector & terminal (E8) No. 2 (+) Engine ground (): CHECK HARNESS BETWEEN ENGINE COOLANT TEMPERATURE SENSOR AND ECM CONNECTOR. Measure voltage between engine coolant temperature sensor connector and engine ground. Connector & terminal (E8) No. 2 (+) Engine ground ():
Go to step 4.
Go to step 5.
Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ECM and engine coolant temperature sensor connector Poor contact in engine coolant temperature sensor connector Poor contact in ECM connector Poor contact in coupling connector Poor contact in joint connector
EN(DOHC TURBO)-133
No. 5

Step CHECK HARNESS BETWEEN ENGINE COOLANT TEMPERATURE SENSOR AND ECM CONNECTOR. 1) Turn ignition switch to OFF. 2) Measure resistance of harness between engine coolant temperature sensor connector and engine ground. Connector & terminal (E8) No. 1 Engine ground: Check Is the resistance less than 5 ? Yes Replace engine coolant temperature sensor. <Ref. to FU(DOHC TURBO)-29, Engine Coolant Temperature Sensor.> No Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ECM and engine coolant temperature sensor connector Poor contact in engine coolant temperature sensor connector Poor contact in ECM connector Poor contact in coupling connector Poor contact in joint connector
EN(DOHC TURBO)-134

MEMO:
EN(DOHC TURBO)-135
P: DTC P0121 THROTTLE POSITION SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (HIGH INPUT)
S088521B19
DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: Erroneous idling Engine stalls. Poor driving performance Fuel is cut. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode < Ref. to EN(DOHC TURBO)47, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(DOHC TURBO)-44, Inspection Mode.>. WIRING DIAGRAM: LHD MODEL
S2M2193
EN(DOHC TURBO)-136

RHD MODEL
S2M2194
No. 1
Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0122, P0123 or P1507?
Yes Inspect DTC P0122, P0123 or P1507 using List of Diagnostic Trouble Code (DTC). <Ref. to EN(DOHC TURBO)-82, List of Diagnostic Trouble Code (DTC).> NOTE: In this case, it is not necessary to inspect DTC P0121.
No Replace throttle position sensor. <Ref. to FU(DOHC TURBO)-33, Throttle Position Sensor.>
EN(DOHC TURBO)-137
Q: DTC P0122 THROTTLE POSITION SENSOR CIRCUIT LOW INPUT

S088521B20
DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: Erroneous idling Engine stalls. Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(DOHC TURBO)47, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(DOHC TURBO)-44, Inspection Mode.>. WIRING DIAGRAM: LHD MODEL
S2M2193
EN(DOHC TURBO)-138

RHD MODEL
S2M2194
EN(DOHC TURBO)-139
No. 1

Step Check Is the value less than 0.1 CHECK CURRENT DATA. V? 1) Start engine. 2) Read data of throttle position sensor signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(DOHC TURBO)-36, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Instruction Manual. Yes Go to step 2. No Even if MIL lights up, the circuit has returned to a normal condition at this time. A temporary poor contact of the connector may be the cause. NOTE: In this case, repair the following: Poor contact in throttle position sensor connector Poor contact in ECM connector Poor contact in coupling connector Go to step 3.
Go to step 4.
Go to step 6.
EN(DOHC TURBO)-140

No. 6 Step CHECK HARNESS BETWEEN ECM AND THROTTLE POSITION SENSOR CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connectors from throttle position sensor. 3) Turn ignition switch to ON. 4) Measure voltage between throttle position sensor connector and engine ground. Connector & terminal (E13) No. 1 (+) Engine ground (): Check Is the voltage more than 4.5 V? Yes Go to step 7.
No Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between throttle position sensor and ECM connector Poor contact in throttle position sensor connector Poor contact in ECM connector Poor contact in coupling connector Poor contact in joint connector Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between throttle position sensor and ECM connector Poor contact in ECM connector Poor contact in throttle position sensor connector Poor contact in coupling connector Go to step 9.
CHECK HARNESS BETWEEN ECM AND THROTTLE POSITION SENSOR CONNECTOR. 1) Turn ignition switch to OFF. 2) Measure resistance of harness between ECM connector and throttle position sensor connector. Connector & terminal (B135) No. 7 (E13) No. 3:
Go to step 8.
CHECK HARNESS BETWEEN ECM AND THROTTLE POSITION SENSOR CONNECTOR. Measure resistance of harness between throttle position sensor connector and engine ground. Connector & terminal (E13) No. 3 Engine ground: CHECK POOR CONTACT. Check poor contact in throttle position sensor connector.
Repair ground short circuit in harness between throttle position sensor and ECM connector.
Is there poor contact in Repair poor conthrottle position sensor contact in throttle nector? position sensor connector.
Replace throttle position sensor. <Ref. to FU(DOHC TURBO)-33, Throttle Position Sensor.>
EN(DOHC TURBO)-141

S088521B21
R: DTC P0123 THROTTLE POSITION SENSOR CIRCUIT HIGH INPUT

S2M2193
EN(DOHC TURBO)-142

RHD MODEL
S2M2194
EN(DOHC TURBO)-143
No. 1

Step Check Is the value more than 4.9 CHECK CURRENT DATA. V? 1) Start engine. 2) Read data of throttle position sensor signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(DOHC TURBO)-36, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Instruction Manual. Yes Go to step 2. No Even if MIL lights up, the circuit has returned to a normal condition at this time. A temporary poor contact of the connector may be the cause. NOTE: In this case, repair the following: Poor contact in throttle position sensor connector Poor contact in ECM connector Poor contact in coupling connector Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between throttle position sensor and ECM connector Poor contact in coupling connector Poor contact in joint connector Replace throttle position sensor. <Ref. to FU(DOHC TURBO)-33, Throttle Position Sensor.>
CHECK HARNESS BETWEEN THROTTLE POSITION SENSOR AND ECM CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from throttle position sensor. 3) Measure resistance of harness between throttle position sensor connector and engine ground. Connector & terminal (E13) No. 2 Engine ground:
Go to step 3.
CHECK HARNESS BETWEEN THROTTLE POSITION SENSOR AND ECM CONNECTOR. 1) Turn ignition switch to ON. 2) Measure voltage between throttle position sensor connector and engine ground. Connector & terminal (E13) No. 3 (+) Engine ground ():
Repair battery short circuit in harness between throttle position sensor and ECM connector. After repair, replace ECM. <Ref. to FU(DOHC TURBO)-47, Engine Control Module.>
EN(DOHC TURBO)-144

MEMO:
EN(DOHC TURBO)-145
S: DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL
S088521B22
DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: Engine would not return to idling. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(DOHC TURBO)47, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(DOHC TURBO)-44, Inspection Mode.>. WIRING DIAGRAM:
S2M2192
EN(DOHC TURBO)-146

No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0117 or P0118? Yes Inspect DTC P0117 or P0118 using List of Diagnostic Trouble Code (DTC). <Ref. to EN(DOHC TURBO)-82, List of Diagnostic Trouble Code (DTC).> NOTE: In this case, it is not necessary to inspect DTC P0125. Replace thermostat. <Ref. to CO-23, Thermostat.> No Go to step 2.
CHECK ENGINE COOLING SYSTEM. NOTE: Check the following items. Thermostat open stuck Coolant level Coolant freeze Tire diameter
Is there a fault in engine cooling system?
Replace engine coolant temperature sensor. <Ref. to FU(DOHC TURBO)-29, Engine Coolant Temperature Sensor.>
EN(DOHC TURBO)-147
T: DTC P0131 FRONT OXYGEN (A/F) SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (LOW INPUT)
S088521B24
NOTE: For the diagnostic procedure, refer to DTC P0132. <Ref. to EN(DOHC TURBO)-150, DTC P0132 FRONT OXYGEN (A/F) SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (HIGH INPUT) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(DOHC TURBO)-148

MEMO:
EN(DOHC TURBO)-149
U: DTC P0132 FRONT OXYGEN (A/F) SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (HIGH INPUT)
S088521B25
S2M2187
EN(DOHC TURBO)-150

No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0031, P0032, P1131, P1134 or P1139? Yes Inspect DTC P0031, P0032, P1131, P1134 or P1139 using List of Diagnostic Trouble Code (DTC).<Ref. to EN(DOHC TURBO)-82, List of Diagnostic Trouble Code (DTC).> Go to step 3. No Go to step 2.
CHECK FRONT (A/F) OXYGEN SENSOR DATA. 1) Start engine. 2) While observing the Subaru Select Monitor or OBD-II general scan tool screen, warm-up the engine until coolant temperature is above 70C (158F). If the engine is already warmed-up, operate at idle speed for at least 1 minute. 3) Read data of front oxygen (A/F) sensor signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(DOHC TURBO)-36, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Instruction Manual. CHECK REAR OXYGEN SENSOR SIGNAL. 1) Race engine at speeds from idling to 5,000 rpm for a total of 5 cycles. NOTE: To increase engine speed to 5,000 rpm, slowly depress accelerator pedal, taking approximately 5 seconds, and quickly release accelerator pedal to decrease engine speed. 2) Operate the LED operation mode for engine. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the LED OPERATION MODE FOR ENGINE. <Ref. to EN(DOHC TURBO)-36, Subaru Select Monitor.> CHECK EXHAUST SYSTEM. Check exhaust system parts. NOTE: Check the following items. Loose installation of portions Damage (crack, hole etc.) of parts Looseness of front oxygen (A/F) sensor Looseness and ill fitting of parts between front oxygen (A/F) sensor and rear oxygen sensor
Go to step 4.
Does the LED of {Rear O2 Rich Signal} blink?
Repair poor contact in front oxygen (A/F) sensor and rear oxygen sensor connector.
Check rear oxygen sensor circuit. <Ref. to FU(DOHC TURBO)-44, Rear Oxygen Sensor.>
EN(DOHC TURBO)-151
V: DTC P0133 FRONT OXYGEN (A/F) SENSOR CIRCUIT SLOW RESPONSE

S088521B26
S2M2187
EN(DOHC TURBO)-152

No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0031, P0032, P0131, P0132, P1130, P1131, P1134 or P1139? Yes Inspect DTC P0031, P0032, P0131, P0132, P1130, P1131, P1134 or P1139 using List of Diagnostic Trouble Code (DTC). <Ref. to EN(DOHC TURBO)-82, List of Diagnostic Trouble Code (DTC).> NOTE: In this case, it is not necessary to inspect DTC P0133. Repair exhaust system. No Go to step 2.
Is there a fault in exhaust CHECK EXHAUST SYSTEM. system? NOTE: Check the following items. Loose installation of front portion of exhaust pipe onto cylinder heads Loose connection between front exhaust pipe and front catalytic converter Damage of exhaust pipe resulting in a hole
EN(DOHC TURBO)-153

S088521B28
W: DTC P0136 REAR OXYGEN SENSOR CIRCUIT MALFUNCTION

S2M2188
EN(DOHC TURBO)-154

No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0131 or P0132? Is the failure cause of P0131 or P0132 in the fuel system? Yes Go to step 2. No Go to step 3.
CHECK FAILURE CAUSE OF P0131 or P0132. Inspect DTC P0131 or P0132 using List of Diagnostic Trouble Code (DTC). <Ref. to EN(DOHC TURBO)-82, List of Diagnostic Trouble Code (DTC).>
Does the value fluctuate? CHECK REAR OXYGEN SENSOR DATA. 1) Warm-up the engine until engine coolant temperature is above 70C (158F), and keep the engine speed at 2,000 rpm to 3,000 rpm for two minutes. 2) Read data of rear oxygen sensor signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA SHOWN ON DISPLAY FOR ENGINE. <Ref. to EN(DOHC TURBO)-36, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Instruction Manual. Is the value fixed between CHECK REAR OXYGEN SENSOR DATA. Read data of rear oxygen sensor signal using 0.2 and 0.4 V? Subaru Select Monitor or OBD-II General Scan Tool. CHECK HARNESS BETWEEN ECM AND REAR OXYGEN SENSOR CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connectors from ECM and rear oxygen sensor. 3) Measure resistance of harness between ECM and rear oxygen sensor connector. Connector & terminal (B135) No. 26 (B19) No. 4: CHECK HARNESS BETWEEN REAR OXYGEN SENSOR AND ECM CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from rear oxygen sensor. 3) Turn ignition switch to ON. 4) Measure voltage between rear oxygen sensor harness connector and engine ground or chassis ground. Connector & terminal (B19) No. 3 (+) Engine ground ():
Check fuel system. NOTE: In this case, it is not necessary to inspect DTC P0136. Go to step 7.
Go to step 3.
Go to step 4.
Go to step 5.
Is the resistance more than Repair open cir3 ? cuit in harness between ECM and rear oxygen sensor connector.
Replace rear oxygen sensor. <Ref. to FU(DOHC TURBO)-44, Rear Oxygen Sensor.> Go to step 6.
Replace rear oxygen sensor. <Ref. to FU(DOHC TURBO)-44, Rear Oxygen Sensor.>
Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between rear oxygen sensor and ECM connector Poor contact in rear oxygen sensor connector Poor contact in ECM connector
EN(DOHC TURBO)-155
No. 7

Step CHECK EXHAUST SYSTEM. Check exhaust system parts. NOTE: Check the following items. Loose installation of portions Damage (crack, hole etc.) of parts Looseness and ill fitting of parts between front oxygen (A/F) sensor and rear oxygen sensor Check Is there a fault in exhaust system? Yes Repair or replace faulty parts. No Replace rear oxygen sensor. <Ref. to FU(DOHC TURBO)-44, Rear Oxygen Sensor.>
EN(DOHC TURBO)-156

MEMO:
EN(DOHC TURBO)-157

S088521B29
X: DTC P0139 REAR OXYGEN SENSOR CIRCUIT SLOW RESPONSE

S2M2188
EN(DOHC TURBO)-158

No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0136? Yes Inspect DTC P0136 using List of Diagnostic Trouble Code (DTC). <Ref. to EN(DOHC TURBO)-82, List of Diagnostic Trouble Code (DTC).> NOTE: In this case, it is not necessary to inspect DTC P0139.
No Replace rear oxygen sensor. <Ref. to FU(DOHC TURBO)-44, Rear Oxygen Sensor.>
EN(DOHC TURBO)-159

S088521B33
Y: DTC P0171 FUEL TRIM MALFUNCTION (A/F TOO LEAN)
NOTE: For the diagnostic procedure, refer to DTC P0172. <Ref. to EN(DOHC TURBO)-161, DTC P0172 FUEL TRIM MALFUNCTION (A/F TOO RICH) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(DOHC TURBO)-160
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) Z: DTC P0172 FUEL TRIM MALFUNCTION (A/F TOO RICH)
S088521B32
CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(DOHC TURBO)47, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(DOHC TURBO)-44, Inspection Mode.>.
No. 1 2 Step CHECK EXHAUST SYSTEM. Check Are there holes or loose bolts on exhaust system? CHECK AIR INTAKE SYSTEM. Are there holes, loose bolts or disconnection of hose on air intake system? Is fuel pressure between CHECK FUEL PRESSURE. 284 and 314 kPa (2.9 WARNING: Place NO FIRE signs near the working 3.2 kg/cm2, 41 46 psi)? area. Be careful not to spill fuel on the floor. 1) Release fuel pressure. (1) Disconnect connector from fuel pump relay. (2) Start the engine and run it until it stalls. (3) After the engine stalls, crank it for five more seconds. (4) Turn ignition switch to OFF. 2) Connect connector to fuel pump relay. 3) Disconnect fuel delivery hose from fuel filter, and connect fuel pressure gauge. 4) Install fuel filler cap. 5) Start the engine and idle while gear position is neutral. 6) Measure fuel pressure while disconnecting pressure regulator vacuum hose from intake manifold. WARNING: Before removing fuel pressure gauge, release fuel pressure. NOTE: If fuel pressure does not increase, squeeze fuel return hose 2 to 3 times, then measure fuel pressure again. Yes Repair exhaust system. Repair air intake system. Go to step 4. No Go to step 2. Go to step 3.
Repair the following items. Fuel pressure too high Clogged fuel return line or bent hose Fuel pressure too low Improper fuel pump discharge Clogged fuel supply line
EN(DOHC TURBO)-161
No. 4

Step Check Is fuel pressure between CHECK FUEL PRESSURE. 206 and 235 kPa (2.1 After connecting pressure regulator vacuum 2.4 kg/cm2, 30 34 psi)? hose, measure fuel pressure. WARNING: Before removing fuel pressure gauge, release fuel pressure. NOTE: If fuel pressure does not increase, squeeze fuel return hose 2 to 3 times, then measure fuel pressure again. If out of specification as measured at this step, check or replace pressure regulator and pressure regulator vacuum hose. Yes Go to step 5. No Repair the following items. Fuel pressure too high Faulty pressure regulator Clogged fuel return line or bent hose Fuel pressure too low Faulty pressure regulator Improper fuel pump discharge Clogged fuel supply line Replace engine coolant temperature sensor. <Ref. to FU(DOHC TURBO)-29, Engine Coolant Temperature Sensor.>
CHECK ENGINE COOLANT TEMPERATURE SENSOR. 1) Start the engine and warm-up completely. 2) Read data of engine coolant temperature sensor signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(DOHC TURBO)-36, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Instruction Manual. CHECK INTAKE MANIFOLD PRESSURE SENSOR. 1) Start the engine and warm-up engine until coolant temperature is greater than 60C (140F). 2) Place the shift lever in neutral position. 3) Turn A/C switch to OFF. 4) Turn all accessory switches to OFF. 5) Read data of intake manifold pressure sensor signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(DOHC TURBO)-36, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedure, refer to the OBD-II General Scan Tool Instruction Manual. Specification: Intake manifold absolute pressure Ignition ON 73.3 106.6 kPa (550 800 mmHg, 21.65 31.50 inHg) Idling 24.0 41.3 kPa (180 310 mmHg, 7.09 12.20 inHg)
Is temperature greater than Go to step 6. 60C (140F)?
Is the value within the specifications?
Go to step 7.
Replace mass air flow and intake manifold pressure sensor. <Ref. to FU(DOHC TURBO)-34, Mass Air Flow and Intake Air Temperature Sensor.>
EN(DOHC TURBO)-162

No. 7 Step CHECK INTAKE AIR TEMPERATURE SENSOR. 1) Start the engine and warm-up engine until coolant temperature is greater than 60C (140F). 2) Place the shift lever in neutral position. 3) Turn A/C switch to OFF. 4) Turn all accessory switches to OFF. 5) Open front hood. 6) Measure ambient temperature. 7) Read data of intake manifold pressure sensor signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(DOHC TURBO)-36, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedure, refer to the OBD-II General Scan Tool Instruction Manual. Check Is value obtained when ambient temperature is subtracted from intake air temperature greater than 10C (14F) and less than 50C (122F)? Yes Contact your Subaru distributor. NOTE: Inspection by DTM is required, because probable cause is deterioration of multiple parts.
No Check mass air flow and intake air temperature sensor. <Ref. to FU(DOHC TURBO)-34, Mass Air Flow and Intake Air Temperature Sensor.>
EN(DOHC TURBO)-163
AA: DTC P0244 WASTEGATE CONTROL SOLENOID VALVE MALFUNCTION (HIGH INPUT)
S088521H65
DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: Erroneous idling Engine stalls. Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(DOHC TURBO)47, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(DOHC TURBO)-44, Inspection Mode.>. WIRING DIAGRAM:
S2M2195
EN(DOHC TURBO)-164

No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0245 or P0246? Yes Inspect DTC P0245 or P0246 using List of Diagnostic Trouble Code (DTC). <Ref. to EN(DOHC TURBO)-82, List of Diagnostic Trouble Code (DTC).> NOTE: In this case, it is not necessary to inspect DTC P0121.
No Replace wastegate control solenoid valve. <Ref. to FU(DOHC TURBO)-41, Wastegate Control Solenoid Valve.>
EN(DOHC TURBO)-165
AB: DTC P0245 WASTEGATE CONTROL SOLENOID VALVE CIRCUIT LOW INPUT
S088521H66
DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: Erroneous idling CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(DOHC TURBO)47, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(DOHC TURBO)-44, Inspection Mode.>. WIRING DIAGRAM:
S2M2195
EN(DOHC TURBO)-166

No. 1 Step CHECK OUTPUT SIGNAL FROM ECM. 1) Turn ignition switch to ON. 2) Measure voltage between ECM and chassis ground. Connector & terminal (B137) No. 24 (+) Chassis ground ():
Check Yes No Is the voltage more than 10 Even if MIL lights Go to step 2. V? up, the circuit has returned to a normal condition at this time. Contact with your Subaru distributor. NOTE: Inspection by DTM is required, because probable cause is deterioration of multiple parts. Go to step 3. CHECK HARNESS BETWEEN WASTEGATE Is the resistance less than Repair ground 10 ? short circuit in CONTROL SOLENOID VALVE AND ECM harness between CONNECTOR. ECM and waste1) Turn ignition switch to OFF. gate control sole2) Disconnect connectors from wastegate noid valve concontrol solenoid valve and ECM. nector. 3) Measure resistance of harness between wastegate control solenoid valve connector and engine ground. Connector & terminal (B127) No. 1 Engine ground: Repair open cirCHECK HARNESS BETWEEN WASTEGATE Is the resistance less than Go to step 4. 1 ? cuit in harness CONTROL SOLENOID VALVE AND ECM between ECM CONNECTOR. and wastegate Measure resistance of harness between ECM control solenoid and wastegate control solenoid valve of harvalve connector. ness connector. NOTE: Connector & terminal In this case, (B137) No. 24 (B127) No. 1: repair the following: Open circuit in harness between ECM and wastegate control solenoid valve connector Is the resistance between Go to step 5. Replace wasteCHECK WASTEGATE CONTROL SOLE30 and 34 ? gate control soleNOID VALVE. noid valve. <Ref. 1) Remove wastegate control solenoid valve. to FU(DOHC 2) Measure resistance between purge control TURBO)-41, solenoid valve terminals. Wastegate Control Terminals Solenoid Valve.> No. 1 No. 2: Repair open cirCHECK POWER SUPPLY TO WASTEGATE Is the voltage more than 10 Go to step 6. V? cuit in harness CONTROL SOLENOID VALVE. between main 1) Turn ignition switch to ON. relay and waste2) Measure voltage between wastegate congate control soletrol solenoid valve and engine ground. noid valve conConnector & terminal nector. (B127) No. 2 (+) Engine ground ():
EN(DOHC TURBO)-167
No. 6

Step Check Is there poor contact in CHECK POOR CONTACT. Check poor contact in wastegate control sole- wastegate control solenoid valve connector? noid valve connector. Yes Repair poor contact in wastegate control solenoid valve connector. No Contact your Subaru distributor. NOTE: Inspection by DTM is required, because probable cause is deterioration of multiple parts.
EN(DOHC TURBO)-168

MEMO:
EN(DOHC TURBO)-169
AC: DTC P0246 WASTEGATE CONTROL SOLENOID VALVE CIRCUIT HIGH INPUT
S088521H67
DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: Erroneous idling CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(DOHC TURBO)47, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(DOHC TURBO)-44, Inspection Mode.>. WIRING DIAGRAM:
S2M2195
EN(DOHC TURBO)-170

No. 1 Step CHECK OUTPUT SIGNAL FROM ECM. 1) Turn ignition switch to ON. 2) Measure voltage between ECM and chassis ground. Connector & terminal (B137) No. 24 (+) Chassis ground (): CHECK POOR CONTACT. Check poor contact in ECM connector. Check Yes Is the voltage more than 10 Go to step 3. V? No Go to step 2.
CHECK HARNESS BETWEEN WASTEGATE Is the voltage more than 10 Repair battery V? short circuit in CONTROL SOLENOID VALVE AND ECM harness between CONNECTOR. ECM and waste1) Turn ignition switch to OFF. gate control sole2) Disconnect connector from wastegate connoid valve control solenoid valve. nector. After 3) Turn ignition switch to ON. repair, replace 4) Measure voltage between ECM and chasECM. <Ref. to sis ground. FU(DOHC Connector & terminal TURBO)-47, (B137) No. 24 (+) Chassis ground Engine Control (): Module.> Is the resistance less than Replace wasteCHECK WASTEGATE CONTROL SOLE1 ? gate control soleNOID VALVE. noid valve <Ref. 1) Turn ignition switch to OFF. to FU(DOHC 2) Measure resistance between wastegate TURBO)-41, control solenoid valve terminals. Wastegate Control Terminals Solenoid Valve.> No. 1 No. 2: and ECM <Ref. to FU(DOHC TURBO)-47, Engine Control Module.> CHECK POOR CONTACT. Is there poor contact in Repair poor conCheck poor contact in ECM connector. ECM connector? tact in ECM connector.
Replace ECM. <Ref. to FU(DOHC TURBO)-47, Engine Control Module.> Go to step 4.
Go to step 5.
EN(DOHC TURBO)-171

S088521B37
AD: DTC P0301 CYLINDER 1 MISFIRE DETECTED
NOTE: For the diagnostic procedure, refer to DTC P0304. <Ref. to EN(DOHC TURBO)-172, DTC P0304 CYLINDER 4 MISFIRE DETECTED , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
AE: DTC P0302 CYLINDER 2 MISFIRE DETECTED
S088521B38
AF: DTC P0303 CYLINDER 3 MISFIRE DETECTED
S088521B39
AG: DTC P0304 CYLINDER 4 MISFIRE DETECTED
S088521B40
DTC DETECTING CONDITION: Two consecutive driving cycles with fault Immediately at fault recognition (A misfire which could damage catalyst occurs.) TROUBLE SYMPTOM: Engine stalls. Erroneous idling Rough driving CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode < Ref. to EN(DOHC TURBO)47, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(DOHC TURBO)-44, Inspection Mode.>.
EN(DOHC TURBO)-172

S2M2186
EN(DOHC TURBO)-173
RHD MODEL
EN0965
EN(DOHC TURBO)-174

No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. Yes Inspect DTC P0106, P0107, P0108, P0117, P0118 or P0125 using List of Diagnostic Trouble Code (DTC). <Ref. to EN(DOHC TURBO)-82, List of Diagnostic Trouble Code (DTC).> NOTE: In this case, it is not necessary to inspect DTC P0301, P0302, P0303 and P0304. Is the voltage more than 10 Go to step 7. V? Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0106, P0107, P0108, P0117, P0118 or P0125? No Go to step 2.
CHECK OUTPUT SIGNAL FROM ECM. 1) Turn ignition switch to ON. 2) Measure voltage between ECM connector and chassis ground on faulty cylinders. Connector & terminal #1 (B137) No. 1 (+) Chassis ground (): #2 (B136) No. 6 (+) Chassis ground (): #3 (B136) No. 5 (+) Chassis ground (): #4 (B136) No. 4 (+) Chassis ground (): CHECK HARNESS BETWEEN FUEL INJECTOR AND ECM CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from fuel injector on faulty cylinders. 3) Disconnect connector from ECM. 4) Measure voltage between ECM connector and engine ground on faulty cylinders. Connector & terminal #1 (E5) No. 1 Engine ground: #2 (E16) No. 1 Engine ground: #3 (E6) No. 1 Engine ground: #4 (E17) No. 1 Engine ground: CHECK HARNESS BETWEEN FUEL INJECTOR AND ECM CONNECTOR. Measure resistance of harness connector between ECM connector and fuel injector on faulty cylinders. Connector & terminal #1 (B137) No. 1 (E5) No. 1: #2 (B136) No. 6 (E16) No. 1: #3 (B136) No. 5 (E6) No. 1: #4 (B136) No. 4 (E17) No. 1:
Go to step 3.
Repair ground short circuit in harness between fuel injector and ECM connector.
Go to step 4.
Go to step 5.
Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ECM and fuel injector connector Poor contact in coupling connector
EN(DOHC TURBO)-175
No. 5

Step CHECK FUEL INJECTOR. Measure resistance between fuel injector terminals on faulty cylinder. Terminals No. 1 No. 2: CHECK POWER SUPPLY LINE. 1) Turn ignition switch to ON. 2) Measure voltage between fuel injector and engine ground on faulty cylinders. Connector & terminal #1 (E5) No. 2 (+) Engine ground (): #2 (E16) No. 2 (+) Engine ground (): #3 (E6) No. 2 (+) Engine ground (): #4 (E17) No. 2 (+) Engine ground (): No Replace faulty fuel injector. <Ref. to FU(DOHC TURBO)-37, Fuel Injector.> Is the voltage more than 10 Repair poor con- Repair harness V? tact in all connec- and connector. tors in fuel injector NOTE: In this case, circuit. repair the following: Open circuit in harness between main relay and fuel injector connector on faulty cylinders Poor contact in coupling connector Poor contact in main relay connector Poor contact in fuel injector connector on faulty cylinders Go to step 8. CHECK HARNESS BETWEEN FUEL INJEC- Is the voltage more than 10 Repair battery V? short circuit in TOR AND ECM CONNECTOR. harness between 1) Turn ignition switch to OFF. ECM and fuel 2) Disconnect connector from fuel injector on injector. After faulty cylinder. repair, replace 3) Turn ignition switch to ON. ECM. <Ref. to 4) Measure voltage between ECM connector FU(DOHC and chassis ground on faulty cylinders. TURBO)-47, Connector & terminal Engine Control #1 (B137) No. 1 (+) Chassis ground Module.> (): #2 (B136) No. 6 (+) Chassis ground (): #3 (B136) No. 5 (+) Chassis ground (): #4 (B136) No. 4 (+) Chassis ground (): Go to step 9. Is the resistance less than Replace faulty CHECK FUEL INJECTOR. 1 ? fuel injector <Ref. 1) Turn ignition switch to OFF. to FU(DOHC 2) Measure resistance between fuel injector TURBO)-37, Fuel terminals on faulty cylinder. Injector.> and Terminals ECM <Ref. to No. 1 No. 2: FU(DOHC TURBO)-47, Engine Control Module.> CHECK INSTALLATION OF CAMSHAFT Is camshaft position sensor Tighten camshaft Go to step 10. POSITION SENSOR/CRANKSHAFT POSIor crankshaft position sen- position sensor or TION SENSOR. sor loosely installed? crankshaft position sensor. Check Yes Is the resistance between 5 Go to step 6. and 20 ?
EN(DOHC TURBO)-176

No. 10 Step CHECK CRANKSHAFT SPROCKET. Remove timing belt cover. Check Is crankshaft sprocket rusted or does it have broken teeth?
11
Is timing belt dislocated CHECK INSTALLATION CONDITION OF from its proper position? TIMING BELT. Turn crankshaft using ST, and align alignment mark on crankshaft sprocket with alignment mark on cylinder block. ST 499987500 CRANKSHAFT SOCKET CHECK FUEL LEVEL. Is the fuel meter indication higher than the Lower level?
12
13
14
CHECK STATUS OF CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL). 1) Clear memory using Subaru Select Monitor. <Ref. to EN(DOHC TURBO)-47, Clear Memory Mode.> 2) Start engine, and drive the vehicle more than 10 minutes. CHECK CAUSE OF MISFIRE DIAGNOSED.
Is the MIL coming on or blinking?
Yes No Go to step 11. Replace crankshaft sprocket. <Ref. to ME(DOHC TURBO)-57, Crankshaft Sprocket.> Repair installation Go to step 12. condition of timing belt. <Ref. to ME(DOHC TURBO)-48, Timing Belt Assembly.> Go to step 13. Replenish fuel so fuel meter indication is higher than the Lower level. After replenishing fuel, Go to step 13. Go to step 15. Go to step 14.
Was the cause of misfire Finish diagnostics diagnosed when the engine operation, if the is running? engine has no abnormality. NOTE: Ex. Remove spark plug cord, etc.
Repair poor contact. NOTE: In this case, repair the following: Poor contact in ignitor connector Poor contact in ignition coil connector Poor contact in fuel injector connector on faulty cylinders Poor contact in ECM connector Poor contact in coupling connector
EN(DOHC TURBO)-177
No. 15

Step CHECK AIR INTAKE SYSTEM. Check Is there a fault in air intake system? Yes No Go to step 16. Repair air intake system. NOTE: Check the following items: Are there air leaks or air suction caused by loose or dislocated nuts and bolts? Are there cracks or any disconnection of hoses? Go to step 21. Go to step 17.
16
17
CHECK MISFIRE SYMPTOM. 1) Turn ignition switch to ON. 2) Read diagnostic trouble code (DTC). Subaru Select Monitor <Ref. to EN(DOHC TURBO)-36, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Operation Manual. NOTE: Perform diagnosis according to the items listed below. CHECK DIAGNOSTIC TROUBLE CODE (DTC) ON DISPLAY.
Does the Subaru Select Monitor or OBD-II general scan tool indicate only one DTC?
18
19
20
21
ONLY ONE CYLINDER
Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0301 and P0302? Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0303 and P0304? Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0301 and P0303? Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0302 and P0304? Is there a fault in that cylinder?
Go to step 22.
Go to step 18.
Go to step 23.
Go to step 19.
Go to step 24.
Go to step 20.
Go to step 25.
Go to step 26.
Repair or replace faulty parts. NOTE: Check the following items. Spark plug Fuel injector Compression ratio
Go to DTC P0171 and P0172. <Ref. to EN(DOHC TURBO)-160, DTC P0171 FUEL TRIM MALFUNCTION (A/F TOO LEAN) -, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(DOHC TURBO)-178

No. 22 Step GROUP OF #1 AND #2 CYLINDERS Check Are there faults in #1 and #2 cylinders? Yes Repair or replace faulty parts. NOTE: Check the following items. Spark plugs Fuel injectors Ignition coil Compression ratio If no abnormal is discovered, check for IGNITION CONTROL SYSTEM of #1 and #2 cylinders side. <Ref. to EN(DOHC TURBO)-72, IGNITION CONTROL SYSTEM, Diagnostics for Engine Starting Failure.> Repair or replace faulty parts. NOTE: Check the following items. Spark plugs Fuel injectors Ignition coil If no abnormal is discovered, check for 16. D: IGNITION CONTROL SYSTEM of #3 and #4 cylinders side. <Ref. to EN(DOHC TURBO)-72, IGNITION CONTROL SYSTEM, Diagnostics for Engine Starting Failure.> Repair or replace faulty parts. NOTE: Check the following items. Spark plugs Fuel injectors Skipping timing belt teeth
No Go to DTC P0171 and P0172. <Ref. to EN(DOHC TURBO)-160, DTC P0171 FUEL TRIM MALFUNCTION (A/F TOO LEAN) -, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
23
Go to DTC P0171 and P0172. <Ref. to EN(DOHC TURBO)-160, DTC P0171 FUEL TRIM MALFUNCTION (A/F TOO LEAN) -, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
24
Go to DTC P0171 and P0172. <Ref. to EN(DOHC TURBO)-160, DTC P0171 FUEL TRIM MALFUNCTION (A/F TOO LEAN) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(DOHC TURBO)-179
No. 25

Step GROUP OF #2 AND #4 CYLINDERS Check Are there faults in #2 and #4 cylinders? No Go to DTC P0171 and P0172. <Ref. to EN(DOHC TURBO)-160, DTC P0171 FUEL TRIM MALFUNCTION (A/F TOO LEAN) , Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Go to DTC P0171 Repair or replace and P0172. <Ref. faulty parts. NOTE: to EN(DOHC Check the followTURBO)-160, ing items. DTC P0171 FUEL TRIM MAL- Spark plugs Fuel injectors FUNCTION (A/F Compression TOO LEAN) , Diagnostic Proce- ratio dure with Diagnostic Trouble Code (DTC).> Yes Repair or replace faulty parts. NOTE: Check the following items. Spark plugs Fuel injectors Compression ratio Skipping timing belt teeth
26
CYLINDER AT RANDOM
Is the engine idle rough?
EN(DOHC TURBO)-180

MEMO:
EN(DOHC TURBO)-181

S088521F94
AH: DTC P0327 KNOCK SENSOR CIRCUIT LOW INPUT

EN0975
EN(DOHC TURBO)-182

No. 1 Step Check Yes Is the resistance more than Go to step 2. CHECK HARNESS BETWEEN KNOCK 700 k? SENSOR AND ECM CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM. 3) Measure resistance between ECM harness connector and chassis ground. Connector & terminal (B135) No. 4 Chassis ground:
No Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between knock sensor and ECM connector Poor contact in knock sensor connector Poor contact in coupling connector Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between knock sensor and ECM connector Poor contact in knock sensor connector Poor contact in coupling connector Tighten knock sensor installation bolt securely.
Replace knock sensor. <Ref. to FU(DOHC TURBO)-32, Knock Sensor.>
EN(DOHC TURBO)-183

S088521F95
AI: DTC P0328 KNOCK SENSOR CIRCUIT HIGH INPUT

EN0975
EN(DOHC TURBO)-184

No. 1 Step CHECK HARNESS BETWEEN KNOCK SENSOR AND ECM CONNECTOR. Measure resistance of harness between ECM connector and chassis ground. Connector & terminal (B135) No. 4 Chassis ground: CHECK KNOCK SENSOR. 1) Disconnect connector from knock sensor. 2) Measure resistance between knock sensor connector terminal and engine ground. Terminal No. 2 Engine ground: Check Is the resistance less than 400 k? Yes Go to step 2. No Go to step 3.
Is the voltage more than 2 CHECK INPUT SIGNAL FOR ECM. V? 1) Connect connectors to ECM and knock sensor. 2) Turn ignition switch to ON. 3) Measure voltage between ECM and chassis ground. Connector & terminal (B135) No. 4 (+) Chassis ground ():
Repair ground short circuit in harness between knock sensor connector and ECM connector. NOTE: The harness between both connectors is shielded. Repair short circuit of harness together with shield. Even if MIL lights Repair poor conup, the circuit has tact in ECM conreturned to a nor- nector. mal condition at this time. (However, the possibility of poor contact still remains.) NOTE: In this case, repair the following: Poor contact in knock sensor connector Poor contact in ECM connector Poor contact in coupling connector Replace knock sensor. <Ref. to FU(DOHC TURBO)-32, Knock Sensor.>
EN(DOHC TURBO)-185
AJ: DTC P0335 CRANKSHAFT POSITION SENSOR CIRCUIT MALFUNCTION

S088521B42
DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: Engine stalls. Failure of engine to start CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(DOHC TURBO)47, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(DOHC TURBO)-44, Inspection Mode.>. WIRING DIAGRAM:
EN0976
EN(DOHC TURBO)-186

No. 1 Step Check Yes Is the resistance more than Repair harness CHECK HARNESS BETWEEN CRANK100 k? and connector. SHAFT POSITION SENSOR AND ECM NOTE: CONNECTOR. In this case, 1) Turn ignition switch to OFF. repair the follow2) Disconnect connector from crankshaft posiing: tion sensor. Open circuit in 3) Measure resistance of harness between harness between crankshaft position sensor connector and crankshaft posiengine ground. tion sensor and Connector & terminal ECM connector (E10) No. 1 Engine ground: Poor contact in ECM connector Poor contact in coupling connector Is the resistance less than Repair ground CHECK HARNESS BETWEEN CRANK10 ? short circuit in SHAFT POSITION SENSOR AND ECM harness between CONNECTOR. crankshaft posiMeasure resistance of harness between tion sensor and crankshaft position sensor connector and ECM connector. engine ground. NOTE: Connector & terminal The harness (E10) No. 1 Engine ground: between both connectors are shielded. Repair ground short circuit in harness together with shield. Is the resistance less than Go to step 4. CHECK HARNESS BETWEEN CRANK5 ? SHAFT POSITION SENSOR AND ECM CONNECTOR. Measure resistance of harness between crankshaft position sensor connector and engine ground. Connector & terminal (E10) No. 2 Engine ground: No Go to step 2.
Go to step 3.
CHECK CONDITION OF CRANKSHAFT POSITION SENSOR.
Go to step 5.
CHECK CRANKSHAFT POSITION SENSOR. Is the resistance between 1 Repair poor conand 4 k? tact in crankshaft 1) Remove crankshaft position sensor. position sensor 2) Measure resistance between connector connector. terminals of crankshaft position sensor. Terminals No. 1 No. 2:
Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between crankshaft position sensor and ECM connector Poor contact in ECM connector Poor contact in coupling connector Tighten crankshaft position sensor installation bolt securely. Replace crankshaft position sensor. <Ref. to FU(DOHC TURBO)-30, Crankshaft Position Sensor.>
EN(DOHC TURBO)-187
AK: DTC P0336 CRANKSHAFT POSITION SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM

S088521B43
DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: Engine stalls. Failure of engine to start CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(DOHC TURBO)47, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(DOHC TURBO)-44, Inspection Mode.>. WIRING DIAGRAM:
EN0976
EN(DOHC TURBO)-188

No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0335? Yes Inspect DTC P0335 using List of Diagnostic Trouble Code (DTC). <Ref. to EN(DOHC TURBO)-82, List of Diagnostic Trouble Code (DTC).> Go to step 3. No Go to step 2.
CHECK CONDITION OF CRANKSHAFT POSITION SENSOR. Turn ignition switch to OFF. CHECK CRANKSHAFT SPROCKET. Remove front belt cover.
Are crankshaft sprocket Replace crankteeth cracked or damaged? shaft sprocket. <Ref. to FU(DOHC TURBO)-30, Crankshaft Position Sensor.> Is timing belt dislocated Repair installation CHECK INSTALLATION CONDITION OF from its proper position? condition of timing TIMING BELT. belt. <Ref. to Turn crankshaft using ST, and align alignment ME(DOHC mark on crankshaft sprocket with alignment TURBO)-48, Timmark on cylinder block. ing Belt AssemST 499987500 CRANKSHAFT SOCKET bly.>
Tighten crankshaft position sensor installation bolt securely. Go to step 4.
Replace crankshaft position sensor. <Ref. to FU(DOHC TURBO)-30, Crankshaft Position Sensor.>
EN(DOHC TURBO)-189
AL: DTC P0340 CAMSHAFT POSITION SENSOR CIRCUIT MALFUNCTION

S088521B44
DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: Engine stalls. Failure of engine to start CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode < Ref. to EN(DOHC TURBO)47, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(DOHC TURBO)-44, Inspection Mode.>. WIRING DIAGRAM:
EN0977
EN(DOHC TURBO)-190

No. 1 Check Yes Is the resistance more than Repair harness 100 k? and connector. NOTE: In this case, repair the following: Open circuit in harness between camshaft position sensor and ECM connector Poor contact in ECM connector Poor contact in coupling connector CHECK HARNESS BETWEEN CAMSHAFT Is the resistance less than Repair ground 10 ? short circuit in POSITION SENSOR AND ECM CONNECharness between TOR. camshaft position Measure resistance of harness between camsensor and ECM shaft position sensor connector and engine connector. ground. NOTE: Connector & terminal The harness (E15) No. 1 Engine ground: between both connectors are shielded. Repair ground short circuit in harness together with shield. CHECK HARNESS BETWEEN CAMSHAFT Is the resistance less than Go to step 4. 5 ? POSITION SENSOR AND ECM CONNECTOR. Measure resistance of harness between camshaft position sensor connector and engine ground. Connector & terminal (E15) No. 2 Engine ground: Step CHECK HARNESS BETWEEN CAMSHAFT POSITION SENSOR AND ECM CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from camshaft position sensor. 3) Measure resistance of harness between camshaft position sensor connector and engine ground. Connector & terminal (E15) No. 1 Engine ground: No Go to step 2.
Go to step 3.
Go to step 5.
CHECK CAMSHAFT POSITION SENSOR. 1) Remove camshaft position sensor. 2) Measure resistance between connector terminals of camshaft position sensor. Terminals No. 1 No. 2:
Is the resistance between 1 Repair poor conand 4 k? tact in camshaft position sensor connector.
Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between camshaft position sensor and ECM connector Poor contact in ECM connector Poor contact in coupling connector Tighten camshaft position sensor installation bolt securely. Replace camshaft position sensor. <Ref. to FU(DOHC TURBO)-31, Camshaft Position Sensor.>
EN(DOHC TURBO)-191
AM: DTC P0341 CAMSHAFT POSITION SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM

S088521B45
DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: Engine stalls. Failure of engine to start CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode < Ref. to EN(DOHC TURBO)47, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(DOHC TURBO)-44, Inspection Mode.>. WIRING DIAGRAM:
EN0977
EN(DOHC TURBO)-192

No. 1 Yes Inspect DTC P0340 using List of Diagnostic Trouble Code (DTC). <Ref. to EN(DOHC TURBO)-82, List of Diagnostic Trouble Code (DTC).> CHECK HARNESS BETWEEN CAMSHAFT Is the resistance more than Repair harness 100 k? and connector. POSITION SENSOR AND ECM CONNECNOTE: TOR. In this case, 1) Turn ignition switch to OFF. repair the follow2) Disconnect connector from camshaft posiing: tion sensor. Open circuit in 3) Measure resistance of harness between harness between camshaft position sensor connector and camshaft position engine ground. sensor and ECM Connector & terminal connector (E15) No. 1 Engine ground: Poor contact in ECM connector Poor contact in coupling connector CHECK HARNESS BETWEEN CAMSHAFT Is the resistance less than Repair ground 10 ? short circuit in POSITION SENSOR AND ECM CONNECharness between TOR. camshaft position Measure resistance of harness between camsensor and ECM shaft position sensor connector and engine connector. ground. NOTE: Connector & terminal The harness (E15) No. 1 Engine ground: between both connectors are shielded. Repair ground short circuit in harness together with shield. CHECK HARNESS BETWEEN CAMSHAFT Is the resistance less than Go to step 5. 5 ? POSITION SENSOR AND ECM CONNECTOR. Measure resistance of harness between camshaft position sensor connector and engine ground. Connector & terminal (E15) No. 2 Engine ground: Step CHECK ANY OTHER DTC ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0340? No Go to step 2.
Go to step 3.
Go to step 4.
Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between camshaft position sensor and ECM connector Poor contact in ECM connector Poor contact in coupling connector
EN(DOHC TURBO)-193
No. 5

Step CHECK CONDITION OF CAMSHAFT POSITION SENSOR. Check Is the camshaft position sensor installation bolt tightened securely? No Tighten camshaft position sensor installation bolt securely. Is the resistance between 1 Go to step 7. Replace camshaft and 4 k? position sensor. <Ref. to FU(DOHC TURBO)-31, Camshaft Position Sensor.> Is the camshaft position Go to step 8. Tighten camshaft sensor installation bolt position sensor tightened securely? installation bolt securely. Are camshaft sprocket Replace camshaft Go to step 9. teeth cracked or damaged? sprocket. <Ref. to ME(DOHC TURBO)-56, Camshaft Sprocket.> Is timing belt dislocated Repair installation Replace camshaft from its proper position? condition of timing position sensor. <Ref. to belt. <Ref. to FU(DOHC ME(DOHC TURBO)-48, Tim- TURBO)-31, Camshaft Position ing Belt AssemSensor.> bly.> Yes Go to step 6.
CHECK CAMSHAFT POSITION SENSOR. 1) Remove camshaft position sensor. 2) Measure resistance between connector terminals of camshaft position sensor. Terminals No. 1 No. 2: CHECK CONDITION OF CAMSHAFT POSITION SENSOR. Turn ignition switch to OFF. CHECK CAMSHAFT SPROCKET. Remove front belt cover. <Ref. to ME(DOHC TURBO)-47, Belt Cover.>
CHECK INSTALLATION CONDITION OF TIMING BELT. Turn camshaft using ST, and align alignment mark on camshaft sprocket with alignment mark on timing belt cover LH. ST 499207400 CAMSHAFT SPROCKET WRENCH
EN(DOHC TURBO)-194

MEMO:
EN(DOHC TURBO)-195
AN: DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD

S088521B46
DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: Engine stalls. Idle mixture is out of specifications. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(DOHC TURBO)47, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(DOHC TURBO)-44, Inspection Mode.>. WIRING DIAGRAM:
S2M2196
EN(DOHC TURBO)-196

No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0031, P0032, P0131, P0132, P0133, P1130, P1131, P1134, P1139, P0037, P0038, P0136 and P0139? Yes No Go to step 2. Inspect the relevant DTC using List of Diagnostic Trouble Code (DTC). <Ref. to EN(DOHC TURBO)-82, List of Diagnostic Trouble Code (DTC).> NOTE: In this case, it is not necessary to inspect DTC P0420. Repair or replace Go to step 3. exhaust system. <Ref. to EX(DOHC TURBO)-2, General Description.>
CHECK EXHAUST SYSTEM. Check for gas leaks or air suction caused by loose or dislocated nuts and bolts, and open hole at exhaust pipes. NOTE: Check the following positions. Between cylinder head and front exhaust pipe Between front exhaust pipe and front catalytic converter Between front catalytic converter and rear catalytic converter CHECK REAR CATALYTIC CONVERTER. Separate rear catalytic converter from rear exhaust pipe.
Is there damage at rear face of rear catalyst?
CHECK FRONT CATALYTIC CONVERTER. Remove front catalytic converter.
Is there damage at rear face or front face of front catalyst?
Replace front catalytic converter <Ref. to EC(DOHC TURBO)-3, Front Catalytic Converter.> and rear catalytic converter. <Ref. to EC(DOHC TURBO)-4, Rear Catalytic Converter.> Replace front catalytic converter. <Ref. to EC(DOHC TURBO)-3, Front Catalytic Converter.>
Go to step 4.
EN(DOHC TURBO)-197
AO: DTC P0444 EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CONTROL VALVE CIRCUIT LOW INPUT
S088521G47
DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: Erroneous idling CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode < Ref. to EN(DOHC TURBO)47, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(DOHC TURBO)-44, Inspection Mode.>. WIRING DIAGRAM:
S2M2197
EN(DOHC TURBO)-198

No. 1 Step CHECK OUTPUT SIGNAL FROM ECM. 1) Turn ignition switch to ON. 2) Measure voltage between ECM and chassis ground. Connector & terminal (B137) No. 16 (+) Chassis ground (): Check Yes No Is the voltage more than 10 Even if MIL lights Go to step 2. V? up, the circuit has returned to a normal condition at this time. Contact your Subaru distributor. NOTE: Inspection by DTM is required, because probable cause is deterioration of multiple parts. Go to step 3. Is the resistance less than Repair ground 10 ? short circuit in harness between ECM and purge control solenoid valve connector.
CHECK HARNESS BETWEEN PURGE CONTROL SOLENOID VALVE AND ECM CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connectors from purge control solenoid valve and ECM. 3) Measure resistance of harness between purge control solenoid valve connector and engine ground. Connector & terminal (E4) No. 2 Engine ground: Is the resistance less than CHECK HARNESS BETWEEN PURGE 1 ? CONTROL SOLENOID VALVE AND ECM CONNECTOR. Measure resistance of harness between ECM and purge control solenoid valve of harness connector. Connector & terminal (B137) No. 16 (E4) No. 2:
Go to step 4.
CHECK PURGE CONTROL SOLENOID VALVE. 1) Remove purge control solenoid valve. 2) Measure resistance between purge control solenoid valve terminals. Terminals No. 1 No. 2: CHECK POWER SUPPLY TO PURGE CONTROL SOLENOID VALVE. 1) Turn ignition switch to ON. 2) Measure voltage between purge control solenoid valve and engine ground. Connector & terminal (E4) No. 1 (+) Engine ground ():
Go to step 5.
Repair open circuit in harness between ECM and purge control solenoid valve connector. NOTE: In this case, repair the following: Open circuit in harness between ECM and purge control solenoid valve connector Poor contact in coupling connector Replace purge control solenoid valve. <Ref. to EC(DOHC TURBO)-7, Purge Control Solenoid Valve.> Repair open circuit in harness between main relay and purge control solenoid valve connector.
EN(DOHC TURBO)-199
No. 6

Step CHECK POOR CONTACT. Check poor contact in purge control solenoid valve connector. Check Is there poor contact in purge control solenoid valve connector? Yes Repair poor contact in purge control solenoid valve connector. No Contact your Subaru distributor. NOTE: Inspection by DTM is required, because probable cause is deterioration of multiple parts.
EN(DOHC TURBO)-200

MEMO:
EN(DOHC TURBO)-201
AP: DTC P0445 EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH INPUT
S088521G48
DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: Erroneous idling CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode < Ref. to EN(DOHC TURBO)47, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(DOHC TURBO)-44, Inspection Mode.>. WIRING DIAGRAM:
S2M2197
EN(DOHC TURBO)-202

No. 1 Step CHECK OUTPUT SIGNAL FROM ECM. 1) Turn ignition switch to OFF. 2) Connect test mode connector at the lower portion of instrument panel (on the driver s side), to the side of the center console box. 3) Turn ignition switch to ON. 4) While operating purge control solenoid valve, measure voltage between ECM and chassis ground. NOTE: Purge control solenoid valve operation can be executed using Subaru Select Monitor. For procedure, refer to Compulsory Valve Operation Check Mode. <Ref. to EN(DOHC TURBO)-48, Compulsory Valve Operation Check Mode.> Connector & terminal (B137) No. 16 (+) Chassis ground (): CHECK OUTPUT SIGNAL FROM ECM. 1) Turn ignition switch to ON. 2) Measure voltage between ECM and chassis ground. Connector & terminal (B137) No. 16 (+) Chassis ground (): CHECK POOR CONTACT. Check poor contact in ECM connector. Check Does voltage change between 0 and 10 V? Yes Go to step 2.
No Even if MIL light up, the circuit has returned to a normal condition at this time. In this case, repair poor contact in ECM connector.
Go to step 3.
CHECK HARNESS BETWEEN PURGE CONTROL SOLENOID VALVE AND ECM CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from purge control solenoid valve. 3) Turn ignition switch to ON. 4) Measure voltage between ECM and chassis ground. Connector & terminal (B137) No. 16 (+) Chassis ground (): CHECK PURGE CONTROL SOLENOID VALVE. 1) Turn ignition switch to OFF. 2) Measure resistance between purge control solenoid valve terminals. Terminals No. 1 No. 2:
Is the voltage more than 10 Repair battery V? short circuit in harness between ECM and purge control solenoid valve connector. After repair, replace ECM. <Ref. to FU(DOHC TURBO)-47, Engine Control Module.> Go to step 6. Is the resistance less than Replace purge 1 ? control solenoid valve <Ref. to EC(DOHC TURBO)-7, Purge Control Solenoid Valve.> and ECM <Ref. to FU(DOHC TURBO)-47, Engine Control Module.>
Replace ECM. <Ref. to FU(DOHC TURBO)-47, Engine Control Module.> Go to step 5.
EN(DOHC TURBO)-203
No. 6

Step CHECK POOR CONTACT. Check poor contact in ECM connector. Check Is there poor contact in ECM connector? Yes Repair poor contact in ECM connector. No Replace ECM. <Ref. to FU(DOHC TURBO)-47, Engine Control Module.>
EN(DOHC TURBO)-204

MEMO:
EN(DOHC TURBO)-205
AQ: DTC P0461 FUEL LEVEL SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM

S088521B54
DTC DETECTING CONDITION: Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(DOHC TURBO)47, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(DOHC TURBO)-44, Inspection Mode.>.
EN(DOHC TURBO)-206

WIRING DIAGRAM:
S2M2198
EN(DOHC TURBO)-207
No. 1

Step CHECK ANY OTHER DTC ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0462 or P0463? Yes Inspect DTC P0462 or P0463 using List of Diagnostic Trouble Code (DTC). <Ref. to EN(DOHC TURBO)-82, List of Diagnostic Trouble Code (DTC).> NOTE: In this case, it is not necessary to inspect this trouble. No Replace fuel level sensor <Ref. to FU(DOHC TURBO)-62, Fuel Level Sensor.> and fuel sub level sensor <Ref. to FU(DOHC TURBO)-63, Fuel Sub Level Sensor.>
EN(DOHC TURBO)-208

MEMO:
EN(DOHC TURBO)-209

S088521B55
AR: DTC P0462 FUEL LEVEL SENSOR CIRCUIT LOW INPUT

EN(DOHC TURBO)-210

WIRING DIAGRAM:
S2M2198
EN(DOHC TURBO)-211
No. 1

Step CHECK SPEEDOMETER AND TACHOMETER OPERATION IN COMBINATION METER. Check Does speedometer and tachometer operate normally? Yes Go to step 2. No Repair or replace combination meter. <Ref. to IDI-4, Combination Meter System.> Go to step 3.
CHECK INPUT SIGNAL FOR ECM. 1) Turn ignition switch to ON. (Engine OFF) 2) Measure voltage between ECM connector and chassis ground. Connector & terminal (B135) No. 25 (+) Chassis ground (): CHECK INPUT SIGNAL FOR ECM. (USING SUBARU SELECT MONITOR.) Read data of fuel level sensor signal using Subaru Select Monitor. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(DOHC TURBO)-36, Subaru Select Monitor.>
Is the voltage less than 0.12 V?
Go to step 6.
Does the value change less than 0.12 V by shaking harness and connector of ECM while monitoring the value with Subaru Select Monitor?
CHECK INPUT VOLTAGE OF ECM. 1) Turn ignition switch to OFF. 2) Separate fuel tank cord connector (R57) and rear wiring harness connector (R15). 3) Turn ignition switch to ON. 4) Measure voltage of harness between ECM connector and chassis ground. Connector & terminal (B135) No. 25 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND COMBINATION METER. 1) Turn ignition switch to OFF. 2) Disconnect connector from connector (i10), (i12) and ECM connector. 3) Measure resistance between ECM and chassis ground. Connector & terminal (B135) No. 25 Chassis ground:
Go to step 4.
Even if MIL lights up, the circuit has returned to a normal condition at this time. A temporary poor contact of the connector may be the cause. NOTE: In this case, repair the following: Poor contact in combination meter connector Poor contact in ECM connector Poor contact in coupling connectors Go to step 7.
Repair ground short circuit in harness between ECM and combination meter connector.
EN(DOHC TURBO)-212

No. 6 Step Check Is the resistance less than CHECK HARNESS BETWEEN ECM AND 10 ? COMBINATION METER. Measure resistance between ECM and combination meter connector. Connector & terminal (B135) No. 25 (i11) No. 1: Yes Repair or replace combination meter. <Ref. to IDI-4, Combination Meter System.>
No Repair open circuit between ECM and combination meter connector. NOTE: In this case, repair the following: Poor contact in coupling connector Repair ground short circuit in fuel tank cord.
10
CHECK FUEL TANK CORD. 1) Turn ignition switch to OFF. 2) Disconnect connector from fuel sub level sensor. 3) Measure resistance between fuel sub level sensor and chassis ground. Connector & terminal (R59) No. 1 Chassis ground: CHECK FUEL TANK CORD. 1) Disconnect connector from fuel pump assembly. 2) Measure resistance between fuel pump assembly and chassis ground. Connector & terminal (R59) No. 2 Chassis ground: CHECK FUEL LEVEL SENSOR. 1) Remove fuel pump assembly. <Ref. to FU(DOHC TURBO)-60, Fuel Pump.> 2) Measure resistance between fuel level sensor and terminals with its float set to the full position. Terminals No. 3 No. 5: CHECK FUEL SUB LEVEL SENSOR. 1) Remove fuel sub level sensor. <Ref. to FU(DOHC TURBO)-63, Fuel Sub Level Sensor.> 2) Measure resistance between fuel sub level sensor and terminals with its float set to the full position. Terminals No. 1 No. 2:
Repair ground short circuit in fuel tank cord.
Go to step 10.
Replace fuel level sensor.
Repair poor contact in harness between ECM and combination meter connector.
Replace fuel sub level sensor.
EN(DOHC TURBO)-213

S088521B56
AS: DTC P0463 FUEL LEVEL SENSOR CIRCUIT HIGH INPUT

CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode<Ref. to EN(DOHC TURBO)47, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(DOHC TURBO)-44, Inspection Mode.>.
EN(DOHC TURBO)-214

WIRING DIAGRAM:
S2M2198
EN(DOHC TURBO)-215
No. 1

Step CHECK SPEEDOMETER AND TACHOMETER OPERATION IN COMBINATION METER. Check Does speedometer and tachometer operate normally? Yes Go to step 2. No Repair or replace combination meter. <Ref. to IDI-4, Combination Meter System.> Even if MIL lights up, the circuit has returned to a normal condition at this time. A temporary poor contact of the connector may be the cause. NOTE: In this case, repair the following: Poor contact in fuel pump connector Poor contact in coupling connector Repair battery short circuit between ECM and combination meter connector.
CHECK INPUT SIGNAL FOR ECM. 1) Turn ignition switch to ON. (Engine OFF) 2) Measure voltage between ECM connector and chassis ground. Connector & terminal (B135) No. 25 (+) Chassis ground ():
Go to step 3.
CHECK INPUT VOLTAGE OF ECM. 1) Turn ignition switch to OFF. 2) Disconnect combination meter connector (i10) and ECM connector. 3) Turn ignition switch to ON. 4) Measure voltage of harness between ECM and chassis ground. Connector & terminal (B135) No. 25 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND FUEL TANK CORD. 1) Turn ignition switch to OFF. 2) Separate fuel tank cord connector (R57) and rear wiring harness connector (R15). 3) Measure resistance between ECM and fuel tank cord. Connector & terminal (B135) No. 25 (R15) No. 2: CHECK HARNESS BETWEEN FUEL TANK CORD AND CHASSIS GROUND. Measure resistance between fuel tank cord and chassis ground. Connector & terminal (R15) No. 6 Chassis ground:
Go to step 4.
Go to step 5.
Repair open circuit between ECM and fuel tank cord.
Go to step 6.
Repair open circuit between fuel tank cord and chassis ground. NOTE: In this case, repair the following: Poor contact in coupling connectors
EN(DOHC TURBO)-216

No. 6 Step CHECK FUEL TANK CORD. 1) Disconnect connector from fuel level sensor. 2) Measure resistance between fuel level sensor and coupling connector. Connector & terminal (R57) No. 6 (R58) No. 5: CHECK FUEL TANK CORD. 1) Disconnect connector from fuel sub level sensor. 2) Measure resistance between fuel level sensor and fuel sub level sensor. Connector & terminal (R58) No. 3 (R59) No. 2: CHECK FUEL TANK CORD. Measure resistance between fuel sub level sensor and coupling connector. Connector & terminal (R57) No. 2 (R59) No. 1: CHECK FUEL LEVEL SENSOR. 1) Remove fuel pump assembly. <Ref. to FU(DOHC TURBO)-60, Fuel Pump.> 2) While moving fuel level sensor float up and down, measure resistance between fuel level sensor terminals. Terminals No. 3 No. 5: CHECK FUEL SUB LEVEL SENSOR. 1) Remove fuel sub level sensor. <Ref. to FU(DOHC TURBO)-63, Fuel Sub Level Sensor.> 2) While moving fuel sub level sensor float up and down, measure resistance between fuel sub level sensor terminals. Terminals No. 1 No. 2: Check Is the resistance less than 10 ? Yes Go to step 7.
No Repair open circuit between coupling connector and fuel level sensor.
Go to step 8.
Repair open circuit between fuel level sensor and fuel sub level sensor.
Repair open circuit between coupling connector and fuel sub level sensor. Is the resistance more than Replace fuel level Go to step 10. 53 ? sensor. <Ref. to FU(DOHC TURBO)-62, Fuel Level Sensor.>
Go to step 9.
10
Is the resistance more than Replace fuel sub 45 ? level sensor. <Ref. to FU(DOHC TURBO)-63, Fuel Sub Level Sensor.>
Replace combination meter. <Ref. to IDI-15, Combination Meter Assembly.>
EN(DOHC TURBO)-217

S088521G01
AT: DTC P0464 FUEL LEVEL SENSOR INTERMITTENT INPUT

CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode < Ref. to EN(DOHC TURBO)47, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(DOHC TURBO)-44, Inspection Mode.>.
EN(DOHC TURBO)-218

WIRING DIAGRAM:
S2M2198
EN(DOHC TURBO)-219
No. 1

Step CHECK ANY OTHER DTC ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0462 or P0463? Yes Inspect DTC P0462 or P0463 using List of Diagnostic Trouble Code (DTC). <Ref. to EN(DOHC TURBO)-82, List of Diagnostic Trouble Code (DTC).> Go to step 3. No Go to step 2.
CHECK FUEL LEVEL SENSOR. 1) Remove fuel pump assembly. <Ref. to FU(DOHC TURBO)-60, Fuel Pump.> 2) While moving fuel level sensor float up and down, make sure that the resistance between fuel level sensor terminals changes smoothly. Terminals No. 3 No. 5: CHECK FUEL SUB LEVEL SENSOR. 1) Remove fuel sub level sensor. <Ref. to FU(DOHC TURBO)-63, Fuel Sub Level Sensor.> 2) While moving fuel sub level sensor float up and down, make sure that the resistance between fuel level sensor terminals changes smoothly. Terminals No. 1 No. 2:
Does the resistance change smoothly between approx. 0.5 and approx. 52 ?
Replace fuel level sensor. <Ref. to FU(DOHC TURBO)-62, Fuel Level Sensor.>
Does the resistance change smoothly between approx. 0.5 and approx. 44 ?
Repair poor contact in ECM, combination meter and coupling connectors.
Replace fuel sub level sensor. <Ref. to FU(DOHC TURBO)-63, Fuel Sub Level Sensor.>
EN(DOHC TURBO)-220

MEMO:
EN(DOHC TURBO)-221

S088521B57
AU: DTC P0480 COOLING FAN RELAY 1 CIRCUIT LOW INPUT

CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode < Ref. to EN(DOHC TURBO)47, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(DOHC TURBO)-44, Inspection Mode.>.
EN(DOHC TURBO)-222

WIRING DIAGRAM:
S2M2199
EN(DOHC TURBO)-223
No. 1

Step CHECK OUTPUT SIGNAL FROM ECM. 1) Turn ignition switch to OFF. 2) Connect test mode connector at the lower portion of instrument panel (on the driver s side), to the side of the center console box. 3) Turn ignition switch to ON. 4) While operating radiator fan relay, measure voltage between ECM terminal and ground. NOTE: Radiator fan relay operation can be executed using Subaru Select Monitor. For procedure, refer to Compulsory Valve Operation Check Mode. < Ref. to EN(DOHC TURBO)-36, Subaru Select Monitor.> Connector & terminal (B137) No. 17 (+) Chassis ground (): CHECK GROUND SHORT CIRCUIT IN RADIATOR MAIN FAN RELAY CONTROL CIRCUIT. 1) Turn ignition switch to OFF. 2) Disconnect connectors from ECM. 3) Measure resistance of harness between ECM connector and chassis ground. Connector & terminal (B137) No. 17 Chassis ground: CHECK POWER SUPPLY FOR RELAY. 1) Remove main fan relay from A/C relay holder. 2) Turn ignition switch to ON. 3) Measure voltage between fuse and relay box (F/B) connector and chassis ground. Connector & terminal (F66) No. 27 (+) Chassis ground (): CHECK MAIN FAN RELAY. 1) Turn ignition switch to OFF. 2) Remove main fan relay. 3) Measure resistance of main fan relay. Terminal No. 26 No. 25: CHECK MAIN FAN RELAY. 1) Connect battery to terminals No. 27 and No. 28 of main fan relay. 2) Measure resistance of main fan relay. Terminal No. 26 No. 25: CHECK OPEN CIRCUIT IN MAIN FAN RELAY CONTROL CIRCUIT. Measure resistance of harness between ECM and main fan relay connector. Connector & terminal (B137) No. 17 (F66) No. 27: Check Does voltage change between 0 and 10 V? Yes Repair poor contact in ECM connector. No Go to step 2.
Repair ground short circuit in radiator fan relay control circuit.
Go to step 3.
Repair open circuit in harness between ignition switch and fuse and relay box (F/B) connector.
Go to step 6.
Go to step 7.
Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ECM and main fan relay connector Poor contact in coupling connector
EN(DOHC TURBO)-224

No. 7 Step CHECK POOR CONTACT. Check poor contact in ECM or main fan relay connector. Check Yes Repair poor conIs there poor contact in ECM or main fan relay contact in ECM or main fan relay nector? connector.
No Contact your Subaru distributor.
EN(DOHC TURBO)-225

S088521B58
AV: DTC P0483 COOLING FAN FUNCTION PROBLEM

DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: Occurrence of noise Overheating
CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode < Ref. to EN(DOHC TURBO)47, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(DOHC TURBO)-44, Inspection Mode.>. NOTE: If the vehicle, with the engine idling, is placed very close to a wall or another vehicle, preventing normal cooling function, the OBD system may detect malfunction.
EN(DOHC TURBO)-226

WIRING DIAGRAM:
S2M2199
EN(DOHC TURBO)-227
No. 1

Step CHECK ANY OTHER DTC ON DISPLAY. Check Is there any other DTC on display? Yes Inspect the relevant DTC using List of Diagnostic Trouble Code (DTC). <Ref. to EN(DOHC TURBO)-82, List of Diagnostic Trouble Code (DTC).> No Check radiator fan, fan motor and thermostat. <Ref. to CO-8, Radiator Main Fan System.> and <Ref. to CO-11, Radiator Sub Fan System.> If thermostat is stuck, replace thermostat.
EN(DOHC TURBO)-228

MEMO:
EN(DOHC TURBO)-229

S088521B59
AW: DTC P0500 VEHICLE SPEED SENSOR MALFUNCTION

S2M2200
No. 1
Check Is the transmission type AT?
Yes Go to step 2.
No Go to step 3.
EN(DOHC TURBO)-230

Yes No Go to step 3. Check front vehicle speed sensor signal circuit. <Ref. to AT-58, TROUBLE CODE 33 FRONT VEHICLE SPEED SENSOR , Diagnostic Procedure with Trouble Code.> Does speedometer operate Go to step 4. Check speedomnormally? eter and vehicle speed sensor. <Ref. to IDI-17, Speedometer.> and <Ref. to AT-32, Front Vehicle Speed Sensor.> and <Ref. to AT-36, Rear Vehicle Speed Sensor.> and <Ref. to AT-37, Torque Converter Turbine Speed Sensor.> Is the resistance less than Repair poor con- Repair harness 10 ? tact in ECM con- and connector. nector. NOTE: In this case, repair the following: Open circuit in harness between ECM and combination meter connector Poor contact in ECM connector Poor contact in combination meter connector Poor contact in coupling connector
EN(DOHC TURBO)-231
AX: DTC P0506 IDLE CONTROL SYSTEM RPM LOWER THAN EXPECTED
S088521B61
DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: Engine is difficult to start. Engine does not start. Erroneous idling Engine stalls. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode < Ref. to EN(DOHC TURBO)47, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(DOHC TURBO)-44, Inspection Mode.>. WIRING DIAGRAM:
S2M2201
EN(DOHC TURBO)-232

No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0508 or P0509 Yes Inspect DTC P0505 or P1505 using List of Diagnostic Trouble Code (DTC). <Ref. to EN(DOHC TURBO)-82, List of Diagnostic Trouble Code (DTC).> NOTE: In this case, it is not necessary to inspect DTC P0506. Go to step 4. No Go to step 2.
CHECK IDLE AIR CONTROL SOLENOID VALVE. 1) Turn ignition switch to OFF. 2) Remove idle air control solenoid valve from throttle body. <Ref. to FU(DOHC TURBO)-36, REMOVAL, Idle Air Control Solenoid Valve.> 3) Using an air gun, force air into idle air control solenoid valve by-pass air inlet. Confirm that forced air subsequently escapes from both main air passage and assist air passage. CHECK IDLE AIR CONTROL SOLENOID VALVE DUTY RATIO. 1) Turn ignition switch to ON. 2) Start engine, and warm-up the engine. 3) Turn all accessory switches to OFF. 4) Read data of idle air control solenoid valve duty ratio using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedures, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(DOHC TURBO)-36, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Instruction Manual. CHECK BY-PASS AIR LINE. 1) Turn ignition switch to OFF. 2) Remove idle air control solenoid valve from throttle body. <Ref. to FU(DOHC TURBO)-36, REMOVAL, Idle Air Control Solenoid Valve.> 3) Remove throttle body to intake manifold. <Ref. to FU(DOHC TURBO)-14, REMOVAL, Throttle Body.> 4) Using an air gun, force air into solenoid valve installation area and throttle valve interior. Confirm that forced air subsequently escapes from both these areas.
Does air flow out?
Replace idle air control solenoid valve. <Ref. to FU(DOHC TURBO)-36, Idle Air Control Solenoid Valve.> After replace, Go to step 3. END.
Is the value more than 60%?
Go to step 4.
Does air flow out?
Replace idle air control solenoid valve. <Ref. to FU(DOHC TURBO)-36, Idle Air Control Solenoid Valve.>
Replace throttle body. <Ref. to FU(DOHC TURBO)-14, Throttle Body.>
EN(DOHC TURBO)-233
AY: DTC P0507 IDLE CONTROL SYSTEM RPM HIGHER THAN EXPECTED
S088521B62
DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: Engine keeps running at higher revolution than specified idling revolution. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode < Ref. to EN(DOHC TURBO)47, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(DOHC TURBO)-44, Inspection Mode.>. WIRING DIAGRAM:
S2M2201
EN(DOHC TURBO)-234

No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0508 or P0509 Yes Inspect DTC P0508 or P0509 using List of Diagnostic Trouble Code (DTC). <Ref. to EN(DOHC TURBO)-82, List of Diagnostic Trouble Code (DTC).> NOTE: In this case, it is not necessary to inspect DTC P0507. Go to step 3. No Go to step 2.
CHECK THROTTLE CABLE.
Does throttle cable have play for adjustment?
Is there a fault in air intake CHECK AIR INTAKE SYSTEM. system? 1) Turn ignition switch to ON. 2) Start engine, and idle it. 3) Check the following items. Loose installation of intake manifold, idle air control solenoid valve and throttle body Cracks of intake manifold gasket, idle air control solenoid valve gasket and throttle body gasket Disconnections of vacuum hoses
Repair air suction and leaks.
Adjust throttle cable. <Ref. to SP-12, INSTALLATION, Accelerator Control Cable.> Replace idle air control solenoid valve. <Ref. to FU(DOHC TURBO)-36, Idle Air Control Solenoid Valve.>
EN(DOHC TURBO)-235

S088521H68
AZ: DTC P0508 IDLE CONTROL SYSTEM CIRCUIT LOW INPUT

DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: Erroneous idling Engine stalls. Engine breathing
S2M2201
EN(DOHC TURBO)-236

No. 1 Step CHECK OUTPUT SIGNAL FROM ECM. 1) Turn ignition switch to ON. 2) Measure voltage between ECM and chassis ground. Connector & terminal (B136) No. 10 (+) Chassis ground (): CHECK POWER SUPPLY TO IDLE AIR CONTROL SOLENOID VALVE. 1) Turn ignition switch to OFF. 2) Disconnect connector from idle air control solenoid valve. 3) Turn ignition switch to ON. 4) Measure voltage between idle air control solenoid valve and engine ground. Connector & terminal (E7) No. 2 (+) Engine ground (): Check Is the voltage more than 3 V? Yes Repair poor contact in ECM connector. No Go to step 2.
CHECK HARNESS BETWEEN ECM AND IDLE AIR CONTROL SOLENOID VALVE CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM. 3) Measure resistance of harness between ECM and idle air control solenoid valve connector. Connector & terminal (B136) No. 10 (E7) No. 1:
Go to step 4.
CHECK HARNESS BETWEEN ECM AND IDLE AIR CONTROL SOLENOID VALVE CONNECTOR. Measure resistance of harness between ECM and chassis ground. Connector & terminal (B136) No. 10 Chassis ground: CHECK GROUND CIRCUIT OF IDLE AIR CONTROL SOLENOID VALVE. Measure resistance of harness between idle air control solenoid valve connector and engine ground. Connector & terminal (E7) No. 3 Engine ground: CHECK POOR CONTACT. Check poor contact in ECM and idle air control solenoid valve connectors.
Repair ground short circuit in harness between ECM and idle air control solenoid valve connector. Go to step 6.
Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between idle air control solenoid valve and main relay connector Poor contact in coupling connector Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ECM and idle air control solenoid valve connector Poor contact in coupling connector Go to step 5.
Is there poor contact in Repair poor conECM and idle air control tact in ECM and solenoid valve connectors? idle air control solenoid valve connectors.
Repair open circuit in harness between idle air control solenoid valve connector and engine ground terminal. Replace idle air control solenoid valve. <Ref. to FU(DOHC TURBO)-36, Idle Air Control Solenoid Valve.>
EN(DOHC TURBO)-237

S088521H10
BA: DTC P0509 IDLE CONTROL SYSTEM CIRCUIT HIGH INPUT

DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: Erroneous idling Engine stalls. Engine breathing
S2M2201
EN(DOHC TURBO)-238

No. 1 Step CHECK THROTTLE CABLE. Check Does throttle cable have play for adjustment? Yes Go to step 2.
No Adjust throttle cable. <Ref. to SP-12, INSTALLATION, Accelerator Control Cable.> Go to step 4.
CHECK OUTPUT SIGNAL FROM ECM. 1) Turn ignition switch to ON. 2) Measure voltage between ECM and chassis ground. Connector & terminal (B136) No. 10 (+) Chassis ground (): CHECK OUTPUT SIGNAL FROM ECM. 1) Turn ignition switch to OFF. 2) Disconnect connector from idle air control solenoid valve. 3) Turn ignition switch to ON. 4) Measure voltage between ECM and chassis ground. Connector & terminal (B136) No. 10 (+) Chassis ground ():
CHECK OUTPUT SIGNAL FROM ECM. Measure voltage between ECM and chassis ground. Connector & terminal (B136) No. 10 (+) Chassis ground ():
Is the voltage more than 10 Repair battery V? short circuit in harness between ECM and idle air control solenoid valve connector. After repair, replace ECM. <Ref. to FU(DOHC TURBO)-47, Engine Control Module.> Repair battery Does the voltage change more than 10 V by shaking short circuit in harness between harness and connector of ECM and idle air ECM while monitoring the control solenoid value with voltage meter? valve connector. After repair, replace ECM. <Ref. to FU(DOHC TURBO)-47, Engine Control Module.>
Replace idle air control solenoid valve <Ref. to FU(DOHC TURBO)-36, Idle Air Control Solenoid Valve.> and ECM <Ref. to FU(DOHC TURBO)-47, Engine Control Module.>. Contact your Subaru distributor. NOTE: Inspection by DTM is required, because probable cause is deterioration of multiple parts.
EN(DOHC TURBO)-239

S088521G02
BB: DTC P0512 STARTER SWITCH CIRCUIT HIGH INPUT

S2M2181
EN(DOHC TURBO)-240

No. 1 Step Check CHECK OPERATION OF STARTER MOTOR. Does starter motor operate when ignition switch to NOTE: Place the inhibitor switch in each position. (AT ON? model) Yes Repair battery short circuit in starter motor circuit.
No Check starter motor circuit. <Ref. to EN(DOHC TURBO)-64, STARTER MOTOR CIRCUIT, Diagnostics for Engine Starting Failure.>
EN(DOHC TURBO)-241
BC: DTC P0545 EXHAUST GAS TEMPERATURE SENSOR CIRCUIT LOW INPUT
S088521H69
S2M2202
EN(DOHC TURBO)-242

No. 1 Step CHECK CURRENT DATA. 1) Start engine. 2) Read data of exhaust gas temperature sensor signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(DOHC TURBO)-36, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Instruction Manual. CHECK HARNESS BETWEEN EXHAUST GAS TEMPERATURE SENSOR AND ECM CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from exhaust gas temperature sensor. 3) Turn ignition switch to ON. 4) Read data of exhaust gas temperature sensor signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(DOHC TURBO)-36, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Instruction Manual. Check Is the value greater than 1200C (2192F)? Yes Go to step 2.
No Repair poor contact. NOTE: In this case, repair the following: Poor contact in exhaust gas temperature sensor Poor contact in ECM Poor contact in joint connector Repair ground short circuit in harness between exhaust gas temperature sensor and ECM connector.
Is the value less than 372C (702F)?
Replace exhaust gas temperature sensor. <Ref. to FU(DOHC TURBO)-46, Exhaust Temperature Sensor.>
EN(DOHC TURBO)-243
BD: DTC P0546 EXHAUST GAS TEMPERATURE SENSOR CIRCUIT HIGH INPUT
S088521H70
S2M2202
EN(DOHC TURBO)-244

No. 1 Step CHECK CURRENT DATA. 1) Start engine. 2) Read data of exhaust gas temperature sensor signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(DOHC TURBO)-36, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Instruction Manual. CHECK HARNESS BETWEEN EXHAUST GAS TEMPERATURE SENSOR AND ECM CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from exhaust gas temperature sensor. 3) Measure voltage between exhaust gas temperature sensor connector and engine ground. Connector & terminal (B279) No. 1 (+) Engine ground (): CHECK HARNESS BETWEEN EXHAUST GAS TEMPERATURE SENSOR AND ECM CONNECTOR. 1) Turn ignition switch to ON. 2) Measure voltage between exhaust gas temperature sensor connector and engine ground. Connector & terminal (B279) No. 1 (+) Engine ground (): CHECK HARNESS BETWEEN EXHAUST GAS TEMPERATURE SENSOR AND ECM CONNECTOR. Measure voltage between exhaust gas temperature sensor connector and engine ground. Connector & terminal (B279) No. 1 (+) Engine ground (): Check Is the value less than 372C (702F)? Yes Go to step 2.
No Repair poor contact. NOTE: In this case, repair the following: Poor contact in exhaust gas temperature sensor Poor contact in ECM Poor contact in joint connector
Go to step 3. Is the voltage more than 10 Repair battery V? short circuit in harness between ECM and exhaust gas temperature sensor connector.
Go to step 4. Is the voltage more than 10 Repair battery V? short circuit in harness between ECM and exhaust gas temperature sensor connector.
Go to step 5.
Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ECM and exhaust gas temperature sensor connector Poor contact in exhaust gas temperature sensor connector Poor contact in ECM connector Poor contact in joint connector
EN(DOHC TURBO)-245
No. 5

Step CHECK HARNESS BETWEEN EXHAUST GAS TEMPERATURE SENSOR AND ECM CONNECTOR. 1) Turn ignition switch to OFF. 2) Measure resistance of harness between exhaust gas temperature sensor connector and engine ground. Connector & terminal (B279) No. 2 Engine ground: Check Is the resistance less than 5 ? Yes Replace exhaust gas temperature sensor. <Ref. to FU(DOHC TURBO)-46, Exhaust Temperature Sensor.> No Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ECM and exhaust gas temperature sensor connector Poor contact in exhaust gas temperature sensor connector Poor contact in ECM connector Poor contact in joint connector
EN(DOHC TURBO)-246

MEMO:
EN(DOHC TURBO)-247
BE: DTC P0604 INTERNAL CONTROL MODULE MEMORY CHECK SUM ERROR
S088521G03
DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: Engine does not start. Engine stalls. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(DOHC TURBO)47, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(DOHC TURBO)-44, Inspection Mode.>.
EN(DOHC TURBO)-248

S2M2182
EN(DOHC TURBO)-249
RHD MODEL
S2M2183
No. 1
Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0604?
Yes Replace ECM. <Ref. to FU(DOHC TURBO)-47, Engine Control Module.>
EN(DOHC TURBO)-250

MEMO:
EN(DOHC TURBO)-251

S088521B64
BF: DTC P0703 BRAKE SWITCH INPUT MALFUNCTION

CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(DOHC TURBO)47, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(DOHC TURBO)-44, OPERATION, Inspection Mode.>. WIRING DIAGRAM:
S2M2203
No. 1
Step CHECK OPERATION OF BRAKE LIGHT.
Check Yes Does brake light come on Go to step 2. when depressing the brake pedal?
No Repair or replace brake light circuit.
EN(DOHC TURBO)-252

No. 2 Step CHECK HARNESS BETWEEN TCM AND BRAKE LIGHT SWITCH CONNECTOR. 1) Disconnect connectors from TCM and brake light switch. 2) Measure resistance of harness between TCM and brake light switch connector. Connector & terminal Without cruise control (B55) No. 12 (B64) No. 2: With cruise control (B55) No. 12 (B65) No. 3: Check Is the resistance less than 1 ? Yes Go to step 3.
No Repair or replace harness and connector. NOTE: In this case, repair the following: Open circuit in harness between TCM and brake light switch connector Poor contact in TCM connector Poor contact in brake light switch connector Repair ground short circuit in harness between TCM and brake light switch connector. Adjust or replace brake light switch. <Ref. to LI-31, STOP LIGHT SWITCH, INSPECTION, Stop Light System.> Adjust or replace brake light switch. <Ref. to LI-31, STOP LIGHT SWITCH, INSPECTION, Stop Light System.> Replace TCM. <Ref. to AT-48, Transmission Control Module (TCM).>
CHECK HARNESS BETWEEN TCM AND BRAKE LIGHT SWITCH CONNECTOR. Measure resistance of harness between TCM and chassis ground. Connector & terminal (B55) No. 12 Chassis ground: CHECK INPUT SIGNAL FOR TCM. 1) Connect connectors to TCM and brake light switch. 2) Measure voltage between TCM and chassis ground. Connector & terminal (B55) No. 12 (+) Chassis ground ():
Is the voltage less than 1 V Go to step 5. when releasing the brake pedal?
Is the voltage more than 10 Go to step 6. CHECK INPUT SIGNAL FOR TCM. V when depressing the Measure voltage between TCM and chassis brake pedal? ground. Connector & terminal (B55) No. 12 (+) Chassis ground ():
CHECK POOR CONTACT. Check poor contact in TCM connector.
EN(DOHC TURBO)-253

S088521B70
BG: DTC P0731 GEAR 1 INCORRECT RATIO
NOTE: For the diagnostic procedure, refer to DTC P0734. <Ref. to EN(DOHC TURBO)-255, DTC P0734 GEAR 4 INCORRECT RATIO , Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
BH: DTC P0732 GEAR 2 INCORRECT RATIO
S088521B71
BI: DTC P0733 GEAR 3 INCORRECT RATIO
S088521B72
EN(DOHC TURBO)-254
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) BJ: DTC P0734 GEAR 4 INCORRECT RATIO
S088521B73
DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: Shift point too high or too low; engine brake not effected in 3 range; excessive shift shock; excessive tight corner braking CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(DOHC TURBO)47, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(DOHC TURBO)-44, OPERATION, Inspection Mode.>. WIRING DIAGRAM:
No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. Check Is there any other DTC on display? Yes No Go to step 2. Inspect relevant DTC using List of Diagnostic Trouble Code (DTC). <Ref. to EN(DOHC TURBO)-82, List of Diagnostic Trouble Code (DTC).> Repair or replace Go to step 3. throttle position sensor circuit.
CHECK THROTTLE POSITION SENSOR CIRCUIT. Check throttle position sensor circuit. <Ref. to AT-50, TROUBLE CODE 31 THROTTLE POSITION SENSOR , Diagnostic Procedure with Trouble Code.> CHECK FRONT VEHICLE SPEED SENSOR CIRCUIT. Check front vehicle speed sensor circuit. <Ref. to AT-58, TROUBLE CODE 33 FRONT VEHICLE SPEED SENSOR , Diagnostic Procedure with Trouble Code.> CHECK TORQUE CONVERTER TURBINE SPEED SENSOR CIRCUIT. Check torque converter turbine speed sensor circuit. <Ref. to AT-64, TROUBLE CODE 36 TORQUE CONVERTER TURBINE SPEED SENSOR , Diagnostic Procedure with Trouble Code.> CHECK POOR CONTACT. Check poor contact in TCM connector. CHECK MECHANICAL TROUBLE. Check mechanical trouble in automatic transmission.
Is there any trouble in vehicle speed sensor 2 circuit?
Repair or replace vehicle speed sensor 2 circuit.
Go to step 4.
Go to step 5.
Go to step 6.
EN(DOHC TURBO)-255
BK: DTC P0741 TORQUE CONVERTER CLUTCH SYSTEM MALFUNCTION

S088521G04
DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: No lock-up (after engine warm-up) No shift or excessive tight corner braking CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(DOHC TURBO)47, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(DOHC TURBO)-44, OPERATION, Inspection Mode.>.
No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. Check Is there any other DTC on display? Yes No Go to step 2. Inspect the relevant DTC using List of Diagnostic Trouble Code (DTC). <Ref. to EN(DOHC TURBO)-82, List of Diagnostic Trouble Code (DTC).> Repair or replace Go to step 3. lock-up duty solenoid circuit.
CHECK LOCK-UP DUTY SOLENOID CIRCUIT. Check lock-up duty solenoid circuit. <Ref. to AT-96, TROUBLE CODE 77 LOCK-UP DUTY SOLENOID , Diagnostic Procedure with Trouble Code.> CHECK THROTTLE POSITION SENSOR CIRCUIT. Check throttle position sensor circuit. <Ref. to AT-50, TROUBLE CODE 31 THROTTLE POSITION SENSOR , Diagnostic Procedure with Trouble Code.> CHECK TORQUE CONVERTER TURBINE SPEED SENSOR CIRCUIT. Check torque converter turbine speed sensor circuit. <Ref. to AT-64, TROUBLE CODE 36 TORQUE CONVERTER TURBINE SPEED SENSOR , Diagnostic Procedure with Trouble Code.> CHECK ENGINE SPEED INPUT CIRCUIT. Check engine speed input circuit. <Ref. to AT-42, TROUBLE CODE 11 ENGINE SPEED SIGNAL , Diagnostic Procedure with Trouble Code.> CHECK INHIBITOR SWITCH CIRCUIT. Check inhibitor switch circuit. <Ref. to AT-122, CHECK INHIBITOR SWITCH., Diagnostic Procedure for No-trouble Code.> CHECK BRAKE LIGHT SWITCH CIRCUIT. Check brake light switch circuit. <Ref. to AT-111, CHECK BRAKE SWITCH., Diagnostic Procedure for No-trouble Code.>
Is there any trouble in lock-up duty solenoid circuit?
Repair or replace throttle position sensor circuit.
Go to step 4.
Go to step 5.
Is there any trouble in engine speed input circuit?
Repair or replace engine speed input circuit.
Go to step 6.
Is there any trouble in inhibitor switch circuit?
Repair or replace inhibitor switch circuit. Repair or replace brake light switch circuit.
Go to step 7.
Is there any trouble in brake light switch circuit?
Go to step 8.
EN(DOHC TURBO)-256

No. 8 Step CHECK ATF TEMPERATURE SENSOR CIRCUIT. Check ATF temperature sensor circuit. <Ref. to AT-46, TROUBLE CODE 27 - ATF TEMPERATURE SENSOR , Diagnostic Procedure with Trouble Code.> CHECK POOR CONTACT. Check poor contact in TCM connector. CHECK MECHANICAL TROUBLE. Check mechanical trouble in automatic transmission. Check Yes Is there any trouble in ATF Repair or replace temperature sensor circuit? ATF temperature sensor circuit. No Go to step 9.
10
Go to step 10.
EN(DOHC TURBO)-257
BL: DTC P1086 TUMBLE GENERATOR VALVE #2 (LH) POSITION SENSOR CIRCUIT LOW INPUT
S088521H71
S2M2204
EN(DOHC TURBO)-258

RHD MODEL
S2M2205
EN(DOHC TURBO)-259
No. 1

Step Check Is the value less than 0.1 CHECK CURRENT DATA. V? 1) Start engine. 2) Read data of tumble generator valve position sensor signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(DOHC TURBO)-36, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Instruction Manual. Yes Go to step 2. No Even if MIL lights up, the circuit has returned to a normal condition at this time. A temporary poor contact of the connector may be the cause. NOTE: In this case, repair the following: Poor contact in throttle position sensor connector Poor contact in ECM connector Poor contact in coupling connector Go to step 3.
CHECK INPUT SIGNAL FOR ECM. Measure voltage between ECM connector and chassis ground while tumble generator valve is fully closed. Connector & terminal (B135) No. 9 (+) Chassis ground (): CHECK INPUT SIGNAL FOR ECM. Measure voltage between ECM connector and chassis ground. Connector & terminal (B135) No. 9 (+) Chassis ground ():
Go to step 4.
Go to step 6.
EN(DOHC TURBO)-260

No. 6 Step Check Is the voltage more than CHECK HARNESS BETWEEN ECM AND 4.5 V? TUMBLE GENERATOR VALVE POSITION SENSOR CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connectors from tumble generator valve position sensor. 3) Turn ignition switch to ON. 4) Measure voltage between tumble generator valve position sensor connector and engine ground. Connector & terminal (E50) No. 1 (+) Engine ground (): Yes Go to step 7.
No Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between tumble generator valve position sensor and ECM connector Poor contact in tumble generator valve position sensor connector Poor contact in ECM connector Poor contact in coupling connector Poor contact in joint connector Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between tumble generator valve position sensor and ECM connector Poor contact in ECM connector Poor contact in tumble generator valve position sensor connector Poor contact in coupling connector Go to step 9.
CHECK HARNESS BETWEEN ECM AND TUMBLE GENERATOR VALVE POSITION SENSOR CONNECTOR. 1) Turn ignition switch to OFF. 2) Measure resistance of harness between ECM connector and tumble generator valve position sensor connector. Connector & terminal (B135) No. 13 (E50) No. 3:
Go to step 8.
CHECK HARNESS BETWEEN ECM AND TUMBLE GENERATOR VALVE POSITION SENSOR CONNECTOR. Measure resistance of harness between tumble generator valve position sensor connector and engine ground. Connector & terminal (E50) No. 3 Engine ground: CHECK POOR CONTACT. Check poor contact in tumble generator valve position sensor connector.
Repair ground short circuit in harness between tumble generator valve position sensor and ECM connector. Repair poor contact in tumble generator valve position sensor connector.
Is there poor contact in tumble generator valve position sensor connector?
Replace tumble generator valve assembly. <Ref. to FU(DOHC TURBO)-40, Tumble Generator Valve Assembly.>
EN(DOHC TURBO)-261
BM: DTC P1087 TUMBLE GENERATOR VALVE #2 (LH) POSITION SENSOR CIRCUIT HIGH INPUT
S088521H72
S2M2204
EN(DOHC TURBO)-262

RHD MODEL
S2M2205
EN(DOHC TURBO)-263
No. 1

Step Check Is the value more than 4.9 CHECK CURRENT DATA. V? 1) Start engine. 2) Read data of tumble generator valve position sensor signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(DOHC TURBO)-36, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Instruction Manual. Yes Go to step 2. No Even if MIL lights up, the circuit has returned to a normal condition at this time. A temporary poor contact of the connector may be the cause. NOTE: In this case, repair the following: Poor contact in tumble generator valve position sensor connector Poor contact in ECM connector Poor contact in coupling connector Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between tumble generator valve position sensor and ECM connector Poor contact in coupling connector Poor contact in joint connector Replace tumble generator valve assembly. <Ref. to FU(DOHC TURBO)-40, Tumble Generator Valve Assembly.>
CHECK HARNESS BETWEEN TUMBLE GENERATOR VALVE POSITION SENSOR AND ECM CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from tumble generator valve position sensor. 3) Measure resistance of harness between tumble generator valve position sensor connector and engine ground. Connector & terminal (E50) No. 2 Engine ground:
Go to step 3.
Is the voltage more than CHECK HARNESS BETWEEN TUMBLE 4.9 V? GENERATOR VALVE POSITION SENSOR AND ECM CONNECTOR. 1) Turn ignition switch to ON. 2) Measure voltage between tumble generator valve position sensor connector and engine ground. Connector & terminal (E50) No. 3 (+) Engine ground ():
Repair battery short circuit in harness between tumble generator valve position sensor and ECM connector. After repair, replace ECM. <Ref. to FU(DOHC TURBO)-47, Engine Control Module.>
EN(DOHC TURBO)-264

MEMO:
EN(DOHC TURBO)-265
BN: DTC P1088 TUMBLE GENERATOR VALVE #1 (RH) POSITION SENSOR CIRCUIT LOW INPUT
S088521H75
S2M2206
EN(DOHC TURBO)-266

RHD MODEL
S2M2207
EN(DOHC TURBO)-267
No. 1

Step Check Is the value less than 0.1 CHECK CURRENT DATA. V? 1) Start engine. 2) Read data of tumble generator valve position sensor signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(DOHC TURBO)-36, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Instruction Manual. Yes Go to step 2. No Even if MIL lights up, the circuit has returned to a normal condition at this time. A temporary poor contact of the connector may be the cause. NOTE: In this case, repair the following: Poor contact in tumble generator valve position sensor connector Poor contact in ECM connector Poor contact in coupling connector Go to step 3.
Go to step 4.
Go to step 6.
EN(DOHC TURBO)-268

No. 6 Step Check Is the voltage more than CHECK HARNESS BETWEEN ECM AND 4.5 V? TUMBLE GENERATOR VALVE POSITION SENSOR CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connectors from tumble generator valve position sensor. 3) Turn ignition switch to ON. 4) Measure voltage between tumble generator valve position sensor connector and engine ground. Connector & terminal (E54) No. 1 (+) Engine ground (): Yes Go to step 7.
No Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between tumble generator valve position sensor and ECM connector Poor contact in throttle position sensor connector Poor contact in ECM connector Poor contact in coupling connector Poor contact in joint connector Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between tumble generator valve position sensor and ECM connector Poor contact in ECM connector Poor contact in tumble generator valve position sensor connector Poor contact in coupling connector Go to step 9.
CHECK HARNESS BETWEEN ECM AND TUMBLE GENERATOR VALVE POSITION SENSOR CONNECTOR. 1) Turn ignition switch to OFF. 2) Measure resistance of harness between ECM connector and tumble generator valve position sensor connector. Connector & terminal (B135) No. 23 (E54) No. 3:
Go to step 8.
CHECK HARNESS BETWEEN ECM AND TUMBLE GENERATOR VALVE POSITION SENSOR CONNECTOR. Measure resistance of harness between tumble generator valve position sensor connector and engine ground. Connector & terminal (E54) No. 3 Engine ground: CHECK POOR CONTACT. Check poor contact in tumble generator valve position sensor connector.
Repair ground short circuit in harness between tumble generator valve position sensor and ECM connector. Repair poor contact in tumble generator valve position sensor connector.
Is there poor contact in tumble generator valve position sensor connector?
Replace tumble generator valve assembly. <Ref. to FU(DOHC TURBO)-40, Tumble Generator Valve Assembly.>
EN(DOHC TURBO)-269
BO: DTC P1089 TUMBLE GENERATOR VALVE #1 (RH) POSITION SENSOR CIRCUIT HIGH INPUT
S088521H76
S2M2206
EN(DOHC TURBO)-270

RHD MODEL
S2M2207
EN(DOHC TURBO)-271
No. 1

Step Check Is the value more than 4.9 CHECK CURRENT DATA. V? 1) Start engine. 2) Read data of tumble generator valve position sensor signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(DOHC TURBO)-36, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedures, refer to the OBD-II General Scan Tool Instruction Manual. Yes Go to step 2. No Even if MIL lights up, the circuit has returned to a normal condition at this time. A temporary poor contact of the connector may be the cause. NOTE: In this case, repair the following: Poor contact in tumble generator valve position sensor connector Poor contact in ECM connector Poor contact in coupling connector Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between tumble generator valve position sensor and ECM connector Poor contact in coupling connector Poor contact in joint connector Replace tumble generator valve assembly. <Ref. to FU(DOHC TURBO)-40, Tumble Generator Valve Assembly.>
CHECK HARNESS BETWEEN TUMBLE GENERATOR VALVE POSITION SENSOR AND ECM CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from tumble generator valve position sensor. 3) Measure resistance of harness between tumble generator valve position sensor connector and engine ground. Connector & terminal (E54) No. 2 Engine ground:
Go to step 3.
Is the voltage more than CHECK HARNESS BETWEEN TUMBLE 4.9 V? GENERATOR VALVE POSITION SENSOR AND ECM CONNECTOR. 1) Turn ignition switch to ON. 2) Measure voltage between tumble generator valve position sensor connector and engine ground. Connector & terminal (E54) No. 3 (+) Engine ground ():
Repair battery short circuit in harness between tumble generator valve position sensor and ECM connector. After repair, replace ECM. <Ref. to FU(DOHC TURBO)-47, Engine Control Module.>
EN(DOHC TURBO)-272
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) BP: DTC P1090 TUMBLE GENERATOR VALVE SYSTEM #1 (RH) MALFUNCTION (STUCK OPEN)
S088521H77
DTC DETECTING CONDITION: Immediately at fault recognition CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(DOHC TURBO)47, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(DOHC TURBO)-44, Inspection Mode.>.
No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate P1088, P1089, P1094 or P1095? Yes No Go to step 2. Inspect DTC P1088, P1089, P1094 or P1095 using List of Diagnostic Trouble Code (DTC) <Ref. to EN(DOHC TURBO)-82, List of Diagnostic Trouble Code (DTC).> Clean tumble genReplace tumble erator valve. generator valve assembly. <Ref. to FU(DOHC TURBO)-40, Tumble Generator Valve Assembly.>
CHECK TUMBLE GENERATOR VALVE RH 1) Remove tumble generator valve assembly. 2) Check tumble generator valve body.
Does tumble generator valve move smoothly? (No dirt or foreign materials clogged)
EN(DOHC TURBO)-273
BQ: DTC P1091 TUMBLE GENERATOR VALVE SYSTEM #1 (RH) MALFUNCTION (STUCK CLOSE)
S088521H78
EN(DOHC TURBO)-274
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) BR: DTC P1092 TUMBLE GENERATOR VALVE SYSTEM #2 (LH) MALFUNCTION (STUCK OPEN)
S088521H79
EN(DOHC TURBO)-275
BS: DTC P1093 TUMBLE GENERATOR VALVE SYSTEM #2 (LH) MALFUNCTION (STUCK CLOSE)
S088521H80
EN(DOHC TURBO)-276

MEMO:
EN(DOHC TURBO)-277
BT: DTC P1094 TUMBLE GENERATOR VALVE CIRCUIT #1 (OPEN CIRCUIT)

S088521H81
S2M2208
EN(DOHC TURBO)-278

No. 1 Step CHECK HARNESS BETWEEN ECM AND TUMBLE GENERATOR VALVE ACTUATOR CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from tumble generator valve actuator and ECM connector. 3) Measure resistance between tumble generator valve actuator and ECM connector. Connector & terminal (E55) No. 1 (B84) No. 4: (E55) No. 2 (B84) No. 5: Check Is the resistance less than 1? Yes Go to step 2.
No Repair open circuit between ECM and tumble generator valve connector. NOTE: In this case, repair the following: Open circuit in harness between ECM and tumble generator valve actuator connector. Poor contact in coupling connector. Replace tumble generator valve assembly. <Ref. to FU(DOHC TURBO)-40, Tumble Generator Valve Assembly.>
CHECK POOR CONTACT. Check poor contact in tumble generator valve actuator connector.
Is there poor contact in tumble generator valve actuator connector.
Repair poor contact in tumble generator valve actuator connector.
EN(DOHC TURBO)-279
BU: DTC P1095 TUMBLE GENERATOR VALVE CIRCUIT #1 (OVERCURRENT)

S088521H82
S2M2208
EN(DOHC TURBO)-280

No. 1 Step Check Is the voltage less than CHECK HARNESS BETWEEN ECM AND TUMBLE GENERATOR VALVE ACTUATOR 5V? CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from tumble generator valve connector. 3) Measure voltage between tumble generator valve actuator and chassis ground. Connector & terminal (E55) No. 1 (+) Chassis ground (): (E55) No. 2 (+) Chassis ground (): Yes Replace tumble generator valve assembly. <Ref. to FU(DOHC TURBO)-40, Tumble Generator Valve Assembly.>
No Repair battery short circuit between ECM and tumble generator valve actuator.
EN(DOHC TURBO)-281
BV: DTC P1096 TUMBLE GENERATOR VALVE CIRCUIT #2 (OPEN CIRCUIT)

S088521H83
S2M2209
EN(DOHC TURBO)-282

No. 1 Step CHECK HARNESS BETWEEN ECM AND TUMBLE GENERATOR VALVE ACTUATOR CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from tumble generator valve and ECM connector. 3) Measure resistance between tumble generator valve actuator and ECM connector. Connector & terminal (E51) No. 1 (B84) No. 10: (E51) No. 2 (B84) No. 11: Check Is the resistance less than 1? Yes Go to step 2.
No Repair open circuit between ECM and tumble generator valve connector. NOTE: In this case, repair the following: Open circuit in harness between ECM and tumble generator valve actuator connector. Poor contact in coupling connector. Replace tumble generator valve assembly. <Ref. to FU(DOHC TURBO)-40, Tumble Generator Valve Assembly.>
CHECK POOR CONTACT. Check poor contact in tumble generator valve actuator connector.
Is there poor contact in tumble generator valve actuator connector.
Repair poor contact in tumble generator valve actuator connector.
EN(DOHC TURBO)-283
BW: DTC P1097 TUMBLE GENERATOR VALVE CIRCUIT #2 (OVERCURRENT)

S088521H84
S2M2209
EN(DOHC TURBO)-284

No. 1 Step Check Is the voltage less than CHECK HARNESS BETWEEN ECM AND TUMBLE GENERATOR VALVE ACTUATOR 5V? CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from tumble generator valve connector. 3) Measure voltage between tumble generator valve actuator and chassis ground. Connector & terminal (E51) No. 1 (+) Chassis ground (): (E51) No. 2 (+) Chassis ground (): Yes Replace tumble generator valve assembly. <Ref. to FU(DOHC TURBO)-40, Tumble Generator Valve Assembly.>
No Repair battery short circuit between ECM and tumble generator valve actuator.
EN(DOHC TURBO)-285
BX: DTC P1110 ATMOSPHERIC PRESSURE SENSOR CIRCUIT LOW INPUT

S088521B84
No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P1110? Yes No It is not necessary Replace ECM. to inspect DTC <Ref. to P1110. FU(DOHC TURBO)-47, Engine Control Module.> NOTE: Atmospheric pressure sensor is built into ECM.
BY: DTC P1111 ATMOSPHERIC PRESSURE SENSOR CIRCUIT HIGH INPUT

S088521B85
No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P1111? Yes No It is not necessary Replace ECM. to inspect DTC <Ref. to P1111. FU(DOHC TURBO)-47, Engine Control Module.> NOTE: Atmospheric pressure sensor is built into ECM.
EN(DOHC TURBO)-286
DIAGNOSTIC PROCEDURE WITH DIAGNOSTIC TROUBLE CODE (DTC) BZ: DTC P1112 ATMOSPHERIC PRESSURE SENSOR CIRCUIT RANGE/ PERFORMANCE PROBLEM
S088521B86
No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0106, P0107, P0108, P1110 or P1111? Yes Inspect DTC P0106, P0107, P0108, P1110 or P1111 using List of Diagnostic Trouble Code (DTC).<Ref. to EN(DOHC TURBO)-82, List of Diagnostic Trouble Code (DTC).> No Replace ECM. <Ref. to FU(DOHC TURBO)-47, Engine Control Module.> NOTE: Atmospheric pressure sensor is built into ECM.
EN(DOHC TURBO)-287
CA: DTC P1130 FRONT OXYGEN (A/F) SENSOR CIRCUIT MALFUNCTION (OPEN CIRCUIT)
S088521B92
S2M2187
EN(DOHC TURBO)-288

No. 1 Step Check Is the resistance less than CHECK HARNESS BETWEEN ECM AND FRONT OXYGEN (A/F) SENSOR CONNEC- 1 ? TOR. 1) Turn ignition switch to OFF. 2) Disconnect connectors from ECM and front oxygen (A/F) sensor connector. 3) Measure resistance of harness between ECM and front oxygen (A/F) sensor connector. Connector & terminal (B137) No. 29 (B18) No. 3: (B137) No. 19 (B18) No. 4: Yes Go to step 2.
No Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ECM and front oxygen (A/F) sensor connector Poor contact in front oxygen (A/F) sensor connector Poor contact in ECM connector Replace front oxygen (A/F) sensor. <Ref. to FU(DOHC TURBO)-42, Front Oxygen (A/F) Sensor.>
Is there poor contact in CHECK POOR CONTACT. Check poor contact in front oxygen (A/F) senfront oxygen (A/F) sensor connector? sor connector.
Repair poor contact in front oxygen (A/F) sensor connector.
EN(DOHC TURBO)-289
CB: DTC P1131 FRONT OXYGEN (A/F) SENSOR CIRCUIT MALFUNCTION (SHORT CIRCUIT)
S088521B93
S2M2187
EN(DOHC TURBO)-290

No. 1 Step CHECK HARNESS BETWEEN ECM AND FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM. 3) Measure resistance of harness between ECM connector and chassis ground. Connector & terminal (B137) No. 19 Chassis ground: CHECK HARNESS BETWEEN ECM AND FRONT OXYGEN (A/F) SENSOR CONNECTOR. Measure resistance of harness between ECM connector and chassis ground. Connector & terminal (B137) No. 29 Chassis ground: CHECK OUTPUT SIGNAL FOR ECM. 1) Connect connector to ECM. 2) Turn ignition switch to ON. 3) Measure voltage between ECM connector and chassis ground. Connector & terminal (B137) No. 19 (+) Chassis ground (): CHECK OUTPUT SIGNAL FOR ECM. Measure voltage between ECM connector and chassis ground. Connector & terminal (B137) No. 19 (+) Chassis ground (): Check Yes Is the resistance more than Go to step 2. 10 ?
No Repair ground short circuit in harness between ECM and front oxygen (A/F) sensor connector.
Is the resistance more than Go to step 3. 10 ?
Repair ground short circuit in harness between ECM and front oxygen (A/F) sensor connector. Go to step 5.
Go to step 4.
CHECK OUTPUT SIGNAL FOR ECM. Measure voltage between ECM connector and chassis ground. Connector & terminal (B137) No. 29 (+) Chassis ground (): CHECK OUTPUT SIGNAL FOR ECM. Measure voltage between ECM connector and chassis ground. Connector & terminal (B137) No. 29 (+) Chassis ground ():
Is the voltage more than 10 Repair battery V? short circuit in harness between ECM and front oxygen (A/F) sensor connector. After repair, replace ECM. <Ref. to FU(DOHC TURBO)-47, Engine Control Module.> Is the voltage more than Go to step 6. 4.95 V?
Is the voltage more than 10 Repair battery V? short circuit in harness between ECM and front oxygen (A/F) sensor connector. After repair, replace ECM. <Ref. to FU(DOHC TURBO)-47, Engine Control Module.>
Replace front oxygen (A/F) sensor. <Ref. to FU(DOHC TURBO)-42, Front Oxygen (A/F) Sensor.> Repair poor contact in ECM connector.
EN(DOHC TURBO)-291
CC: DTC P1134 FRONT OXYGEN (A/F) SENSOR MICRO-COMPUTER PROBLEM

S088521B96
S2M2187
EN(DOHC TURBO)-292

No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P1134? Yes Replace ECM. <Ref. to FU(DOHC TURBO)-47, Engine Control Module.>
EN(DOHC TURBO)-293
CD: DTC P1139 FRONT OXYGEN (A/F) SENSOR #1 HEATER CIRCUIT RANGE/PERFORMANCE PROBLEM
S088521B97
S2M2187
EN(DOHC TURBO)-294

No. 1 Step CHECK HARNESS BETWEEN ECM AND FRONT OXYGEN (A/F) SENSOR CONNECTOR. 1) Start engine, and warm-up the engine. 2) Turn ignition switch to OFF. 3) Disconnect connectors from ECM and front oxygen (A/F) sensor. 4) Measure resistance of harness between ECM and front oxygen (A/F) sensor connector. Connector & terminal (B137) No. 5 (B18) No. 1: (B137) No. 4 (B18) No. 1: CHECK HARNESS BETWEEN ECM AND FRONT OXYGEN (A/F) SENSOR CONNECTOR. Measure resistance of harness between ECM and front oxygen (A/F) sensor connector. Connector & terminal (B137) No. 19 (B18) No. 4: (B137) No. 29 (B18) No. 3: CHECK HARNESS BETWEEN ECM AND FRONT OXYGEN (A/F) SENSOR CONNECTOR. Measure resistance of harness between main relay and front oxygen (A/F) sensor connector. Connector & terminal (B47) No. 4 (B18) No. 2: CHECK FRONT OXYGEN (A/F) SENSOR. Measure resistance between front oxygen (A/F) sensor connector terminals. Terminals No. 2 No. 1: Check Is the resistance less than 1 ? Yes Go to step 2.
No Repair open circuit in harness between ECM and front oxygen (A/F) sensor connector.
Go to step 3.
Repair open circuit in harness between ECM and front oxygen (A/F) sensor connector.
Go to step 4.
Repair open circuit in harness between ECM and front oxygen (A/F) sensor connector.
Go to step 5.
CHECK POOR CONTACT. Check poor contact in ECM and front oxygen (A/F) sensor connector.
Is there poor contact in ECM or front oxygen (A/F) sensor connector?
Replace front oxygen (A/F) sensor. <Ref. to FU(DOHC TURBO)-42, Front Oxygen (A/F) Sensor.> Repair poor con- Replace front oxygen (A/F) sensor. tact in ECM or front oxygen (A/F) <Ref. to sensor connector. FU(DOHC TURBO)-42, Front Oxygen (A/F) Sensor.>
EN(DOHC TURBO)-295
CE: DTC P1141 MASS AIR FLOW SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (LOW INPUT)
S088521B98
S2M2189
EN(DOHC TURBO)-296

No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. Check Does Subaru select monitor or OBD-II general scan tool indicate DTC P0102 or P0103? Yes Inspect DTC P0102 or P0103 using List of Diagnostic Trouble Code (DTC). <Ref. to EN(DOHC TURBO)-82, List of Diagnostic Trouble Code (DTC).> NOTE: In this case, it is not necessary to inspect DTC P1141.
No Replace mass air flow and intake air temperature sensor.
EN(DOHC TURBO)-297
CF: DTC P1142 THROTTLE POSITION SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (LOW INPUT)
S088521B99
DTC DETECTING CONDITION: Two consecutive driving cycles with fault TROUBLE SYMPTOM: Erroneous idling Engine stalls. Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(DOHC TURBO)47, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(DOHC TURBO)-44, Inspection Mode.>. WIRING DIAGRAM: LHD MODEL
S2M2193
EN(DOHC TURBO)-298

RHD MODEL
S2M2194
No. 1
Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0122 or P0123?
Yes Inspect DTC P0122 or P0123 using List of Diagnostic Trouble Code (DTC). <Ref. to EN(DOHC TURBO)-82, List of Diagnostic Trouble Code (DTC).> NOTE: In this case, it is not necessary to inspect DTC P1142.
No Replace throttle position sensor. <Ref. to FU(DOHC TURBO)-33, Throttle Position Sensor.>
EN(DOHC TURBO)-299
CG: DTC P1146 PRESSURE SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM (HIGH INPUT)
S088521G07
DTC DETECTING CONDITION: Two consecutive driving cycles with fault CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(DOHC TURBO)47, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(DOHC TURBO)-44, Inspection Mode.>. WIRING DIAGRAM: LHD MODEL
S2M2190
EN(DOHC TURBO)-300

RHD MODEL
S2M2191
No. 1
Step CHECK ANY OTHER DTC ON DISPLAY. NOTE: In this case, it is not necessary to inspect DTC P0106.
Yes Inspect DTC P0107, P0108 or P1112 using List of Diagnostic Trouble Code (DTC). <Ref. to EN(DOHC TURBO)-82, List of Diagnostic Trouble Code (DTC).> Are there holes, loose bolts Repair air intake or disconnection of hose on system. air intake system?
Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0107, P0108 or P1112?
No Go to step 2.
Go to step 3.
EN(DOHC TURBO)-301
No. 3

Step CHECK PRESSURE SENSOR. 1) Start the engine and warm-up engine until coolant temperature is greater than 60C (140F). 2) Place the shift lever in the selector lever in N or P position. 3) Turn A/C switch to OFF. 4) Turn all accessory switches to OFF. 5) Read data of intake manifold pressure sensor signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(DOHC TURBO)-36, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedure, refer to the OBD-II General Scan Tool Instruction Manual. Specification: Intake manifold absolute pressure Ignition ON 73.3 106.6 kPa (550 800 mmHg, 21.65 31.50 inHg) Idling 20.0 46.7 kPa (150 350 mmHg, 5.91 13.78 inHg) CHECK THROTTLE POSITION. Read data of throttle position signal using Subaru Select Monitor or OBD-II general scan tool. NOTE: Subaru Select Monitor For detailed operation procedure, refer to the READ CURRENT DATA FOR ENGINE. <Ref. to EN(DOHC TURBO)-36, Subaru Select Monitor.> OBD-II general scan tool For detailed operation procedure, refer to the OBD-II General Scan Tool Instruction Manual. CHECK THROTTLE POSITION. Check Is the value within the specifications? Yes Go to step 4. No Replace pressure sensor. <Ref. to FU(DOHC TURBO)-35, Pressure Sensor.>
Go to step 5.
Is throttle positioning ratio equal to or more than 85% when throttle is fully open?
Replace pressure sensor. <Ref. to FU(DOHC TURBO)-35, Pressure Sensor.>
EN(DOHC TURBO)-302

MEMO:
EN(DOHC TURBO)-303
CH: DTC P1244 WASTEGATE CONTROL SOLENOID VALVE RANGE/PERFORMANCE PROBLEM (LOW INPUT)
S088521H86
S2M2195
EN(DOHC TURBO)-304

No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0245 or P0246? Yes Inspect DTC P0245 or P0246 using List of Diagnostic Trouble Code (DTC). <Ref. to EN(DOHC TURBO)-82, List of Diagnostic Trouble Code (DTC).> NOTE: In this case, it is not necessary to inspect DTC P1142.
EN(DOHC TURBO)-305
CI: DTC P1245 WASTEGATE CONTROL SOLENOID VALVE MALFUNCTION (FAIL-SAFE)

S088521H87
S2M2195
EN(DOHC TURBO)-306

No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0244, P0245, P0246 or P1244? Yes Inspect DTC P0244, P0245, P0246 or P1244 using List of Diagnostic Trouble Code (DTC). <Ref. to EN(DOHC TURBO)-82, List of Diagnostic Trouble Code (DTC).> NOTE: In this case, it is not necessary to inspect DTC P0507.
EN(DOHC TURBO)-307
CJ: DTC P1301 FIRE DUE TO INCREASED EXHAUST TEMPERATURE

S088521H88
DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: Erroneous idling Engine stalls Poor driving performance CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(DOHC TURBO)47, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(DOHC TURBO)-44, Inspection Mode.>. WIRING DIAGRAM:
S2M2202
EN(DOHC TURBO)-308

No. 1 Step Check Does failure for repair or CHECK ANY OTHER DTC. replacement exist? Conduct troubleshooting for all DTC P0301, P0302, P0303 and P0304. <Ref. to EN(DOHC TURBO)-82, List of Diagnostic Trouble Code (DTC).> Yes Repair or replace failure, then replace precatalytic converter.
No Contact your Subaru distributor. NOTE: Inspection by DTM is required, because probable cause is deterioration of multiple parts.
EN(DOHC TURBO)-309
CK: DTC P1312 EXHAUST GAS TEMPERATURE CIRCUIT MALFUNCTION

S088521H89
S2M2202
EN(DOHC TURBO)-310

No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0545, P0546 or P1544? Yes Inspect DTC P0545, P0546 or P1544 using List of Diagnostic Trouble Code (DTC). <Ref. to EN(DOHC TURBO)-82, List of Diagnostic Trouble Code (DTC).> NOTE: In this case, it is not necessary to inspect DTC P1312.
No Replace exhaust gas temperature sensor. <Ref. to FU(DOHC TURBO)-46, Exhaust Temperature Sensor.>
EN(DOHC TURBO)-311

S088521G08
CL: DTC P1480 COOLING FAN RELAY 1 CIRCUIT HIGH INPUT

EN(DOHC TURBO)-312

WIRING DIAGRAM:
S2M2199
EN(DOHC TURBO)-313
No. 1

Step CHECK OUTPUT SIGNAL FROM ECM. 1) Turn ignition switch to OFF. 2) Connect test mode connector at the lower portion of instrument panel (on the driver s side), to the side of the center console box. 3) Turn ignition switch to ON. 4) While operating radiator fan relay, measure voltage between ECM and chassis ground. NOTE: Radiator fan relay operation can be executed using Subaru Select Monitor. For procedure, refer to Compulsory Valve Operation Check Mode.<Ref. to EN(DOHC TURBO)-48, Compulsory Valve Operation Check Mode.> Connector & terminal (B137) No. 17 (+) Chassis ground (): (B137) No. 28 (+) Chassis ground (): CHECK SHORT CIRCUIT IN RADIATOR FAN RELAY CONTROL CIRCUIT. 1) Turn ignition switch to OFF. 2) Remove main fan relay and sub fan relay. (with A/C models) 3) Disconnect test mode connector. 4) Turn ignition switch to ON. 5) Measure voltage between ECM and chassis ground. Connector & terminal (B137) No. 17 (+) Chassis ground (): (B137) No. 28 (+) Chassis ground (): CHECK MAIN FAN RELAY. 1) Turn ignition switch to OFF. 2) Remove main fan relay. 3) Measure resistance of main fan relay. Terminal No. 26 No. 25: CHECK MAIN FAN RELAY. 1) Connect battery to terminals No. 27 and No. 28 of main fan relay. 2) Measure resistance of main fan relay. Terminal No. 26 No. 25: CHECK SUB FAN RELAY. 1) Turn ignition switch to OFF. 2) Measure resistance of main fan relay. Terminal No. 17 No. 18: Check Does voltage change between 0 and 10 V? Yes No Even if MIL lights Go to step 2. up, the circuit has returned to a normal condition at this time. In this case, repair poor contact in ECM connector.
Is the voltage more than 10 Repair battery V? short circuit in radiator fan relay control circuit. After repair, replace ECM. <Ref. to FU(DOHC TURBO)-47, Engine Control Module.>
Go to step 3.
Go to step 5.
Replace main fan relay and ECM. <Ref. to FU(DOHC TURBO)-47, Engine Control Module.> Replace main fan relay and ECM. <Ref. to FU(DOHC TURBO)-47, Engine Control Module.> Replace sub fan relay and ECM. <Ref. to FU(DOHC TURBO)-47, Engine Control Module.>
EN(DOHC TURBO)-314

No. 6 Step CHECK SUB FAN RELAY. 1) Connect battery to terminals No. 20 and No. 19 of sub fan relay. 2) Measure resistance of main fan relay. Terminal No. 17 No. 18: CHECK POOR CONTACT. Check poor contact in ECM connector. Check Is the resistance less than 1 ? Yes Go to step 7.
No Replace sub fan relay and ECM. <Ref. to FU(DOHC TURBO)-47, Engine Control Module.> Replace ECM. <Ref. to FU(DOHC TURBO)-47, Engine Control Module.>
EN(DOHC TURBO)-315
CM: DTC P1507 IDLE CONTROL SYSTEM MALFUNCTION (FAIL-SAFE)

S088521C16
DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: Engine keeps running at higher revolution than specified idling revolution. Fuel is cut according to fail-safe function. CAUTION: After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(DOHC TURBO)47, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(DOHC TURBO)-44, Inspection Mode.>. WIRING DIAGRAM:
S2M2201
EN(DOHC TURBO)-316

No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0506, P0507, P0508, P0509 or P1142? Yes Inspect DTC P0506, P0507, P0508, P0509 or P1142 using List of Diagnostic Trouble Code (DTC). <Ref. to EN(DOHC TURBO)-82, List of Diagnostic Trouble Code (DTC).> NOTE: In this case, it is not necessary to inspect DTC P0507. Repair air suction and leaks. No Go to step 2.
Go to step 3.
Go to step 4.
Are foreign particles in byCHECK AIR BY-PASS LINE. pass air line? 1) Turn ignition switch to OFF. 2) Remove idle air control solenoid valve from throttle body. <Ref. to FU(DOHC TURBO)-36, Idle Air Control Solenoid Valve.> 3) Confirm that there are no foreign particles in by-pass air line.
Adjust throttle cable. <Ref. to SP-12, Accelerator Control Cable.> Replace idle air control solenoid valve. <Ref. to FU(DOHC TURBO)-36, Idle Air Control Solenoid Valve.>
EN(DOHC TURBO)-317

S088521G09
CN: DTC P1518 STARTER SWITCH CIRCUIT LOW INPUT

S2M2181
EN(DOHC TURBO)-318

No. 1 Step Check CHECK OPERATION OF STARTER MOTOR. Does starter motor operate when ignition switch to NOTE: ST? Place the inhibitor switch in the P or N position (AT model). Yes Repair harness and connector. NOTE: In this case, repair the following: Open or ground short circuit in harness between ECM and starter motor connector. Poor contact in ECM connector.
No Check starter motor circuit. <Ref. to EN(DOHC TURBO)-64, STARTER MOTOR CIRCUIT, Diagnostics for Engine Starting Failure.>
EN(DOHC TURBO)-319

S088521H90
CO: DTC P1544 HIGH EXHAUST TEMPERATURE DETECTED

DTC DETECTING CONDITION: Immediately at fault recognition TROUBLE SYMPTOM: Erroneous idling Poor driving performance
S2M2202
EN(DOHC TURBO)-320

No. 1 Step CHECK ANY OTHER DTC ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0335, P0336, P0340, P0341, P0545, P0546, P1312, P0102, P0103, P0101, P1141, P0301, P0302, P0303, P0304, P1301, P0171, P0133, P1134, P0131, P0132, P1130, P1131, P1139, P0031, P0032, P0139, P0136, P0039 or P0037? Yes Inspect DTC P0335, P0336, P0340, P0341, P0545, P0546, P1312, P0102, P0103, P0101, P1141, P0301, P0302, P0303, P0304, P1301, P0171, P0133, P1134, P0131, P0132, P1130, P1131, P1139, P0031, P0032, P0139, P0136, P0039 or P0037 using List of Diagnostic Trouble Code (DTC). <Ref. to EN(DOHC TURBO)-82, List of Diagnostic Trouble Code (DTC).> NOTE: In this case, it is not necessary to inspect DTC P1544. Repair or replace failure, then replace precatalytic converter. No Go to step 2.
Is there a fault in exhaust CHECK EXHAUST SYSTEM. system? Check exhaust system parts. NOTE: Check the following items. Loose installation of exhaust manifold Cracks or hole of exhaust manifold Loose installation of front oxygen (A/F) sensor
EN(DOHC TURBO)-321

S088521C27
CP: DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION

EN(DOHC TURBO)-322

S2M2182
EN(DOHC TURBO)-323
RHD MODEL
S2M2183
EN(DOHC TURBO)-324

No. 1 Step CHECK INPUT SIGNAL FOR ECM. 1) Turn ignition switch to OFF. 2) Measure voltage between ECM and chassis ground. Connector & terminal (B137) No. 10 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND MAIN FUSE BOX CONNECTOR. 1) Disconnect connector from ECM. 2) Measure resistance of harness between ECM and chassis ground. Connector & terminal (B137) No. 10 Chassis ground: CHECK FUSE SBF-5. Check Yes Is the voltage more than 10 Repair poor conV? tact in ECM connector. No Go to step 2.
Repair ground short circuit in harness between ECM connector and battery terminal. Replace fuse.
Go to step 3.
Is fuse blown?
Repair harness and connector. NOTE: In this case, repair the following: Open circuit in harness between ECM and battery Poor contact in ECM connector Poor contact in battery terminal
EN(DOHC TURBO)-325
CQ: DTC P1590 NEUTRAL POSITION SWITCH CIRCUIT HIGH INPUT (AT MODEL)
S088521G83
S2M2210
EN(DOHC TURBO)-326

No. 1 Step CHECK DTC P0705 ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0705? Yes Inspect DTC P0705 using List of Diagnostic Trouble Code (DTC). <Ref. to EN(SOHC)-82, List of Diagnostic Trouble Code (DTC).> Go to step 3. No Go to step 2.
CHECK INPUT SIGNAL FOR ECM. 1) Turn ignition switch to ON. 2) Measure voltage between ECM and chassis ground in selector lever N and P positions. Connector & terminal (B134) No. 8 (+) Chassis ground (): CHECK INPUT SIGNAL FOR ECM. Measure voltage between ECM and chassis ground in selector lever except for N and P positions. Connector & terminal (B134) No. 8 (+) Chassis ground (): CHECK POOR CONTACT. Check poor contact in ECM connector.
Go to step 5.
Go to step 4.
Go to step 5.
CHECK INPUT SIGNAL FOR ECM. Measure voltage between ECM and chassis ground. Connector & terminal (B134) No. 8 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND INHIBITOR SWITCH CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connectors from ECM and inhibitor switch. 3) Measure resistance of harness between ECM and inhibitor switch connector. Connector & terminal (B134) No. 8 (T7) No. 12:
Is the voltage more than 10 Repair battery V? short circuit in harness between ECM and inhibitor switch connector. Is the resistance less than Go to step 7. Repair harness 1 ? and connector. NOTE: In this case, repair the following: Open circuit in harness between ECM and inhibitor switch connector Poor contact in coupling connector Poor contact in inhibitor switch connector Poor contact in ECM connector
EN(DOHC TURBO)-327
No. 7

Step CHECK INHIBITOR SWITCH GROUND LINE. Measure resistance of harness between inhibitor switch connector and engine ground. Connector & terminal (T7) No. 7 Engine ground: Check Is the resistance less than 5 ? Yes Go to step 8. No Repair open circuit in harness between inhibitor switch connector and starter motor ground line. NOTE: In this case, repair the following: Open circuit in harness between inhibitor switch connector and starter motor ground line Poor contact in starter motor connector Poor contact in starter motor ground Starter motor Replace inhibitor switch. <Ref. to AT-28, Inhibitor Switch.>
CHECK INHIBITOR SWITCH. Measure resistance between inhibitor switch connector receptacles terminals in selector lever N and P positions. Terminals No. 7 No. 12: CHECK SELECTOR CABLE CONNECTION.
Go to step 9.
Repair selector cable connection. <Ref. to CS-10, Select Cable.>
EN(DOHC TURBO)-328

MEMO:
EN(DOHC TURBO)-329
CR: DTC P1591 NEUTRAL POSITION SWITCH CIRCUIT LOW INPUT (AT MODEL)
S088521G84
S2M2210
EN(DOHC TURBO)-330

No. 1 Step CHECK DTC P0705 ON DISPLAY. Check Does the Subaru Select Monitor or OBD-II general scan tool indicate DTC P0705? Yes No Go to step 2. Inspect DTC P0705 using List of Diagnostic Trouble Code (DTC). <Ref. to EN(SOHC)-82, List of Diagnostic Trouble Code (DTC).> Even if MIL lights Go to step 3. up, the circuit has returned to a normal condition at this time. Repair ground short circuit in harness between ECM and transmission harness connector. Go to step 4.
CHECK INPUT SIGNAL FOR ECM. 1) Turn ignition switch to ON. 2) Measure voltage between ECM and chassis ground. Connector & terminal (B134) No. 8 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND TRANSMISSION HARNESS CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connectors from ECM and transmission harness connector (T3). 3) Measure resistance of harness between ECM connector and chassis ground. Connector & terminal (B134) No. 8 Chassis ground: CHECK TRANSMISSION HARNESS CONNECTOR. 1) Disconnect connector from inhibitor switch. 2) Measure resistance of harness between transmission harness connector and engine ground. Connector & terminal (T3) No. 12 Engine ground: CHECK INHIBITOR SWITCH. Measure resistance between inhibitor switch connector receptacles terminals in selector lever except for N position. Terminals No. 7 No. 12: CHECK SELECTOR CABLE CONNECTION.
Is the voltage between 4.5 and 5.5 V at except N and P positions?
Repair ground short circuit in harness between transmission harness and inhibitor switch connector.
Go to step 5.
Is the resistance more than Go to step 6. 1 M at except N and P positions?
Replace inhibitor switch. <Ref. to AT-28, Inhibitor Switch.>
Repair selector cable connection. <Ref. to CS-10, Select Cable.>
EN(DOHC TURBO)-331
CS: DTC P1594 AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL CIRCUIT MALFUNCTION
S088521G12
S2M2211
No. 1
Step CHECK DRIVING CONDITION. 1) Start and warm-up the engine until the radiator fan makes one complete rotation. 2) Drive the vehicle.
Check Is AT shift control functioning properly?
Yes Go to step 2.
EN(DOHC TURBO)-332

No. 2 Step CHECK ACCESSORY. Check Are car phone and/or CB installed on vehicle? Yes Repair grounding line of car phone or CB system.
EN(DOHC TURBO)-333
CT: DTC P1595 AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL CIRCUIT LOW INPUT
S088521G13
S2M2211
EN(DOHC TURBO)-334

No. 1 Step CHECK HARNESS BETWEEN ECM AND TCM CONNECTOR. 1) Turn ignition switch to ON. 2) Measure voltage between ECM and chassis ground. Connector & terminal (B135) No. 20 (+) Chassis ground (): Check Is the voltage less than 1 V? Yes Go to step 2.
No Even if MIL lights up, the circuit has returned to a normal condition at this time. NOTE: In this case, repair the following: Poor contact in ECM connector Poor contact in TCM connector Go to step 3.
CHECK HARNESS BETWEEN ECM AND TCM CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM and TCM. 3) Measure resistance of harness between ECM and chassis ground. Connector & terminal (B135) No. 20 Chassis ground: CHECK OUTPUT SIGNAL FOR ECM. 1) Connect connector to ECM. 2) Turn ignition switch to ON. 3) Measure voltage between ECM and chassis ground. Connector & terminal (B135) No. 20 (+) Chassis ground (): CHECK TROUBLE CODE FOR AUTOMATIC TRANSMISSION. Read trouble code for automatic transmission. <Ref. to AT-22, Read Diagnostic Trouble Code.>
Go to step 4.
Does trouble code appear Inspect trouble for automatic transmission? code for automatic transmission. <Ref. to AT-42, Diagnostic Procedure with Trouble Code.>
EN(DOHC TURBO)-335
CU: DTC P1596 AUTOMATIC TRANSMISSION DIAGNOSIS INPUT SIGNAL CIRCUIT HIGH INPUT
S088521G14
S2M2211
EN(DOHC TURBO)-336

No. 1 Step CHECK HARNESS BETWEEN ECM AND TCM CONNECTOR. 1) Turn ignition switch to ON. 2) Measure voltage between ECM and chassis ground. Connector & terminal (B135) No. 20 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND TCM CONNECTOR. Measure voltage between ECM connector and chassis ground. Connector & terminal (B135) No. 20 (+) Chassis ground (): CHECK HARNESS BETWEEN ECM AND TCM CONNECTOR. Measure voltage between ECM connector and chassis ground. Connector & terminal (B135) No. 20 (+) Chassis ground (): CHECK OUTPUT SIGNAL FROM ECM. Measure voltage between ECM and chassis ground. Connector & terminal (B135) No. 20 (+) Chassis ground (): Check Yes Is the voltage more than 10 Repair battery V? short circuit in harness between ECM and TCM connector. No Go to step 2.
Go to step 5.
Go to step 3.
Go to step 4.
Does the voltage change from 1 V to 4 V while monitoring the value with voltage meter?
CHECK HARNESS BETWEEN ECM AND TCM CONNECTOR. Measure voltage between TCM and chassis ground. Connector & terminal (B56) No. 21 (+) Chassis ground (): CHECK POOR CONTACT. Check poor contact in TCM connector.
Even if MIL lights up, the circuit has returned to a normal condition at this time. NOTE: In this case, repair the following: Poor contact in ECM connector Poor contact in TCM connector Go to step 6.
Repair open circuit in harness between ECM and TCM connector. Check TCM power supply line and grounding line.
EN(DOHC TURBO)-337
CV: DTC P1701 CRUISE CONTROL SET SIGNAL CIRCUIT MALFUNCTION FOR AUTOMATIC TRANSMISSION
S088521C29
S2M2212
EN(DOHC TURBO)-338

No. 1 Step CHECK HARNESS BETWEEN TCM AND CCM CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect connectors from TCM and CCM. 3) Measure resistance of harness between TCM and CCM connector. Connector & terminal (B55) No. 22 (B94) No. 3: CHECK HARNESS BETWEEN TCM AND CCM CONNECTOR. Measure resistance of harness between TCM and chassis ground. Connector & terminal (B55) No. 22 Chassis ground: CHECK INPUT SIGNAL FOR TCM. 1) Connect connector to TCM and CCM. 2) Lift-up the vehicle or set the vehicle on free rollers. CAUTION: On AWD models, raise all wheels off ground. 3) Start the engine. 4) Cruise control main switch to ON. 5) Move selector lever to D and slowly increase vehicle speed to 50 km/h (31 MPH). 6) Cruise control command switch to ON. 7) Measure voltage between TCM and chassis ground. Connector & terminal (B55) No. 22 (+) Chassis ground (): CHECK POOR CONTACT. Check poor contact in TCM connector. Check Is the resistance less than 1 ? Yes Go to step 2.
No Repair open circuit in harness between TCM and CCM connector.
Go to step 3. Repair short circuit in harness between TCM and CCM connector.
Is the resistance less than 1 V?
Go to step 4.
Check cruise control command switch circuit. <Ref. to CC-10, Cruise Control Command Switch.>
EN(DOHC TURBO)-339
CW: DTC P1711 ENGINE TORQUE CONTROL SIGNAL 1 CIRCUIT MALFUNCTION

S088521G17
S2M2213
EN(DOHC TURBO)-340

Go to step 3.
Go to step 5.
Replace ECM. <Ref. to FU(DOHC TURBO)-49, Engine Control Module.> Repair open circuit in harness between ECM and TCM connector.
Go to step 6.
EN(DOHC TURBO)-341
CX: DTC P1712 ENGINE TORQUE CONTROL SIGNAL 2 CIRCUIT MALFUNCTION

S088521G18
S2M2214
EN(DOHC TURBO)-342

Go to step 3.
Go to step 5.
Replace ECM. <Ref. to FU(DOHC TURBO)-49, Engine Control Module.> Repair open circuit in harness between ECM and TCM connector.
Go to step 6.
EN(DOHC TURBO)-343

S088257

A: INSPECTION
1. ENGINE
S088257A1001 S088257A10
NOTE: Malfunction of parts other than those listed is also possible. <Ref. to ME(DOHC TURBO)-91, Engine Trouble in General.>
Symptom Problem parts 1) Idle air control solenoid valve 2) Pressure sensor 3) Mass air flow and intake temperature sensor 4) Ignition parts (*1) 5) Engine coolant temperature sensor (*2) 6) Crankshaft position sensor (*3) 7) Camshaft position sensor (*3) 8) Fuel injection parts (*4) 1) Idle air control solenoid valve 2) Pressure sensor 3) Mass air flow and intake temperature sensor 4) Engine coolant temperature sensor (*2) 5) Ignition parts (*1) 6) Air intake system (*5) 7) Fuel injection parts (*4) 8) Throttle position sensor 9) Crankshaft position sensor (*3) 10) Camshaft position sensor (*3) 11) Oxygen sensor 12) Fuel pump and fuel pump relay 1) Idle air control solenoid valve 2) Engine coolant temperature sensor 3) Accelerator cable (*6) 4) Throttle position sensor 5) Pressure sensor 6) Mass air flow and intake air temperature sensor 1) Pressure sensor 2) Mass air flow and intake temperature sensor 3) Throttle position sensor 4) Fuel injection parts (*4) 5) Fuel pump and fuel pump relay 6) Engine coolant temperature sensor (*2) 7) Crankshaft position sensor (*3) 8) Camshaft position sensor (*3) 9) A/C switch and A/C cut relay 10) Engine torque control signal circuit 11) Ignition parts (*1) 1) Pressure sensor 2) Mass air flow and intake temperature sensor 3) Engine coolant temperature sensor (*2) 4) Crankshaft position sensor (*3) 5) Camshaft position sensor (*3) 6) Purge control solenoid valve 7) Fuel injection parts (*4) 8) Throttle position sensor 9) Fuel pump and fuel pump relay
1. Engine stalls during idling.
2. Rough idling
3. Engine does not return to idle.
4. Poor acceleration
5. Engine stalls or engine sags or hesitates at acceleration.
EN(DOHC TURBO)-344

Symptom Problem parts 1) Pressure sensor 2) Mass air flow and intake temperature sensor 3) Engine coolant temperature sensor (*2) 4) Crankshaft position sensor (*3) 5) Camshaft position sensor (*3) 6) Fuel injection parts (*4) 7) Throttle position sensor 8) Fuel pump and fuel pump relay 1) Pressure sensor 2) Mass air flow and intake temperature sensor 3) Engine coolant temperature sensor 4) Knock sensor 5) Fuel injection parts (*4) 6) Fuel pump and fuel pump relay 1) Pressure sensor 2) Mass air flow and intake temperature sensor 3) Engine coolant temperature sensor (*2) 4) Fuel injection parts (*4) 5) Fuel pump and fuel pump relay
6. Surge
7. Spark knock
*1: Check ignition coil & ignitor assembly and spark plug. *2: Indicate the symptom occurring only in cold temperatures. *3: Ensure the secure installation. *4: Check fuel injector, fuel pressure regulator and fuel filter. *5: Inspect air leak in air intake system. *6: Adjust accelerator cable.
EN(DOHC TURBO)-345
MEMO:
EN(DOHC TURBO)-346
G8050GE6
CONTROL SYSTEMS
CS
1. 2. 3. 4. 5. 6. 7. Page General Description.....................................................................................2 Select Lever ................................................................................................7 Select Cable ..............................................................................................10 MT Gear Shift Lever..................................................................................13 MT Drive Select Lever ..............................................................................19 Drive Select Cable ....................................................................................21 General Diagnostic Table ..........................................................................22
Control Systems
GENERAL DESCRIPTION
S501001
A: SPECIFICATIONS
S501001E49
Item Vibration torque of rod against lever
Nm (kgf-m, ft-lb)
Specification 0.7 (0.07, 0.5) or less
CS-2

S501001A05
Control Systems
1. AT SELECT LEVER
S501001A0501
S3M0584A
(1) (2) (3) (4) (5) (6) (7) (8) (9)
Button A Button B Spring (button) Grip Indicator cover Selector lever lower Pin Packing Plate
(10) (11) (12) (13) (14) (15) (16) (17) (18)
Detent spring Selector lever upper Rod Indicator light bulb Clip Snap pin Outer cable Inner cable Nut (front)
(19) Nut (rear) (20) Front cover

Tightening torque: Nm (kgf-m, ft-lb) T1: 5.9 (0.6, 4.3) T2: 25 (2.5, 18.1) T3: 32 (3.3, 24)
CS-3
Control Systems
GENERAL DESCRIPTION
S501001A0502
2. MT GEAR SHIFT LEVER
S3M0537B
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
Gear shift knob Console boot Boot plate (Non-Turbo model) Lever Bush A Bush B Locking wire Boot Snap ring O-ring
(11) (12) (13) (14) (15) (16) (17) (18) (19) (20)
Bush C Straight pin Cushion rubber Bush D Joint Rod Bracket Washer Stay Spacer
(21) Boot plate (Turbo model) (22) Boot and insulator (23) Front cover
Tightening torque: Nm (kgf-m, ft-lb) T1: 4.5 (0.46, 3.3) T2: 11.8 (1.20, 8.7) T3: 18 (1.8, 13.0) T4: 24.5 (2.5, 18.1)
CS-4
GENERAL DESCRIPTION
3. DRIVE SELECT LEVER
S501001A0503
Control Systems
S3M0642A
(1) (2) (3) (4) (5)
Knob Cap Plate Bushing Cable
(6) (7) (8) (9) (10)
Spring Lever Clamp Clevis pin Snap ring
CS-5
Control Systems
GENERAL DESCRIPTION
S501001A03
C: CAUTION
Wear working clothing, including a cap, protective goggles, and protective shoes during operation. Remove contamination including dirt and corrosion before removal, installation or disassembly. Keep the disassembled parts in order and protect them from dust or dirt. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly, and replacement. Use SUBARU genuine grease etc. or the equivalent. Do not mix grease etc. with that of another grade or from other manufacturers. Be sure to tighten fasteners including bolts and nuts to the specified torque. Place shop jacks or safety stands at the specified points. Apply grease onto sliding or revolution surfaces before installation. Before installing O-rings or snap rings, apply sufficient amount of grease to avoid damage and deformation. Before securing a part on a vise, place cushioning material such as wood blocks, aluminum plate, or shop cloth between the part and the vise. Before disconnecting electrical connectors, be sure to disconnect negative terminal from battery.
CS-6
SELECT LEVER
Control Systems
S501548A11
2. Select Lever
A: REMOVAL
S501548
B: INSTALLATION
S501548A18
1) Install the select indicator light connector.
1) Set vehicle on a lift. 2) Disconnect battery ground terminal from battery. 3) Move the select lever to the N position. 4) Lift-up the vehicle. 5) Remove heat shield cover. (Non-Turbo model)
S3M0548
2) Install the select lever to vehicle. NOTE: Do not allow the select lever to catch on the wiring harnesses, etc. during installation.
S3M0025
6) Disconnect cable from select lever and then remove cable bracket.
S3M0539
S3M0538B
(A) (B)
Adjusting nuts Cable bracket
7) Remove front cover. <Ref. to EI-30, REMOVAL, Consol Box.> 8) Disconnect connectors, and remove the stay. 9) Remove the six bolts to take out the select lever assembly from body.
3) Install the front cover. <Ref. to EI-30, INSTALLATION, Console Box.> 4) Lift-up the vehicle. 5) Move the select lever to the N position, then adjust the select cable position. <Ref. to CS-11, ADJUSTMENT, Select Cable.> 6) Install heat shield cover. (Non-Turbo model)
S3M0025
S3M0539
CS-7
Control Systems
SELECT LEVER
2) Remove indicator light. NOTE: Be careful not to break the indicator light during removal.
7) Inspect the following items. If the following inspection reveals problems, adjust the select cable and inhibitor switch. <Ref. to CS-11, ADJUSTMENT, Select Cable.> and <Ref. to AT-28, ADJUSTMENT, Inhibitor Switch.> (1) The engine starts operating when select lever is in position P or N, but not in other positions. (2) The back-up light is lit when the select lever is in position R, but not in other positions. (3) Check select lever operation. WARNING: Stop the engine while checking operation of select lever. Check that select lever does not move from N to R without pushing the button. Check that select lever does not move from R to P without pushing the button. Check that select lever does not move from P to R without pushing the button. Check that select lever does not move from 3 to 2 without pushing the button.
S3M0541
3) Detach indicator cover from plate, and remove clip.
S3M0542
4) Remove clip.
G3M0717
C: DISASSEMBLY
S501548A06
1) Remove connector from plate.
S3M0543
5) Remove the two screws.
S3M0540
CS-8
SELECT LEVER
6) While pressing select lever button, remove select lever grip and indicator cover from upper select lever, and then remove the select lever button and spring. CAUTION: Position the select lever grip carefully so that the select lever button does not jump out.
Control Systems
S501548A02
D: ASSEMBLY
1) Clean all parts before assembly. 2) Apply grease [NIGTIGHT LYW No. 2 or equivalent] to each parts. <Ref. to CS-3 AT SELECT LEVER, COMPONENT, General Description.> 3) Assembly is in the reverse order of disassembly. NOTE: Install indicator cover so that harness does not interfere with select lever operation.
S3M0544A
(A) (B) (C) (D) (E) (F)
Select lever grip Harness Upper select lever Button Spring Indicator cover
S3M0546
Be careful to install the spring and button into the select lever grip in the correct direction.
7) Remove cap and then the straight pin. 8) Remove lower select lever, and then lift upper select lever from plate.
S3M0547A
S3M0545A
(A) (B) (C) (D) (E)
Lower select lever Upper select lever Plate Cap Straight pin
4) After completion of fitting, transfer select lever to range P 1, then check whether the indicator and select lever agree, whether the pointer and position mark agree and what the operating force is.
E: INSPECTION
S501548A10
1) Inspect removed parts by comparing with new ones for deformation, damage and wear. Correct or replace if defective. 2) Make sure the following parts operate properly before assembly. (1) Button in the grip: It should slide smoothly. (2) Grip on the select lever: When pushing the grip on the select lever by hand, screw holes should be aligned. (3) Select lever and rod: They should move smoothly.
CS-9
Control Systems
SELECT CABLE
S501549
3. Select Cable
A: REMOVAL
8) Disconnect cable from select lever and then remove cable bracket.
S501549A18
1) Set vehicle on a lift. 2) Disconnect battery ground terminal from battery. 3) Prior to removal, set lever to N position. 4) Lift-up the vehicle. 5) Remove heat shield cover. (Non-turbo model)
S3M0538B
(A) (B)
Adjusting nuts Cable bracket
9) Remove select cable from plate assembly.
S3M0025
6) Remove snap pin from range select lever.
B3M1029B
(A) (B) (C) (D)
Range select lever Snap pin Select cable Clamp
7) Remove plate assembly from transmission case.
B3M1030E
(A) (B) (C)
Select cable Plate ASSY Clamp
CS-10
SELECT CABLE B: INSTALLATION

S501549A11
Control Systems
6) Install heat shield cover. (Non-turbo model)
1) Install select cable to plate assembly. Tightening torque: 32 Nm (3.3 kgf-m, 24 ft-lb) 2) Install select cable to range select lever. 3) Install plate assembly to transmission. Tightening torque: T: 24.5 Nm (2.5 kgf-m, 18.1 ft-lb)
S3M0025
C: INSPECTION
S501549A10
B3M1030G
(A) (B)
Select cable Plate ASSY
4) Install snap pin to range select lever.
Check the removed cable and replace if damaged, rusty, or malfunctioning. 1) Check for smooth operation of the cable. 2) Check the inner cable for damage and rust. 3) Check the outer cable for damage, bends, and cracks. 4) Check the boot for damage, cracks, and deterioration. 5) Move select lever from P position to 1 position. You should be able to feel the detentes in each position. If the detentes cannot be felt or the position pointer is improperly aligned, adjust the cable.
D: ADJUSTMENT
S501549A01
1) Set lever to N position. 2) Lift-up the vehicle. 3) Remove heat shield cover.
B3M1029B
(A) (B) (C) (D)
Range select lever Snap pin Select cable Clamp
5) Move the select lever to the N position, then adjust the select cable position. <Ref. to CS-11 ADJUSTMENT, Select Cable.>
S3M0025
CS-11
Control Systems
SELECT CABLE
7) After completion of fitting, make sure that the select lever operates smoothly all across the operating range. 8) Install in the reverse order of removal.
4) Loosen the adjusting nut on each side.
B3M1792A
(A) (B)
Adjusting nut A Adjusting nut B
5) Turn adjusting nut B until it lightly touches the connector.
B3M1793A
(A) (B) (C) (D) (E) (F)
Front side Select lever Connector Adjusting nut B Contact point Adjusting nut A
6) While preventing adjusting nut B from moving with a wrench, tighten adjusting nut A. Tightening torque: 7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
B3M1794A
(A) (B)
Adjusting nut A Adjusting nut B
CS-12
MT GEAR SHIFT LEVER
Control Systems
4. MT Gear Shift Lever

A: REMOVAL
S501236A18
S501236
9) Remove stay from transmission bracket.
1) Set the vehicle on the lift. 2) Remove gear shift knob. 3) Remove front cover. <Ref. to EI-30, REMOVAL, Console Box.> 4) Remove the four screws to take out the boot and insulator assembly from boot plate. (Turbo model) 5) Remove boot plate from body.
B3M1823A
(A) (B)
Stay Transmission bracket
10) Remove rod from joint.
B3M0615
6) Lift-up the vehicle. 7) Remove rear exhaust pipe and muffler. Non-turbo model with OBD: <Ref. to EX(SOHC)-9, REMOVAL, Rear Exhaust.> and <Ref. to EX(SOHC)-11, REMOVAL, Muffler.> Non-turbo model without OBD: <Ref. to EX(SOHCw/oOBD)-10, REMOVAL, Rear Exhaust.> and <Ref. to EX(SOHCw/oOBD)-12, REMOVAL, Muffler.> Turbo model: <Ref. to EX(DOHC TURBO)-14, REMOVAL, Rear Exhaust.> and <Ref. to EX(DOHC TURBO)-15, REMOVAL, Muffler.> 8) Remove heat shield cover. (Non-turbo model)
B3M1824A
(A) (B)
Stay Rod
11) Remove cushion rubber from body.
B3M1825A
(A) (B)
Stay Cushion rubber
S2M0215
CS-13
Control Systems
MT GEAR SHIFT LEVER

4) Mount cushion rubber on the body. Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft-lb)
12) Remove joint and then extract straight pin.
B3M1826A
(A) (B)
Joint Straight pin (A) (B) Cushion rubber Stay
B3M1825A
13) Lower the vehicle. 14) Remove gear shift lever.
5) Connect rod to the joint. Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft-lb)
B3M1827
B: INSTALLATION
S501236A11
1) Install the joint to the transmission and secure with the straight pin. 2) Insert gear shift lever from room side. NOTE: After inserting rod and stay, temporarily put them onto transmission mount.
B3M1824A
(A) (B)
Joint Rod
6) Connect stay to transmission bracket. Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft-lb)
B3M1827 B3M1823A
(A) (B)
CS-14
MT GEAR SHIFT LEVER

7) Install heat shield cover. (Non-turbo model)
Control Systems
S501236A06
C: DISASSEMBLY
1) Disassemble locking wire.
S2M0215
8) Install rear exhaust pipe and muffler. Non-turbo model with OBD: <Ref. to EX(SOHC)-9, INSTALLATION, Rear Exhaust.> and <Ref. to EX(SOHC)-11, INSTALLATION, Muffler.> Non-turbo model without OBD: <Ref. to EX(SOHCw/oOBD)-10, INSTALLATION, Rear Exhaust.> and <Ref. to EX(SOHCw/oOBD)12, INSTALLATION, Muffler.> Turbo model: <Ref. to EX(DOHC TURBO)-14, INSTALLATION, Rear Exhaust.> and <Ref. to EX(DOHC TURBO)15, INSTALLATION, Muffler.> 9) Mount boot plate on body. Tightening torque: 4.5 Nm (0.46 kgf-m, 3.3 ft-lb)
B3M0617C
(A) (B)
Locking wire Stay
2) Remove rod from gear shift lever.
B3M1828A
(A) (B) (C)
Rod Gear shift lever Stay
3) Remove snap ring from bushing D, then disconnect stay.
B3M0615
10) Install boot and insulator assembly on boot plate. (Turbo model) 11) Install front cover, gear shift knob. <Ref. to EI-30, INSTALLATION, Console Box.>
B3M0619B
(A) (B) (C)
Snap ring Bushing D Boot
4) Remove boot from gear shift lever.
CS-15
Control Systems
MT GEAR SHIFT LEVER D: ASSEMBLY

S501236A02
5) Remove bushing and cushion rubber from stay.
1) Clean all parts before assembly. 2) Mount the bushing B and cushion rubber on the stay.
B3M0830D
(A) (B) (C)
Bushing Stay Cushion rubber (A) (B) Bushing Cushion rubber
B3M0830C
6) Remove O-ring, then disconnect bushing D.
3) Mount each part; boot, O-ring, bushing A, spacer, bushing B, bushing D and straight pin on the gear shift lever. CAUTION: Always use new O-rings. Apply grease [DNIGTIGHT LYW No. 2 or equivalent] to the inner and side surfaces of the bushing when installing the spacer.
B3M0620C
(A) (B) (C)
O-ring A O-ring B Bushing D
7) Draw out straight pin, then remove bushing C from gear shift lever.
B3M0623C
B3M0621B
(A) (B)
Straight pin Bushing C
(A) (B) (C) (D) (E) (F) (G) (H)
Boot O-ring B Bushing A Spacer Bushing C Bushing D Straight pin O-ring A
CS-16
MT GEAR SHIFT LEVER

4) Insert the gear shift lever into the boot hole. 5) Install snap ring and stay to the bushing D.
Control Systems
9) Check the swing torque of the rod in relation to the gear shift lever. If the torque exceeds the specification, replace bushing or retighten nuts. Rocking torque: 0.7 Nm (0.07 kgf-m, 0.5 ft-lb) or less
B3M0619C
(A) (B)
Snap ring Bushing D

B3M1829C
6) Tighten with locking wire to the extent that the boot will not come off. CAUTION: Always use new locking wire.
(A) (B) Center of rotation Swing torque
10) Check that there is no excessive play and that parts move smoothly.
B3M0617C
(A) (B)
Locking wire Stay
7) Insert the rod into the boot hole. 8) Connect rod to gear shift lever. Tightening torque: 11.8 Nm (1.2 kgf-m, 8.7 ft-lb)
B3M1828A
(A) (B) (C)
Rod Shift lever Stay
CS-17
Control Systems
MT GEAR SHIFT LEVER

S501236A10
E: INSPECTION
1) Check each part (bushing A, cushion rubber, spacer, boot, stay and rod, etc.) for deformation, damage and wear. Repair or replace any defective part. Determine defective parts by comparing with new parts.
B3M1765A
(A) (B) (C) (D) (E) (F)
Bushing A Cushion rubber Spacer Boot Stay Rod
2) Check the swing torque of the rod in relation of the gear shift lever. If the torque exceeds the specification, replace bushing or retighten nuts. Rocking torque: 0.7 Nm (0.07 kgf-m, 0.5 ft-lb) or less
B3M1829C
(A) (B)
Center of rotation Swing torque
CS-18
MT DRIVE SELECT LEVER
Control Systems
S501235A11
5. MT Drive Select Lever

A: REMOVAL
S501235A18
S501235
B: INSTALLATION
1) Install drive select lever. Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft-lb) 2) Set drive select lever to HI position.
1) To immobilize vehicle, put the select lever in 1st and block the tires. 2) Disconnect battery ground terminal from battery. 3) Set drive select lever to HI position. 4) Remove the drive select lever knob.
B3M1516A
(A)
S3M0086A
HI position
(A)
Drive select lever knob
3) Be sure to insert cable end bolt into lever arm slit.
5) Remove console box. <Ref. to EI-30 Console Box.> 6) Remove the bolt installing drive select lever assembly on body.
B3M1517A
(A) (B)
Cable end bolt Lever arm
G3M0766
4) Tighten nut where cable end bolt comes to a stop. Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft-lb) 5) Install in the reverse order of removal.
7) Remove nut, clamp and then disconnect the cable from drive select lever assembly.
B3M1846A
(A) (B) (C)
Nut Drive select lever Clamp
CS-19
Control Systems
MT DRIVE SELECT LEVER

S501235A06
C: DISASSEMBLY
1) Remove spring.
B3M2132A
(A)
Spring
2) Remove lever, cap and bushing.
B3M2133A
(A) (B) (C) (D) (E)
Washer Bushing Plate Cap Lever

S501235A02
D: ASSEMBLY
1) Assemble in the reverse order of disassembly. Tightening torque: 1.6 Nm (0.16 kgf-m, 1.2 ft-lb) 2) Make sure the select lever moves smoothly.
E: INSPECTION
S501235A10
1) Make sure the select lever moves smoothly. If it does not move smoothly, repair or replace it. 2) Make sure the drive select lever is not damaged. If it is damaged, repair or replace it.
CS-20
DRIVE SELECT CABLE
Control Systems
S501717A01
6. Drive Select Cable

A: REMOVAL
S501717A18
S501717
D: ADJUSTMENT
1) Set the drive select lever to HI position. 2) Remove the drive select lever knob.
1) Remove the drive select lever. <Ref. to CS-19 REMOVAL, MT Drive Select Lever.> 2) Remove intake duct. <Ref. to IN(SOHC)-8, REMOVAL, Air Intake Duct.> 3) Remove air cleaner case. <Ref. to IN(SOHC)-7, REMOVAL, Air Cleaner Case.> 4) Remove snap pin and clevis pin. 5) Loosen the nut and disconnect the cable from cable bracket.
S3M0086A
3) Remove console box. <Ref. to EI-30, Console Box.> 4) Loosen the nut. 5) Make sure transmission is in HI position. If isnt, pull on cable to put transmission in HI position. 6) Tighten the nut in the location where the cable end bolt stops naturally.
S3M0641A
Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft-lb) 7) Make sure to move transmission to HI or LO position by moving the drive select lever. If it doesnt, readjust cable.
(A) (B) (C)
Snap pin Clevis pin Nut
6) Remove cable from the under side of vehicle.
G3M0769
B: INSTALLATION
S501717A11
1) Install in the reverse order of removal. 2) Make sure the drive select lever operates properly.
C: INSPECTION
S501717A10
1) Make sure to move transmission to HI or LO position by moving the drive select lever. If it doesnt, adjust the cable.<Ref. to CS-21 ADJUSTMENT, Drive Select Cable.> 2) Make sure cable operates smoothly. If it catches or fails to work properly, repair or replace it. 3) Check cable for damage.
CS-21
Control Systems

S501257

A: INSPECTION
Symptom 1. AT select lever
S501257A10
Possible cause (1) Starter does not run. (2) Back-up light does not light up.
Remedy Adjust select cable and inhibitor switch, or inspect circuit. Adjust select cable and inhibitor switch, or inspect circuit.
CS-22
AUTOMATIC TRANSMISSION
AT
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Page General Description.....................................................................................2 Automatic Transmission Fluid .....................................................................9 Differential Gear Oil ...................................................................................11 Road Test ..................................................................................................12 Stall Test....................................................................................................13 Time Lag Test............................................................................................15 Line Pressure Test ....................................................................................16 Transfer Clutch Pressure Test...................................................................18 Automatic Transmission Assembly............................................................19 Transmission Mounting System ................................................................25 Extension Case Oil Seal ...........................................................................27 Inhibitor Switch ..........................................................................................28 Front Vehicle Speed Sensor .....................................................................32 Rear Vehicle Speed Sensor......................................................................36 Torque Converter Turbine Speed Sensor .................................................37 Control Valve Body....................................................................................38 Shift Solenoids, Duty Solenoids and ATF Temperature Sensor ...............41 ATF Filter...................................................................................................46 Transmission Control Module (TCM) ........................................................48 ATF Cooler Pipe and Hose .......................................................................49
Automatic Transmission
GENERAL DESCRIPTION
S502001
A: SPECIFICATIONS
Model Type Stall torque ratio Nominal diameter Stall speed (at sea level) One-way clutch
S502001E49
5. PLANETARY GEAR AND PLATE

Non-turbo model
S502001E4901
S502001E4905
Turbo model 33 21 75 42 17 75
1. TORQUE CONVERTER CLUTCH
Non-turbo model Turbo model Symmetric, 3 element, single stage, 2 phase torque converter 2.0 2.2 1.9 2.1 236 mm (9.29 in) 246 mm (9.69 in) 2,100 2,600 2,150 2,950 rpm rpm Sprague type one-way clutch
S502001E4902
2. OIL PUMP
Type Driving method Number of teeth
Pracoid constant-displacement pump Driven by engine Inner rotor 9 Outer rotor 10
3. TRANSMISSION CONTROL ELEMENT

S502001E4903
Type Multi-plate clutch Multi-plate brake One-way clutch (sprague type)
4-forward, 1-reverse, double-row planetary gears 3 sets 2 sets 1 sets

S502001E4904
Tooth number of front sun gear Tooth number of front pinion Tooth number of front internal gear Tooth number of rear sun gear Tooth number of rear pinion Tooth number of rear internal gear Drive & driven plate number of high clutch Drive & driven plate number of low clutch Drive & driven plate number of reverse clutch Drive & driven plate number of 2-4 brake Drive & driven plate number of low & reverse brake
4. TRANSMISSION GEAR RATIO

1st 2nd 3rd 4th Rev
Gear ratio 2.785 1.545 1.000 0.694 2.272
AT-2
GENERAL DESCRIPTION
6. SELECTOR POSITION
P (Park) R (Reverse)
S502001E4906
S502001E4908
8. COOLING AND HARNESS

Cooling system ATF cooling system (Radiation capacity) Inhibitor switch Transmission harness
Transmission in neutral, output member immovable, and engine start possible Transmission in reverse for backing
Liquid-cooled cooler incorporated in radiator 4.630 kW (3,981 kcal/h, 15,797 BTU/h) 12 poles 20 poles
S502001E4909
Transmission in neutral and engine start posN (Neutral) sible Automatic gear change 1st 2nd 3rd D (Drive) 4th Automatic gear change 1st 2nd 3rd 3 (3rd) 4th Automatic gear change 1st 2nd 3rd 2 (2nd) 4th 1st gear locked (Deceleration possible 1st 1 (1st) 2nd 3rd 4th) Control Hydraulic remote control method
9. TRANSFER
Model Transfer clutch Drive & driven plate number of transfer clutch Control method Lubricant 1st reduction gear ratio
Non-turbo model Turbo model Hydraulic multi-plate clutch 4 6
7. HYDRAULIC CONTROL AND LUBRICATION S502001E4907

Electronic/hydraulic control [Four forward speed changes by electrical signals of vehicle speed and accelerator (throttle) opening] Dexron III type Automatic transmission fluid 8.4 8.7 (8.9 9.2 US qt, 7.4 7.7 Imp qt) 9.3 9.6 (9.8 10.1 US qt, 8.2 8.4 Imp qt) Forced feed lubrication with oil pump Automatic transmission fluid (above mentioned)
S502001E4910
Electronic, hydraulic type The same Automatic transmission fluid used in automatic transmission 1.000 (53/53)
Type
Fluid Non-turbo model Turbo model Lubrication system Oil
Fluid capacity
10. FINAL REDUCTION

Model Front final gear ratio
Turbo model 4.111 (37/9)
Non-turbo model 4.444 (40/9)
Lubrication oil
H3M1235A
Front differential oil capacity
1.2
(1.3 US qt, 1.1 Imp qt)
AT-3
GENERAL DESCRIPTION
S502001A05
B: COMPONENT
NOTE: For information about other transmission mounting components, refer to AUTOMATIC TRANSMISSION <Pub. No. G0853ZE> a separate publication.
1. TRANSMISSION MOUNTING
S502001A0501
S2M0197A
(1) (2) (3) (4)
Pitching stopper Rear cushion rubber Crossmember Stopper
Tightening torque: Nm (kgf-m, ft-lb) T1: 35 (3.6, 26) T2: 39 (4.0, 29) T3: 50 (5.1, 37) T4: 58 (5.9, 43) T5: 70 (7.1, 51)
AT-4

S502001A03
Wear working clothing, including a cap, protective goggles, and protective shoes during operation. Remove contamination including dirt and corrosion before removal, installation, and disassembly. Keep the disassembled parts in order and protect them from dust or dirt. Until the oil pan is removed, do not place with the oil pan side facing up to prevent foreign matter from entering the valve body. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. When disassembling the case and other light alloy parts, use a plastic hammer to force it apart. Do not pry it apart with a screwdriver or other tool. Be careful not to burn your hands, because each part on the vehicle is hot after running. Use SUBARU genuine gear oil, grease etc. or the equivalent. Do not mix gear oil, grease etc. with
that of another grade or from other manufacturers. Be sure to tighten fasteners including bolts and nuts to the specified torque. Place shop jacks or safety stands at the specified points. Apply gear oil onto sliding or revolution surfaces before installation. Replace deformed or otherwise damaged snap rings with new ones. Before installing O-rings or oil seals, apply sufficient amount of ATF fluid to avoid damage and deformation. Be careful not to incorrectly install or fail to install O-rings, snap rings and other such parts. Before securing a part on a vise, place cushioning material such as wood blocks, aluminum plate, or shop cloth between the part and the vise. Avoid damaging the mating surface of the case. Before applying sealant, completely remove the old seal.
D: PREPARATION TOOL
1. SPECIAL TOOLS
ILLUSTRATION
S502001A1701
S502001A17
DESCRIPTION PULLER ASSY
REMARKS Used for removing extension case oil seal.
B3M1977
498057300
INSTALLER
Used for installing extension oil seal.
B3M1972
AT-5
ILLUSTRATION
GENERAL DESCRIPTION
TOOL NUMBER 498575400 DESCRIPTION OIL PRESSURE GAUGE ASSY REMARKS Used for measuring oil pressure.
B3M2040
498897200
ADAPTER
Used oil pump housing when measuring reverse clutch pressure and line pressure.
B3M2041
498545400
FILTER WRENCH
Used for removing and installing ATF filter.
B3M2042
498277200
STOPPER SET
Used for removing and installing automatic transmission assembly to engine.
B3M2043
AT-6
GENERAL DESCRIPTION
ILLUSTRATION TOOL NUMBER 41099AA020 DESCRIPTION ENGINE SUPPORT
REMARKS Used for supporting engine.
B3M1976
41099AA010
ENGINE SUPPORT BRACKET
Used for supporting engine.
B3M1975
499977300
CRANK PULLEY WRENCH
Used for removing and installing bolts which secure torque converter to the drive plate.
B2M4157
24082AA150 CARTRIDGE (Newly adopted tool)
Troubleshooting for electrical systems.
B2M3876
AT-7
ILLUSTRATION
GENERAL DESCRIPTION
TOOL NUMBER 22771AA030 DESCRIPTION SELECT MONITOR KIT REMARKS Troubleshooting for electrical systems. English: 22771AA030 (Without printer) German: 22771AA070 (Without printer) French: 22771AA080 (Without printer) Spanish: 22771AA090 (Without printer)
B2M3877

TOOL NAME Circuit Tester
S502001A1702
REMARKS Used for measuring resistance, voltage and ampere.
AT-8
AUTOMATIC TRANSMISSION FLUID
2. Automatic Transmission Fluid

S502248
A: INSPECTION
S502248A10
1) Check the level of the ATF. (1) Raise ATF temperature to 60 to 80C (140 to 176F) from 40 to 60C (104 to 140F) (when cold) by driving a distance of 5 to 10 km (3 to 6 miles). NOTE: The level of ATF varies with fluid temperature. Pay attention to the fluid temperature when checking oil level.
Time for temperature rise to 60C (140F) with atmospheric temperature of 0C (32F): More than 25 minutes <Reference> Time for temperature rise to 30C (86F) with atmospheric temperature of 0C (32F): Approx. 8 minutes By running the vehicle Time for temperature rise to 60C (140F) with atmospheric temperature of 0C (32F): More than 10 minutes (5) Method for checking fluid level upon delivery or at periodic inspection Check fluid level after a warm-up run of approx. 10 minutes. During the warm-up period, the automatic transmission functions can also be checked. 2) Check the fluid for leaks. Check for leaks in the transmission. If there are leaks, it is necessary to repair or replace gasket, oil seals, plugs or other parts.
B: REPLACEMENT
B3M1020B
S502248A20
1) Lift vehicle. 2) Drain ATF completely. CAUTION: Directly after the engine has been running, the ATF is hot. Be careful not to burn yourself. NOTE: Tighten ATF drain plug after draining ATF. Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
(A) (B) (C)
ATF level gauge Upper level Lower level
(2) Make sure the vehicle is level. After selecting all positions (P, R, N, D, 3, 2, 1), set the select leveler in P range. Measure fluid level with the engine idling. NOTE: After running, idle the engine for one or two minutes before measurement. (3) If the fluid level is below the center between upper and lower marks, add the recommended ATF until the fluid level is found within the specified range (above the center between upper and lower marks). When the transmission is hot, the level should be above the center of upper and lower marks, and when it is cold, the level should be found below the center of these two marks. CAUTION: Use care not to exceed the upper limit level. ATF level varies with temperature. Remember that the addition of fluid to the upper limit mark when the transmission is cold will result in the overfilling of fluid. (4) Fluid temperature rising speed By idling the engine
B3M1036B
(A) (B) (C)
Oil pan Drain plug Differential oil drain plug
3) Lower the vehicle. 4) Pour ATF into the oil charge pipe. Recommended fluid: Dexron III type automatic transmission fluid
AT-9
AUTOMATIC TRANSMISSION FLUID
Capacity: Fill the same amount of fluid drained from drain plug hole. Capacity when transmission is overhauled: Non-turbo model: 8.4 8.7 (8.9 9.2 US qt, 7.4 7.71 Imp qt) Turbo model: 9.3 9.6 (9.8 10.1 US qt, 8.2 8.4 Imp qt) 5) Check the level and leaks of the ATF. <Ref. to AT-9 INSPECTION, Automatic Transmission Fluid.>
AT-10
DIFFERENTIAL GEAR OIL
3. Differential Gear Oil

A: INSPECTION
S502150A10
S502150
3) Lower the vehicle. 4) Pour gear oil into the gauge hole. Recommended fluid: Use GL-5 or equivalent. Gear oil capacity: 1.2 (1.3 US qt, 1.1 Imp qt) 5) Check the level of the differential gear oil. <Ref. to AT-11 INSPECTION, Differential Gear Oil.>
1) Park vehicle on a level surface. 2) Remove oil level gauge and wipe it clean. 3) Reinsert the level gauge all the way. Be sure that the level gauge is correctly inserted and in the proper orientation. 4) Remove it again and note the reading. If the differential gear oil level is below the L line, add oil to bring the level up to the F line. 5) To prevent overfilling the differential gear oil, do not add oil above the F line.
S3M0478A
(A) (B)
Upper level Lower level

S502150A20
B: REPLACEMENT
1) Lift vehicle. 2) Drain differential gear oil completely. CAUTION: Directly after the engine has been running, the differential gear oil is hot. Be careful not to burn yourself. NOTE: Tighten differential gear oil drain plug after draining differential gear oil. Tightening torque: 44 Nm (4.5 kgf-m, 32.5 ft-lb)
B3M1036B
(A) (B) (C)
AT-11
ROAD TEST
10. OIL LEAKS
S502247A1010
4. Road Test
S502247
A: INSPECTION
After the driving test, inspect for oil leaks.

S502247A10 S502247A1001
1. GENERAL PRECAUTION
Road tests should be conducted to properly diagnose the condition of the automatic transmission. CAUTION: When performing test, do not exceed posted speed limit.
2. D RANGE SHIFT FUNCTION
S502247A1002
Check shifting between 1st 2nd 3rd 4th while driving on normal city streets.
3. D RANGE SHIFT SHOCK
S502247A1003
Check the shock level when shifting up during normal driving.
4. KICK-DOWN FUNCTION
S502247A1004
Check kick-down for each gear. Also check the kick-down shock level.
5. ENGINE BRAKE OPERATION
S502247A1005
Check the 3rd gear engine brake when shifting between D 3rd range while driving in 4th gear of D range [50 to 60 km/h (31 to 37 MPH)]. Check the 2nd gear engine brake when shifting between 3 2 range while driving in the 3 range 3rd gear [40 to 50 km/h (25 to 31 MPH)]. Check the 1st gear engine brake when shifting between 2 1 range while driving in the 2 range 2nd gear [20 to 30 km/h ( 12 to 19 MPH)].
6. LOCK-UP FUNCTION
S502247A1006
Check that rpm does not change sharply when the axle pedal is lightly depressed when driving on flat roads at normal speed in the lock-up range.
7. P RANGE OPERATION
S502247A1007
Stop the vehicle on an uphill grade of 5% or more and shift to P range. Check that the vehicle does not move when the parking brake is released.
8. UNUSUAL SOUNDS AND VIBRATION

S502247A1008
Check for unusual sounds and vibration while driving and during shifting.
9. CLIMBING CONTROL FUNCTION
S502247A1009
Check that gear remains in 3rd when going up a grade. Check that gear remains in 3rd when applying the brakes while going down a grade.
AT-12
STALL TEST
5. Stall Test
S502246
A: INSPECTION
S502246A10
1. GENERAL INFORMATION
S502246A1001
The stall test is of extreme importance in diagnosing the condition of the automatic transmission and the engine. It should be conducted to measure the engine stall speeds in R and 2 ranges. Purposes of the stall test: 1) To check the operation of the automatic transmission clutch. 2) To check the operation of the torque converter clutch. 3) To check engine performance.
9) If stall speed in 2 range is higher than specifications, low clutch slipping and 2-4 brake slipping may occur. To identify it, conduct the same test as above in D range. 10) Perform the stall tests with the select lever in the R range. NOTE: Do not continue the stall test for MORE THAN FIVE SECONDS at a time (from closed throttle, fully open throttle to stall speed reading). Failure to follow this instruction causes the engine oil and ATF to deteriorate and the clutch and brake to be adversely affected. Be sure to cool down the engine for at least one minute after each stall test with the select lever set in the P or N range and with the idle speed lower than 1,200 rpm. If the stall speed is higher than the specified range, attempt to finish the stall test in as short a time as possible, in order to prevent the automatic transmission from sustaining damage. Stall speed (at sea level): Non-turbo model: 2,100 2,600 rpm Turbo model: 2,150 2,950 rpm
2. TEST METHODS
S502246A1002
1) Preparations before test: (1) Check that throttle valve opens fully. (2) Check that engine oil level is correct. (3) Check that coolant level is correct. (4) Check that ATF level is correct. (5) Check that differential gear oil level is correct. (6) Increase ATF temperature to 50 to 80C (122 to 176F) by idling the engine for approximately 30 minutes (with select lever set to N or P). 2) Install an engine tachometer at a location visible from the driver s compartment and mark the stall speed range on the tachometer scale. 3) Place the wheel chocks at the front and rear of all wheels and engage the parking brake. 4) Move the manual linkage to ensure it operates properly, and shift the select lever to the 2 range. 5) While forcibly depressing the foot brake pedal, gradually depress the accelerator pedal until the engine operates at full throttle.
B3M0286C
(A) (B)
Brake pedal Accelerator pedal
6) When the engine speed is stabilized, read that speed quickly and release the accelerator pedal. 7) Shift the select lever to Neutral, and cool down the engine by idling it for more than one minute. 8) Record the stall speed.
AT-13
STALL TEST
3. EVALUATION
S502246A1003
Stall speed (at sea level) Less than specifications
Position 2, R D
Greater than specifications
Cause Throttle valve not fully open Erroneous engine operation Torque converter clutchs one-way clutch slipping Line pressure too low Low clutch slipping One-way clutch malfunctioning Line pressure too low Reverse clutch slipping Low & reverse brake slipping Line pressure too low Low clutch slipping 2-4 brake slipping
AT-14
TIME LAG TEST
6. Time Lag Test

A: INSPECTION
S502245
S502245A10
S502245A1001
If the select lever is shifted while the engine is idling, there will be a certain time elapse or lag before the shock can be felt. This is used for checking the condition of the low clutch, reverse clutch, low & reverse brake and one-way clutch. CAUTION: Perform the test at normal operation fluid temperature 60 to 80C (140 to 176F). Be sure to allow a one minute interval between tests. Make three measurements and take the average value.
2. TEST METHODS
S502245A1002
1) Fully apply the parking brake. 2) Start the engine. Check idling speed (A/C OFF). 3) Shift the select lever from N to D range. Using a stop watch, measure the time it takes from shifting the lever until the shock is felt. Time lag: Less than 1.2 seconds 4) In same manner, measure the time lag for N R. Time lag: Less than 1.5 seconds
3. EVALUATION
S502245A1003
1) If N D time lag is longer than specified: Line pressure too low Low clutch worn One-way clutch not operating properly 2) If N R time lag is longer than specified: Line pressure too low Reverse clutch worn Low & reverse brake worn
AT-15
LINE PRESSURE TEST

S502244
7. Line Pressure Test

A: MEASUREMENT
S502244A14
2. TEST METHODS
S502244A1402
S502244A1401
If the clutch or the brake shows a sign of slippage or shifting sensation is not correct, the line pressure should be checked. Excessive shocks during upshifting or shifting takes place at a higher point than under normal circumstances, may be due to the line pressure being too high. Slippage or inability to operate the vehicle may, in most cases, be due to loss of oil pressure for the operation of the clutch, brake or control valve. 1) Line pressure measurement (under no load) CAUTION: Before measuring line pressure, jack-up all wheels. Maintain temperature of ATF at approximately 50C (122F) during measurement. (ATF will reach the above temperature after idling the engine for approximately 30 minutes with select lever in N or P.) 2) Line pressure measurement (under heavy load) CAUTION: Before measuring line pressure, apply both foot and parking brakes with all wheels chocked (Same as for stall test conditions). Measure line pressure when select lever is in R, 2 with engine under stall conditions. Measure line pressure within 5 seconds after shifting the select lever to each position. (If line pressure needs to be measured again, allow the engine to idle and then stop. Wait for at least one minute before measurement.) Maintain the temperature of ATF at approximately 50C (122F) during measurement. (ATF will reach the above temperature after idling the engine for approximately 30 minutes with the select lever in N or P.)
1) Temporarily attach the ST to a suitable place in the driver s compartment, remove the blind plug located in front of the toe board and pass the hose of the ST to the engine compartment. ST 498575400 OIL PRESSURE GAUGE ASSY
B3M0568C
(A) (B) (C)
Pressure gauge hose Hole in toe board (blank cap hole) Brake pedal
2) Remove the test plug and install ST instead. ST 498897200 OIL PRESSURE GAUGE ADAPTER
B3M1046C
(A)
Test plug
3) Connect ST1 with ST2. ST1 498897200 OIL PRESSURE GAUGE ADAPTER ST2 498575400 OIL PRESSURE GAUGE ASSY
AT-16
LINE PRESSURE TEST

4) Check for duty ratio changes by opening and closing throttle valve using Subaru Select Monitor. (1) Insert the cartridge to Subaru Select Monitor. <Ref. to AT-5 PREPARATION TOOL, General Description.>
S2M0286
(2) Connect Subaru Select Monitor to data link connector. 5) Check line pressure in accordance with the following chart.
3. EVALUATION
Range position 2
S502244A1403
R D
Standard line pressure Line presThrottle Line pressure sure duty position kPa (kg/cm2, psi) ratio (%) 1,128 1,304 5 Full open (11.5 13.3, 164 189) 1,520 1,716 5 Full open (15.5 17.5, 220 249) 304 412 100 Full closed (3.1 4.2, 44 60)
AT-17
TRANSFER CLUTCH PRESSURE TEST

2. EVALUATION
S502159A1002
8. Transfer Clutch Pressure Test

S502159
A: INSPECTION
1. TEST METHODS
S502159A10
S502159A1001
Check transfer clutch pressure in accordance with the following chart in the same manner as with line pressure test. <Ref. to AT-16, Line Pressure Test.> ST 498897700 OIL PRESSURE ADAPTER SET ST 498575400 OIL PRESSURE GAUGE ASSY AWD mode: D range FWD mode: P range, engine speed 2,000 rpm CAUTION: Before setting in FWD mode, install spare fuse on FWD mode switch.
NOTE: If oil pressure is not produced or if it does not change in the AWD mode, the transfer duty solenoid or transfer valve assembly may be malfunctioning. If oil pressure is produced in the FWD mode, the problem is similar to that in the AWD mode.
Standard transfer clutch pressure kPa (kg/cm2, psi) FWD Duty ratio Throttle AWD mode mode (%) position 932 1,089 Full 5 (9.5 11.1, closed 135 158) 2/3 216 294 60 throttle (2.2 3.0, 31 43) 95 Full open 0 (0, 0)
B3M1047C
(A)
Test plug
AT-18
AUTOMATIC TRANSMISSION ASSEMBLY
9. Automatic Transmission Assembly

S502207
9) Install ST to torque converter clutch case. ST 498277200 STOPPER SET
A: REMOVAL
S502207A18
1) Set vehicle on a lift. 2) Open front hood fully, and support with stay. 3) Disconnect battery ground terminal. 4) Remove air intake duct and cleaner case. (Nonturbo model) <Ref. to IN(SOHC)-8, REMOVAL, Air Intake Duct.> and <Ref. to IN(SOHC)-7, REMOVAL, Air Cleaner Case.> 5) Remove air cleaner case stay. (Non-turbo model)
H2M1961A
S2M0901 S2M0126
6) Remove intercooler. (Turbo model) <Ref. to IN(DOHC TURBO)-10, REMOVAL, Intercooler.> 7) Disconnect the following connectors. (1) Transmission harness connector
11) Separate torque converter clutch from drive plate. (1) Remove service hole plug. (2) Remove bolts which hold torque converter clutch to drive plate. (3) While rotating the engine, remove other bolts using ST. CAUTION: Be careful not to drop bolts into torque converter clutch housing. ST 499977300 CRANK PULLEY WRENCH
S2M0212
(2) Transmission ground terminal 8) Remove starter. <Ref. to SC-5, REMOVAL, Starter.>
S2M0207
AT-19

With OBD: <Ref. to EX(SOHC)-9, REMOVAL, Rear Exhaust Pipe.> and <Ref. to EX(SOHC)-11, REMOVAL, Muffler.> Without OBD: <Ref. to EX(SOHCw/oOBD)-10, REMOVAL, Rear Exhaust Pipe.> and <Ref. to EX(SOHCw/oOBD)12, REMOVAL, Muffler.> 17) Remove center, rear exhaust pipe and muffler. (Turbo model) <Ref. to EX(DOHC TURBO)-9, REMOVAL, Center Exhaust Pipe.>, <Ref. to EX(DOHC TURBO)-14, REMOVAL, Rear Exhaust Pipe.> and <Ref. to EX(DOHC TURBO)-15, REMOVAL, Muffler.> 18) Remove heat shield cover. (If equipped)
12) Remove ATF level gauge. CAUTION: Plug opening to prevent entry of foreign particles into transmission fluid.
S2M0908
13) Set ST. NOTE: Also is available Part No. 41099AA010. ST 41099AA020 ENGINE SUPPORT ASSY
S2M0215
19) Remove hanger bracket from right side of transmission. 20) Remove under cover. 21) Drain ATF to remove ATF drain plug.
G2M0313
14) Remove bolt which holds right upper side of transmission to engine.
B3M1036C
(A) (B)
B3M2044
Oil pan Drain plug
15) Remove front and center exhaust pipe. (Nonturbo model) With OBD: <Ref. to EX(SOHC)-5, REMOVAL, Front Exhaust Pipe.> Without OBD: <Ref. to EX(SOHCw/oOBD)-6, REMOVAL, Front Exhaust Pipe.> 16) Remove rear exhaust pipe and muffler. (Nonturbo model)
AT-20

22) Disconnect ATF cooler hoses from pipes of transmission side, and remove ATF level gauge guide.
26) Remove nuts which hold lower side of transmission to engine.
B3M2047 S2M0909
27) Place transmission jack under transmission. CAUTION: Always support transmission case with a transmission jack. On AT vehicles, make sure that the support plates of transmission jack dont touch the oil pan. 28) Remove transmission rear crossmember from vehicle.
23) Remove propeller shaft. <Ref. to DS-14 REMOVAL, Propeller Shaft.> 24) Remove shift select cable. <Ref. to CS-10 REMOVAL, Select Cable.> 25) Remove front drive shafts from transmission. (1) Disconnect stabilizer link from transverse link. (2) Remove bolt securing ball joint of transverse link to housing.
S4M0090
B2M3407
(3) Lower transverse link. (4) Remove spring pins and separate front drive shafts from each side of the transmission. CAUTION: Discard removing spring pin. Replace with a new one.
29) Remove transmission. CAUTION: Move transmission and torque converter as a unit away from engine.
B2M0035
G2M0325
30) Separate transmission assembly and rear cushion rubber.
AT-21

S502207A11
B: INSTALLATION
1) Install rear cushion rubber to transmission assembly. Tightening torque: 38 Nm (3.9 kgf-m, 28 ft-lb) 2) Install ST to torque converter clutch case. ST 498277200 STOPPER SET
6) Tighten nuts and bolts which hold lower side of transmission to engine. Tightening torque: 50 Nm (5.1 kgf-m, 36.9 ft-lb)
B3M2047
H2M1961A
7) Lower the vehicle. 8) Connect engine and transmission. (1) Remove ST from torque converter clutch case. NOTE: Be careful not to drop the ST into the torque converter clutch case when removing ST. ST 498277200 STOPPER SET (2) Install starter. <Ref. to SC-6 INSTALLATION, Starter.> (3) Tighten bolt which holds right upper side of transmission to engine.
3) Install transmission onto engine. (1) Gradually raise transmission with transmission jack.
B2M0035
(2) Engage them at splines. 4) Install transmission rear crossmember. Tightening torque: T1: 35 Nm (3.6 kgf-m, 26 ft-lb) T2: 70 Nm (7.1 kgf-m, 51 ft-lb)
B3M2044
B2M3407A
5) Take off transmission jack.
AT-22

9) Install torque converter clutch to drive plate. (1) Tighten bolts which hold torque converter clutch to drive plate. (2) Tighten other bolts while rotating the engine by using ST. CAUTION: Be careful not to drop bolts into torque converter clutch housing. ST 499977300 CRANK PULLEY WRENCH Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
(2) Install front drive shaft into transmission. (3) Drive spring pin into chamfered hole of drive shaft. CAUTION: Always use a new spring pin.
G2M0325
(4) Install ball joints of lower arm into knuckle arm of housing, and tighten installing bolts. Tightening torque: 49 Nm (5.0 kgf-m, 36 ft-lb)
S2M0207
(3) Clog plug onto service hole. 10) Remove ST.
B2M3402A
(A) (B)
G2M0313
Transverse link Ball joint
13) Install stabilizer link to front transverse link. Tightening torque: 30 Nm (3.1 kgf-m, 22 ft-lb)
S4M0355A
S2M0126C
12) Lift vehicle. Install front drive shafts into transmission. (1) Lift vehicle.
(A) (B) (C)
Stabilizer Stabilizer link Transverse link
14) Install shift select cable onto select lever. <Ref. to CS-11 INSTALLATION, Select Cable.>
AT-23

23) Install ATF level gauge.
15) Install ATF level gauge guide, and connect ATF cooler hoses to pipe.
S2M0214 S2M0909
16) Install propeller shaft. <Ref. to DS-15 INSTALLATION, Propeller Shaft.> 17) Install heat shield cover. (If equipped)
24) Connect the following connectors. (1) Transmission harness connectors (2) Transmission ground terminal 25) Install air cleaner case stay. Tightening torque: 16 Nm (1.6 kgf-m, 11.6 ft-lb) 26) Install air cleaner case and intake duct. (Nonturbo model) <Ref. to IN(SOHC)-7, INSTALLATION, Air Cleaner Case.> and <Ref. to IN(SOHC)-8, INSTALLATION, Air Intake Duct.> 27) Install intercooler. (Turbo model) <Ref. to IN(DOHC TURBO)-10, INSTALLATION, Intercooler.> 28) Connect battery ground terminal. 29) Fill ATF up to the middle of the COLD side on level gauge by using the gauge hole. Recommended fluid: Dexron III type automatic transmission fluid Fluid capacity: Non-turbo model 8.4 8.7 (8.9 9.2 US qt, 7.4 8.4 Imp qt) Turbo model 9.3 9.6 (9.8 10.1 US qt, 8.2 8.4 Imp qt) 30) Take off vehicle from lift arms. 31) Check select lever operation. <Ref. to AT-28, INSPECTION, Inhibitor Switch.> 32) Check the ATF level. <Ref. to AT-9, Automatic Transmission Fluid.> 33) Check the vehicle on the road tester. <Ref. to AT-12, Road Test.>
S2M0215
18) Install rear exhaust pipe and muffler assembly. (Non-turbo model) With OBD: <Ref. to EX(SOHC)-11, INSTALLATION, Muffler.> and <Ref. to EX(SOHC)-9, INSTALLATION, Rear Exhaust Pipe.> Without OBD: <Ref. to EX(SOHCw/oOBD)-12, INSTALLATION, Muffler.> and <Ref. to EX(SOHCw/oOBD)-10, INSTALLATION, Rear Exhaust Pipe.> 19) Install front and center exhaust pipe. (Nonturbo model) With OBD: <Ref. to EX(SOHC)-6, INSTALLATION, Front Exhaust Pipe.> Without OBD: <Ref. to EX(SOHCw/oOBD)-7, INSTALLATION, Front Exhaust Pipe.> 20) Install center, rear exhaust pipe and muffler. (Turbo model) <Ref. to EX(DOHC TURBO)-10, INSTALLATION, Center Exhaust Pipe.>, <Ref. to EX(DOHC TURBO)-14, INSTALLATION, Rear Exhaust Pipe.> and <Ref. to EX(DOHC TURBO)15, INSTALLATION, Muffler.> 21) Install under cover. 22) Lower the vehicle.
AT-24
TRANSMISSION MOUNTING SYSTEM
10. Transmission Mounting System

S502233
A: REMOVAL
S502233A18
1. PITCHING STOPPER
S502233A1801
CAUTION: Always support transmission case with a transmission jack. On AT vehicle, make sure that the support plates of transmission jack dont touch the oil pan.
1) Disconnect battery ground terminal. 2) Remove the air intake duct and cleaner case. (Non-turbo model) <Ref. to IN(SOHC)-8, REMOVAL, Air Intake Duct.> and <Ref. to IN(SOHC)-7, REMOVAL, Air Cleaner Case.> 3) Remove intercooler. (Turbo model) <Ref. to IN(DOHC TURBO)-10, INSTALLATION, Intercooler.> 4) Remove the pitching stopper.
G2M0326
7) Remove the crossmember.
S2M0126
2. CROSSMEMBER AND CUSHION RUBBER S502233A1802

1) Set vehicle on a lift. 2) Disconnect battery ground terminal. 3) Lift vehicle and support it with sturdy racks. 4) Remove the front, center, rear exhaust pipes and muffler. CAUTION: When removing exhaust pipes, be careful each exhaust pipe does not drop out. 5) Remove the heat shield cover. (If equipped) 8) Remove the rear cushion rubber.
B2M3407
B: INSTALLATION
S502233A11
1. PITCHING STOPPER
S502233A1101
1) Install the pitching stopper. Tightening torque: T1: 50 Nm (5.1 kgf-m, 37 ft-lb) T2: 58 Nm (5.9 kgf-m, 43 ft-lb)
S2M0215
S2M0126D
6) Set the transmission jack under the transmission.
2) Install the air intake duct and cleaner case. (Non-turbo model) <Ref. to IN(SOHC)-7, INSTALLATION, Air Cleaner Case.> and <Ref. to IN(SOHC)-8, INSTALLATION, Air Intake Duct.>
AT-25
TRANSMISSION MOUNTING SYSTEM C: INSPECTION

S502233A10
3) Install intercooler. (Turbo model) <Ref. to IN(DOHC TURBO)-10, INSTALLATION, Intercooler.>
Repair or replace parts if the results of the inspection below are not satisfactory.

1) Install the rear cushion rubber. Tightening torque: 38 Nm (3.9 kgf-m, 28 ft-lb) 2) Install the crossmember. Tightening torque: T1: 35 Nm (3.6 kgf-m, 26 ft-lb) T2: 70 Nm (7.1 kgf-m, 51 ft-lb)
1. PITCHING STOPPER
S502233A1001
Make sure that the pitching stopper is not bent or damaged. Make sure that the rubber is not stiff, cracked, or otherwise damaged.

Make sure that the crossmember is not bent or damaged. Make sure that the cushion rubber is not stiff, cracked, or otherwise damaged.
B2M3407A
3) Remove the transmission jack. 4) Install the heat shield cover. (If equipped) 5) Install the front, center, rear exhaust pipes and the muffler. (Non-turbo model) With OBD: <Ref. to EX(SOHC)-6, INSTALLATION, Front Exhaust Pipe.>, <Ref. to EX(SOHC)-9, INSTALLATION, Rear Exhaust Pipe.> and <Ref. to EX(SOHC)-11, INSTALLATION, Muffler.> Without OBD: <Ref. to EX(SOHCw/oOBD)-7, INSTALLATION, Front Exhaust Pipe.>, <Ref. to EX(SOHCw/ oOBD)-10, INSTALLATION, Rear Exhaust Pipe.> and <Ref. to EX(SOHCw/oOBD)-10, INSTALLATION, Rear Exhaust Pipe.> 6) Install center, rear exhaust pipes and muffler. (Turbo model) <Ref. to EX(DOHC TURBO)-10, INSTALLATION, Center Exhaust Pipe.>, <Ref. to EX(DOHC TURBO)-14, INSTALLATION, Rear Exhaust Pipe.> and <Ref. to EX(DOHC TURBO)15, INSTALLATION, Muffler.> 7) Install under cover.
AT-26
EXTENSION CASE OIL SEAL
11. Extension Case Oil Seal

A: INSPECTION
S502718A10
S502718
Make sure ATF does not leak from the joint of the transmission and propeller shaft. If so, replace oil seal. <Ref. to AT-27 REPLACEMENT, Extension Case Oil Seal.>
ST 498057300 INSTALLER 10) Install the propeller shaft. <Ref. to DS-15 INSTALLATION, Propeller Shaft.> 11) Install the heat shield cover. (If equipped) 12) Install the rear exhaust pipe and muffler. Non-turbo model: With OBD <Ref. to EX(SOHC)-11, INSTALLATION, Muffler.> and <Ref. to EX(SOHC)-9, INSTALLATION, Rear Exhaust Pipe.> Without OBD <Ref. to EX(SOHCw/oOBD)-12, INSTALLATION, Muffler.> and <Ref. to EX(SOHCw/oOBD)-10, INSTALLATION, Rear Exhaust Pipe.> Turbo model: <Ref. to EX(DOHC TURBO)-14, INSTALLATION, Rear Exhaust Pipe.> and <Ref. to EX(DOHC TURBO)-15, INSTALLATION, Muffler.> 13) Pour ATF and check the ATF level. <Ref. to AT-9 Automatic Transmission Fluid.>
B: REPLACEMENT
1) 2) 3) 4)
S502718A20
Set vehicle on a lift. Lift vehicle. Clean transmission exterior. Drain ATF completely.
NOTE: Tighten ATF drain plug after draining ATF. Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
B3M1036B
(G) (H) (I)
5) Remove the rear exhaust pipe and muffler. Non-turbo model: With OBD <Ref. to EX(SOHC)-9, REMOVAL, Rear Exhaust Pipe.> and <Ref. to EX(SOHC)11, REMOVAL, Muffler.> Without OBD <Ref. to EX(SOHCw/oOBD)-10, REMOVAL, Rear Exhaust Pipe.> and <Ref. to EX(SOHCw/oOBD)-12, REMOVAL, Muffler.> Turbo model: <Ref. to EX(DOHC TURBO)-14, REMOVAL, Rear Exhaust Pipe.> and <Ref. to EX(DOHC TURBO)-15, REMOVAL, Muffler.> 6) Remove the heat shield cover. (If equipped) 7) Remove the propeller shaft. <Ref. to DS-14 REMOVAL, Propeller Shaft.> 8) Using ST, remove the oil seal. ST 398527700 PULLER ASSY 9) Using ST, install the oil seal.
AT-27
INHIBITOR SWITCH
S502243
12. Inhibitor Switch

A: INSPECTION
S502243A10
When driving condition or starter motor operation is erroneous, first check the shift linkage for improper operation. If the shift linkage is functioning properly, check the inhibitor switch. 1) Disconnect inhibitor switch connector. 2) Check continuity in inhibitor switch circuits with select lever moved to each position. CAUTION: Also check that continuity in ignition circuit does not exist when select lever is in R, D, 3, 2 and 1 ranges. NOTE: If inhibitor switch is inoperative, check for poor contact of connector on transmission side.
Position P R N D 3 2 1 P/N R Pin No. 43 42 41 48 47 46 45 12 11 10 9
3) Check if there is continuity at equal points when the select lever is turned 1.5 in both directions from the N range. If there is continuity in one direction and the continuity in the other or if there is continuity at unequal points, adjust the inhibitor switch. <Ref. to AT-28 ADJUSTMENT, Inhibitor Switch.>
S3M0479A
(A) (B)
Continuity does not exist. Continuity exists.
Signal sent to TCM
4) Repeat the above checks. If there are abnormalities, adjust the select cable. <Ref. to CS-11 ADJUSTMENT, Select Cable.>
B: ADJUSTMENT
S502243A01
Ignition circuit Back-up light circuit
1) Shift the select lever to the N range. 2) Loosen the three inhibitor switch securing bolts. 3) Insert ST as vertical as possible into the holes in the inhibitor switch lever and switch body. ST 499267300 STOPPER PIN
B3H0016B
B3M1027A
4) Tighten the three inhibitor switch bolts. Tightening torque: 3.4 Nm (0.35 kgf-m, 2.5 ft-lb) 5) Repeat the above checks. If the inhibitor switch is determined to be faulty, replace it.
AT-28
INHIBITOR SWITCH C: REMOVAL

S502243A18
1) Set vehicle on a lift. 2) Move select lever to neutral position. 3) Remove air cleaner case. <Ref. to IN(SOHC)-7, REMOVAL, Air Cleaner Case.> 4) Remove intercooler. <Ref. to IN(DOHC TURBO)-10, REMOVAL, Intercooler.> 5) Disconnect inhibitor switch connector.
10) Remove plate assembly from transmission case.
B3M1030H
(A) (B)
11) Remove bolts.

B3M1028B
(A)
Inhibitor switch
6) 7) 8) 9)
Remove inhibitor switch connector from stay. Lift vehicle. Remove under cover. Remove snap pin from range select lever.
B3M1031B
(A)
Inhibitor switch
12) Move range select lever to parking position (left side).
B3M1029C
(A) (B) (C)
Snap pin Select cable Range select lever
B3M1032B
(A)
Range select lever
AT-29
INHIBITOR SWITCH
5) Install select cable to range select lever. 6) Install plate assembly to transmission. Tightening torque: T: 24.5 Nm (2.50 kgf-m, 18.1 ft-lb)
13) Remove inhibitor switch from transmission.
B3M1033B
(A)
Inhibitor switch
B3M1030I
14) Remove inhibitor switch connector from inhibitor switch.
D: INSTALLATION
S502243A11
(A) (B)
1) Connect inhibitor switch connector. 2) Install inhibitor switch to transmission case.
7) Install snap pin to range select lever.
B3M1029C B3M1033B
(A)
Inhibitor switch
(A) (B) (C)
Snap ring Select cable Range select lever
3) Move range select lever to neutral position. 4) Using ST, tighten bolts of inhibitor switch. ST 499267300 STOPPER PIN Tightening torque: 3.4 Nm (0.35 kgf-m, 2.5 ft-lb)
8) Install under cover. 9) Lower the vehicle. 10) Install inhibitor switch connector from stay. 11) Connect inhibitor switch connector.
B3M1028B B3M1034B
(A) (B)
Inhibitor switch Range select lever
(A)
Inhibitor switch
12) Install air cleaner case. (Non-turbo model) <Ref. to IN(SOHC)-7, INSTALLATION, Air Cleaner Case.>
AT-30
INHIBITOR SWITCH
13) Install intercooler. <Ref. to IN(DOHC TURBO)-10, INSTALLATION, Intercooler.> 14) Inspect inhibitor switch. <Ref. to AT-28 INSPECTION, Inhibitor Switch.>
AT-31
FRONT VEHICLE SPEED SENSOR
13. Front Vehicle Speed Sensor

S502709
A: REMOVAL
S502709A18
1) Set vehicle on a lift. 2) Disconnect battery ground terminal.
B3M1036B
(A) (B) (C)
G6M0095
3) Remove air cleaner case. (Non-turbo model) <Ref. to IN(SOHC)-7, REMOVAL, Air Cleaner Case.> 4) Remove intercooler. (Turbo model) <Ref. to IN(DOHC TURBO)-10, REMOVAL, Intercooler.> 5) Disconnect transmission connector.
S3M0039B
(A)
Transmission connector
11) Remove front, center, rear exhaust pipes and muffler. (Non-turbo model) With OBD: <Ref. to EX(SOHC)-5, REMOVAL, Front Exhaust Pipe.>, <Ref. to EX(SOHC)-9, REMOVAL, Rear Exhaust Pipe.> and <Ref. to EX(SOHC)-11, REMOVAL, Muffler.> Without OBD: <Ref. to EX(SOHCw/oOBD)-6, REMOVAL, Front Exhaust Pipe.>, <Ref. to EX(SOHCw/oOBD)-10, REMOVAL, Rear Exhaust Pipe.> and <Ref. to EX(SOHCw/oOBD)-12, REMOVAL, Muffler.> 12) Remove center, rear exhaust pipe and muffler. (Turbo model) <Ref. to EX(DOHC TURBO)-9, REMOVAL, Center Exhaust Pipe.>, <Ref. to EX(DOHC TURBO)-14, REMOVAL, Rear Exhaust Pipe.> and <Ref. to EX(DOHC TURBO)-15, REMOVAL, Muffler.> 13) Remove the shield cover. (If equipped) 14) Remove the propeller shaft. <Ref. to DS-14 REMOVAL, Propeller Shaft.> 15) Place transmission jack under transmission. CAUTION: Always support transmission case with a transmission jack. On AT vehicle, make sure that the support plates of transmission jack dont touch the oil pan.
6) Remove the transmission connector from stay. 7) Lift vehicle. 8) Remove under cover. 9) Clean transmission exterior. 10) Drain ATF completely. NOTE: Tighten ATF drain plug after draining ATF. Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
G2M0326
16) Remove the transmission rear crossmember bolts.
AT-32
21) Remove the transmission jack. 22) Remove oil pan. 23) Disconnect duty solenoids and ATF temperature sensor connectors. Remove connectors from clip and disconnect connectors.
S2M0221
17) Lower the AT jack. NOTE: Do not separate the AT jack and transmission. 18) Remove the oil cooler outlet pipe. CAUTION: When removing outlet pipe, be careful not to lose balls and springs used with retaining screws. 19) Remove front and rear vehicle speed sensor and torque converter turbine speed sensor. Front vehicle speed sensor and torque converter turbine speed sensor
(A) (B) (C) (D) (E) (F) (G) (H) (I) (J) Lock-up duty solenoid (Blue) Low clutch timing solenoid (Gray) Line pressure duty solenoid (Red) Shift solenoid 2 (Yellow) Shift solenoid 1 (Green) 2-4 brake timing solenoid (Black) 2-4 brake duty solenoid (Red) ATF temperature sensor Transfer duty solenoid (Brown) Transmission ground
B2M2263I
24) Remove harness assembly.
B3M1066B
(A) (B)
Front vehicle speed sensor Torque converter turbine speed sensor
Rear vehicle speed sensor
B3M1056B
(A) (B)
Rear vehicle speed sensor Front vehicle speed sensor
20) Attach transmission rear crossmember bolt and tighten temporarily.
AT-33

S502709A11
B: INSTALLATION
1) Pass the harness assembly through the hole in the transmission case.
3) Apply proper amount of liquid gasket to the entire oil pan mating surface. Fluid packing: Three Bond 1217B
B3M1067
B3M1040
2) Connect harness connectors. Connect connectors of same color, and secure connectors to valve body sing clips. Tightening torque (transmission ground terminal): 8 Nm (0.8 kgf-m, 5.8 ft-lb)
4) Install the oil pan. Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft-lb) 5) Place transmission jack under transmission. CAUTION: Always support transmission case with a transmission jack. On AT vehicle, make sure that the support plates of transmission jack dont touch the oil pan.
B2M2263I
(A) (B) (C) (D) (E) (F) (G) (H) (I) (J)
Lock-up duty solenoid (Blue) Low clutch timing solenoid (Gray) Line pressure duty solenoid (Red) Shift solenoid 2 (Yellow) Shift solenoid 1 (Green) 2-4 brake timing solenoid (Black) 2-4 brake duty solenoid (Red) ATF temperature sensor Transfer duty solenoid (Brown) Transmission ground
G2M0326
6) Remove the transmission rear crossmember bolts.
S2M0221
7) Lower the AT jack. NOTE: Do not separate the AT jack and transmission.
AT-34

8) Remove the oil cooler outlet pipe. CAUTION: When removing outlet pipe, be careful not to lose balls and springs used with retaining screws. 9) Install the front and rear vehicle speed sensor, and also the torque converter turbine speed sensor, and then fasten the harness. Tightening torque: 7 Nm (0.7 kgf-m, 5.1 ft-lb) 10) Install oil cooler outlet pipe. CAUTION: Be sure to use a new aluminum washer. Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft-lb) 11) Install transmission rear crossmember bolts. Tightening torque: 75 Nm (7.6 kgf-m, 55 ft-lb) 12) Install propeller shaft. <Ref. to DS-15 INSTALLATION, Propeller Shaft.> 13) Install shield cover. (If equipped) 14) Install front, center, rear exhaust pipes and muffler. (Non-turbo model) With OBD: <Ref. to EX(SOHC)-6, INSTALLATION, Front Exhaust Pipe.>, <Ref. to EX(SOHC)-9, INSTALLATION, Rear Exhaust Pipe.> and <Ref. to EX(SOHC)-11, REMOVAL, Muffler.> Without OBD: <Ref. to EX(SOHCw/oOBD)-7, INSTALLATION, Front Exhaust Pipe.>, <Ref. to EX(SOHCw/ oOBD)-10, INSTALLATION, Rear Exhaust Pipe.> and <Ref. to EX(SOHCw/oOBD)-12, INSTALLATION, Muffler.> 15) Install center, rear exhaust pipe and muffler. (Turbo model) <Ref. to EX(DOHC TURBO)-10, INSTALLATION, Center Exhaust Pipe.>, <Ref. to EX(DOHC TURBO)-14, INSTALLATION, Rear Exhaust Pipe.> and <Ref. to EX(DOHC TURBO)15, INSTALLATION, Muffler.> 16) Install under cover. (Turbo model) 17) Lower the vehicle. 18) Install the transmission connector to the stay. 19) Install air cleaner case. (Non-turbo model) <Ref. to IN(SOHC)-7, INSTALLATION, Air Cleaner Case.> 20) Install intercooler. (Turbo model) <Ref. to IN(DOHC TURBO)-10, INSTALLATION, Intercooler.>
AT-35
REAR VEHICLE SPEED SENSOR
14. Rear Vehicle Speed Sensor

S502710
A: REMOVAL
S502710A18
When removing the rear vehicle speed sensor, refer to Front Vehicle Speed Sensor. <Ref. to AT-32 REMOVAL, Front Vehicle Speed Sensor.>
B: INSTALLATION
S502710A11
When installing the rear vehicle speed sensor, refer to Front Vehicle Speed Sensor. <Ref. to AT-34 INSTALLATION, Front Vehicle Speed Sensor.>
AT-36
TORQUE CONVERTER TURBINE SPEED SENSOR
15. Torque Converter Turbine Speed Sensor

S502711
A: REMOVAL
S502711A18
When removing the torque converter turbine speed sensor, refer to Front Vehicle Speed Sensor. <Ref. to AT-32 REMOVAL, Front Vehicle Speed Sensor.>
B: INSTALLATION
S502711A11
When installing the torque converter turbine speed sensor, refer to Front Vehicle Speed Sensor. <Ref. to AT-34 INSTALLATION, Front Vehicle Speed Sensor.>
AT-37
CONTROL VALVE BODY

S502564
16. Control Valve Body

A: REMOVAL
S502564A18
8) Disconnect duty solenoids and ATF temperature sensor connectors. Remove connectors from clip and disconnect connectors.
1) Set vehicle on a lift. 2) Disconnect battery ground terminal from battery. 3) Lift vehicle. 4) Clean transmission exterior. 5) Remove under cover. 6) Drain ATF completely. NOTE: Tighten ATF drain plug after draining ATF. Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
B2M2263I
(A) (B) (C) (D) (E) (F) (G) (H) (I) (J)
B3M1036B
9) Remove the control valve. CAUTION: When removing control valve body, be careful not to interfere with transfer duty solenoid wiring.
(A) (B) (C)
7) Remove the oil pan. NOTE: Remove and clean the magnet. Remove the old gasket on the oil pan and transmission case completely.
B3M1037
AT-38
CONTROL VALVE BODY B: INSTALLATION

S502564A11
4) Attach the magnet at the specified position.
1) Set the range select lever in N position. 2) Install the control valve and ground earth terminal. Tightening torque: 8 Nm (0.8 kgf-m, 5.8 ft-lb)
B3M1105
B3M1037A
(A) (B)
Short bolts Long bolts
3) Connect all connector.
B3M1040
6) Install the oil pan. Tightening torque: 4.9 Nm (0.5 kgf-m, 3.6 ft-lb)
B2M2263I
7) Install under cover. (Turbo model) 8) Pour ATF into the oil charge pipe. Recommended fluid: Dexron III type automatic transmission fluid Fluid capacity: Non-turbo model 8.4 8.7 (8.9 9.2 US qt, 7.4 7.7 Imp qt) Turbo model 9.3 9.6 (9.8 10.1 US qt, 8.2 8.4 Imp qt) 9) Check the level of the ATF. <Ref. to AT-9 Automatic Transmission Fluid.>
(A) (B) (C) (D) (E) (F) (G) (H) (I) (J)
AT-39
CONTROL VALVE BODY

S502564A06
C: DISASSEMBLY
Refer to AUTOMATIC TRANSMISSION <Pub. No. G0853ZE> a separate publication.
D: ASSEMBLY
S502564A02
E: INSPECTION
S502564A10
AT-40
SHIFT SOLENOIDS, DUTY SOLENOIDS AND ATF TEMPERATURE SENSOR
17. Shift Solenoids, Duty Solenoids and ATF Temperature Sensor

S502227
8) Disconnect solenoid and sensor connectors. Remove connectors from clip and disconnect connectors.
A: REMOVAL
S502227A18
1) Set vehicle on a lift. 2) Disconnect battery ground terminal from battery. 3) Lift vehicle. 4) Remove under cover. 5) Clean transmission exterior. 6) Drain ATF completely. NOTE: Tighten ATF drain plug after draining ATF. Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
B2M2263J
(A) (B) (C) (D) (E) (F) (G) (H) (I)
Lock-up duty solenoid (Blue) Low clutch timing solenoid (Gray) Line pressure duty solenoid (Red) Shift solenoid 2 (Yellow) Shift solenoid 1 (Green) 2-4 brake timing solenoid (Black) 2-4 brake duty solenoid (Red) ATF temperature sensor Transfer duty solenoid (Brown)
9) Remove solenoids, duty solenoids and ATF temperature sensor.
B3M1036C
(A) (B)
Oil pan Drain plug
7) Remove oil pan.
B3M1039A
(A) (B) (C) (D) (E) (F) (G) (H)
Lock-up duty solenoid (Blue) Low clutch timing solenoid (Gray) Line pressure duty solenoid (Red) Shift solenoid 2 (Yellow) Shift solenoid 1 (Green) 2-4 brake timing solenoid (Black) 2-4 brake duty solenoid (Red) ATF temperature sensor
1. TRANSFER DUTY SOLENOID AND TRANSFER VALVE BODY S502227A1801

1) Set vehicle on a lift. 2) Disconnect battery ground terminal. 3) Remove air intake duct. <Ref. to IN(SOHC)-8, REMOVAL, Air Intake Duct.> 4) Remove air cleaner case. <Ref. to IN(SOHC)-7, REMOVAL , Air Cleaner Case.> 5) Remove intercooler. (Turbo model) <Ref. to IN(DOHC TURBO)-10, REMOVAL, Intercooler.>
AT-41

13) Remove rear crossmember. (1) Support transmission using a transmission jack and raise slightly. (2) Remove bolts and nuts as shown in Figure.
S2M0126
7) Remove front exhaust pipe with center exhaust pipe. (Non-turbo model) With OBD: <Ref. to EX(SOHC)-5, REMOVAL, Front Exhaust Pipe.> Without OBD: <Ref. to EX(SOHCw/oOBD)-6, REMOVAL, Front Exhaust Pipe.> 8) Remove center exhaust pipe. (Turbo Model) <Ref. to EX(DOHC TURBO)-9, REMOVAL, Center Exhaust Pipe.> 9) Remove rear exhaust pipe and muffler. (Nonturbo model) Non-turbo model with OBD: <Ref. to EX(SOHC)-9, REMOVAL, Rear Exhaust Pipe.> and <Ref. to EX(SOHC)-11, REMOVAL, Muffler.> Non-turbo model without OBD: <Ref. to EX(SOHCw/oOBD)-10, REMOVAL, Rear Exhaust Pipe.> and <Ref. to EX(SOHCw/oOBD)12, REMOVAL, Muffler.> Turbo model: <Ref. to EX(DOHC TURBO)-14, REMOVAL, Rear Exhaust Pipe.> and <Ref. to EX(DOHC TURBO)15, REMOVAL, Muffler.> 10) Raise vehicle and drain ATF.
S2M0221
14) Remove rear vehicle speed sensor.
B3M1043
15) Remove select cable nut.
G3M0308
16) Move gear select cable so that extension bolts can be removed. 17) Remove bolts.
B3M1036B
(A) (B) (C)
11) Remove heat shield cover. (If equipped) 12) Remove propeller shaft. <Ref. to DS-14, REMOVAL, Propeller Shaft.>
AT-42

18) Remove extension case. NOTE: Use a container to catch oil flowing from extension.
B: INSTALLATION
S502227A11
1) Install solenoids and ATF temperature sensor. Tightening torque: T: 8 Nm (0.8 kgf-m, 5.8 ft-lb)
B3M1044
19) Disconnect transfer duty solenoid connector. 20) Remove transfer duty solenoid and transfer valve body.
B3M1039B
(A) (B) (C) (D) (E) (F) (G) (H)
Lock-up duty solenoid (Blue) Low clutch timing solenoid (Gray) Line pressure duty solenoid (Red) Shift solenoid 2 (Yellow) Shift solenoid 1 (Green) 2-4 brake timing solenoid (Black) 2-4 brake duty solenoid (Red) ATF temperature sensor
2) Connect harness connectors. Connect connectors of same color, and secure connectors to valve body using clips.
B3M1045F
(A) (B) (C)
Transfer valve body Transfer duty solenoid connector Transfer duty solenoid
B2M2263J
(A) (B) (C) (D) (E) (F) (G) (H) (I)
Lock-up duty solenoid (Blue) Low clutch timing solenoid (Gray) Line pressure duty solenoid (Red) Shift solenoid 2 (Yellow) Shift solenoid 1 (Green) 2-4 brake timing solenoid (Black) 2-4 brake duty solenoid (Red) ATF temperature sensor Transfer duty solenoid (Brown)
AT-43

1. TRANSFER DUTY SOLENOID AND TRANSFER VALVE BODY S502227A1101
1) Install transfer duty solenoid and transfer valve body. (1) Install transfer duty solenoid and transfer valve body. Tightening torque: T: 8 Nm (0.8 kgf-m, 5.8 ft-lb) (2) Connect transfer duty solenoid connector.
B3M1040
4) Install oil pan. Tightening torque: 4.9 Nm (0.50 kgf-m, 3.6 ft-lb)
B3M1045G
(A) (B) (C)
Transfer valve body Transfer duty solenoid connector Transfer duty solenoid
2) Install extension case to transmission case. (1) Tighten 11 bolts.

B3M1036C
Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft-lb) (2) Install select cable. (3) Adjust the select cable. <Ref. to CS-11, ADJUSTMENT, Select Cable.> 3) Install rear vehicle speed sensor. Tightening torque: T: 7 Nm (0.7 kgf-m, 5.1 ft-lb)
(A) (B)
Oil pan Drain plug
5) Fill ATF up to the middle of the COLD side on level gauge by using the gauge hole. Recommended fluid: Dexron III type automatic transmission fluid Fluid capacity: Turbo model: 9.3 9.6 (9.8 10.1 US qt, 8.2 8.4 Imp qt) Non-turbo model: 8.4 8.7 (8.9 9.2 US qt, 7.4 7.7 Imp qt) 6) Check the ATF level. <Ref. to AT-9, Automatic Transmission Fluid.>
B3M1043A
AT-44

4) Install rear crossmember. (1) Tighten bolts. Tightening torque: T1: 35 Nm (3.6 kgf-m, 26 ft-lb) T2: 70 Nm (7.1 kgf-m, 51.4 ft-lb) 10) Install pitching stopper. Tightening torque: T1: 49 Nm (5.0 kgf-m, 36.2 ft-lb) T2: 57 Nm (5.8 kgf-m, 42 ft-lb)
S2M0126C S2M0221B
(2) Lower and remove transmission jack. 5) Install propeller shaft. <Ref. to DS-15, INSTALLATION, Propeller Shaft.> 6) Install front exhaust pipe and center exhaust pipe. (Non-turbo model) With OBD: <Ref. to EX(SOHC)-6, INSTALLATION, Front Exhaust Pipe.> Without OBD: <Ref. to EX(SOHCw/oOBD)-7, INSTALLATION, Front Exhaust Pipe.> 7) Install rear exhaust pipe and muffler. (Non-turbo model) With OBD: <Ref. to EX(SOHC)-11, INSTALLATION, Muffler.> and <Ref. to EX(SOHC)-9, INSTALLATION, Rear Exhaust Pipe.> Without OBD: <Ref. to EX(SOHCw/oOBD)-12, INSTALLATION, Muffler.> and <Ref. to EX(SOHCw/oOBD)-10, INSTALLATION, Rear Exhaust Pipe.> 8) Install center, rear exhaust pipe and muffler. (Turbo model) <Ref. to EX(DOHC TURBO)-10, INSTALLATION, Center Exhaust Pipe.>, <Ref. to EX(DOHC TURBO)-15, INSTALLATION, Muffler.> and <Ref. to EX(DOHC TURBO)-14, INSTALLATION, Rear Exhaust Pipe.> 9) Install under cover.
11) Install air cleaner case. (Non-turbo model) <Ref. to IN(SOHC)-7, INSTALLATION, Air Cleaner Case.> 12) Install intercooler. (Turbo model) <Ref. to IN(DOHC TURBO)-10, INSTALLATION, Intercooler.> 13) Fill ATF up to the middle of the COLD side on level gauge by using the gauge hole. Recommended fluid: Dexron III type automatic transmission fluid Fluid capacity: Non-turbo model; 8.4 - 8.7 L (8.9 - 9.2 US qt, 7.4 - 7.3 lmp qt) Turbo model; 9.3 - 9.6 L (9.8 - 10.1 US qt, 8.2 - 8.4 lmp qt) 14) Check the ATF level. <Ref. to AT-9, Automatic Transmission Fluid.>
AT-45
ATF FILTER
S502226
18. ATF Filter

A: REMOVAL
S502226A18
NOTE: The ATF filter is maintenance free. 1) Lift vehicle. 2) Using ST, remove ATF filter. ST 498545400 OIL FILTER WRENCH
B3M1665B
(A)
ATF filter
3) Get new ATF filter and apply a thin coat of ATF to the oil seal.
AT-46
ATF FILTER B: INSTALLATION

S502226A11
1) Install ATF filter. Turn it by hand, being careful not to damage oil seal. 2) Using ST, tighten ATF filter to transmission case. Calculate ATF filter torque specifications using the following formula. T2 = L1/(L1 + L2) T1 T1: 14 Nm (1.4 kgf-m, 10.1 ft-lb) [Required torque setting] T2: Tightening torque L1: ST length 0.078 m (3.07 in) L2: Torque wrench length Example:
Torque wrench length mm (in) 100 (3.94) 150 (5.91) 200 (7.87) 250 (9.84) Tightening torque Nm (kgf-m, ft-lb) 6 (0.6, 4.3) 5 (0.5, 3.6) 4 (0.4, 2.9) 3 (0.3, 2.2)
CAUTION: Align ST with torque wrench while tightening ATF filter. ST 498545400 OIL FILTER WRENCH 3) Add ATF. 4) Inspect level of ATF. <Ref. to AT-9 Automatic Transmission Fluid.>
C: INSPECTION
S502226A10
Replace the part if any defect is found from the inspection. Check for rust, hole, ATF leaks, and other damage.
AT-47
TRANSMISSION CONTROL MODULE (TCM)

RHD model
19. Transmission Control Module (TCM)

S502225
A: REMOVAL
S502225A18
B3M1593A
(A) (B)
Transmission control module Column shaft
4) Remove transmission control module.

G6M0095
B: INSTALLATION
S502225A11
2) Remove lower cover and then disconnect connector.
1) Install transmission control module. Tightening torque: LHD model 7.5 Nm (0.76 kgf-m, 5.5 ft-lb) RHD model 25 Nm (2.5 kgf-m, 18.1 ft-lb)
LHD model
S5M0044B
(A)
Clip
3) Disconnect connectors from transmission control module.

LHD model (A) (B) Transmission control module Brake pedal bracket
S3M0646A
RHD model
S3M0646A
(A) (B)
Transmission control module Brake pedal bracket

B3M1593A
(A) (B)
Transmission control module Column shaft
2) Install in the reverse order of removal.
AT-48
ATF COOLER PIPE AND HOSE
20. ATF Cooler Pipe and Hose

S502565
7) Remove ATF cooler pipe from cylinder head.
A: REMOVAL
1) 2) 3) 4) 5)
S502565A18
1. NON-TURBO MODEL
S502565A1804
Set vehicle on a lift. Remove battery and washer tank. Lift vehicle. Remove the under cover. Disconnect ATF cooler hose from radiator.
S3M0619
NOTE: Do not remove with a screwdriver or other pointed tools. When the hose is difficult to remove, wrap a shop cloth around the hose to protect it. Turn it with pliers, and then pull directly out with your hand.
8) Remove the oil cooler inlet and outlet pipes. CAUTION: When removing outlet pipe, be careful not to lose ball and spring used with retaining screw.
S2M0895
B3M1053B
6) Disconnect ATF cooler hoses from pipes. NOTE: Do not remove with a screwdriver or other pointed tools. When the hose is difficult to remove, wrap a shop cloth around the hose to protect it. Turn it with pliers, and then pull directly out with your hand.
(A) (B)
Inlet pipe Outlet pipe

S502565A1805
2. TURBO MODEL
1) 2) 3) 4) 5)
Set vehicle on a lift. Remove battery and washer tank. Lift vehicle. Remove the under cover. Disconnect ATF cooler hose from radiator. (1) Remove radiator. <Ref. to CO-25, REMOVAL, Radiator.> (2) Remove radiator under cover. (3) Remove ATF cooler hose from radiator.
S2M0909
AT-49

8) Remove the oil cooler inlet and outlet pipes. CAUTION: When removing outlet pipe, be careful not to lose ball and spring used with retaining screw.
6) Disconnect ATF cooler hoses from pipes. NOTE: Do not remove with a screwdriver or other pointed tools. When the hose is difficult to remove, wrap a shop cloth around the hose to protect it. Turn it with pliers, and then pull directly out with your hand.
B3M1053B
(A) (B)

S502565A11
B: INSTALLATION
1. NON-TURBO MODEL
S502565A1104
1) Install the oil cooler outlet and inlet pipes. CAUTION: Be sure to use a new aluminum washer. Tightening torque: T1: 44 Nm (4.5 kgf-m, 32.5 ft-lb) T2: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
B3M2053
7) Remove ATF cooler pipe from frame.
B3M1053C
(A) (B)
2) Install ATF cooler pipe to cylinder head.
TR0331 S3M0619
AT-50

3) Connect ATF cooler hose to pipe transmission side. NOTE: Install so that the hose is not folded over, excessively bent, or twisted. Be careful to insert the hose to the specified position.
S502565A1105
2. TURBO MODEL
1) Install the oil cooler outlet and inlet pipes. CAUTION: Be sure to use a new aluminum washer. Tightening torque: T1: 44 Nm (4.5 kgf-m, 32.5 ft-lb) T2: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
S2M0909
4) Connect ATF cooler hose to pipe of radiator side. NOTE: Install so that the hose is not folded over, excessively bent, or twisted. Be careful to insert the hose to the specified position.
B3M1053C
(A) (B)
2) Install ATF cooler pipe to frame.
S2M0895
5) Install the under cover. 6) Install battery and washer tank. 7) Fill ATF. <Ref. to AT-9 Automatic Transmission Fluid.> NOTE: Make sure there are no ATF leaks in joints between the transmission, radiator, pipes, and hoses.
TR0331
3) Connect ATF cooler hose to pipe transmission side.
AT-51
NOTE: Install so that the hose is not folded over, excessively bent, or twisted. Be careful to insert the hose to the specified position.
S2M0909
4) Connect ATF cooler hose to pipe of radiator side. (1) Install ATF cooler hoses to radiator. (2) Install radiator under cover. (3) Install radiator. <Ref. to CO-27, INSTALLATION, Radiator.> 5) Install the under cover. 6) Install battery and washer tank. 7) Fill ATF. <Ref. to AT-9 Automatic Transmission Fluid.> NOTE: Make sure there are no ATF leaks in joints between the transmission, radiator, pipes, and hoses.
AT-52
ATF COOLER PIPE AND HOSE C: INSPECTION

S502565A10
Repair or replace any defective hoses, pipes, clamps, and washers found from the inspection below. 1) Check for ATF leaks in joints between the transmission, radiator, pipes, and hoses. 2) Check for deformed clamps. 3) Lightly bend the hose and check for cracks in the surface and other damage. 4) Pinch the hose with your fingers and check for poor elasticity. Also check for poor elasticity in the parts where the clamp was by pressing with your fingernail. 5) Check for peeling, cracks, and deformation at the tip of the hose.
AT-53
MEMO:
AT-54
MANUAL TRANSMISSION AND DIFFERENTIAL
MT
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. Page General Description.....................................................................................2 Transmission Gear Oil ..............................................................................31 Manual Transmission Assembly................................................................32 Transmission Mounting System ................................................................39 Oil Seal......................................................................................................41 Switches and Harness ..............................................................................42 Vehicle Speed Sensor...............................................................................44 Preparation for Overhaul...........................................................................45 Transfer Case and Extension Case Assembly .........................................46 Oil Pump....................................................................................................50 Transfer Drive Gear ..................................................................................52 Transfer Driven Gear ................................................................................54 Center Differential .....................................................................................56 Reverse Check Sleeve..............................................................................57 Transmission Case....................................................................................60 Main Shaft Assembly for Single-Range ....................................................67 Main Shaft Assembly for Dual-Range.......................................................73 Input Shaft Assembly ................................................................................79 Drive Pinion Shaft Assembly.....................................................................83 Front Differential Assembly .......................................................................92 Speedometer Gear....................................................................................98 Reverse Idler Gear....................................................................................99 Shifter Fork and Rod...............................................................................101 Counter Gear...........................................................................................104 General Diagnostic..................................................................................106
Manual Transmission and Differential
GENERAL DESCRIPTION
S503001
A: SPECIFICATIONS
S503001E49
1. MANUAL TRANSMISSION AND DIFFERENTIAL

Model Non-Turbo
S503001E4901
Type 1st 2nd 3rd Transmission gear ratio 4th 5th Reverse High Auxiliary transmission gear ratio Low Type of gear Front reduction Final gear Gear ratio Type of gear Transfer Gear ratio Rear reduction gear Type of gear Final Gear ratio Front differential Type and number of gear Center differenType and number of gear tial Transmission gear oil Transmission gear oil capacity
Dual-range 5 2-forward speeds and 1 2-reverse 3.454 2.062 1.448 1.088 0.871 1.000 1.447
Turbo Without oil pump With oil pump Single-range 5-forward speeds and 1-reverse 3.454 1.947 1.366 0.972 0.738 3.333 Hypoid 4.444 Helical
4.111 1.000
1.081
4.0
Hypoid 4.111 4.444 4.111 Straight bevel gear (Bevel pinion: 2, Bevel gear: 2) Straight bevel gear (Bevel pinion: 2, Bevel gear: 2 and viscous coupling) GL-5 (4.2 US qt, 3.5 3.5 (3.7 US qt, 3.11 4.4 (4.7 US qt, 3.9 Imp qt) Imp qt) Imp qt)
2. TRANSMISSION GEAR OIL

Recommended oil
S503001E4902
3. TRANSMISSION CASE ASSEMBLY

S503001E4903
Drive pinion shim adjustment Hypoid gear backlash 0.13 0.18 mm (0.0051 0.0071 in)
Drive pinion shim Thickness Part No. mm (in) 0.150 32295AA071 (0.0059) 0.175 32295AA081 (0.0069) 0.200 32295AA091 (0.0079) 0.225 32295AA101 (0.0089) Thickness mm (in) 0.250 (0.0098) 0.275 (0.0108) 0.300 (0.0118) 0.500 (0.0197)
Part No. 32295AA031 32295AA041

B1H0024
32295AA051 32295AA061
MT-2
GENERAL DESCRIPTION
Selection of main shaft rear plate
Main shaft rear plate Dimension A mm Part No. (in) 4.00 4.13 32294AA041 (0.1575 0.1626) 3.87 3.99 32294AA051 (0.1524 0.1571) Snap ring to counter washer clearance 0.05 0.35 mm (0.0020 0.0138 in) Snap ring (Outer-19) Part No. Thickness mm (in) 031319000 1.50 (0.0591) 805019010 1.72 (0.0677) Input shaft holder adjustment Dimension D mm (in) 52.50 53.11 (2.0669 2.0909) 52.00 52.49 (2.0472 2.0665) 51.26 51.99 (2.0181 2.0468) Number of shim 1 2
S503001E4904
Snap ring (Inner-68) to bearing clearance 0 0.12 mm (0 0.0047 in) Snap ring (Inner-68) Part No. Thickness mm (in) 805168020 1.84 (0.0724) 805168030 1.92 (0.0756) 805168040 2.00 (0.0787)
Mark 1 2
6. MAIN SHAFT
S503001E4911
Snap ring (Outer-25) to synchronizer hub clearance 0.060 0.100 mm (0.0024 0.0039 in) Snap ring (Outer-25) Thickness Part No. mm (in) 2.42 (0.0953) 805025055 2.47 (0.0972) 805025056 2.52 (0.0992) 805025057 2.57 (0.1012) 805025058
Part No. 805025051 805025052 805025053 805025054
Thickness mm (in) 2.62 (0.1031) 2.67 (0.1051) 2.72 (0.1071) 2.37 (0.0933)
7. REVERSE IDLER GEAR
S503001E4905
4. DRIVE PINION ASSEMBLY
Adjustment of reverse idler gear position Reverse idler gear to transmission case (LH) wall clearance 6.0 7.5 mm (0.236 0.295 in)
Part No. 32820AA070 32820AA080 32820AA090 Reverse shifter lever Mark Remarks 7 Further from case wall 8 Standard Closer to the case 9 wall
Preload adjustment of thrust bearing Starting torque 0.3 0.8 Nm (0.03 0.08 kgf-m, 0.2 0.6 ft-lb)
Adjusting washer No. 1 Part No. Thickness mm (in) 803025051 3.925 (0.1545) 803025052 3.950 (0.1555) 803025053 3.975 (0.1565) 803025054 4.000 (0.1575) 803025055 4.025 (0.1585) 803025056 4.050 (0.1594) 803025057 4.075 (0.1604) Adjusting washer No. 2 Part No. Thickness mm (in) 803025059 3.850 (0.1516) 803025054 4.000 (0.1575) 803025058 4.150 (0.1634)
After installing a suitable reverse shifter lever, adjust reverse idler gear to transmission case wall clearance to within 0 to 0.5 mm (0 to 0.020 in) using washers.
Washer (20.5 26 t) Thickness Part No. mm (in) 0.4 (0.016) 803020154 1.1 (0.043) 803020155 1.5 (0.059) Thickness mm (in) 1.9 (0.075) 2.3 (0.091)
Part No. 803020151 803020152 803020153
5. INPUT SHAFT ASSEMBLY
S503001E4910
Snap ring (Outer-28) to ball bearing clearance 0 0.12 mm (0 0.0047 in) Snap ring (Outer-28) Part No. Thickness mm (in) 805028050 2.48 (0.0976) 805028060 2.56 (0.1008) 805028070 2.64 (0.1039)
MT-3
GENERAL DESCRIPTION
S503001E4906
8. SHIFTER FORK AND ROD
9. TRANSFER CASE
S503001E4907
Select suitable shifter forks so that both coupling sleeve and reverse driven gear are positioned in the center of their synchromesh mechanisms. Rod end clearance A: 1st-2nd 3rd-4th 0.4 1.4 mm (0.016 0.055 in) B: 3rd-4th 5th 0.5 1.3 mm (0.020 0.051 in)
Part No. 32804AA060 32804AA070 32804AA080 1st-2nd shifter fork Mark Remarks Approach to 1st gear 1 by 0.2 mm (0.008 in) No mark Standard Approach to 2nd gear 3 by 0.2 mm (0.008 in) 3rd-4th shifter fork Mark Remarks Approach to 4th gear 1 by 0.2 mm (0.008 in) No mark Standard Approach to 3rd gear 3 by 0.2 mm (0.008 in)
Neutral position adjustment

Part No. 32190AA000 32190AA010 Adjustment shim Thickness mm (in) 0.15 (0.0059) 0.30 (0.0118)
Part No. 32188AA090 32188AA100 32188AA110
Reverse accent shaft Mark Remarks Neutral position is 3 closer to 1st. 0 Standard Neutral position is 1 closer to reverse gear.
Reverse check plate adjustment

Part No. 32189AA000 32189AA010 33189AA020 32189AA030 Reverse check plate Mark Angle Remarks Arm stops closer to 0 28 5th gear. Arm stops closer to 1 31 5th gear. Arm stops in the cen2 34 ter. Arm stops closer to 3 37 reverse gear. Arm stops closer to 4 40 reverse gear.
Part No. 32810AA061 32810AA071 32810AA101
Non-Turbo model
Part No. 32812AA201 32812AA211 32812AA221 5th shifter fork Mark Remarks Approach to 5th gear 4 by 0.2 mm (0.008 in) 5 Standard Become distant from 6 5th gear by 0.2 mm (0.008 in)
32189AA040
Turbo model
Part No. 32812AA231 32812AA241 32812AA251 5th shifter fork Mark Remarks Approach to 5th gear 7 by 0.2 mm (0.008 in) No mark Standard Become distant from 9 5th gear by 0.2 mm (0.008 in)
MT-4
GENERAL DESCRIPTION
10. EXTENSION ASSEMBLY
S503001E4908

S503001E4909
11. FRONT DIFFERENTIAL
Thrust washer (50 61 t) to taper roller bearing table outer race side clearance 0.2 0.3 mm T (0.0008 0.012 in T) NOTE: T: Tight
Thrust washer (50 61 t) Part No. Thickness mm (in) 803050060 0.50 (0.0197) 803050061 0.55 (0.0217) 803050062 0.60 (0.0236) 803050063 0.65 (0.0256) 803050064 0.70 (0.0276) 803050065 0.75 (0.0295) 803050066 0.80 (0.0315) 803050067 0.85 (0.0335) 803050068 0.90 (0.0354) 803050069 0.95 (0.0374) 803050070 1.00 (0.0394) 803050071 1.05 (0.0413) 803050072 1.10 (0.0433) 803050073 1.15 (0.0453) 803050074 1.20 (0.0472) 803050075 1.25 (0.0492) 803050076 1.30 (0.0512) 803050077 1.35 (0.0531) 803050078 1.40 (0.0551) 803050079 1.45 (0.0571)
Bevel gear to pinion backlash 0.13 0.18 mm (0.0051 0.0071 in)

Washer (38.1 50 t) Thickness Part No. mm (in) 0.925 0.950 803038023 (0.0364 0.0374) 0.975 1.000 (0.0384 0.0394) Thickness mm (in) 1.025 1.050 (0.0404 0.0413)
Part No.
803038021
803038022
Pinion shaft to axle drive shaft clearance 0 0.2 mm (0 0.008 in)

Snap ring (Outer-28) Thickness Part No. mm (in) 1.05 (0.0413) 805028012 Thickness mm (in) 1.20 (0.0472)
Part No. 805028011
Thrust washer to center differential side clearance 0.15 0.35 mm (0.0059 0.0138 in)
Part No. 803036050 803036054 803036051 803036055 803036052 803036056 803036053 803036057 803036058 Thrust washer Thickness mm (in) 0.9 (0.035) 1.0 (0.039) 1.1 (0.043) 1.2 (0.047) 1.3 (0.051) 1.4 (0.055) 1.5 (0.059) 1.6 (0.063) 1.7 (0.067)
MT-5
GENERAL DESCRIPTION
B: COMPONENT
S503001A05
1. TRANSMISSION CASE
S503001A0501
S3M0616A
MT-6
GENERAL DESCRIPTION
(1) Transmission case ASSY (Turbo model) (2) Gasket (3) Drain plug (4) Snap ring (Outer) (5) Speedometer driven gear (6) Washer (7) Speedometer shaft (8) Snap ring (Outer) Size 8 mm bolt 10 mm bolt (9) (10) (11) (12) (13) Oil seal Clamp Pitching stopper bracket Clip Oil level gauge (Non-turbo model) (14) Oil seal (Non-turbo model) (15) Transmission case ASSY (Nonturbo model) All models <5> <15> <1> <4> <16> <17>

(16) High-low cable bracket A (Nonturbo model) (17) High-low cable bracket B (Nonturbo model) (18) Oil level gauge (Turbo model) (19) Inlet pipe (with oil pump)
Tightening torque: Nm (kgf-m, ft-lb) 25 (2.5, 18.1) 39 (4.0, 28.9)
MT-7
GENERAL DESCRIPTION
S503001A0502
2. DRIVE PINION ASSEMBLY
S3M0423B
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14)
Drive pinion shaft Roller bearing Washer Thrust bearing Needle bearing Driven shaft Key Woodruff key Drive pinion collar Needle bearing Snap ring (Outer) Washer Sub gear 1st driven gear
(15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28)
Baulk ring 1st-2nd synchronizer hub Insert key Reverse driven gear Outer baulk ring Synchro cone Inner baulk ring 2nd driven gear 2nd driven gear bush 3rd-4th driven gear Driven pinion shim Roller bearing 5th driven gear Lock washer
(29) (30) (31) (32) (33) (34) (35)
Lock nut Washer Thrust bearing Differential bevel gear sleeve Washer Lock washer Lock nut
Tightening torque: Nm (kgf-m, ft-lb) T1: 29 (3.0, 21.7) T2: 118 (12.0, 86.8) T3: 265 (27, 195)
MT-8
GENERAL DESCRIPTION
3. MAIN SHAFT ASSEMBLY
S503001A0503
B3M2120B
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14)
Oil seal Needle bearing Transmission main shaft Needle bearing 3rd drive gear Inner baulk ring (Turbo model) 3rd synchro cone (Turbo model) Outer baulk ring (Turbo model) 3rd-4th coupling sleeve 3rd-4th synchronizer hub 3rd-4th shifting insert key 4th baulk ring 4th drive gear 4th needle bearing race
(15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28)
Needle bearing 4th gear thrust washer Ball bearing Baulk ring (Nonturbo model) 5th gear thrust washer 5th needle bearing race Needle bearing Main shaft rear plate 5th drive gear 5th baulk ring 5th-Rev shifting insert key 5th-Rev synchronizer hub 5th-Rev coupling sleeve Rev baulk ring
(29) (30) (31) (32) (33) (34) (35) (36) (37) (38)
Rev synchro cone Ball bearing Synchro cone stopper Snap ring Lock washer Lock nut Reverse idler gear shaft Straight pin Reverse idler gear Washer
MT-9
GENERAL DESCRIPTION
S503001A0508
4. AUXILIARY TRANSMISSION GEARS
B3M2173B
MT-10
GENERAL DESCRIPTION
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18) O-ring High-low counter shaft Straight pin High-low counter washer Counter gear Needle bearing Counter gear collar Snap ring (Outer-19) Input shaft holder Input shaft shim Oil seal O-ring Snap ring (Outer-28) Oil squeeze Straight pin Snap ring (Outer-28) Ball bearing Snap ring (Inner-68) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (29) (30) (31) (32) (33) (34) (35) (36) Input shaft Needle bearing Snap ring (Outer-25) High-low baulk ring High-low coupling sleeve High-low synchronizer spring High-low synchronizer hub Shifting insert High-low baulk ring Friction damper Input low gear Needle bearing Input low gear spacer Ball Main shaft Straight pin High-low shifter lever Washer

(37) (38) (39) (40) (41) (42) (43) (44) (45) (46) High-low shifter shaft Low switch Gasket Straight pin High-low shifter fork High-low shifter piece Ball Spring Gasket Plug
Tightening torque: Nm (kgf-m, ft-lb) T1: 15.7 (1.6, 11.6) T2: 20 (2, 14.5) T3: 25 (2.5, 18.1)
MT-11
GENERAL DESCRIPTION
S503001A0504
5. SHIFTER FORK AND SHIFTER ROD
H3M1966A
(1) (2) (3) (4) (5) (6) (7) (8)
Shifter arm 5th shifter fork Straight pin Reverse fork rod Checking ball plug Gasket Checking ball spring Ball
(9) (10) (11) (12) (13) (14) (15) (16)
3rd-4th fork rod Interlock plunger 1st-2nd fork rod 3rd-4th shifter fork 1st-2nd shifter fork Ball Spring Snap ring (Outer)
(17) Reverse fork rod arm (18) Reverse shifter lever

MT-12
GENERAL DESCRIPTION

S503001A0509
6. TRANSFER CASE AND EXTENSION CASE FOR MODEL WITHOUT OIL PUMP
B3M2179B
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15)
Oil guide Gasket Transfer case Ball Reverse accent spring Gasket Plug Oil seal Snap ring (Inner) Reverse check plate Reverse check spring Reverse return spring Reverse check cam Reverse accent shaft Return spring cap
(16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (29) (30)
Return spring O-ring Adjusting select shim Reverse check sleeve Gasket Neutral switch Gasket Back-up light switch Roller bearing Transfer driven gear Roller bearing Adjusting washer Ball bearing Center differential Adjusting washer
(31) (32) (33) (34) (35) (36) (37)
Transfer drive gear Ball bearing Extension case Oil seal Dust cover Shift bracket Snap ring
Tightening torque: Nm (kgf-m, ft-lb) T1: 6.4 (0.65, 4.7) T2: 10 (1.0, 7.2) T3: 25 (2.5, 18.1) T4: 26 (2.7, 20) T5: 40 (4.1, 29.7)
MT-13
GENERAL DESCRIPTION
S503001A0510
7. TRANSFER CASE AND EXTENSION CASE FOR MODEL WITH OIL PUMP
S3M0617A
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18) (19)
Oil guide Gasket Transfer case Ball Reverse accent spring Gasket Plug Oil seal Gasket Neutral switch Back-up light switch Snap ring (Inner) Reverse check plate Reverse check spring Reverse check cam Return spring Reverse accent shaft Return spring cap Return spring
(20) (21) (22) (23) (24) (25) (26) (27) (28) (29) (30) (31) (32) (33) (34) (35) (36) (37) (38)
O-ring Adjusting select shim Reverse check sleeve Shift bracket Oil pump cover O-ring Oil pump shaft Inner rotor Outer rotor Relief valve Return spring O-ring Dust cover Oil seal Outlet pipe Washer Extension case Oil strainer Straight pin
(39) (40) (41) (42) (43) (44) (45) (46) (47) (48)
Snap ring Ball bearing Transfer drive gear Washer Center differential Ball bearing Adjusting washer Roller bearing Transfer driven gear Roller bearing
Tightening torque: Nm (kgf-m, ft-lb) T1: 6.4 (0.65, 4.7) T2: 10 (1.0, 7.2) T3: 13 (1.3, 9.4) T4: 26 (2.7, 20) T5: 40 (4.1, 30)
MT-14
GENERAL DESCRIPTION
8. FRONT DIFFERENTIAL
S503001A0506
H3M1967B
(1) (2) (3) (4) (5) (6) (7)
Drive pinion shaft Hypoid driven gear Pinion shaft Straight pin Washer Differential bevel gear Differential bevel pinion
(8) (9) (10) (11) (12) (13) (14)
Snap ring (Outer) Roller bearing Differential case Oil seal Differential side retainer O-ring Axle drive shaft
(15) Retainer lock plate

MT-15
GENERAL DESCRIPTION
S503001A0507
9. TRANSMISSION MOUNTING
S2M0196C
(1) (2) (3) (4) (5) (6)
Pitching stopper Spacer Cushion C Front plate Rear cushion rubber Rear crossmember
(7) (8) (9) (10)
Cushion D Center crossmember Rear plate Front crossmember
Tightening torque: Nm (kgf-m, ft-lb) T1: 35 (3.6, 26) T2: 50 (5.1, 37) T3: 58 (5.9, 43) T4: 70 (7.1, 51) T5: 140 (14.3, 103)
MT-16

S503001A03
Wear working clothing, including a cap, protective goggles, and protective shoes during operation. Remove contamination including dirt and corrosion before removal, installation, and disassembly. Keep the disassembled parts in order and protect them from dust or dirt. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. When disassembling the case and other light alloy parts, use a plastic hammer to force it apart. Do not pry it apart with a screwdriver or other tool. Be careful not to burn your hands, because each part on the vehicle is hot after running. Use SUBARU genuine gear oil, grease etc. or the equivalent. Do not mix gear oil, grease etc. with that of another grade or from other manufacturers.
Be sure to tighten fasteners including bolts and nuts to the specified torque. Place shop jacks or safety stands at the specified points. Apply gear oil onto sliding or revolution surfaces before installation. Replace deformed or otherwise damaged snap rings with new ones. Before installing O-rings or oil seals, apply sufficient amount of gear oil to avoid damage and deformation. Be careful not to incorrectly install or fail to install O-rings, snap rings and other such parts. Before securing a part on a vise, place cushioning material such as wood blocks, aluminum plate, or shop cloth between the part and the vise. Avoid damaging the mating surface of the case. Before applying sealant, completely remove the old seal.
D: PREPARATION TOOL
1. SPECIAL TOOLS
ILLUSTRATION
S503001A1701
S503001A17
DESCRIPTION REMOVER II
REMARKS Used for removing and installing spring pin (6 mm).
B3M1938
399411700
ACCENT BALL INSTALLER
Used for installing reverse shifter rail arm.
B3M1939
MT-17

ILLUSTRATION
GENERAL DESCRIPTION
DESCRIPTION PULLER SET REMARKS Used for removing and installing roller bearing (Differential). (1) BOLT (899521412) (2) PULLER (399527702) (3) HOLDER (399527703) (4) ADAPTER (398497701) (5) BOLT (899520107) (6) NUT (021008000)
B3M1940A
399780104
WEIGHT
Used for measuring preload on roller bearing.
B3M1941
498077000
5TH DRIVEN GEAR Used for removing roller bearing of drive pinion REMOVER shaft.
B3M1942
498077300
CENTER DIFFERENTIAL BEARING REMOVER
Used for removing the center differential cover ball bearing.
B3M1943
MT-18
GENERAL DESCRIPTION
ILLUSTRATION TOOL NUMBER 498147000 DESCRIPTION DEPTH GAUGE
REMARKS Used for adjusting main shaft axial end play.
B3M1944
498247001
MAGNET BASE
Used for measuring backlash between side gear and pinion, and hypoid gear. Used with DIAL GAUGE (498247100).
B3M1945
498247100
DIAL GAUGE
Used for measuring backlash between side gear and pinion, and hypoid gear. Used with MAGNET BASE (498247001).
B3M1946
498427100
STOPPER
Used for securing the drive pinion shaft assembly and driven gear assembly when removing the drive pinion shaft assembly lock nut.
B3M1947
MT-19

ILLUSTRATION
GENERAL DESCRIPTION
DESCRIPTION REMARKS MAIN SHAFT STOP- Used for removing and installing transmission PER main shaft lock nut.
B3M1948
498937000
HOLDER
Used for removing and installing transmission main shaft lock nut.
B3M1949
499277100
BUSH 1-2 INSTALLER
Used for installing 1st driven gear thrust plate and 1st-2nd driven gear bush. Used for installing roller bearing outer races to differential case.
B3M1950
499277200
INSTALLER
Used for press-fitting the 2nd driven gear, roller bearings, and 5th driven gear onto the driven shaft.
B3M1951
MT-20
GENERAL DESCRIPTION
ILLUSTRATION TOOL NUMBER 499757002 DESCRIPTION INSTALLER
REMARKS Used for installing snap ring (OUT 25), and ball bearing (25 x 26 x 17). Used for installing bearing cone of transfer driven gear (extension core side).
B3M1952
499787000
WRENCH ASSY
Used for removing and installing differential side retainer.
B3M1953
499827000
PRESS
Used for installing speedometer oil seal when installing speedometer cable to transmission.
B3M1954
499857000
5TH DRIVEN GEAR Used for removing 5th driven gear. REMOVER
B3M1955
MT-21

ILLUSTRATION
GENERAL DESCRIPTION
DESCRIPTION RACE 4-5 INSTALLER REMARKS Used for installing 4th needle bearing race and ball bearing onto transmission main shaft. Used with REMOVER (899714110).
B3M1956
499917500
DRIVE PINION GAUGE ASSY
Used for adjusting drive pinion shim.
B3M1957
499927100
HANDLE
Used for fitting transmission main shaft.
B3M1958
499937100
TRANSMISSION STAND SET
Stand used for transmission disassembly and assembly.
B3M1959
MT-22
GENERAL DESCRIPTION
ILLUSTRATION TOOL NUMBER 499987003 DESCRIPTION SOCKET WRENCH (35)
REMARKS Used for removing and installing driven pinion lock nut and main shaft lock nut.
B3M1960
499987300
SOCKET WRENCH (50)
Used for removing and installing driven gear assembly lock nut.
B3M1961
899714110
REMOVER
Used for fixing transmission main shaft, drive pinion, rear drive shaft.
B3M1962
899864100
REMOVER
Used for removing parts on transmission main shaft and drive pinion.
B3M1963
MT-23

ILLUSTRATION
GENERAL DESCRIPTION
DESCRIPTION HOLDER REMARKS Used for tightening lock nut on sleeve.
B3M1964
899904100
REMOVER
Used for removing and installing straight pin.
B3M1965
899988608
SOCKET WRENCH (27)
Used for removing and installing drive pinion lock nut.
B3M1966
398497701
ADAPTER
Used for installing roller bearing onto differential case. Used with INSTALLER (499277100).
B3M1967
MT-24
GENERAL DESCRIPTION
REMARKS Used for installing driven gears to driven shaft.
B3M1968
899824100
PRESS
Used for installing speedometer shaft oil seal.
B3M1969
499987100
SOCKET WRENCH (35)
B3M1970
899984103
SOCKET WRENCH (35)
B3M1971
MT-25

ILLUSTRATION
GENERAL DESCRIPTION
DESCRIPTION INSTALLER REMARKS Used for installing extension oil seal.
B3M1972
498255400
PLATE
Used for measuring backlash.
B3M1973
498077400
REMOVER
Used for removing synchronizer cone of main shaft. Used for removing 5th driven gear of drive pinion shaft.
B3M1974
41099AA010
ENGINE SUPPORT BRACKET
Used for supporting engine.
B3M1975
MT-26
GENERAL DESCRIPTION
ILLUSTRATION TOOL NUMBER 41099AA020 DESCRIPTION ENGINE SUPPORT
REMARKS Used for supporting engine.
B3M1976
398527700
PULLER ASSY
Used for removing and installing extension case roller bearing.
B3M1977
398643600
GAUGE
Used for measuring total end play, extension end play and drive pinion height.
B3M1978
38177700
INSTALLER
Used for installing bearing cone of transfer driven gear (transfer case side). Used for installing ball bearing of transfer drive gear.
B3M1905
MT-27

ILLUSTRATION
GENERAL DESCRIPTION
DESCRIPTION DUMMY COLLAR REMARKS Used for installing input shaft holder oil seal. For dual-range model.
B3M2122
398663600
PLIERS
Used for removing and installing input shaft snap ring. For dual-range model.
B3M2123
499757001
SNAP RING GUIDE
Used for installing snap ring (OUT 25). For dual-range model.
B3M2124
899858600
RETAINER
Used for removing ball bearing. For dual-range model.
B3M2125
899474100
EXPANDER
Used for removing and installing snap ring. For dual-range model.
B3M2126
MT-28
GENERAL DESCRIPTION
REMARKS Used when pressing ball bearings into input shaft. For dual-range model.
B3M2127
399513600
INSTALLER
Used when pressing ball bearings into input shaft. For dual-range model.
B3M2129

S503001A1702
MT-29
GENERAL DESCRIPTION
MEMO:
MT-30
TRANSMISSION GEAR OIL
2. Transmission Gear Oil

A: INSPECTION
S503219A10
S503219
5) Pour gear oil into the gauge hole. Recommended gear oil: Use GL-5 or equivalent. Gear oil capacity: Turbo model without oil pump; 3.5 (3.7 US qt, 3.1 Imp qt) Turbo model with oil pump; 4.4 (4.7 US qt, 3.9 Imp qt) Non-turbo model; 4.0 (4.2 US qt, 3.5 Imp qt) 6) Check the level of the transmission gear oil. CAUTION: When inserting the level gauge into transmission gear, align the protrusion on the side of the top part of the level gauge with the notch in the gauge hole. NOTE: The level should be within the specified range marked on the gauge.
1) Park vehicle on a level surface. 2) Turn ignition switch to OFF, and wait until the engine cools. 3) Remove oil level gauge and wipe it clean. 4) Reinsert the level gauge all the way. Be sure that the level gauge is correctly inserted and in the proper direction. 5) Pull out the oil level gauge again and check the oil level on it. If it is below the lower level, add oil through the oil level gauge hole to bring the level up to the upper level.
GI0042A
B: REPLACEMENT
S503219A20
1) Pull out oil level gauge. 2) Lift-up the vehicle. 3) Drain transmission gear oil completely. CAUTION: Directly after the engine has been running, the transmission gear oil is hot. Be careful not to burn yourself. NOTE: Tighten transmission gear oil drain plug after draining transmission gear oil. Tightening torque: 44 Nm (4.5 kgf-m, 32.5 ft-lb)
S3M0470A
(A) (B)
Drain plug Gasket
MT-31
MANUAL TRANSMISSION ASSEMBLY

(3) High-low switch model) Non-turbo model connector (Non-turbo
3. Manual Transmission Assembly

S503224
A: REMOVAL
S503224A18
1) Set vehicle on a lift. 2) Open front hood fully, and support with stay. 3) Disconnect battery ground terminal. 4) Move gear shift lever to N, and release the parking brake. 5) Remove air intake duct and cleaner case. (Nonturbo model) <Ref. to IN(SOHC)-8, REMOVAL, Air Intake Duct.> and <Ref. to IN(SOHC)-7, REMOVAL , Air Cleaner Case.> 6) Remove air cleaner case stay. (Non-turbo model)
S2M0743
Turbo model
S2M0900
TR0428
7) Remove intercooler (Turbo model) <Ref. to IN(DOHC TURBO)-10, REMOVAL, Intercooler.> 8) Disconnect the following connectors. (1) Neutral position switch connector (2) Back-up light switch connector
(4) Vehicle speed sensor
S2M0907
(5) Transmission ground terminal. 9) Remove snap pin and pin from the drive select cable.
MT-32

10) Remove the drive select cable on the transmission. (Non-turbo model)
S2M0126 S2M0745B
14) Set ST. NOTE: Also is available Part No. 41099AA010. ST 41099AA020 ENGINE SUPPORT ASSY
(A) (B) (C)
Snap pin Pin Drive select cable
11) Remove starter. <Ref. to SC-5, REMOVAL, Starter.> 12) Remove operating cylinder from transmission. Non-turbo model
G2M0313
TR0069
Turbo model
15) Separate clutch release fork from release bearing. (Turbo model) (1) Remove plug using 10 mm hexagon wrench.
S2M1935 TR0070
MT-33

19) Remove rear exhaust pipe and muffler. CAUTION: When removing exhaust pipes, be careful each exhaust pipe does not drop out. 20) Remove heat shield cover. (If equipped) 21) Remove hanger bracket from right side of transmission.
(2) Screw 6 mm dia. bolt into release fork shaft, and remove it.
B2M0032
S2M1936A
(A) (B)
Shaft Bolt
22) Remove propeller shaft. <Ref. to DS-14, REMOVAL, Propeller Shaft.> 23) Remove gear shift rod and stay from transmission. (1) Disconnect stay from transmission. (2) Disconnect rod from transmission.
(3) Raise release fork and unfasten release bearing tabs to free release fork. CAUTION: Step (4) is required to prevent interference with engine when removing engine from transmission. 16) Remove bolt which holds right upper side of transmission to engine.
(A) (B) Stay Rod
B3M1824A
24) Disconnect stabilizer link from transverse link. 25) Remove bolt securing ball joint of transverse link to housing.
B2M2791
17) Remove front and center exhaust pipes. (Nonturbo model) with OBD <Ref. to EX(SOHC)-5, REMOVAL, Front Exhaust Pipe.> without OBD <Ref. to EX(SOHCw/oOBD)-6, REMOVAL, Front Exhaust Pipe.> 18) Remove center exhaust pipe. (Turbo model). <Ref. to EX(DOHC TURBO)-9, REMOVAL, Center Exhaust Pipe.>
G4M0491
MT-34

26) Remove spring pins and separate front drive shafts from each side of the transmission. CAUTION: Discard removing spring pin. Replace with a new one.
30) Remove transmission rear crossmember from vehicle.
G2M0831
31) Remove transmission.

G2M0325
27) Remove nuts which hold lower side of transmission to engine.
CAUTION: Move transmission jack toward rear until main shaft is withdrawn from clutch cover. 32) Separate transmission assembly and rear cushion rubber.
B: INSTALLATION
S503224A11
1) Install rear cushion rubber to transmission assembly. Tightening torque: 34 Nm (3.5 kgf-m, 25.3 ft-lb) 2) Install clutch release lever and bearing onto transmission. (Turbo model) <Ref. to CL-21, INSTALLATION, Release Bearing and Lever.> 3) Install transmission onto engine. (1) Gradually raise transmission with transmission jack. (2) Engage them at splines. CAUTION: Be careful not to strike main shaft against clutch cover. 4) Install transmission rear crossmember. Tightening torque: T1: 70 Nm (7.1 kgf-m, 51 ft-lb) T2: 140 Nm (14.3 kgf-m, 103 ft-lb)
B2M2790
28) Disconnect oil cooler hoses to pipe. (Turbo model with oil pump) 29) Place transmission jack under transmission. CAUTION: Always support transmission case with a transmission jack.
G2M0326
G2M0832
MT-35

9) Remove ST.
5) Take off transmission jack. 6) Tighten nuts which hold lower side of transmission to engine. Tightening torque: 50 Nm (5.1 kgf-m, 36.9 ft-lb)
G2M0313
10) Push clutch release lever to fit bearing into clutch cover.
B2M2790
7) Connect engine and transmission. (1) Install starter. <Ref. to SC-6, INSTALLATION, Starter.> (2) Tighten bolt which holds right upper side of transmission to engine. Tightening torque: 50 Nm (5.1 kgf-m, 36.9 ft-lb)
H2M1818
B2M2791
8) Install plug. Tightening torque: 44 Nm (4.5 kgf-m, 32.5 ft-lb)

S2M0126C
12) Lift-up the vehicle. 13) Connect oil cooler hoses to pipe. (Turbo model with oil pump) 14) Install front drive shaft into transmission.
S2M1846A
(A) (B)
Plug Transmission ASSY
MT-36

15) Drive spring pin into chamfered hole of drive shaft. CAUTION: Always use a new spring pin.
18) Connect rod to the joint. Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft-lb)
B3M1824A G2M0325
16) Install ball joints of lower arm into knuckle arm of housing, and tighten installing bolts. Tightening torque: 49 Nm (5.0 kgf-m, 36 ft-lb)
(A) (B)
Joint Rod
19) Connect stay to transmission bracket. Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft-lb)
B2M3402A
B3M1823A
(A) (B)
Transverse link Ball joint
(A) (B)
17) Install stabilizer link from transverse link. Tightening torque: 30 Nm (3.1 kgf-m, 22.1 ft-lb)
20) Install propeller shaft. <Ref. to DS-15, INSTALLATION, Propeller Shaft.> 21) Install heat shield cover. (if equipped) 22) Install hanger bracket on right side of transmission.
TR0089 B2M0032
MT-37

Turbo model
23) Install rear exhaust pipe and muffler. Non-turbo model with OBD: <Ref. to EX(SOHC)-11, INSTALLATION, Muffler.> and <Ref. to EX(SOHC)-9, INSTALLATION, Rear Exhaust Pipe.> Non-turbo model without OBD: <Ref. to EX(SOHCw/oOBD)-12, INSTALLATION, Muffler.> and <Ref. to EX(SOHCw/oOBD)-10, INSTALLATION, Rear Exhaust Pipe.> Turbo model: <Ref. to EX(DOHC TURBO)-15, INSTALLATION, Muffler.> and <Ref. to EX(DOHC TURBO)-14, INSTALLATION, Rear Exhaust Pipe.> 24) Install front exhaust pipe and center exhaust pipe. (Non-turbo model) Without OBD: <Ref. to EX(SOHCw/oOBD)-7, INSTALLATION, Front Exhaust Pipe.> With OBD: <Ref. to EX(SOHC)-6, INSTALLATION, Front Exhaust Pipe.>
TR0070
28) Connect the following connectors. (1) Transmission ground terminal Tightening torque: 13 Nm (1.3 kgf-m, 9.4 ft-lb) (2) Vehicle speed sensor connector (3) Neutral position switch connector (4) Back-up light switch connector (5) High-low switch connector (Non-turbo model) 29) Install air cleaner case stay. Tightening torque: 16 Nm (1.6 kgf-m, 11.6 ft-lb) 30) Install air cleaner case and intake duct. (Nonturbo model) <Ref. to IN(SOHC)-7, INSTALLATION, Air Cleaner Case.>, <Ref. to IN(SOHC)-8, INSTALLATION, Air Intake Duct.> 31) Install intercooler. (Turbo model) <Ref. to IN(DOHC TURBO)-10, INSTALLATION, Intercooler.> 32) Connect battery ground terminal. 33) Pour gear oil and check the oil level. <Ref. to MT-31, Transmission Gear Oil.> 34) Take off vehicle from lift arms.
G2M0290
25) Install center exhaust pipe. (Turbo model) <Ref. to EX(DOHC TURBO)-10, INSTALLATION, Center Exhaust Pipe.> 26) Install under cover. 27) Install operating cylinder. Tightening torque: 37 Nm (3.8 kgf-m, 27.5 ft-lb) Non-turbo model
TR0069
MT-38
4. Transmission Mounting System

S503233
5) Remove the heat shield cover. (If equipped)
A: REMOVAL
S503233A18
1. PITCHING STOPPER
S503233A1801
1) Disconnect battery ground terminal. 2) Remove the cleaner case. (Non-turbo model) <Ref. to IN(SOHC)-7, REMOVAL, Air Cleaner Case.> 3) Remove intercooler. (Turbo model) <Ref. to IN(DOHC TURBO)-10, REMOVAL, Intercooler.> 4) Remove the pitching stopper.
S2M0215
6) Set the transmission jack under the transmission body. CAUTION: Always support transmission case with a transmission jack. 7) Remove the rear crossmember.
S2M0126

1) Disconnect battery ground terminal. 2) Jack-up vehicle and support it with sturdy racks. 3) Remove the front, center, rear exhaust pipes and muffler. (Non-turbo model) With OBD: <Ref. to EX(SOHC)-5, REMOVAL, Front Exhaust Pipe.>, <Ref. to EX(SOHC)-9, REMOVAL, Rear Exhaust Pipe.> and <Ref. to EX(SOHC)-11, REMOVAL, Muffler.> Without OBD: <Ref. to EX(SOHCw/oOBD)-6, REMOVAL, Front Exhaust Pipe.>, <Ref. to EX(SOHCw/oOBD)-10, REMOVAL, Rear Exhaust Pipe.> and <Ref. to EX(SOHCw/oOBD)-12, REMOVAL, Muffler.> CAUTION: When removing exhaust pipes, be careful each exhaust pipe does not drop out. 4) Remove center, rear exhaust pipes and muffler. <Ref. to EX(DOHC TURBO)-9, REMOVAL, Center Exhaust Pipe.>, <Ref. to EX(DOHC TURBO)-14, REMOVAL, Rear Exhaust Pipe.> and <Ref. to EX(DOHC TURBO)-15, REMOVAL, Muffler.>
G2M0831
8) Remove the rear cushion rubber.
B: INSTALLATION
S503233A11
1. PITCHING STOPPER
S503233A1101
1) Install the pitching stopper. Tightening torque: T1: 50 Nm (5.1 kgf-m, 37 ft-lb) T2: 58 Nm (5.9 kgf-m, 43 ft-lb)
S2M0126C
2) Install the cleaner case. (Non-turbo model) <Ref. to IN(SOHC)-7, INSTALLATION, Air Cleaner Case.>
MT-39

Make sure that the crossmember is not bent or damaged. Make sure that the cushion rubber is not stiff, cracked, or otherwise damaged.
3) Install intercooler. <Ref. to IN(DOHC TURBO)10, INSTALLATION, Intercooler.> 4) Connect battery ground terminal.

1) Install the rear cushion rubber. Tightening torque: 35 Nm (3.6 kgf-m, 26 ft-lb) 2) Install the crossmember. Tightening torque: T1: 70 Nm (7.1 kgf-m, 51 ft-lb) T2: 140 Nm (14.3 kgf-m, 103 ft-lb)
G2M0832
3) Remove the transmission jack. 4) Install the heat shield cover. (If equipped) 5) Install the front, center, rear exhaust pipes and the muffler. (Non-turbo model) With OBD: <Ref. to EX(SOHC)-6, INSTALLATION, Front Exhaust Pipe.>, <Ref. to EX(SOHC)-9, INSTALLATION, Rear Exhaust Pipe.> and <Ref. to EX(SOHC)-11, INSTALLATION, Muffler.> Without OBD: <Ref. to EX(SOHCw/oOBD)-7, INSTALLATION, Front Exhaust Pipe.>, <Ref. to EX(SOHCw/ oOBD)-10, INSTALLATION, Rear Exhaust Pipe.> and <Ref. to EX(SOHCw/oOBD)-12, INSTALLATION, Muffler.> 6) Install center, rear exhaust pipes and muffler. (Turbo model) <Ref. to EX(DOHC TURBO)-10, INSTALLATION, Center Exhaust Pipe.>, <Ref. to EX(DOHC TURBO)-14, INSTALLATION, Rear Exhaust Pipe.> and <Ref. to EX(DOHC TURBO)15, INSTALLATION, Muffler.>
C: INSPECTION
S503233A10
Repair or replace parts if the results of the inspection below are not satisfactory.
1. PITCHING STOPPER
S503233A1001
Make sure that the pitching stopper is not bent or damaged. Make sure that the rubber is not stiff, cracked, or otherwise damaged.
MT-40
OIL SEAL
5. Oil Seal
S503143
A: REPLACEMENT
S503143A20
1) Clean transmission exterior. 2) Drain gear oil completely. NOTE: Tighten drain plug after draining gear oil. Tightening torque: 44 Nm (4.5 kgf-m, 32.5 ft-lb)
9) Install the heat shield cover. 10) Install the rear exhaust pipe and muffler. 11) Pour gear oil and check the oil level. <Ref. to MT-31, Transmission Gear Oil.>
B3M0037
3) Remove rear exhaust pipe and muffler. 4) Remove heat shield cover. (If equipped) 5) Remove propeller shaft. <Ref. to DS-14, REMOVAL, Propeller Shaft.> 6) Using ST, remove the oil seal. ST 398527700 PULLER ASSY
B3M2135A
(A)
Oil seal
7) Using ST, install the oil seal. ST 498057300 INSTALLER
B3M1982
8) Install the propeller shaft. <Ref. to DS-15, INSTALLATION , Propeller Shaft.>
MT-41
SWITCHES AND HARNESS

S503232
6. Switches and Harness

A: REMOVAL
S503232A18
1. BACK-UP LIGHT AND NEUTRAL POSITION SWITCH S503232A1801

1) Disconnect connector battery ground terminal. 2) Remove air intake duct and cleaner case. (NonTurbo model) <Ref. to IN(SOHC)-7, REMOVAL, Air Cleaner Case.> and <Ref. to IN(SOHC)-8, REMOVAL, Air Intake Duct.> 3) Remove intercooler. (Turbo model) <Ref. to IN(DOHC TURBO)-10, REMOVAL, Intercooler.> 4) Disconnect connector back-up light switch and neutral position switch. Non-turbo model
B3M1372C
(A) (B)
Neutral switch (Brown connector) Back-up light switch (Gray connector)

S503232A1802
2. HIGH-LOW SWITCH
1) Disconnect connector battery ground terminal. 2) Remove air intake duct and cleaner case. <Ref. to IN (SOHC)-7, REMOVAL, Air Cleaner Case.> and <Ref. to IN (SOHC)-8, REMOVAL, Air Intake Duct.> 3) Disconnect connector high-low switch.
S2M0743A
(A) (B) (C)
Neutral switch (Brown) Back-up light switch (Gray) High-low switch (Black)
S2M0743A
Turbo model
(A) (B) (C) Neutral switch (Brown) Back-up light switch (Gray) High-low switch (Black)
4) Remove HI-LO switch cable from clamp. 5) Remove HI-LO switch.
TR0428
5) Lift-up the vehicle. 6) Remove back-up light switch and neutral position switch with harness.
B3M2128A
(A) (B)
Clamp High-low switch
MT-42
SWITCHES AND HARNESS B: INSTALLATION

S503232A11

S503232A1002
2. NEUTRAL POSITION SWITCH
1. BACK-UP LIGHT SWITCH AND NEUTRAL POSITION SWITCH S503232A1101

1) Install back-up light switch and neutral position switch with harness. Tightening torque: 24.5 Nm (2.5 kgf-m, 18.1 ft-lb)
1) Turn ignition switch to OFF. 2) Disconnect connector neutral position switch. 3) Using the circuit tester, verify the current in neutral position. Also verify that there is no current in positions other than neutral. Non-turbo model
TR0100 B3M1372C
Turbo model
(A) (B)
Neutral switch Back-up light switch
2) Connect connector of back-up light switch and neutral position switch. 3) Install air intake duct and cleaner case. (Nonturbo model) <Ref. to IN(SOHC)-7, INSTALLATION, Air Cleaner Case.> and <Ref. to IN(SOHC)-8, INSTALLATION, Air Intake Duct.> 4) Install intercooler (Turbo model) <Ref. to IN(DOHC TURBO)-10, INSTALLATION, Intercooler.> 5) Connect battery ground terminal.
TR0101
4) Replace defective parts.
2. HIGH-LOW SWITCH
1) Install high-low switch.
3. HIGH-LOW SWITCH
S503232A1102
S503232A1003
Tightening torque: 24.5 Nm (2.5 kgf-m, 18.1 ft-lb) 2) Install HI-LO switch cable to the clamp. 3) Connect connector high-low switch. 4) Install air intake duct and cleaner case. (Nonturbo model) <Ref. to IN(SOHC)-7, INSTALLATION, Air Cleaner Case.> and <Ref. to IN(SOHC)-8, INSTALLATION, Air Intake Duct.> 5) Connect battery ground terminal.
1) Turn ignition switch to OFF. 2) Disconnect connector high-low switch. 3) Set drive select lever in LO position, and make sure continuity exists using circuit tester.
C: INSPECTION
S503232A10
1. BACK-UP LIGHT SWITCH
S503232A1001
B3M2134
Inspect the back-up light switch. <Ref. to LI-29 INSPECTION, Back-up Light System.>
4) Replace defective parts.
MT-43
VEHICLE SPEED SENSOR

S503231
7. Vehicle Speed Sensor

A: REMOVAL
S503231A18
1) Disconnect ground terminal from battery. 2) Lift-up the vehicle. 3) Remove front and center exhaust pipes. (Nonturbo model) With OBD: <Ref. to EX(SOHC)-5, REMOVAL, Front Exhaust Pipe.> Without OBD: <Ref. to EX(SOHCw/oOBD)-6, REMOVAL, Front Exhaust Pipe.> 4) Remove center exhaust pipe. (Turbo model) <Ref. to EX(DOHC TURBO)-9, REMOVAL, Center Exhaust Pipe.> 5) Disconnect connector from vehicle speed sensor. 6) Turn and remove vehicle speed sensor.
5) Install center exhaust pipe. (Turbo model) <Ref. to EX(DOHC TURBO)-10, INSTALLATION, Center Exhaust Pipe.> 6) Lower the vehicle. 7) Connect battery ground terminal.
C: INSPECTION
S503231A10
Inspect the vehicle speed sensor. Non-turbo model with OBD: <Ref. to EN(SOHC)-208, DTC P0500-VEHICLE SPEED SENSOR MALFUNCTION-, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Non-turbo model without OBD: <Ref. to EN(SOHCw/oOBD)-94, DTC 33 VEHICLE SPEED SIGNAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> Turbo model: <Ref. to EN(DOHC TURBO)-230, DTC P0500-VEHICLE SPEED SENSOR MALFUNCTION-, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
B6M1449
B: INSTALLATION
S503231A11
NOTE: Discard vehicle speed sensor and after removal, replace with a new one. Ensure sensor mounting hole is clean and free of foreign matter. Align tip end of key with key groove on end of speedometer shaft during installation. 1) Hand tighten vehicle speed sensor. 2) Tighten vehicle speed sensor using suitable tool. Tightening torque: 5.9 Nm (0.6 kgf-m, 4.3 ft-lb) 3) Connect connector to vehicle speed sensor. 4) Install front and center exhaust pipes. (Nonturbo model) With OBD: <Ref. to EX(SOHC)-6, INSTALLATION, Front Exhaust Pipe.> Without OBD: <Ref. to EX(SOHCw/oOBD)-7, INSTALLATION, Front Exhaust Pipe.>
MT-44

A: PROCEDURE
S503091E45
S503091
1) Clean oil, grease, dirt and dust from transmission. 2) Remove drain plug to drain oil. After draining, retighten it as before. NOTE: Replace gasket with a new one. Tightening torque: 44 Nm (4.5 kgf-m, 32.5 ft-lb)
6) Rotating parts should be coated with oil prior to assembly. 7) All disassembled parts, if to be reused, should be reinstalled in the original positions and directions. 8) Gaskets, lock washers and lock nut must be replaced with new ones. 9) Liquid gasket should be used where specified to prevent leakage.
B3M0037
3) Remove outlet pipe. (With oil pump)
S3M0429B
(A)
Outlet pipe
4) Tighten union screw. (With oil pump) Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft-lb) 5) Attach transmission to ST. ST 499937100 TRANSMISSION STAND SET
G3M0517
MT-45
TRANSFER CASE AND EXTENSION CASE ASSEMBLY

2) Remove bearing cone from the extension case assembly, and install to taper roller bearing of the transfer driven gear.
9. Transfer Case and Extension Case Assembly

S503561
A: REMOVAL
S503561A18
1) Remove the manual transmission assembly from vehicle. <Ref. to MT-32 REMOVAL, Manual Transmission Assembly.> 2) Remove back-up light switch and neutral position switch. <Ref. to MT-42 REMOVAL, Switches and Harness.> 3) Remove transfer case with extension case assembly.
B3M2172A
(A) (B)
Bearing cone (Extension case) Extension case
3) While pressing the bearing cone horizontally, turn the driven shaft ten rotations. 4) Measure height W between transfer case and taper roller bearing on the transfer driven gear.
B3M1373
4) Remove shifter arm. 5) Remove extension case assembly.
B3M1984A
5) Measure depth X. NOTE: Measure with bearing cone and thrust washer removed.
B3M1374
B: INSTALLATION
S503561A11
1) Install center differential and transfer driven gear into transfer case.
B3M1406A
6) Calculate space t using the following equation: t = X W + 0.2 to 0.3 mm (0.008 to 0.012 in) 7) Select nearest washer in the following table:
B3M1983
Standard clearance between thrust washer and taper roller bearing: 0.2 0.3 mm T (0.008 0.012 in T)
MT-46
TRANSFER CASE AND EXTENSION CASE ASSEMBLY

NOTE: T: Tight
Thrust washer (50 61 t) Part No. Thickness mm (in) 803050060 0.50 (0.0197) 803050061 0.55 (0.0217) 803050062 0.60 (0.0236) 803050063 0.65 (0.0256) 803050064 0.70 (0.0276) 803050065 0.75 (0.0295) 803050066 0.80 (0.0315) 803050067 0.85 (0.0335) 803050068 0.90 (0.0354) 803050069 0.95 (0.0374) 803050070 1.00 (0.0394) 803050071 1.05 (0.0413) 803050072 1.10 (0.0433) 803050073 1.15 (0.0453) 803050074 1.20 (0.0472) 803050075 1.25 (0.0492) 803050076 1.30 (0.0512) 803050077 1.35 (0.0531) 803050078 1.40 (0.0551) 803050079 1.45 (0.0571)
10) Measure depth T between extension case and transfer drive gear. ST 398643600 GAUGE
B3M1395A
11) Calculate space U using the following equation: U = S T 12) Select suitable washer in the following table: Standard clearance: 0.15 0.35 mm (0.0059 0.0138 in)
Part No. 803036050 803036054 803036051 803036055 803036052 803036056 803036053 803036057 803036058 Thrust washer Thickness mm (in) 0.9 (0.035) 1.0 (0.039) 1.1 (0.043) 1.2 (0.047) 1.3 (0.051) 1.4 (0.055) 1.5 (0.059) 1.6 (0.063) 1.7 (0.067)
8) Fit thrust washers on transfer drive shaft. 9) Measure depth S between transfer case and center differential. ST 398643600 GAUGE
13) Fit thrust washer on center differential. 14) Install bearing cone into extension case. 15) Apply proper amount of liquid gasket to the transfer case mating surface. Liquid gasket: THREE BOND 1215B
B3M1407A
B3M1985
MT-47
TRANSFER CASE AND EXTENSION CASE ASSEMBLY C: DISASSEMBLY

1. TRANSFER CASE
S503561A06
16) Install extension assembly into transfer case. Tightening torque: 40Nm (4.1 kgf-m, 29.7 ft-lb)
S503561A0601
1) Remove reverse check assembly. <Ref. to MT-57 REMOVAL, Reverse Check Removal.> 2) Remove oil guide.
B3M1374
17) Install shifter arm to transfer case.

B3M1378
2. EXTENSION CASE
S503561A0602
1) Remove transfer drive gear assembly. <Ref. to MT-52 REMOVAL, Transfer Drive Gear.> 2) Remove shift bracket.
B3M1396
18) Hang the shifter arm on the 3rd-4th fork rod.
B3M1381
3) Remove oil seal from extension case. <Ref. to MT-41 Oil Seal.>
B3M1397B
19) Install transfer case with extension case assembly to transmission case. Tightening torque: 25Nm (2.5 kgf-m, 18.1 ft-lb)
B3M1373
MT-48
TRANSFER CASE AND EXTENSION CASE ASSEMBLY D: ASSEMBLY

S503561A02
1. EXTENSION CASE
S503561A0201
1) Using ST, install oil seal to extension case. <Ref. to MT-41, Oil Seal.> CAUTION: Use new oil seal. 2) Install shift bracket to extension case. Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
B3M1381
3) Install transfer drive gear to extension case. <Ref. to MT52 INSTALLATION, Transfer Drive Gear.>
2. TRANSFER CASE
S503561A0202
1) Install oil guide to transfer case. Tightening torque: 6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
B3M1378
2) Install reverse check sleeve assembly to transfer case. <Ref. to MT-57 INSTALLATION, Reverse Check Sleeve.>
MT-49
OIL PUMP
5) Remove oil pump cover from extension.
10. Oil Pump

A: REMOVAL
S503070
S503070A18
For extension case removal procedure, refer to Transfer Case and Extension Case Assembly. <Ref. to MT-46, REMOVAL, Transfer Case and Extension Case Assembly.>
B: INSTALLATION
S503070A11
For extension case installation procedure, refer to Transfer Case Pump and Extension Case Assembly. <Ref. to MT-46, INSTALLATION, Transfer Case and Extension Case Assembly.>
S3M0439B
(A)
Oil pump cover
C: DISASSEMBLY
S503070A06
6) Remove rotor assembly, oil pump shaft and O-ring.
1) Remove transfer drive gear assembly. <Ref. to MT-52, REMOVAL, Transfer Drive Gear.> 2) Remove oil strainer from extension case.
S3M0440A
S3M0618
(A) (B) (C)
Oil pump shaft Rotor ASSY O-ring

S503070A02
3) Remove shift bracket.
D: ASSEMBLY
1) Install rotor assembly and oil pomp shaft to extension case. 2) Install O-ring to oil pump cover. CAUTION: Replace O-ring with a new one. NOTE: Apply a coat of gear oil to the O-ring.
S3M0437
4) Remove relief valve from extension case.
S3M0438
MT-50
OIL PUMP
3) Install oil pump cover to extension case. Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
6) Install oil strainer to extension case. Tightening torque: 6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
S3M0439B
S3M0618
(A)
Oil pump cover
7) Install transfer drive gear. <Ref. to MT-52, INSTALLATION, Transfer Drive Gear.>
4) Install relief valve and return spring to extension case. CAUTION: Replace O-ring with a new one. Tightening torque: 13 Nm (1.3 kgf-m, 9.4 ft-lb)
E: INSPECTION
S503070A10
Use a thickness gauge to measure the chip clearance of the rotor assembly. If the value exceeds standard, replace the rotor as an assembly. Chip clearance: Less than 0.15 mm (0.0059 in)
S3M0442 S3M0441
5) Install shift bracket to extension case. Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
B3M1381
MT-51
TRANSFER DRIVE GEAR

S503229
11. Transfer Drive Gear

A: REMOVAL
S503229A18
1) Remove the manual transmission assembly from vehicle. <Ref. to MT-32 REMOVAL, Manual Transmission Assembly.> 2) Remove back-up light switch and neutral position switch. <Ref. to MT-42 REMOVAL, Switches and Harness.> 3) Remove transfer case with extension case assembly. <Ref. to MT-46 REMOVAL, Transfer Case and Extension Case Assembly.> 4) Remove extension case assembly. 5) Remove transfer driven gear. 6) Remove transfer drive gear.
S3M0443B
(A) (B) (C)
Oil pump shaft Straight pin Transfer drive gear
3) Install transfer driven gear. 4) Install the extension case assembly. 5) Install transfer case and extension case assembly. <Ref. to MT-46 INSTALLATION, Transfer Case and Extension Case Assembly.> 6) Install back-up light switch and neutral position switch. <Ref. to MT-43 INSTALLATION, Switches and Harness.> 7) Install the manual transmission assembly from vehicle. <Ref. to MT-35 INSTALLATION, Manual Transmission Assembly.>
B3M1986
C: DISASSEMBLY
1) Remove snap ring.
S503229A06
B: INSTALLATION
S503229A11
1) Install transfer drive gear. (Without oil pump) Tightening torque: 26 Nm (2.7 kgf-m, 20 ft-lb)
B3M1988
2) Remove ball bearing.
B3M1986
2) Install transfer drive gear to extension case. (With oil pump) Tightening torque: 26 Nm (2.7 kgf-m, 20 ft-lb) CAUTION: Do not use a press machine. Always install the parts by hand. NOTE: Engage the transfer drive gear pin with the extension case pin.
B3M1989
3) Remove straight pin from transfer drive gear. (With oil pump)
MT-52
TRANSFER DRIVE GEAR D: ASSEMBLY

S503229A02
1) Install straight pin to transfer drive gear. (With pump) 2) Set the ST applying to inner race of bearing and instal to drive shaft. ST 398177700 INSTALLER CAUTION: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton)
3) Measure clearance between snap ring and inner race of ball bearing with a thickness gauge. Clearance: 0.01 0.15 mm (0.0004 0.0059 in)
B3M1991
If the measurement is not within the specification, select suitable snap ring.
Snap ring
TR0523
3) Install snap ring on transfer drive shaft. 4) Inspect clearance between snap ring and inner race of ball bearing. <Ref. MT-53, INSPECTION, Transfer Drive Gear.>
Part No. 805030041 805030042 805030043
Thickness mm (in) 1.53 (0.0602) 1.65 (0.0650) 1.77 (0.697)
E: INSPECTION
S503229A10
1) Bearings Replace bearings in the following cases: Broken or rusty bearings Worn or damaged Bearings that fail to turn smoothly or make abnormal noise when turned after gear oil lubrication. 2) Drive gear Replace drive gear in the following cases: If their tooth surfaces and shaft are excessively broken or damaged.
MT-53
TRANSFER DRIVEN GEAR

S503223
12. Transfer Driven Gear

A: REMOVAL
S503223A18
B: INSTALLATION
S503223A11
1) Install bearing cup to extension case and transfer case.
1) Remove the manual transmission assembly from vehicle. <Ref. to MT-32, REMOVAL, Manual Transmission Assembly.> 2) Remove back-up light switch and neutral position switch. <Ref. to MT-42, REMOVAL, Switches and Harness.> 3) Remove transfer case with extension case assembly. <Ref. to MT-46, REMOVAL, Transfer Case and Extension Case Assembly.> 4) Remove extension case assembly. 5) Remove transfer driven gear.
B3M1983
B3M1993A
6) Remove bearing cup from extension case and transfer case.
(A) (B)
Bearing cup (transfer case) Bearing cup (extension case)
2) Install transfer driven gear.
B3M1983
B3M1993A
3) Install transfer case and extension case assembly. <Ref. to MT-46 INSTALLATION, Transfer Case and Extension Case Assembly.> 4) Install back-up light switch and neutral position switch. <Ref. to MT-43 INSTALLATION, Switches and Harness.> 5) Install the manual transmission assembly to vehicle. <Ref. to MT-35 INSTALLATION, Manual Transmission Assembly.>
(A) (B)
Bearing cup (transfer case) Bearing cup (extension case)
MT-54
TRANSFER DRIVEN GEAR C: DISASSEMBLY

S503223A06

S503223A02
D: ASSEMBLY
1) Using ST, remove roller bearing (extension case side). ST 498077000 REMOVER
1) Using ST, install roller bearing (extension case side). ST1 398177700 INSTALLER ST2 899864100 REMOVER CAUTION: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton)
B3M2136A
(A)
Roller bearing
2) Using ST1 and ST2, remove roller bearing (transfer case side). ST1 498077000 REMOVER ST2 899864100 REMOVER
B3M2138A
(A)
Roller bearing
2) Using ST, install roller bearing (transfer case side). ST 499757002 INSTALLER CAUTION: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton)
B3M2137A
(A)
Roller bearing
B3M2139A
(A)
Roller bearing
S503223A10
E: INSPECTION
1) Bearings Replace bearings in the following cases: Broken or rusty bearings Worn or damaged Bearings that fail to turn smoothly or make abnormal noise when turned after gear oil lubrication. 2) Driven gear Replace drive gear in the following cases: If their tooth surfaces and shaft are excessively broken or damaged.
MT-55
CENTER DIFFERENTIAL
S503158
13. Center Differential

A: REMOVAL
S503158A18
D: ASSEMBLY
S503158A02
Install ball bearing to center differential assembly. CAUTION: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
1) Remove the manual transmission assembly from vehicle. <Ref. to MT-32 REMOVAL, Manual Transmission Assembly.> 2) Remove the transfer case with extension case assembly. <Ref. to MT-46 REMOVAL, Transfer Case and Extension Case Assembly.> 3) Remove the extension case assembly. <Ref. to MT-46 REMOVAL, Transfer Case and Extension Case Assembly.> 4) Remove the transfer driven gear. <Ref. to MT-54 REMOVAL, Transfer Driven Gear.> 5) Remove the center differential.
B: INSTALLATION
B3M1399B
S503158A11
1) Install the center differential into transfer case. 2) Install the transfer driven gear. <Ref. to MT-54 INSTALLATION, Transfer Driven Gear.> 3) Install the extension case assembly. <Ref. to MT-46 INSTALLATION, Extension Case Assembly.> 4) Install the transfer case with extension case assembly. <Ref. to MT-46 REMOVAL, Transfer Case and Extension Case Assembly.> 5) Install the back-up light switch and neutral position switch. <Ref. to MT-42 REMOVAL, Switches and Harness.> 6) Install the manual transmission assembly to vehicle. <Ref. to MT-35 INSTALLATION, Manual Transmission Assembly.>
(A)
Ball bearing
S503158A10
E: INSPECTION
1) Bearings Replace bearings in the following cases: Broken or rusty bearings Worn or damaged Bearings that fail to turn smoothly or make abnormal noise when turned after gear oil lubrication. Bearings having other defects 2) Center differential Replace center differential assembly in the following case: Worn or damaged
C: DISASSEMBLY
S503158A06
NOTE: Do not disassemble center differential because it is a non-disassemble part. Remove ball bearing using ST. CAUTION: Do not reuse ball bearing. ST 498077300 CENTER DIFFERENTIAL BEARING REMOVER
B3M1398C
MT-56
REVERSE CHECK SLEEVE
14. Reverse Check Sleeve

A: REMOVAL
S503267A18
S503267
2) Install ball, spring, washer and plug to transfer case. Tightening torque: 10 Nm (1.0 kgf-m, 7.2 ft-lb)
1) Remove the manual transmission assembly from vehicle. <Ref. to MT-32 REMOVAL, Manual Transmission Assembly.> 2) Remove the transfer case with extension case assembly. <Ref. to MT-46 REMOVAL, Transfer Case and Extension Case Assembly.> 3) Remove shifter arm. 4) Remove plug, spring washer and reverse check ball.
B3M1376
B3M1376
3) Install the shifter arm to transfer case assembly. 4) Install the transfer case with extension case assembly. <Ref. to MT-46 INSTALLATION, Transfer Case and Extension Case Assembly.> 5) Install the manual transmission assembly to vehicle. <Ref. to MT-35 INSTALLATION, Manual Transmission Assembly.>
5) Remove the reverse check sleeve.
C: DISASSEMBLY
S503267A06
1) Cover the reverse check sleeve with a rag, and remove snap ring using a screwdriver. NOTE: Replace snap ring with a new one if deformed or weakened.
B3M1377
B: INSTALLATION
S503267A11
1) Install the reverse check sleeve. Tightening torque: 6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
(A) Snap ring
B3M1383C
B3M1377
MT-57
REVERSE CHECK SLEEVE

2) Hook the bent section of reverse check spring over reverse check plate. 3) Rotate cam so that the protrusion of reverse check cam is at the opening in plate. 4) With cam held in that position, install plate onto reverse check sleeve and hold with snap ring. 5) Position O-ring in groove in sleeve.
2) Remove reverse check plate, reverse check spring, reverse check cam, return spring (5th-Rev), reverse accent shaft, return spring cap and return spring (1st-2nd).
E: INSPECTION
S503267A10
B3M1384A
(A) (B) (C) (D) (E) (F) (G)
Reverse check plate Reverse check spring Return spring (5th-Rev) Reverse check cam Reverse accent shaft Return spring cap Return spring (1st-2nd)
Make sure the cutout section of reverse accent shaft is aligned with the opening in reverse check sleeve. Spin cam by hand for smooth rotation. Move cam and shaft all the way toward plate and release. If cam does not return properly, replace reverse check spring; if shaft does not, check for scratches on the inner surface of sleeve. If sleeve is in good order, replace spring.
3) Remove O-ring. NOTE: Reverse check sleeve assembly uses an O-ring which should not be scratched. Be careful not to break adjustment shim placed between reverse check sleeve assembly and case.
D: ASSEMBLY
S503267A02
B3M0048D
1) Install return spring (1st-2nd), return spring cap, reverse accent shaft, check cam, return spring and check spring onto reverse check sleeve. NOTE: Be sure the bent section of reverse check spring is positioned in the groove in check cam.
(A) (B) (C) (D)
Snap ring Reverse check plate Check spring Check cam
Select a suitable reverse accent shaft and reverse check plate. <Ref. to MT-59 ADJUSTMENT, Reverse Check Sleeve.>
B3M1388A
(A) (B) (C) (D) (E) (F) (G)
Reverse check sleeve Return spring (1st-2nd) Return spring cap Reverse accent shaft Return spring (5th-Rev) Reverse check cam Reverse check spring
MT-58
REVERSE CHECK SLEEVE F: ADJUSTMENT

BB30109201 S503267A01
1. NEUTRAL POSITION ADJUSTMENT

1) Shift gear into 3rd gear position. 2) Shifter arm turns lightly toward the 1st/2nd gear side but heavily toward the reverse gear side because of the function of the return spring, until arm contacts the stopper. 3) Make adjustment so that the heavy stroke (reverse side) is a little more than the light stroke (1st/2nd side). 4) To adjust, remove bolts holding reverse check sleeve assembly to the case, move sleeve assembly outward, and place adjustment shim (0 to 1 ea.) between sleeve assembly and case to adjust the clearance. CAUTION: Be careful not to break O-ring when placing shim(s). NOTE: When shim is removed, the neutral position will move closer to reverse; when shim is added, the neutral position will move closer to 1st gear. If shims alone cannot adjust the clearance, replace reverse accent shaft and re-adjust.
Part No. 32190AA000 32190AA010 Adjustment shim Thickness mm (in) 0.15 (0.0059) 0.30 (0.0118)
2. REVERSE CHECK PLATE ADJUSTMENT S503267A0102

1) Shift shifter arm to 5th and then to reverse to see if reverse check mechanism operates properly. 2) Also check to see if arm returns to neutral when released from the reverse position. If arm does not return properly, replace reverse check plate.
Part No. 32189AA000 32189AA010 32189AA020 32189AA030 32189AA040 Reverse check plate (A): No. Angle Remarks Arm stops closer to 0 28 5th gear. Arm stops closer to 1 31 5th gear. Arm stops in the cen2 34 ter. Arm stops closer to 3 37 reverse gear. Arm stops closer to 4 40 reverse gear.
B3M0054D
Part No. 32188AA090 32188AA100 32188AA110
Reverse accent shaft Mark Remarks Neutral position is closer to 3 1st gear. 0 Standard Neutral position is closer to 1 reverse gear.
MT-59
TRANSMISSION CASE
S503266
15. Transmission Case

A: REMOVAL
S503266A18
7) Separate transmission case into right and left cases by loosening coupling bolts and nuts.
1. SINGLE-RANGE
S503266A1801
1) Remove the manual transmission assembly from vehicle. <Ref. to MT-32, REMOVAL, Manual Transmission Assembly.> 2) Remove clutch release lever. <Ref. to CL-20, REMOVAL, Release Bearing and Lever.> 3) Remove transfer case with extension case assembly. <Ref. to MT-46, REMOVAL, Transfer Case and Extension Case Assembly.> 4) Remove bearing mounting bolts.
B3M1359
8) Remove drive pinion shaft assembly from left side transmission case. NOTE: Use a hammer handle, etc. to remove if too tight.
S3M0099
5) Remove main shaft rear plate.

B3M0101H
(A) (B)
Main shaft assembly Drive pinion shaft assembly
9) Remove main shaft assembly. 10) Remove differential assembly. CAUTION: Be careful not to confuse right and left roller bearing outer races. Be careful not to damage retainer oil seal.
S3M0100C
(A)
Main shaft rear plate
6) Put vinyl tape around splines of right and left axle drive shafts to prevent damage to oil seal.
G3M0557
2. DUAL-RANGE
B3M1405B
S503266A1802
(A)
Vinyl tape
1) Remove the manual transmission assembly from vehicle. <Ref. to MT-32, REMOVAL, Manual Transmission Assembly.>
MT-60
TRANSMISSION CASE
2) Remove clutch release lever. <Ref. to CL-20, REMOVAL, Release Bearing and Lever.> 3) Remove transfer case with extension case assembly. <Ref. to MT-46, REMOVAL, Transfer Case and Extension Case Assembly.> 4) Remove the input shaft holder.
7) Remove main shaft rear plate.
S3M0100C
(A)
Main shaft rear plate
8) Put vinyl tape around splines of right and left axle drive shafts to prevent damage to oil seals.
B3M2175A
(A) (B)
Input shaft holder Input shaft
5) Remove the high-low switch. <Ref. to MT-42 REMOVAL, Switches and Harness.> 6) Using ST, drive out straight pin, and remove high-low shifter lever. ST 398791700 REMOVER II NOTE: When driving out straight pin, remove it in the direction that it does not butt against transmission case.
B3M1405B
(A)
Vinyl tape
9) Separate transmission case into right and left cases by loosening seventeen coupling bolts and nuts.
H3M1420B
(A) (B)
Straight pin High-low shifter lever
B3M1359
MT-61
TRANSMISSION CASE
12) Remove main shaft assembly and input shaft assembly. CAUTION: Be careful not to drop input shaft and main shaft as they are separable.
10) Remove drive pinion shaft assembly from left side transmission case. NOTE: Use a hammer handle, etc. to remove if too tight.
B3M0101H
(A) (B)
H3M1424B
11) Removing high-low shifter fork Raise main shaft assembly slightly, and remove high-low shifter fork together with high-low shifter shaft and washer. CAUTION: Be careful not to drop the two high-low shifter pieces.
(A) (B)
Main shaft ASSY Input shaft ASSY
13) Remove differential assembly. CAUTION: Be careful not to confuse right and left roller bearing outer races. Be careful not to damage retainer oil seal.
G3M0557 B3M0075C
(A) (B)
High-low shifter fork Input shaft ASSY
B: INSTALLATION
1. SINGLE-RANGE
S503266A11
S503266A1101
1) Wipe off grease, oil and dust on the mating surfaces of transmission cases with white gasoline. 2) Install the front differential assembly. 3) Install the main shaft assembly. Install needle bearing knock pin hole into transmission case knock pin. 4) Install the drive pinion shaft assembly. Install roller bearing knock pin hole into transmission case knock pin. 5) Apply liquid gasket, and then put case right side and left side together. Liquid gasket: THREE BOND 1215 or equivalent
MT-62
TRANSMISSION CASE
6) Tighten 17 bolts with bracket, clip, etc. as shown in the figure. NOTE: Insert bolts from the bottom and tighten nuts at the top. Put cases together so that drive pinion shim and input shaft holder shim are not caught up in between. Confirm that speedometer gear is meshed. Tightening torque: 8 mm bolt 25 Nm (2.5 kgf-m, 18.1 ft-lb) # 10 mm bolt 39 Nm (4.0 kgf-m, 28.9 ft-lb)
8) Backlash adjustment of hypoid gear and preload adjustment of roller bearing NOTE: Support drive pinion assembly with ST. ST 498427100 STOPPER
B3M1362A
B3M0399B
7) Tighten ball bearing attachment bolts. Tightening torque: 29 Nm (3.0 kgf-m, 21.7 ft-lb)
9) Place the transmission with case left side facing downward and put ST1 on bearing cup. 10) Screw retainer assembly into left case from the bottom with ST2. Fit ST3 on the transmission main shaft. Shift gear into 4th or 5th and turn the shaft several times. Screw in the retainer while turning ST3 until a slight resistance is felt on ST2. This is the contact point of hypoid gear and drive pinion shaft. Repeat the above sequence several times to ensure the contact point. ST1 399780104 WEIGHT ST2 499787000 WRENCH ASSY ST3 499927100 HANDLE
S3M0099 B3M1361A
MT-63
TRANSMISSION CASE
17) After checking the tooth contact of hypoid gears, remove the lock plate. Then loosen retainer until the O-ring groove appears. Fit O-ring into the groove and tighten retainer into the position where retainer has been tightened in. Tighten lock plate. NOTE: Carry out this job on both upper and lower retainers. Tightening torque: T: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
11) Remove weight and screw in retainer without O-ring on the upper side and stop at the point where slight resistance is felt. NOTE: At this point, the backlash between the hypoid gear and drive pinion shaft is zero. ST 499787000 WRENCH ASSY
B3M1360A
12) Fit lock plate. Loosen the retainer on the lower side by 1-1/2 notches of lock plate and turn in the retainer on the upper side by the same amount in order to obtain the backlash. NOTE: The notch on the lock plate moves by 1/2 notch if the plate is turned upside down. 13) Turn in the retainer on the upper side additionally by 1 notch in order to apply preload on taper roller bearing. 14) Tighten temporarily both the upper and lower lock plates and mark both holder and lock plate for later readjustment. 15) Turn transmission main shaft several times while tapping around retainer lightly with plastic hammer. 16) Inspect and adjust backlash and tooth contact of hypoid gear. <Ref. to MT-94 INSPECTION, Front Differential Assembly.>
S3M0014C
18) Selecting of main shaft rear plate <Ref. to MT-72 ADJUSTMENT, Main Shaft Assembly for Single-Range.> 19) Install clutch release lever and bearing. <Ref. to CL21 INSTALLATION, Release Bearing and Lever.> 20) Install transfer case with extension case assembly. <Ref. to MT-46 INSTALLATION, Transfer Case and Extension Case Assembly.> 21) Install the manual transmission assembly into the vehicle.<Ref. to MT-35 INSTALLATION, Manual Transmission Assembly.>
2. DUAL-RANGE
S503266A1102
1) Wipe off grease, oil and dust on the mating surfaces of transmission cases with white gasoline. 2) Install the front differential assembly. 3) Install the main shaft assembly and input shaft assembly. Connect main shaft assembly and input shaft assembly, and install needle bearing knock pin hole into transmission case knock pin. 4) Install the drive pinion shaft assembly. Install roller bearing knock pin hole into transmission case knock pin. 5) Apply liquid gasket, and then put case right side and left side together. Liquid gasket: THREE BOND 1215 or equivalent
MT-64
TRANSMISSION CASE
6) Tighten 17 bolts with bracket, clip, etc. as shown in the figure. NOTE: Insert bolts from the bottom and tighten nuts at the top. Put cases together so that drive pinion shim and input shaft holder shim are not caught up in between. Confirm that speedometer gear is meshed. Tightening torque: 8 mm bolt 25 Nm (2.5 kgf-m, 18.1 ft-lb) # 10 mm bolt 39 Nm (4.0 kgf-m, 28.9 ft-lb)
(A) (B)
8) Tighten input shaft holder attaching bolts. Tightening torque: 20 Nm (2.0 kgf-m, 14.5 ft-lb)
B3M2175A
9) Backlash adjustment of hypoid gear and preload adjustment of roller bearing NOTE: Support drive pinion assembly with ST. ST
S3M0161A
498427100
STOPPER
7) Tighten ball bearing attachment bolts. Tightening torque: 29 Nm (3.0 kgf-m, 21.7 ft-lb)
B3M1362A
10) Place the transmission with case left side facing downward and put ST1 on bearing cup.
S3M0099
MT-65
TRANSMISSION CASE
16) Turn transmission main shaft several times while tapping around retainer lightly with plastic hammer. 17) Inspect and adjust backlash and tooth contact of hypoid gear. <Ref. to MT-94 INSPECTION, Front Differential Assembly.> 18) After checking the tooth contact of hypoid gears, remove the lock plate. Then loosen retainer until the O-ring groove appears. Fit O-ring into the groove and tighten retainer into the position where retainer has been tightened in. Tighten lock plate. NOTE: Carry out this job on both upper and lower retainers. Tightening torque: T: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
11) Screw retainer assembly into left case from the bottom with ST2. Fit ST3 on the transmission main shaft. Shift gear into 4th or 5th and turn the shaft several times. Screw in the retainer while turning ST3 until a slight resistance is felt on ST2. This is the contact point of hypoid gear and drive pinion shaft. Repeat the above sequence several times to ensure the contact point. ST1 399780104 WEIGHT ST2 499787000 WRENCH ASSY ST3 499927100 HANDLE
B3M1361A
12) Remove weight and screw in retainer without O-ring on the upper side and stop at the point where slight resistance is felt. NOTE: At this point, the backlash between the hypoid gear and drive pinion shaft is zero. ST 499787000 WRENCH ASSY
S3M0014C
19) Selection of main shaft rear plate <Ref. to MT-72 ADJUSTMENT, Main Shaft Assembly for Signal-Range.> 20) Install transfer case with extension case assembly. <Ref. to MT-46 INSTALLATION, Transfer Case and Extension Case Assembly.> 21) Install clutch release lever and bearing. <Ref. to CL21 INSTALLATION, Release Bearing and Lever.> 22) Install the manual transmission assembly into the vehicle.<Ref. to MT-35 INSTALLATION, Manual Transmission Assembly.>
B3M1360A
C: INSPECTION
S503266A10
13) Fit lock plate. Loosen the retainer on the lower side by 1-1/2 notches of lock plate and turn in the retainer on the upper side by the same amount in order to obtain the backlash. NOTE: The notch on the lock plate moves by 1/2 notch if the plate is turned upside down. 14) Turn in the retainer on the upper side additionally by 1 notch in order to apply preload on taper roller bearing. 15) Tighten temporarily both the upper and lower lock plates and mark both holder and lock plate for later readjustment.
Check the transmission case for cracks, damage, and oil leaks.
MT-66
MAIN SHAFT ASSEMBLY FOR SINGLE-RANGE

S503713A06
16. Main Shaft Assembly for Single-Range

S503713
C: DISASSEMBLY
A: REMOVAL
S503713A18
1) Remove the manual transmission assembly from vehicle. <Ref. to MT-32 REMOVAL, Manual Transmission Assembly.> 2) Remove transfer case with extension case assembly. <Ref. to MT-46 REMOVAL, Transfer Case and Extension Case Assembly.> 3) Remove transmission case. <Ref. to MT-46 REMOVAL, Transmission Case.> 4) Removes drive pinion shaft assembly. <Ref. to MT-83 REMOVAL, Drive Pinion Shaft Assembly.> 5) Remove main shaft assembly.
1) Put vinyl tape around main shaft splines to protect oil seal from damage. Then pull out oil seal and needle bearing by hand. 2) Remove lock nut from transmission main shaft assembly. NOTE: Remove caulking before taking off lock nut. ST1 ST2 498937000 499987003 HOLDER SOCKET WRENCH (35)
B: INSTALLATION
S503713A11
1) Install the needle bearing and oil seal onto the front of transmission main shaft assembly. CAUTION: Wrap clutch splined section with vinyl tape to prevent damage to oil seal. Apply grease (Unilube #2 or equivalent) to the sealing lip of oil seal. Use a new one. 2) Install needle bearing outer race knock pin hole into transmission case knock pin. NOTE: Align the end face of seal with surface (A) when installing oil seal.
B3M0439A
3) Remove 5th-Rev sleeve and hub assembly, baulk ring, 5th drive gear and needle bearing.
B3M0437B
(A) (B) (C)
5th-Rev sleeve and hub ASSY Baulk ring 5th drive gear
B3M0528A
3) Install the drive pinion assembly. <Ref. to MT-83 INSTALLATION, Drive Pinion Shaft Assembly.> 4) Install transmission case. <Ref. to MT-62 INSTALLATION, Transmission Case.> 5) Install transfer case with extension case assembly. <Ref. to MT-46 INSTALLATION, Transfer Case and Extension Case Assembly.> 6) Install the manual transmission assembly to vehicle. <Ref. to MT-35 INSTALLATION, Manual Transmission Assembly.>
MT-67

6) Using ST1 and ST2, remove the rest of parts. NOTE: Replace sleeve and hub with new ones. Do not attempt to disassemble because they must engage at a specified point. If they should be disassembled, marking engagement point on splines beforehand. ST1 ST2 899864100 REMOVER 899714110 REMOVER
4) Remove snap ring and synchro cone stopper from 5th-Rev sleeve and hub assembly.
B3M0435B
(A) (B)
Synchro cone stopper Snap ring
5) Using ST1, ST2 and a press, remove ball bearing, synchro cone and baulk ring (Rev). NOTE: Replace sleeve and hub with new ones. Do not attempt to disassemble because they must engage at a specified point. If they should be disassembled, mark engagement point on splines beforehand. Do not reuse ball bearing. ST1 ST2 499757002 498077400 INSTALLER SYNCHRO CONE REMOVER
B3M0835A
B3M1365A
(A) (B) (C)
Ball bearing Synchro cone Baulk ring
MT-68
MAIN SHAFT ASSEMBLY FOR SINGLE-RANGE D: ASSEMBLY

S503713A02
1) Assemble each sleeve and hub assembly. NOTE: Position open ends of spring 120 apart.
3) Install 4th needle bearing race onto transmission main shaft using ST1, ST2 and a press. CAUTION: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton). ST1 ST2 899714110 REMOVER 499877000 RACE 4-5 INSTALLER
B3M0543D
(A)
4th needle bearing race
4) Install baulk ring, needle bearing, 4th drive gear and 4th gear thrust washer to transmission main shaft. NOTE: Align baulk ring and gear & hub assembly with key groove.
B3M1366A
2) Install 3rd drive gear, outer baulk ring, synchro cone, inner baulk ring, sleeve and hub assembly for 3rd needle bearing on transmission main shaft. NOTE: Align groove in baulk ring with shifting insert.
S3M0045A
(A) (B)
Groove 4th gear side
B3M0837A
(A) (B) (C) (D) (E) (F)
3rd needle bearing 3rd drive gear Inner baulk ring Synchro cone Outer baulk ring Sleeve and hub ASSY
MT-69

7) Install bearing onto synchro cone. 8) Install baulk ring and synchro cone onto 5thRev sleeve and hub assembly using ST and a press. CAUTION: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton). NOTE: Use new ball bearing. After press fitting, make sure synchro cone rotates freely. ST 499757002 INSTALLER
5) Drive ball bearing onto the rear section of transmission main shaft using ST1, ST2 and a press. CAUTION: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton). ST1 ST2 899714110 REMOVER 499877000 RACE 4-5 INSTALLER
B3M0553F
6) Using ST1 and ST2, install the 5th gear thrust washer and 5th needle bearing race onto the rear section of transmission main shaft. CAUTION: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton). NOTE: Face thrust washer in the correct direction. ST1 ST2 899714110 REMOVER 499877000 RACE 4-5 INSTALLER
B3M1370A
(A) (B) (C)
Baulk ring Synchro cone Ball bearing
9) Install synchro cone stopper and snap ring to 5th-Rev sleeve and hub assembly.
S3M0045A
B3M0435B
(A) (B)
Groove 4th gear thrust washer
(A) (B)
MT-70

10) Install the rest parts to the rear section of transmission main shaft. NOTE: Align groove in baulk ring with shifting insert.
4) Baulk ring Replace the ring in the following cases: When the inner surface and end face are damaged. When the ring inner surface is abnormally or partially worn down. When the contact surface of the synchronizer ring insert is scored or abnormally worn down. 5) Shifting insert key Replace the insert if deformed, excessively worn, or defective in any way.
B3M1371A
(A) (B) (C) (D) (E) (F)
Needle bearing 5th drive gear Baulk ring 5th-Rev sleeve and hub ASSY Lock washer Lock nuts
S3M0189
11) Tighten lock nuts to the specified torque using ST1 and ST2. NOTE: Secure lock nuts in two places after tightening. ST1 ST2 499987003 498937000 SOCKET WRENCH TRANSMISSION HOLDER
6) Oil seal Replace the oil seal if the lip is deformed, hardened, damaged, worn, or defective in any way. 7) O-ring Replace the O-ring if the sealing face is deformed, hardened, damaged, worn, or defective in any way. 8) Gearshift mechanism Repair or replace the gearshift mechanism if excessively worn, bent, or defective in any way.
E: INSPECTION
S503713A10
Disassembled parts should be washed clean first and then inspected carefully. 1) Bearings Replace bearings in the following cases: Bearings whose balls, outer races and inner races are broken or rusty. Worn bearings Bearings that fail to turn smoothly or make abnormal noise when turned after gear oil lubrication. Bearings having other defects 2) Bushing (each gear) Replace the bushing in the following cases: When the sliding surface is damaged or abnormally worn. When the inner wall is abnormally worn. 3) Gears Replace gears with new ones if their tooth surfaces are broken, damaged, or excessively worn. Correct or replace if the cone that contacts the baulk ring is rough or damaged. Correct or replace if the inner surface or end face is damaged.
MT-71

S503713A01
F: ADJUSTMENT
Selection of main shaft rear plate Using ST, measure the amount (A) of ball bearing protrusion from transmission main case surface and select the proper plate in the following table: NOTE: Before measuring, tap the end of main shaft with a plastic hammer lightly in order to make the clearance zero between the main case surface and the moving flange of bearing. ST 498147000 DEPTH GAUGE
Part No. 32294AA041 Mark 1
Dimension (A) mm (in) 4.00 4.13 (0.1575 0.1626) 3.87 3.99 (0.1524 0.1571)
32294AA051
B3M0531A
MT-72
MAIN SHAFT ASSEMBLY FOR DUAL-RANGE

S503714A06
17. Main Shaft Assembly for Dual-Range

S503714
C: DISASSEMBLY
A: REMOVAL
S503714A18
1) Remove the manual transmission assembly from vehicle. <Ref. to MT-32 REMOVAL, Manual Transmission Assembly.> 2) Remove transfer case with extension case assembly. <Ref. to MT-46 REMOVAL, Transfer Case and Extension Case Assembly.> 3) Remove transmission case. <Ref. to MT-46 REMOVAL, Transmission Case.> 4) Removes drive pinion shaft assembly. <Ref. to MT-83 REMOVAL, Drive Pinion Shaft Assembly.> 5) Remove main shaft assembly and input shaft assembly.
1) Put vinyl tape around main shaft splines to protect oil seal from damage. Then pull out oil seal and needle bearing by hand. 2) Remove lock nut from transmission main shaft assembly. NOTE: Remove caulking before taking off lock nut. ST1 ST2 498937000 499987003 TRANSMISSION HOLDER SOCKET WRENCH (35)
B: INSTALLATION
S503714A11
1) Install the needle bearing onto the front of transmission main shaft assembly. 2) Connect main shaft assembly and input shaft assembly. 3) Install needle bearing outer race knock pin hole into transmission case knock pin. 4) Install the drive pinion assembly. <Ref. to MT-83 INSTALLATION, Drive Pinion Shaft Assembly.> 5) Install transmission case. <Ref. to MT-62 INSTALLATION, Transmission Case.> 6) Install transfer case with extension case assembly. <Ref. to MT-46 INSTALLATION, Transfer Case and Extension Case Assembly.> 7) Install the manual transmission assembly to vehicle. <Ref. to MT-35 INSTALLATION, Manual Transmission Assembly.>
B3M0439A
3) Remove 5th-Rev sleeve and hub assembly, baulk ring, 5th drive gear and needle bearing.
B3M0437B
(A) (B) (C)
5th-Rev sleeve and hub ASSY Baulk ring 5th drive gear
4) Remove snap ring and synchro cone stopper from 5th-Rev sleeve and hub assembly.
B3M0435B
(A) (B)
MT-73

6) Using ST1 and ST2, remove the rest of parts. NOTE: Replace sleeve and hub with new ones. Do not attempt to disassemble because they must engage at a specified point. If they should be disassembled, marking engagement point on splines beforehand. ST1 ST2 899864100 REMOVER 899714110 REMOVER
5) Using ST1, ST2 and a press, remove ball bearing, synchro cone and baulk ring (Rev). NOTE: Replace sleeve and hub with new ones. Do not attempt to disassemble because they must engage at a specified point. If they should be disassembled, mark engagement point on splines beforehand. Do not reuse ball bearing. ST1 ST2 499757002 498077400 INSTALLER SYNCHRO CONE REMOVER
B3M1365A
(A) (B) (C)
Ball bearing Synchro cone Baulk ring
B3M0835A
7) Remove snap ring from main shaft. ST 899474100 EXPANDER
H3M1432D
(A)
Snap ring
MT-74

8) Remove the rest of parts.
2) Install 3rd drive gear, baulk ring, sleeve and hub assembly for 3rd-4th needle bearing on transmission main shaft. NOTE: Align groove in baulk ring with shifting insert. 3) Install 4th needle bearing race onto transmission main shaft using ST1, ST2 and a press. ST1 899714110 REMOVER ST2 499877000 RACE 4-5 INSTALLER
S3M0169A
(A) (B) (C) (D) (E) (F) (G)
Sleeve and hub ASSY High-low baulk ring Friction damper Low input gear Needle bearing Input low gear spacer Ball
S503714A02
D: ASSEMBLY
B3M0543D
1) Assemble when each sleeve and hub assembly are disassembled. NOTE: Position open ends of spring 120 apart.
(A)
4th needle bearing race
4) Install baulk ring, needle bearing, 4th drive gear and 4th gear thrust washer to transmission main shaft. NOTE: Face thrust washer in the correct direction.
S3M0444A
(A) (B) (C) (D) (E) (F) (G) (H) (I) (J)
High-low coupling sleeve Shifting insert High-low synchronizer spring High-low synchronizer hub Sleeve Insert key 3rd-4th synchronizer hub Sleeve Insert key 5th-Rev synchronizer hub
S3M0045A
(A) (B)
Groove 4th gear side
MT-75

7) Install bearing onto synchro cone. 8) Install baulk ring and synchro cone onto 5thRev sleeve and hub assembly using ST and a press. NOTE: Use new ball bearing. After press fitting, make sure synchro cone rotates freely. ST 499757002 INSTALLER
5) Drive ball bearing onto the rear section of transmission main shaft using ST1, ST2 and a press. ST1 899714110 REMOVER ST2 499877000 RACE 4-5 INSTALLER
B3M0553F
6) Using ST1 and ST2, install the 5th gear thrust washer and 5th needle bearing race onto the rear section of transmission main shaft. NOTE: Face thrust washer in the correct direction. ST1 ST2 899714110 REMOVER 499877000 RACE 4-5 INSTALLER
(A) (B) (C) Baulk ring Synchro cone Ball bearing
B3M1370A
9) Install synchro cone stopper and snap ring to 5th-Rev sleeve and hub assembly.
S3M0045A
(A) (B)
Groove 4th gear thrust washer

B3M0435B
(A) (B)
MT-76

10) Install the rest parts to the rear section of transmission main shaft. NOTE: Align groove in baulk ring with shifting insert.
13) Install the parts to the front section of transmission main shaft. CAUTION: Be careful not to damage the graded section of transmission main shaft when installing needle bearing. NOTE: Face the grooved side toward input gear. Align high-low baulk rings groove with shifting insert.
B3M1371A
(A) (B) (C) (D) (E) (F)
Needle bearing 5th drive gear Baulk ring 5th-Rev sleeve and hub ASSY Lock washer Lock nuts (A) (B) (C) (D) (E) (F) (G) Ball Input low gear spacer Needle bearing Low input gear Friction damper High-low baulk ring Sleeve and hub ASSY
S3M0169B
11) Tighten lock nuts to the specified torque using ST1 and ST2. NOTE: Secure lock nuts in two places after tightening. ST1 ST2 499987003 498937000 SOCKET WRENCH (35) TRANSMISSION HOLDER
Tightening torque: 118 Nm (12.0 kgf-m, 86.8 ft-lb) 12) Install needle bearing on main shaft.
14) Install snap ring to the rod section of transmission main shaft using ST1 and ST2. CAUTION: Use only new snap ring. NOTE: Select a suitable outer snap ring so that axial clearance between snap ring and hub is held within 0.060 to 0.100 mm (0.0024 to 0.0039 in). ST1 ST2 499757002 499757001
Part No. 805025051 805025052 805025053 805025054 805025055 805025056 805025057 805025058
INSTALLER SNAP RING GUIDE

Snap ring Thickness mm (in) 2.42 (0.0953) 2.47 (0.0972) 2.52 (0.0992) 2.57 (0.1012) 2.62 (0.1031) 2.67 (0.1051) 2.72 (0.1071) 2.37 (0.0933)
MT-77

S503714A10
E: INSPECTION
Disassembled parts should be washed clean first and then inspected carefully. 1) Bearings Replace bearings in the following cases: Bearings whose balls, outer races and inner races are broken or rusty. Worn bearings Bearings that fail to turn smoothly or make abnormal noise when turned after gear oil lubrication. Bearings having other defects 2) Bushing (each gear) Replace the bushing in the following cases: When the sliding surface is damaged or abnormally worn. When the inner wall is abnormally worn. 3) Gears Replace gears with new ones if their tooth surfaces are broken, damaged, or excessively worn. Correct or replace if the cone that contacts the baulk ring is rough or damaged. Correct or replace if the inner surface or end face is damaged. 4) Baulk ring Replace the ring in the following cases: When the inner surface and end face are damaged. When the ring inner surface is abnormally or partially worn down. When the contact surface of the synchronizer ring insert is scored or abnormally worn down. 5) Shifting insert key Replace the insert if deformed, excessively worn, or defective in any way. 6) Oil seal Replace the oil seal if the lip is deformed, hardened, damaged, worn, or defective in any way. 7) O-ring Replace the O-ring if the sealing face is deformed, hardened, damaged, worn, or defective in any way. 8) Gearshift mechanism Repair or replace the gearshift mechanism if excessively worn, bent, or defective in any way.
F: ADJUSTMENT
S503714A01
Choose main shaft rear plate. <Ref. to MT-72 ADJUSTMENT, Main Shaft Assembly for SingleRange.>
MT-78
INPUT SHAFT ASSEMBLY

S503715A06
18. Input Shaft Assembly

A: REMOVAL
S503715A18
S503715
C: DISASSEMBLY
1) Remove the manual transmission assembly from vehicle. <Ref. to MT-32 REMOVAL, Manual Transmission Assembly.> 2) Remove the transfer case with extension case assembly. <Ref. to MT-46 REMOVAL, Transfer Case and Extension Case Assembly.> 3) Remove transmission case. <Ref. to MT-60 REMOVAL, Transmission Case.> 4) Remove drive pinion shaft assembly. <Ref. to MT-83 REMOVAL, Drive Pinion Shaft Assembly.> 5) Remove main shaft assembly and input shaft assembly.
1) Remove O-ring from input shaft holder. Also, remove input shaft holder shim. CAUTION: Use new O-ring. NOTE: Number of shims used varies from none to two.
B: INSTALLATION
S503715A11
1) Install the needle bearing onto the front of the transmission main shaft assembly. 2) Connect main shaft assembly and input shaft assembly. 3) Install needle bearing outer race knock pin hole into transmission case knock pin. 4) Install the drive pinion assembly. <Ref. to MT-83 INSTALLATION, Drive Pinion Shaft.> 5) Install the transmission case. <Ref. to MT-62 INSTALLATION, Transmission Case.> 6) Install the transfer case with extension case assembly. <Ref. to MT-46 INSTALLATION, Transfer Case and Extension Case Assembly.> 7) Install manual transmission assembly on vehicle. <Ref. to MT-35 INSTALLATION, Manual Transmission Assembly.>
S3M0167A
(A) (B) (C)
Input shaft holder O-ring Input shaft holder shim
2) Put vinyl tape around input shaft splines to protect oil seal from damage. 3) Remove inner snap ring. ST 398663600 PLIERS
G3M0828
4) Hold input shaft holder stationary and remove input shaft by tapping its end with a plastic hammer.
H3M1430B
(A) (B)
MT-79
INPUT SHAFT ASSEMBLY D: ASSEMBLY

S503715A02
5) Remove outer snap ring. Then remove oil squeeze plate and straight pin.
1) Install ball bearing onto input shaft. NOTE: Place snap ring between input shaft gear and ball bearing beforehand. Use the table at 5) as a guide in selecting a suitable snap ring. ST1 ST2 899580100 399513600 INSTALLER INSTALLER
S3M0157C
(A) (B)
Snap ring Oil squeeze plate
6) Remove snap ring.
G3M0831
2) Install snap ring on input shaft. NOTE: Select a suitable snap ring so that the axial play of ball bearing is held within 0 to 0.12 mm (0 to 0.0047 in).
S3M0158C
(A)
Snap ring
7) Using a press and ST, remove ball bearing. NOTE: Remove inner snap ring before pressing. ST 498077000 RETAINER
S3M0160C
(A) (B)
Snap ring Thickness gauge Snap ring Part No. 805028050 805028060 805028070 Thickness mm (in) 2.48 (0.0976) 2.56 (0.1008) 2.64 (0.1039)
G3M0830
8) Remove oil seal from input shaft holder.
MT-80

3) Install straight pin and oil squeeze plate to input shaft.
7) Install snap ring to input shaft holder. NOTE: Select a suitable snap ring so that clearance between snap ring and bearing is held within 0 to 0.12 mm (0 to 0.0047 in). ST 398663600 PLIERS
S3M0159C
(A) (B)
Straight pin Oil squeeze plate

G3M0828
4) Install snap ring. 5) Drive oil seal into input shaft holder. NOTE: Apply a coat of grease to sealing lips before installing oil seal. ST 398507703 DUMMY COLLAR
Snap ring Part No. 805168020 805168030 805168040
Thickness mm (in) 1.84 (0.0724) 1.92 (0.0756) 2.00 (0.0787)
8) Install O-ring on input shaft holder.
G3M0833
6) Wind vinyl tape around shaft splines and insert input shaft into holder by lightly tapping it by hand.
(A) (B) O-ring Input shaft holder
S503715A10
S3M0168C
E: INSPECTION
B3M2140A
(A) (B)
Vinyl tape Input shaft
Disassembled parts should be washed clean first and then inspected carefully. 1) Bearings Replace bearings in the following cases: Bearings whose balls, outer races and inner races are broken or rusty. Worn bearings Bearings that fail to turn smoothly or make abnormal noise when turned after gear oil lubrication. Bearings having other defects 2) Bushing (each gear) Replace the bushing in the following cases: When the sliding surface is damaged or abnormally worn.
MT-81
When the inner wall is abnormally worn. 3) Gears Replace gears with new ones if their tooth surfaces are broken, damaged, or excessively worn. Correct or replace if the cone that contacts the baulk ring is rough or damaged. Correct or replace if the inner surface or end face is damaged. 4) Baulk ring Replace the ring in the following cases: When the inner surface and end face are damaged. When the ring inner surface is abnormally or partially worn down. When the contact surface of the synchronizer ring insert is scored or abnormally worn down. 5) Shifting insert key Replace the insert if deformed, excessively worn, or defective in any way. 6) Oil seal Replace the oil seal if the lip is deformed, hardened, damaged, worn, or defective in any way. 7) O-ring Replace the O-ring if the sealing face is deformed, hardened, damaged, worn, or defective in any way. 8) Gearshift mechanism Repair or replace the gearshift mechanism if excessively worn, bent, or defective in any way.
MT-82
DRIVE PINION SHAFT ASSEMBLY
19. Drive Pinion Shaft Assembly

S503269
4) Inspection and adjustment of ST NOTE: Loosen the two bolts and adjust so that the scale indicates 0.5 correctly when the plate end and the scale end are on the same level. Tighten the two bolts. ST 499917500 DRIVE PINION GAUGE ASSY
A: REMOVAL
S503269A18
1) Remove the manual transmission assembly from vehicle. <Ref. to MT-32 REMOVAL, Manual Transmission Assembly.> 2) Remove transfer case with extension case assembly. <Ref. to MT-46 REMOVAL, Transfer Case and Extension Case Assembly.> 3) Remove transmission case. <Ref. to MT-60 REMOVAL, Transmission Case.> 4) Remove drive pinion shaft assembly. NOTE: Use a hammer handle, etc. to remove if too tight.
B3M0064B
(A) (B)
Plate Scale
B3M0101H
(A) (B)

S503269A11
5) Position the ST by inserting the knock pin of ST into the knock hole in the transmission case. ST 499917500 DRIVE PINION GAUGE ASSY 6) Slide the drive pinion gauge scale with finger tip and read the value at the point where it matches with the end face of drive pinion. ST 499917500 DRIVE PINION GAUGE ASSY
B: INSTALLATION
1) Remove differential assembly. 2) Alignment marks/numbers on hypoid gear set The upper number on driven pinion is the match number for combining it with hypoid driven gear. The lower number is for shim adjustment. If no lower number is shown, the value is zero. The number on hypoid driven gear indicates a number for combination with drive pinion.
(A)
B3M0065C
Adjust clearance to zero without shim.
7) The thickness of shim shall be determined by adding the value indicated on drive pinion to the value indicated on the ST. (Add if the number on drive pinion is prefixed by + and subtract if the number is prefixed by .) ST 499917500 DRIVE PINION GAUGE ASSY
G3M0554
3) Place drive pinion shaft assembly on right hand transmission main case without shim and tighten bearing mounting bolts.
MT-83

2) Withdraw drive pinion from driven shaft. Remove differential bevel gear sleeve, adjusting washer No. 1, adjusting washer No. 2, thrust bearing, needle bearing, drive pinion collar, needle bearing and thrust bearing.
8) Select one to three shims from the next table for the value determined as described above and take a shim thickness which is closest to the said value.
Drive pinion shim Part No. Thickness mm (in) 32295AA031 0.150 (0.0059) 32295AA041 0.175 (0.0069) 32295AA051 0.200 (0.0079) 32295AA061 0.225 (0.0089) 32295AA071 0.250 (0.0098) 32295AA081 0.275 (0.0108) 32295AA091 0.300 (0.0118) 32295AA101 0.500 (0.0197)
9) Install differential assembly. <Ref. to MT-92 INSTALLATION, Front Differential Assembly.> 10) Set transmission main shaft assembly and drive pinion assembly in position. (So there is no clearance between the two when moved all the way to the front). Inspect suitable 1st 2nd, 3rd 4th and 5th shifter fork so that coupling sleeve and reverse driven gear are positioned in the center of their cynchronizing mechanisms. <Ref. to MT-88 INSPECTION, Drive Shaft Assembly.> 11) Install transmission case. <Ref. to MT-62 INSTALLATION, Transmission Case.> 12) Install transfer case with extension case assembly. <Ref. to MT-46 INSTALLATION, Transfer Case and Extension Case Assembly.> 13) Install the manual transmission assembly to vehicle. <Ref. to MT-32 INSTALLATION, Manual Transmission Assembly.>
B3M0536G
(A) (B) (C) (D) (E) (F) (G) (H)
Differential bevel gear sleeve Washer No. 1 (25 37.5 t) Thrust bearing (25 37.5 3) Washer No. 2 (25 37.5 4) Needle bearing (25 30 20) Drive pinion collar Needle bearing (30 37 23) Thrust bearing (33 50 3)
3) Remove roller bearing and washer using ST and press. CAUTION: Do not reuse roller bearing. ST 498077000 REMOVER
C: DISASSEMBLY
S503269A06
CAUTION: Attach a cloth to the end of driven shaft (on the frictional side of thrust needle bearing) during disassembly or reassembly to prevent damage. 1) Straighten lock nut at staked portion. Remove the lock nut using ST1, ST2 and ST3. ST1 899884100 HOLDER ST2 498427100 STOPPER ST3 899988608 SOCKET WRENCH (27)
G3M0607
G3M0595
MT-84

4) Straighten lock nut at staked portion. Remove the lock nut using ST1 and ST2. ST1 499987300 SOCKET WRENCH (50) ST2 899884100 HOLDER
9) Remove 2nd driven gear, inner baulk ring, synchro cone and outer baulk ring.
S3M0445A
G3M0608
5) Remove 5th driven gear using ST. ST 499857000 5TH DRIVEN GEAR REMOVER
(A) (B) (C) (D)
2nd driven gear Inner baulk ring Synchro cone Outer baulk ring
10) Remove 1st driven gear, 2nd gear bushing, gear and hub using ST1 and ST2. NOTE: Replace gear and hub if necessary. Do not attempt to disassemble if at all possible because they must engage at a specified point. If they have to be disassembled, mark the engaging point beforehand. ST1 ST2
G3M0609
499757002 INSTALLER 899714110 REMOVER
6) Remove woodruff key. 7) Remove roller bearing, 3rd-4th driven gear using ST1 and ST2. ST1 499757002 INSTALLER ST2 899714110 REMOVER
G3M0611
11) Remove sub gear for 1st driven gear.
G3M0610
8) Remove the key.
MT-85

4) Install 2nd driven gear bushing onto driven shaft using ST1, ST2 and press. CAUTION: Attach a cloth to the end of driven shaft to prevent damage. Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton). NOTE: When press fitting, align oil holes of shaft and bushing. ST1 499277200 INSTALLER ST2 499587000 INSTALLER
D: ASSEMBLY
S503269A02
1) Install sleeve and assembly by matching alignment marks. NOTE: Use new gear and hub assembly, if gear or hub have been replaced.
B3M0077E
(A) (B) (C) (D)
1st gear side 2nd gear side Flush surface Stepped surface
B3M0078F
2) Install washer, snap ring and sub gear to 1st driven gear. 3) Install 1st driven gear, 1st baulk ring, gear and hub assembly onto driven shaft. NOTE: Take care to install gear and hub assembly in proper direction. Align baulk ring and gear & hub assembly with key groove.
5) Install 2nd driven gear, inner baulk ring, synchro cone, outer baulk ring and insert onto driven shaft.
S3M0445A
(A) (B) (C) (D)
2nd driven gear Inner baulk ring Synchro cone Outer baulk ring
MT-86

6) After installing key on driven shaft, install 3rd4th driven gear using ST and press. CAUTION: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton). NOTE: Align groove in baulk ring with insert. ST 499277200 INSTALLER
8) Position woodruff key in groove on the rear of driven shaft. Install 5th driven gear onto drive shaft using ST and press. CAUTION: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton). ST 499277200 INSTALLER
G3M0617 G3M0615
7) Install a set of roller bearings onto the driven shaft using ST and press. CAUTION: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton). ST 499277200 INSTALLER
9) Install lock washer. Install lock nut and tighten to the specified torque using ST. ST 499987300 SOCKET WRENCH (50) Tightening torque: 265 Nm (27 kgf-m, 195 ft-lb)
G3M0618
G3M0616
NOTE: Stake lock nut at two points. Using spring balancer, check that starting torque of roller bearing is 0.1 to 1.5 N (0.01 to 0.15 kgf, 0.02 to 0.33ft).
B3M0079
MT-87

13) Install drive pinion collar, needle bearing, adjusting washer No. 2, thrust bearing, adjusting washer No. 1 and differential bevel gear sleeve in that order. NOTE: Be careful because spacer must be installed in proper direction.
10) Install roller bearing onto drive pinion. NOTE: When installing roller bearing, note its directions (front and rear) because knock pin hole in outer race is offset.
B3M1661A
(A) (B)
Roller bearing Knock pin hole (A) (B) (C) (D) (E) (F) (G) (H) Driven shaft Drive shaft Drive pinion collar Needle bearing (25 30 20) Washer No. 2 (25 36 4) Thrust bearing (25 37.5 3) Washer No. 1 (25 36 t) Differential bevel gear sleeve
S503269A10
B3M0083D
11) Install washer using ST1, ST2 and press. CAUTION: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton). ST1 ST2 499277100 499277200 BUSH 1-2 INSTALLER INSTALLER
E: INSPECTION
B3M0080E
(A)
Washer
Disassembled parts should be washed clean first and then inspected carefully. 1) Bearings Replace bearings in the following cases: Bearings whose balls, outer races and inner races are broken or rusty. Worn bearings Bearings that fail to turn smoothly or make abnormal noise when turned after gear oil lubrication.
12) Install thrust bearing and needle bearing. Install driven shaft assembly.
B3M0082
MT-88

The ball bearing on the rear side of the drive pinion shaft should be checked for smooth rotation before the drive pinion assembly is disassembled. In this case, because a preload is working on the bearing, its rotation feels like it is slightly dragging unlike the other bearings.
When the contact surface of the synchronizer ring insert is scored or abnormally worn down. 5) Shifting insert key Replace the insert if deformed, excessively worn, or defective in any way.
S3M0189 B3M0038E
(A) (B)
Drive pinion shaft Ball bearing
Bearings having other defects 2) Bushing (each gear) Replace the bushing in the following cases: When the sliding surface is damaged or abnormally worn. When the inner wall is abnormally worn. 3) Gears Replace gears with new ones if their tooth surfaces are broken, damaged, or excessively worn. Correct or replace if the cone that contacts the baulk ring is rough or damaged. Correct or replace if the inner surface or end face is damaged. 4) Baulk ring Replace the ring in the following cases: When the inner surface and end face are damaged. When the ring inner surface is abnormally or partially worn down. If the gap between the end faces of the ring and the gear splined part is excessively small when the ring is pressed against the cone. Clearance (A): 0.5 1.0 mm (0.020 0.040 in)
6) Oil seal Replace the oil seal if the lip is deformed, hardened, damaged, worn, or defective in any way. 7) O-ring Replace the O-ring if the sealing face is deformed, hardened, damaged, worn, or defective in any way.
F: ADJUSTMENT
S503269A01
1. THRUST BEARING PRELOAD
S503269A0101
1) After completing the preceding steps 1) through 3), select adjusting washer No. 1 so that dimension (H) is zero through visual check. Position washer (18.3 30 4) and lock washer (18 30 2) and install lock nut (18 13.5).
B3M0538A S3M0188A
MT-89

4) If starting torque is not within specified limit, select new adjusting washer No. 1 and recheck starting torque.
2) Using ST1, ST2 and ST3, tighten lock nut to the specified torque. ST1 899884100 HOLDER ST2 498427100 STOPPER ST3 899988608 SOCKET WRENCH (27) Tightening torque: 118 Nm (12 kgf-m, 86.8 ft-lb)
B3M0536I
(A) (B)
G3M0626
Adjusting washer No.1 Adjusting washer No.2 Adjusting washer No. 1 Part No. Thickness mm (in) 803025051 3.925 (0.1545) 803025052 3.950 (0.1555) 803025053 3.975 (0.1565) 803025054 4.000 (0.1575) 803025055 4.025 (0.1585) 803025056 4.050 (0.1594) 803025057 4.075 (0.1604)
3) After removing ST2, measure starting torque using torque driver. ST1 899884100 HOLDER ST3 899988608 SOCKET WRENCH (27) Starting torque: 0.30.8 Nm (0.030.08 kgf-m, 0.20.6 ft-lb)
5) If specified starting torque range cannot be obtained when a No. 1 adjusting washer is used, then select a suitable No. 2 adjusting washer from those listed in the following table. Repeat steps 1) through 4) to adjust starting torque.
B3M0085A
B3M0536I
(A) (B)
Adjusting washer No. 1 Adjusting washer No. 2 Dimension H Small Large Washer No. 2 Select thicker one. Select thinner one.
Starting torque Low High
Adjusting washer No. 2 Part No. Thickness mm (in) 803025059 3.850 (0.1516) 803025054 4.000 (0.1575) 803025058 4.150 (0.1634)
MT-90

6) Recheck that starting torque is within specified range, then clinch lock nut at four positions.
MT-91
FRONT DIFFERENTIAL ASSEMBLY B: INSTALLATION

S503152A11
20. Front Differential Assembly

S503152
A: REMOVAL
S503152A18
1) Remove the manual transmission assembly from vehicle. <Ref. to MT-32 REMOVAL, Manual Transmission Assembly.> 2) Remove transfer case with extension case assembly. <Ref. to MT-46 REMOVAL, Transfer Case and Extension Case Assembly.> 3) Remove transmission case. <Ref. to MT-60 REMOVAL, Transmission Case.> 4) Removes drive pinion shaft assembly. Remove transfer case with extension case assembly. <Ref. to MT-83 REMOVAL, Drive Pinion Shaft Assembly.> 5) Remove main shaft assembly. Single-range model: <Ref. to MT-67 REMOVAL, Main Shaft Assembly for Single-Range.> Dual-range model: <Ref. to MT-73 REMOVAL, Main Shaft Assembly for Dual-Range.> 6) Remove differential assembly. CAUTION: Be careful not to confuse right and left roller bearing outer races. Be careful not to damage retainer oil seal.
1) Install differential side retainers using ST. ST 499787000 WRENCH ASSY 2) Install differential assembly. CAUTION: Be careful not to fold the sealing lip of oil seal. NOTE: Wrap the left and right splines sections of axle shaft with vinyl tape to prevent scratches.
G3M0557
3) Install main shaft assembly. Single-range model: <Ref. to MT-67 INSTALLATION, Main Shaft Assembly for Single-Range.> Dual-range: <Ref. to MT-73 INSTALLATION, Main Shaft Assembly for Dual-Range.> 4) Install drive pinion assembly. <Ref. to MT-83 INSTALLATION, Drive Pinion Shaft Assembly.> 5) Install transmission case. <Ref. to MT-62 INSTALLATION, Transmission Case.> 6) Install transfer case with extension case assembly. <Ref. to MT-46 INSTALLATION, Transfer Case and Extension Case Assembly.> 7) Install the manual transmission assembly to vehicle. <Ref. to MT-35 INSTALLATION, Manual Transmission Assembly.>
G3M0557
7) Remove differential side retainers using ST. ST 499787000 WRENCH ASSY
C: DISASSEMBLY
S503152A06
1) Remove right and left snap rings from differential, and then remove two axle drive shafts. NOTE: During reassembly, reinstall each axle drive shaft in the same place from which it was removed.
B3M1360A
MT-92
FRONT DIFFERENTIAL ASSEMBLY

2) Loosen twelve bolts and remove hypoid driven gear.
4) Pull out pinion shaft, and remove differential bevel pinion and gear and washer.
B3M0552C
(A) (B) (C) (D)
Pinion shaft Bevel pinion Bevel gear Washer
5) Remove roller bearing using ST. ST 399527700 PULLER SET
B3M0551C
(A) (B) (C)
Snap ring Axle drive shaft Hypoid driven gear
3) Drive out straight pin from differential assembly toward hypoid driven gear. ST 899904100 REMOVER
G3M0668
D: ASSEMBLY
S503152A02
1) Install bevel gear and bevel pinion together with washers, and insert pinion shaft. NOTE: Face the chamfered side of washer toward gear.
G3M0667
B3M0099D
(A) (B) (C)
Bevel pinion Bevel gear Pinion shaft
MT-93

4) Install roller bearing to differential case. CAUTION: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton). NOTE: Be careful because roller bearing outer races are used as a set. ST1 ST2 499277100 398497701 BUSH 1-2 INSTALLER ADAPTER
2) Measure backlash between bevel gear and pinion. If it is not within specifications, install a suitable washer to adjust it. <Ref. to MT-96 ADJUSTMENT, Front Differential Assembly.> NOTE: Be sure the pinion gear tooth contacts adjacent gear teeth during measurement. ST1 ST2 498247001 498247100 MAGNET BASE DIAL GAUGE
Standard backlash: 0.13 0.18 mm (0.0051 0.0071 in)
G3M0671
G3M0670
5) Install hypoid driven gear to differential case using twelve bolts. Tightening torque: T: 62 Nm (6.3 kgf-m, 45.6 ft-lb)
3) Align pinion shaft and differential case at their holes, and drive straight pin into holes from the hypoid driven gear side, using ST. NOTE: Lock straight pin after installing. ST 899904100 REMOVER
B3M0554C
(A) (B)
B3M0609C
Hypoid driven gear Differential case

S503152A10
E: INSPECTION
(A) (B) (C)
Pinion shaft Differential case Straight pin
Repair or replace the differential gear in the following cases: The hypoid drive gear and drive pinion shaft tooth surface are damaged, excessively worn, or seized. The roller bearing on the drive pinion shaft has a worn or damaged roller path. There is damage, wear, or seizure of the differential bevel pinion, differential bevel gear, washer, pinion shaft, and straight pin. The differential case has worn or damaged sliding surfaces.
MT-94

ST1 ST2 498247001 498247100
MAGNET BASE DIAL GAUGE
Standard backlash: 0.13 0.18 mm (0.0051 0.0071 in)
G3M0670
2. HYPOID GEAR BACKLASH
S503152A1002
B3M0558C
(A) (B) (C) (D) (E) (F) (G) (H) (I) (J)
Drive pinion shaft Hypoid driven gear Pinion shaft Straight pin Washer Differential bevel gear Differential bevel pinion Snap ring Roller bearing Differential case
Set ST1, ST2 and ST3. Insert the needle through transmission oil drain plug hole so that the needle comes in contact with the tooth surface at a right angle and check the backlash. ST1 498247001 MAGNET BASE ST2 498247100 DIAL GAUGE ST3 498255400 PLATE Backlash: 0.13 0.18 mm (0.0051 0.0071 in)
1. BEVEL PINION GEAR BACKLASH

S503152A1001
Measure backlash between bevel gear and pinion. If it is not within specifications, install a suitable washer to adjust it. NOTE: Be sure the pinion gear tooth contacts adjacent gear teeth during measurement.
B3M1363A
NOTE: If backlash is outside specified range, adjust it by turning holder in right side case.
3. TOOTH CONTACT OF HYPOID GEAR

S503152A1003
Check tooth contact of hypoid gear as follows: Apply a uniform thin coat of red lead on both tooth surfaces of 3 or 4 teeth of the hypoid gear. Move the hypoid gear back and forth by turning the transmission main shaft until a definite contact pattern is developed on hypoid gear, and judge whether face contact is correct. If it is inaccurate, make adjustment. <Ref. to MT-96 ADJUSTMENT, Front Differential Assembly.>
MT-95

NOTE: Each time holder rotates one tooth, backlash changes by 0.05 mm (0.020 in).
Tooth contact is correct.
B3M0070D
(A) (B) (C) (D)
Toe Coast side Heel Drive side

S503152A01
H3M1203C
3. TOOTH CONTACT OF HYPOID GEAR

S503152A0103
F: ADJUSTMENT
S503152A0101
1. BEVEL PINION GEAR BACKLASH

1) Disassemble the front differential. <Ref. to MT-92 REMOVAL, Front Differential Assembly.> 2) Select a different washer from the table and install.
Washer Part No. 803038021 803038022 803038023 Thickness mm (in) 0.925 0.950 (0.0364 0.0374) 0.975 1.000 (0.0384 0.0394) 1.025 1.050 (0.0404 0.0413)
Adjust until the teeth contact is correct. Backlash is excessive. To reduce backlash, loosen holder on the upper side (case right side) and turn in the holder on the lower side (case left side) by the same amount.
B3M0071
3) Adjust until the specified value is obtained. Standard backlash: 0.13 0.18 mm (0.0051 0.0071 in)
2. HYPOID GEAR BACKLASH
Backlash is insufficient. To increase backlash, loosen holder on the lower side (case left side) and turn in the holder on the upper side (case right side) by the same amount.
S503152A0102
Adjust backlash by turning holder in right side case. ST 499787000 WRENCH ASSY
B3M0072
B3M1360A
MT-96

The drive pinion shim selected before is too thick. Reduce its thickness.
B3M0073
The drive pinion shim selected before is too thin. Increase its thickness.
B3M0074
MT-97
SPEEDOMETER GEAR
S503268
21. Speedometer Gear

A: REMOVAL
S503268A18
1) Remove the manual transmission assembly from vehicle. <Ref. to MT-32 REMOVAL, Manual Transmission Assembly.> 2) Remove back-up light switch and neutral position switch. <Ref. to MT-42 REMOVAL, Switches and Harness.> 3) Remove transfer case with extension case assembly. <Ref. to MT-46 REMOVAL, Transfer Case and Extension Case Assembly.> 4) Remove transmission case. <Ref. to MT-60 REMOVAL, Transmission Case.> 5) Remove vehicle speed sensor. <Ref. to MT-44 REMOVAL, Vehicle Speed Sensor.> 6) Remove outer snap ring and pull out speedometer driven gear. Next, remove oil seal, speedometer shaft and washer.
B3M0525C
(A) (B)
Outer snap ring Speedometer driven gear
4) Install transmission case. <Ref. to MT-62 INSTALLATION, Transmission Case.> 5) Install transfer case with extension case assembly.<Ref. to MT-46 INSTALLATION, Transfer Case and Extension Case Assembly.> 6) Install back-up light switch and neutral position switch. <Ref. to MT-43 INSTALLATION, Switches and Harness.> 7) Install the manual transmission assembly to vehicle. <Ref. to MT-35 INSTALLATION, Manual Transmission Assembly.>
C: INSPECTION
S503268A10
Check the speedometer gear, oil seal and speedometer shaft for damage. Replace if damaged.
B3M0525C
(A) (B)
Outer snap ring Speedometer driven gear

S503268A11
B: INSTALLATION
1) Install washer and speedometer shaft, and press fit oil seal with ST. CAUTION: Use new oil seal, if it has been removed. ST 899824100 or 499827000 PRESS 2) Install vehicle speed sensor. <Ref. to MT-44 INSTALLATION, Vehicle Speed Sensor.> 3) Install speedometer driven gear and snap ring. CAUTION: Use new snap ring, if it has been removed.
MT-98
REVERSE IDLER GEAR
22. Reverse Idler Gear

A: REMOVAL
S503263A18
S503263
1) Remove the manual transmission assembly from vehicle. <Ref. to MT-32 REMOVAL, Manual Transmission Assembly.> 2) Remove back-up light switch and neutral position switch. <Ref. to MT-42 REMOVAL, Switches and Harness.> 3) Remove transfer case with extension case assembly. <Ref. to MT-46 REMOVAL, Transfer Case and Extension Case Assembly.> 4) Remove transmission case. <Ref. to MT-83 REMOVAL, Transmission Case.> 5) Remove drive pinion shaft assembly. <Ref. to MT-83 REMOVAL, Drive Pinion Shaft Assembly.> 6) Remove main shaft assembly. Single-range model: <Ref. to MT-67 REMOVAL, Main Shaft Assembly for Single-Range.> Dual-range model: <Ref. to MT-73 REMOVAL, Main Shaft Assembly for Dual-Range.> 7) Remove differential assembly. <Ref. to MT-92 REMOVAL, Front Differential Assembly.> 8) Remove shifter forks and rods. <Ref. to MT-101 REMOVAL, Shifter Fork and Rod.> 9) Pull out straight pin, and remove idler gear shaft, reverse idler gear and washer.
B3M0526C
(A) (B) (C) (D)
Reverse shifter lever Reverse idler gear Reverse idler gear shaft Straight pin
B3M0524C
(A) (B) (C) (D)
Straight pin Idler gear shaft Idler gear Washer
2) Inspect and adjust clearance between reverse idler gear and transmission case wall. <Ref. to MT-99 INSTALLATION, Reverse Idler Gear.> and <Ref. to MT-100 ADJUSTMENT, Reverse Idler Gear.> 3) Install shifter forks and rods. <Ref. to MT-101 INSTALLATION, Shifter Fork and Rod.> 4) Install differential assembly. <Ref. to MT-92 INSTALLATION, Front Differential Assembly.> 5) Install main shaft assembly. Single-range model: <Ref. to MT-67 INSTALLATION, Main Shaft Assembly for Single-Range.> Dual-range: <Ref. to MT-73 INSTALLATION, Main Shaft Assembly for Dual-Range.> 6) Install drive pinion shaft assembly. <Ref. to MT-83 INSTALLATION, Drive Pinon Shaft Assembly.> 7) Install transmission case. <Ref. to MT-62 INSTALLATION, Transmission Case.> 8) Install transfer case with extension case assembly. <Ref. to MT-46 INSTALLATION, Transfer Case and Extension Case Assembly.> 9) Install back-up light switch and neutral position switch. <Ref. to MT-43 INSTALLATION, Switches and Harness.> 10) Install the manual transmission assembly to vehicle. <Ref. to MT-35 INSTALLATION, Manual Transmission Assembly.>
10) Remove reverse shifter lever.
B: INSTALLATION
S503263A11
1) Install reverse shifter lever, reverse idler gear and reverse idler gear shaft, and secure with straight pin. NOTE: Be sure to install reverse idler shaft from the rear side.
MT-99
REVERSE IDLER GEAR D: ADJUSTMENT

S503263A01
C: INSPECTION
S503263A10
1) Move the reverse shifter rod toward the reverse side. Inspect clearance between reverse idler gear and transmission case wall. If out of specification, select the appropriate reverse shifter lever and adjust. Clearance A: 6.0 7.5 mm (0.236 0.295 in)
1) Select the appropriate reverse shifter lever from the table below, and adjust until the gap between the reverse idler gear and transmission case wall is within specification. Clearance A: 6.0 7.5 mm (0.236 0.295 in)
G3M0796 G3M0796
2) After installing a suitable reverse shifter lever, shift into neutral. Inspect clearance between reverse idler gear and transmission case wall. If out of specification, select the appropriate washer and adjust. Clearance: 0 0.5 mm (0 0.020 in)
Part No. 32820AA070 32820AA080 32820AA090
Reverse shifter lever Mark Remarks Further from case 7 wall 8 Standard 9 Closer to case wall
2) Select the appropriate washer from the table below, and adjust until the gap between the reverse idler gear and transmission case wall is within specification. Clearance: 0 0.5 mm (0 0.020 in)
B3M0063
3) Check the reverse idler gear and shaft for damage. Replace if damaged.
B3M0063
Washer Part No. 803020151 803020152 803020153 803020154 803020155 Thickness mm (in) 0.4 (0.016) 1.1 (0.043) 1.5 (0.059) 1.9 (0.075) 2.3 (0.091)
MT-100
SHIFTER FORK AND ROD
23. Shifter Fork and Rod

A: REMOVAL
S503255A18
S503255
1) Remove the manual transmission assembly from vehicle. <Ref. to MT-32 REMOVAL, Manual Transmission Assembly.> 2) Remove back-up light switch and neutral position switch. <Ref. to MT-42 REMOVAL, Switches and Harness.> 3) Remove transfer case with extension case assembly. <Ref. to MT-46 REMOVAL, Transfer Case and Extension Case Assembly.> 4) Remove transmission case. <Ref. to MT-60 REMOVAL, Transmission Case.> 5) Removes drive pinion shaft assembly. <Ref. to MT-83 REMOVAL, Drive Pinon Shaft Assembly.> 6) Remove main shaft assembly. Single-range model: <Ref. to MT-67 REMOVAL, Main Shaft Assembly for Single-Range.> Dual-range model: <Ref. to MT-73 REMOVAL, Main Shaft Assembly for Dual-Range.> 7) Remove differential assembly. <Ref. to MT-92 REMOVAL, Front Differential Assembly.> 8) Drive out straight pin with ST, and 5th shifter fork. ST 398791700 STRAIGHT PIN REMOVER
B3M0523C
(A) (B) (C)
Straight pin 3-4 fork rod Shifter fork
11) Drive out straight pin, and pull out 1-2 fork rod and shifter fork. 12) Remove outer snap ring, and pull out reverse shifter rod arm from reverse fork rod. Then take out ball, spring and interlock plunger from rod. And then remove rod. NOTE: When pulling out reverse shifter rod arm, be careful not to let ball pop out of arm. 13) Remove reverse shifter lever.
B: INSTALLATION
S503255A11
1) Install reverse arm fork spring, ball and interlock plunger to reverse fork rod arm. Insert reverse fork rod into hole in reverse fork rod arm, and hold it with outer snap ring using ST. CAUTION: Apply grease to plunger to prevent it from falling. ST 399411700 ACCENT BALL INSTALLER 2) Position ball, spring and gasket in reverse shifter rod hole, on left side transmission case, and tighten checking ball plug. CAUTION: Replace gasket with a new one. 3) Install 1-2 fork rod into 1-2 shifter fork via the hole on the rear of the transmission case. 4) Align the holes in rod and fork, and drive straight pin into these holes using ST. CAUTION: Replace straight pin with a new one. NOTE: Set other rods to neutral. Make sure interlock plunger is on the 3-4 fork rod side. ST 398791700 STRAIGHT PIN REMOVER 5) Install interlock plunger onto 3-4 fork rod.
B3M0333I
(A) (B)
Straight pin 5th shifter fork
9) Remove plugs, springs and checking balls. 10) Drive out straight pin, and pull out 3-4 fork rod and shifter fork. NOTE: When removing rod, keep other rods in neutral. Also, when pulling out straight pin, remove it toward the inside of the case so that it does not hit against the case.
MT-101

12) Install drive pinion shaft assembly. <Ref. to MT-83 INSTALLATION, Drive Pinon Shaft Assembly.> 13) Install transmission case. <Ref. to MT-62 INSTALLATION, Transmission Case.> 14) Install transfer case with extension case assembly. <Ref. to MT-46 INSTALLATION, Transfer Case and Extension Case Assembly.> 15) Install back-up light switch and neutral position switch. <Ref. to MT-43 INSTALLATION, Switches and Harness.> 16) Install the manual transmission assembly to vehicle. <Ref. to MT-35 INSTALLATION, Manual Transmission Assembly.>
CAUTION: Apply a coat of grease to plunger to prevent it from falling. 6) Install 3-4 fork rod into 3-4 shifter fork via the hole on the rear of transmission case. 7) Align the holes in rod and fork, and drive straight pin into these holes. CAUTION: Replace straight pin with a new one. NOTE: Set reverse fork rod to neutral. Make sure interlock plunger (installing before) is on the reverse fork rod side. ST 398791700 STRAIGHT PIN REMOVER 8) Install 5th shifter fork onto the rear of reverse fork rod. Align holes in the two parts and drive straight pin into place. CAUTION: Replace straight pin with a new one. ST 398791700 STRAIGHT PIN REMOVER
C: INSPECTION
S503255A10
1) Check the shift shaft and shift rod for damage. Replace if damaged. 2) Gearshift mechanism Repair or replace the gearshift mechanism if excessively worn, bent, or defective in any way. 3) Inspect clearance between 1st, 2nd driven gear and reverse driven gear. If any clearance is not within specifications, replace shifter fork as required. Clearance (a) and (b): 9.5 mm (0.374 in)
B3M0333J
(A) (B) (C)
5th shifter fork Reverse fork rod Straight pin
9) Position balls, checking ball springs and gaskets into 3-4 and 1-2 rod holes, and install plugs. CAUTION: Replace gasket with a new one.
(A) (B) (C) 1st driven gear Reverse driven gear 2nd driven gear
S3M0430A
Part No. 32804AA060 32804AA070 32804AA080

B3M0333J
1st-2nd shifter fork Mark Remarks Approach to 1st gear 1 by 0.2 mm (0.008 in). Standard Become distant from 3 2nd gear by 0.2 mm (0.008 in).
10) Install differential assembly. <Ref. to MT-92 INSTALLATION, Front Differential Assembly.> 11) Install main shaft assembly.
MT-102

4) Inspect clearance between 3rd, 4th drive gear and coupling sleeve. If any clearance is not within specifications, replace shifter fork as required. Clearance (a) and (b): 9.3 mm (0.366 in)
Non-turbo model
Part No. 32812AA201 32812AA211 32812AA221 5th shifter fork Mark Remarks Approach to 5th gear 4 by 0.2 mm (0.008 in). 5 Standard Become distant from 6 5th gear by 0.2 mm (0.008 in).
Turbo model
Part No. 32812AA231
B3M1411A
32812AA241 32812AA251
(A) (B) (C)
3rd drive gear Coupling sleeve 4th drive gear 3rd-4th shifter fork Mark Remarks Approach to 4th gear 1 by 0.2 mm (0.008 in). Standard Become distant from 3 3rd gear by 0.2 mm (0.008 in).
5th shifter fork Mark Remarks Approach to 5th gear 7 by 0.2 mm (0.008 in). Standard Become distant from 9 5th gear by 0.2 mm (0.008 in).
Part No. 32810AA061 32810AA071 32810AA101
6) Inspect rod end clearances (A) and (B). If any clearance is not within specifications, replace rod or fork as required. Clearance (A): 1st 2nd to 3rd 4th: 0.4 1.4 mm(0.016 0.055 in) Clearance (B): 3rd 4th to 5th: 0.5 1.3 mm(0.020 0.051 in)
5) Inspect clearance between 5th drive gear and coupling sleeve. If any clearance is not within specifications, replace shifter fork as required. Clearance (a): 9.3 mm (0.366 in)
B3M0530A
S3M0191A
(A) (B)
5th drive gear Coupling sleeve
MT-103
COUNTER GEAR
6) Remove counter shaft from transmission case, taking care not to drop counter gear and the two washers. CAUTION: Be careful not to damage O-ring. Be careful not to drop straight pin on front side. Be careful not to drop two needle bearings and collar contained in counter gear.
24. Counter Gear

A: REMOVAL
S503716A18
S503716
1) Remove the manual transmission assembly from the vehicle. <Ref. to MT-32 REMOVAL, Manual Transmission Assembly.> 2) Remove the transfer case with extension case assembly. <Ref. to MT-46 REMOVAL, Transfer Case and Extension Case Assembly.> 3) Remove transmission case. <Ref. to MT-60 REMOVAL, Transmission Case.> 4) Move counter gear shaft until it touches transmission case, and remove snap ring with a suitable tool.
H3M1427B
(A) (B) (C)

S3M0102C
Counter shaft Counter gear Washers

S503716A11
B: INSTALLATION
(A)
Snap ring
5) Slide washer at rear of high-low counter shaft, and remove straight pin from counter shaft.
H3M1426D
(A) (B)
Counter gear Straight pin
1) Install O-ring and straight pin onto counter gear shaft. 2) Install the following parts in main case (Rightside), and push the shaft perfectly into case. Counter gear shaft Two counter gear washers Two needle bearings Counter gear collar Counter gear Straight pin Snap ring 3) Install the transmission case. <Ref. to MT-62 INSTALLATION, Transmission Case.> 4) Install the transfer case with extension case assembly. <Ref. to MT-46 INSTALLATION, Transfer Case and Extension Case Assembly.> 5) Install the manual transmission assembly on vehicle. <Ref. to MT-35 INSTALLATION, Manual Transmission Assembly.> NOTE: Make sure that cut-out end surface of counter gear shaft does not protrude above the end surface of the case. Position the cut-out portion of counter gear shaft as shown in the figure.
MT-104
COUNTER GEAR C: INSPECTION

S503716A10
1) After installing snap ring, measure clearance between snap ring and counter washer. Clearance: 0.05 0.35 mm (0.0020 0.0138 in) 2) If the clearance is out of measured value, select a snap ring and install to put clearance within measured value. <Ref. to MT-104 ADJUSTMENT, Counter Gear.>
D: ADJUSTMENT
S503716A01
Selection of snap ring If the measurement is not with in the specification, select suitable snap ring.
Snap ring Part No. 031319000 805019010 Thickness mm (in) 1.50 (0.0591) 1.72 (0.0677)
MT-105
GENERAL DIAGNOSTIC
S503278
25. General Diagnostic

A: INSPECTION
S503278A10
1. MANUAL TRANSMISSION
Symptom 1. Gears are difficult to intermesh. NOTE: The cause for difficulty in shifting gears can be classified into two kinds: one is malfunction of the gear shift system and the other is malfunction of the transmission. However, if the operation is heavy and engagement of the gears is difficult, defective clutch disengagement may also be responsible. Check whether the clutch is correctly functioning, before checking the gear shift system and transmission. 2. Gear slips out. Gear slips out when coasting on rough road. Gear slips out during acceleration.
S503278A1001
Possible cause (a) Worn, damaged or burred chamfer of Replace. internal spline of sleeve and reverse driven gear (b) Worn, damaged or burred chamfer of Replace. spline of gears (c) Worn or scratched bushings (d) Incorrect contact between synchronizer ring and gear cone or wear Replace.
Remedy
Correct or replace.
(a) Defective pitching stopper adjustment (b) Loose engine mounting bolts (c) Worn fork shifter, broken shifter fork rail spring (d) Worn or damaged ball bearing (e) Excessive clearance between splines of synchronizer hub and synchronizer sleeve (f) Worn tooth step of synchronizer hub (responsible for slip-out of 3rd gear) (g) Worn 1st driven gear, needle bearing and race (h) Worn 2nd driven gear, needle bearing and race (i) Worn 3rd drive gear and bushing (j) Worn 4th drive gear and bushing (k) Worn reverse idler gear and bushing (a) Insufficient or improper lubrication 3. Unusual noise comes from transmission. (b) Worn or damaged gears and bearNOTE: ings If an unusual noise is heard when the NOTE: vehicle is parked with its engine idling If the trouble is only wear of the tooth and if the noise ceases when the clutch surfaces, merely a high roaring noise will is disengaged, it may be considered that occur at high speeds, but if any part is the noise comes from the transmission. broken, rhythmical knocking sound will be heard even at low speeds.
Adjust. Tighten or replace. Replace. Replace. Replace.
Replace. Replace. Replace. Replace. Replace. Replace. Lubricate or replace with specified oil. Replace.
MT-106
GENERAL DIAGNOSTIC
2. DIFFERENTIAL
S503278A1002
Symptom 1. Broken differential (case, gear, bearing, etc.) NOTE: Abnormal noise will develop and finally it will become impossible to continue to run due to broken pieces obstructing the gear revolution.
Possible cause (a) Insufficient or improper oil
2. Differential and hypoid gear noises Troubles of the differential and hypoid gear always appear as noise problems. Therefore noise is the first indication of the trouble. However noises from the engine, muffler, tire, exhaust gas, bearing, body, etc. are easily mistaken for the differential noise. Pay special attention to the hypoid gear noise because it is easily confused with other gear noises. There are the following four kinds of noises. Gear noise when driving: If noise increases as vehicle speed increases it may be due to insufficient gear oil, incorrect gear engagement, damaged gears, etc. Gear noise when coasting: Damaged gears due to maladjusted bearings and incorrect shim adjustment Bearing noise when driving or when coasting: Cracked, broken or damaged bearings Noise which mainly occurs when turning: Unusual noise from differential side gear, differential pinion, differential pinion shaft, etc.
(b) Use of vehicle under severe conditions such as excessive load and improper use of clutch (c) Improper adjustment of taper roller bearing (d) Improper adjustment of drive pinion and hypoid driven gear (e) Excessive backlash due to worn differential side gear, washer or differential pinion vehicle under severe operating conditions. (f) Loose hypoid driven gear clamping bolts (a) Insufficient oil
Remedy Disassemble differential and replace broken components and at the same time check other components for any trouble, and replace if necessary. Readjust bearing preload and backlash and face contact of gears. Adjust. Adjust. Add recommended oil to specified level. Do not use vehicle under severe operating conditions. Tighten. Lubricate.
(b) Improper adjustment of hypoid driven Check tooth contact. gear and drive pinion
(c) Worn teeth of hypoid driven gear and Replace as a set. drive pinion Readjust bearing preload.
(d) Loose roller bearing
Readjust hypoid driven gear to drive pinion backlash and check tooth contact.
(e) Distorted hypoid driven gear or differ- Replace. ential case
(f) Worn washer and differential pinion shaft
Replace.
MT-107
GENERAL DIAGNOSTIC
MEMO:
MT-108
CLUTCH SYSTEM
CL
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Page General Description.....................................................................................2 Clutch Disc and Cover ..............................................................................15 Flywheel ....................................................................................................18 Release Bearing and Lever ......................................................................20 Operating Cylinder ....................................................................................23 Master Cylinder .........................................................................................25 Clutch Pipe and Hose ...............................................................................31 Clutch Fluid ...............................................................................................33 Clutch Fluid Air Bleeding...........................................................................34 Clutch Pedal ..............................................................................................37 Clutch Switch.............................................................................................43 General Diagnostic Table ..........................................................................44
Clutch System
GENERAL DESCRIPTION
S504001
A: SPECIFICATIONS
Model Clutch cover Type Diaphragm set load Facing material O.D. I.D. thickness Clutch disc Spline O.D. Depth of rivet head Clutch Clutch Clutch Clutch lever Limit for deflection release lever ratio release bearing pedal Full stroke release Stroke
S504001E49
kg (lb)
mm (in) mm mm mm mm (in) (in) (in) (in)
Standard Limit of sinking
mm (in) mm (in)
Non-turbo Turbo Push type Pull type 580 (1,279) 700 (1,544) Woven (Non asbestos) 225 150 3.5 (8.86 230 150 3.5 (9.06 5.91 0.138) 5.91 0.138) 25.2 (0.992), (No. of teeth: 24) 1.65 2.25 (0.0650 0.0886) 0.3 (0.012) 1.0 (0.039) at R = 107 (4.21) 1.6 1.7 Grease-packed self-aligning 130 135 (5.12 5.31) 13.3 14.7 (0.524 12 13.6 (0.472 0.535) 0.579)
CL-2

S504001A05
Clutch System
1. CLUTCH ASSEMBLY FOR NON-TURBO MODEL
S504001A0504
S2M2066A
(1) (2) (3) (4) (5)
Clutch release lever sealing Retainer spring Pivot Clutch release lever Clip
(6) (7) (8) (9)
Clutch release bearing Clutch cover Clutch disc Flywheel
CL-3
Clutch System
GENERAL DESCRIPTION
S504001A0505
2. CLUTCH ASSEMBLY FOR TURBO MODEL
S2M2158A
(1) (2) (3) (4) (5)
Clutch Clutch Clutch Plug Clutch
release lever sealing release lever release lever shaft release bearing
(6) Clutch cover (7) Clutch disc (8) Flywheel
Tightening torque: Nm (kgf-m, ft-lb) T1: 15.7 (1.6, 11.6) T2: 44 (4.5, 32.5) T3: 72 (7.3, 52.8)
CL-4
GENERAL DESCRIPTION
3. CLUTCH PIPE AND HOSE FOR NON-TURBO MODEL LHD Model
S504001A050601 S504001A0506
Clutch System
S2M2067A
(1) (2) (3) (4) (5) (6)
Operating cylinder Washer Clutch hose Bracket Clip Clutch pipe
(7) (8) (9) (10)
Master cylinder ASSY Clevis pin Snap pin Spacer
CL-5
Clutch System
GENERAL DESCRIPTION
S504001A050602
RHD Model
S2M2159A
(1) (2) (3) (4) (5) (6)
Clamp A Bracket A Master cylinder ASSY Clutch pipe Clamp B Bracket B
(7) Clutch hose (8) Washer (9) Operating cylinder
CL-6
GENERAL DESCRIPTION
4. CLUTCH PIPE AND HOSE FOR TURBO MODEL LHD Model
S504001A050701 S504001A0507
Clutch System
S2M2160A
(1) (2) (3) (4)
Master cylinder ASSY Bracket Clutch hose Washer
(5) Operating cylinder
CL-7
Clutch System
GENERAL DESCRIPTION
S504001A050702
RHD Model
S2M2161A
(1) (2) (3) (4) (5) (6) (7)
Master cylinder ASSY Bracket Sealed cover Clutch pipe and connector ASSY Clutch hose Operating cylinder Connector bracket
(8) (9) (10) (11)
Clip A Clip B Bracket Washer
Tightening torque: Nm (kgf-m, ft-lb) T1: 8 (0.8, 5.8) T2: 15 (1.5, 10.8) T3: 15.7 (1.6, 11.6) T4: 18 (1.8, 13.0) T5: 25 (2.5, 18.1) T6: 37 (3.8, 27.5)
CL-8
GENERAL DESCRIPTION
5. MASTER CYLINDER FOR NON-TURBO MODEL
S504001A0508
Clutch System
S2M0911B
(1) (2) (3) (4) (5)
Reservoir cap Reservoir tank Oil seal Straight pin Master cylinder
(6) (7) (8) (9) (10)
Seat Return spring Piston Push rod Piston stop ring
Tightening torque: Nm (kgf-m, ft-lb) T: 10 (1.0, 7)
CL-9
Clutch System
GENERAL DESCRIPTION
S504001A0509
6. MASTER CYLINDER FOR TURBO MODEL LHD Model

S504001A050901
S2M2154A
(1) (2) (3) (4) (5) (6)
Reservoir cap Reservoir tank Oil seal Straight pin Master cylinder Seat
(7) (8) (9) (10) (11) (12)
Return spring Piston Push rod Piston stop ring Diaphragm spring Gasket
Tightening torque: Nm (kgf-m, ft-lb) T1: 10 (1.0, 7) T2: 46.6 (4.75, 34.4)
CL-10
GENERAL DESCRIPTION
RHD Model
S504001A050902
Clutch System
S2M0615C
(1) (2) (3) (4)
Reservoir cap Reservoir tank Reservoir band Seat
(5) (6) (7) (8)
Master cylinder Piston Push rod Piston stop ring
CL-11
Clutch System
GENERAL DESCRIPTION
S504001A0503
7. CLUTCH PEDAL LHD Model
S504001A050301
S2M2162A
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)
Stopper Bushing Spring pin Snap pin Brake pedal pad Brake pedal Clevis pin Brake pedal spring Clutch pedal pad Clutch pedal Bushing C
(12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22)
Clutch clevis pin Assist rod A Clip Assist spring Assist bushing Assist rod B Spring S Rod S Bushing S O-ring Clip
(23) Clutch switch (With cruise control) (24) Stop light switch (25) Pedal bracket (26) Clutch master cylinder bracket (27) Lever
CL-12
GENERAL DESCRIPTION
RHD Model
S504001A050302
Clutch System
S2M2163A
(1) (2) (3) (4) (5) (6) (7) (8) (9)
Stopper Clutch pedal pad Clutch pedal Bushing C Clutch clevis pin Assist rod A Clip Assist spring Assist bushing
(10) (11) (12) (13) (14) (15) (16)
Assist rod B Spring S Rod S Bushing S O-ring Clip Clutch switch (With cruise control) (17) Spacer
(18) Bushing (19) Clutch pedal bracket

CL-13
Clutch System
GENERAL DESCRIPTION
S504001A03
C: CAUTION
Wear working clothing, including a cap, protective goggles, and protective shoes during operation. Remove contamination including dirt and corrosion before removal, installation or disassembly. Keep the disassembled parts in order and protect them from dust or dirt. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly, and replacement. Be careful not to burn your hands, because each part on the vehicle is hot after running. Use SUBARU genuine fluid, grease etc. or the equivalent. Do not mix fluid, grease etc. with that
of another grade or from other manufacturers. Be sure to tighten fasteners including bolts and nuts to the specified torque. Place shop jacks or safety stands at the specified points. Apply grease onto sliding or revolution surfaces before installation. Before installing O-rings or snap rings, apply sufficient amount of fluid to avoid damage and deformation. Before securing a part on a vise, place cushioning material such as wood blocks, aluminum plate, or shop cloth between the part and the vise. Keep fluid away from the vehicle body. If any fluid contacts the vehicle body, immediately flush the area with water.
D: PREPARATION TOOL
1. SPECIAL TOOLS
ILLUSTRATION
S504001A1701
S504001A17
DESCRIPTION CRANKSHAFT STOPPER
REMARKS Used for stopping rotation of flywheel when loosening tightening bolt, etc.
B2M3853
499747100
CLUTCH DISC GUIDE
Used when installing clutch disc to flywheel.
B2M4112

TOOL NAME Circuit Tester Dial Gauge
S504001A1702
REMARKS Used for measuring resistance, voltage and ampere. Used for measuring clutch disk run-out.
CL-14
CLUTCH DISC AND COVER
Clutch System
2. Clutch Disc and Cover

A: REMOVAL
S504252A18
S504252
ST
499747100
CLUTCH DISC GUIDE
1) Remove transmission assembly from vehicle body. <Ref. to MT-32, REMOVAL, Manual Transmission Assembly.> 2) Install ST on flywheel. ST 498497100 CRANKSHAFT STOPPER
G2M0253
3) Install clutch cover on flywheel and tighten bolts to the specified torque. NOTE: When installing the clutch cover on the flywheel, position the clutch cover so that there is a gap of 120 or more between 0 marks on the flywheel and clutch cover. (0 marks indicate the directions of residual unbalance.) Note the front and rear of the clutch disc when installing. Temporarily tighten bolts by hand. Each bolt should be tightened to the specified torque in a crisscross fashion. Tightening torque: 15.7 Nm (1.6 kgf-m, 11.6 ft-lb)
S2M1847A
(A)
Clutch cover
3) Remove clutch cover and clutch disc. CAUTION: Take care not to allow oil on the clutch disc facing. Do not disassemble either clutch cover or clutch disc.
B: INSTALLATION
S504252A11
1) Install flywheel and ST. ST 498497100 CRANKSHAFT STOPPER
B2M3361A
2) Insert ST into the clutch disc and install them on the flywheel by inserting the ST end into the pilot bearing.
B2M1011B
(A)
0 marks
4) Remove ST. ST 499747100 CLUTCH DISC GUIDE 5) Install transmission assembly. <Ref. to MT-35, INSTALLATION, Manual Transmission.>
CL-15
Clutch System

S504252A10
C: INSPECTION
1. CLUTCH DISC
ST
499747100
CLUTCH DISC GUIDE
S504252A1001
1) Facing wear Measure the depth of rivet head from the surface of facing. Replace if facings are worn locally or worn down to less than the specified value. Depth of rivet head: Limit of sinking 0.3 mm (0.012 in) CAUTION: Do not wash clutch disc with any cleaning fluid.
Limit for deflection: 1.0 mm (0.039 in) at R = 107 mm (4.21 in)
B2M0330B
5) Worn spline, loose rivets and torsion spring failure Replace defective parts.
B2M0328
2) Hardened facing Correct by using emery paper or replace. 3) Oil soakage on facing Replace clutch disc and inspect transmission front oil seal, transmission case mating surface, engine rear oil seal and other points for oil leakage.
B2M0333B
(A) (B) (C)
Spline Rivet Torsion spring

S504252A1002
2. CLUTCH COVER
NOTE: Visually check for the following items without disassembling, and replace or repair if defective. 1) Loose thrust rivet. 2) Damaged or worn bearing contact area at center of diaphragm spring.
B2M0329B
(A)
Facing
4) Deflection on facing If deflection exceeds the specified value at the outer circumference of facing, repair or replace.
S2M1849A
(A) (B)
Thrust rivet Diaphragm spring
CL-16

3) Damaged or worn disc contact surface of pressure plate. 4) Loose strap plate setting bolt. 5) Worn diaphragm sliding surface.
Clutch System
S2M1850A
(A) (B)
Pressure plate Strap plate
CL-17
Clutch System
FLYWHEEL
S504250
3. Flywheel
A: REMOVAL
B: INSTALLATION
S504250A11
S504250A18
1) Remove transmission assembly. <Ref. to MT-32, REMOVAL, Manual Transmission Assembly.> 2) Install ST on flywheel. ST 498497100 CRANKSHAFT STOPPER
1) Install flywheel and ST. ST 498497100 CRANKSHAFT STOPPER
B2M3361A
2) Tighten the flywheel attaching bolts to the specified torque.

G2M0242
3) Remove clutch cover and clutch disc. <Ref. to CL-15, REMOVAL, Clutch Disc and Cover.> CAUTION: Take care not to allow oil on the clutch disc facing. Do not disassemble either clutch cover or clutch disc. 4) Using ST, remove flywheel. ST 498497100 CRANKSHAFT STOPPER
NOTE: Tighten flywheel installing bolts gradually. Each bolt should be tightened to the specified torque in a crisscross fashion. Tightening torque: 72 Nm (7.3 kgf-m, 52.8 ft-lb)
B2M0331B
3) Install clutch disc and cover. <Ref. to CL-15, INSTALLATION, Clutch Disc and Cover.> 4) Install transmission assembly. <Ref. to MT-35 INSTALLATION, Manual Transmission Assembly.>
B2M0332B
(A)
Flywheel
CL-18
FLYWHEEL C: INSPECTION
S504250A10
Clutch System
CAUTION: Since this bearing is grease sealed and is of a non-lubrication type, do not wash with gasoline or any solvent. 1) Damage of facing and ring gear If defective, replace flywheel.
S2M1851A
(A) (B)
Flywheel Ring gear
2) Smoothness of rotation Rotate ball bearing applying pressure in thrust direction. 3) If noise or excessive play is noted, replace flywheel.
CL-19
Clutch System
RELEASE BEARING AND LEVER

2. TURBO MODEL
S504251A1804
4. Release Bearing and Lever

S504251
A: REMOVAL
S504251A18
1. NON-TURBO MODEL
S504251A1803
1) Remove transmission assembly from vehicle body. <Ref. to MT-32 REMOVAL, Manual Transmission Assembly.> 2) Remove the two clips from clutch release lever and remove release bearing. CAUTION: Be careful not to deform clips. 3) Remove release lever seal.
1) Remove transmission assembly from vehicle body. <Ref. to MT-32, REMOVAL, Manual Transmission Assembly.> 2) Remove clutch release lever from transmission. 3) Put clutch release bearing in engine side. 4) Remove clutch release bearing from clutch cover using flat-type screwdriver.
S2M1843A
(A)
Clutch release bearing
B2M4222A
(A) (B)
Clutch release lever Release lever seal
4) Remove release lever retainer spring from release lever pivot with a screwdriver by accessing it through clutch housing release lever hole. Then remove release lever.
B2M4223A
(A) (B)
Clutch release lever Screwdriver
CL-20
RELEASE BEARING AND LEVER B: INSTALLATION

S504251A11
Clutch System
S504251A1104
2. TURBO MODEL
CAUTION: Before or during assembling, lubricate the following points with a light coat of grease. Contact surface of lever and pivot Contact surface of lever and bearing Transmission main shaft spline (Use grease containing molybdenum disulfide.) Contact surface of lever and operating cylinder
1) Apply grease to each parts. <Ref. CL-3, COMPONENT, General Description.> Grease: SUNLIGHT2 (P/N 003602010) 2) Position both clutch release lever and bearing on transmission. 3) Install clutch release lever shaft. CAUTION: Be sure to fit groove on clutch release lever shaft into pin located at through-hole.
1. NON-TURBO MODEL
S504251A1103
1) While pushing release lever to pivot and twisting it to both sides, fit retainer spring onto the constricted portion of pivot. NOTE: Apply grease (SUNLIGHT 2: P/N 003602010) to contact point of release lever and operating cylinder. <Ref. to CL-3, COMPONENT, General Description.> Confirm that retainer spring is securely fitted by observing it through the main case hole.
S2M1845A
(A) (B) (C)
Release fork Release shaft Spring pin
4) With clutch release lever held in that position, connect engine and transmission. <Ref. to MT-35, INSTALLATION, Manual Transmission Assembly.>
C: INSPECTION
B2M4224A
S504251A10
1. RELEASE BEARING
S504251A1001
(A)
Release lever
2) Install release bearing and fasten it with two clips. 3) Install release lever seal.
CAUTION: Since this bearing is grease sealed and is of a non-lubrication type, do not wash with gasoline or any solvent when servicing the clutch. 1) Check the bearing for smooth movement by applying force in the radial direction. Radial direction stroke: 1.4 mm (0.055 in)
B2M4222A
(A) (B)
Release lever Release lever seal

B2M0173B
4) Install transmission assembly. <Ref. to MT-35, INSTALLATION, Manual Transmission Assembly.>
(A)
Bearing case
CL-21
Clutch System
RELEASE BEARING AND LEVER
2) Check the bearing for smooth rotation by applying pressure in the thrust direction.
S2M1844A
(A)
Bearing case
3) Check wear and damage of bearing case surface contacting with lever.
2. RELEASE LEVER
S504251A1002
1) Check lever pivot portion and the point of contact with release bearing case for wear.
S2M1102E
(A) (B) (C)
Clutch release lever Pivot Clutch release bearing
CL-22
OPERATING CYLINDER
Clutch System
S504253A1802
5. Operating Cylinder
A: REMOVAL
S504253A18
S504253
2. TURBO MODEL
1. NON-TURBO MODEL
S504253A1801
1) Remove intercooler. <Ref. to IN(DOHC TURBO)-10, REMOVAL, Intercooler.> 2) Remove clutch hose from operating cylinder. CAUTION: Cover hose joint to prevent clutch fluid from flowing out.
1) Remove air cleaner case. <Ref. to IN(SOHC)-7, REMOVAL, Air Cleaner Case.> 2) Remove clutch hose from operating cylinder. CAUTION: Cover hose joint to prevent clutch fluid from flowing out.
S2M1842B
(A) (B)
B2M1179J
Clutch hose Operating cylinder
3) Remove operating cylinder from transmission.
(A) (B)
3) Remove operating cylinder from transmission.
S2M1853A
(A)
Operating cylinder
B2M1263
CL-23
Clutch System
OPERATING CYLINDER
S504253A11
B: INSTALLATION
1. NON-TURBO MODEL
S504253A1101
1) Install in the reverse order of removal. NOTE: Before installing operating cylinder, apply grease (SUNLIGHT 2: P/N 003602010) to contact point of release lever and operating cylinder. Tightening torque: T1: 18 Nm (1.8 kgf-m, 13.0 ft-lb) T2: 37 Nm (3.8 kgf-m, 27.5 ft-lb)
NOTE: Be sure to install the clutch hose with the mark side facing upward. Be careful not to twist the clutch hose during installation.
H2M2666B
(A) (B) (C)
Marking Clutch hose Operating cylinder
B2M1179C
2) After bleeding air from operating cylinder, ensure that clutch operates properly. <Ref. to CL-34, Clutch Fluid Air Bleeding.>
2) After bleeding air from operating cylinder, ensure that clutch operates properly. <Ref. to CL-34 Clutch Fluid Air Bleeding.>
C: INSPECTION
S504253A10
2. TURBO MODEL
S504253A1102
1) Install in the reverse order of removal. Tightening torque: T1: 18 Nm (1.8 kgf-m, 13.0 ft-lb) T2: 37 Nm (3.8 kgf-m, 27.5 ft-lb)
1) Check operating cylinder for damage. If operating cylinder is damaged, replace it. 2) Check operating cylinder for fluid leakage or damage on boot. If any leakage or damage is found, replace operating cylinder.
G2M0978
CL-24
MASTER CYLINDER
Clutch System
6. Master Cylinder
A: REMOVAL
S504168A18
S504168
2) Remove snap pin, clevis pin and separate push rod of master cylinder from clutch pedal.
1. NON-TURBO MODEL
S504168A1801
1) Thoroughly drain brake fluid from reservoir tank. 2) Remove snap pin, clevis pin and separate push rod of master cylinder from clutch pedal.
B4M1189E
(A) (B) (C) (D)
Clevis pin Snap pin Push rod Lock nut
B4M1189E
(A) (B) (C) (D)
3) Remove intercooler. <Ref. to IN(DOHC TURBO)-10, REMOVAL, Intercooler.> 4) Remove clutch hose from master cylinder. CAUTION: Plug up hose connection to prevent clutch fluid from spilling out.
3) Remove air cleaner case and air intake duct. 4) Remove clutch pipe from master cylinder. 5) Remove master cylinder with reservoir tank. CAUTION: Be extremely careful not to spill brake fluid. Brake fluid spilt on the vehicle body will harm the paint surface; wipe it off quickly if spilt.
S2M1213C
(A) (B)
Master cylinder Clutch hose
5) Remove master cylinder with reservoir tank.
S2M0352F
(A) (B)
Master cylinder Clutch pipe

S504168A1802
2. TURBO LHD MODEL
1) Thoroughly drain brake fluid from reservoir tank.

S2M1214A
(A) (B) (C)
Bracket Reservoir tank Master cylinder
CL-25
Clutch System
MASTER CYLINDER
S504168A1803
3. TURBO RHD MODEL
1) Thoroughly drain brake fluid from reservoir tank. 2) Remove snap pin, clevis pin and separate push rod of master cylinder from clutch pedal.
6) Slightly lift clutch pipe on master cylinder, then remove master cylinder and reservoir tank as a single unit. CAUTION: Be careful not to bend or twist clutch pipe.
B4M1189E
H2M1824B
(A) (B) (C) (D)
(A) (B) (C)
Reservoir tank Sealed cover Clamp

S504168A11
3) Remove intercooler. <Ref. to IN(DOHC TURBO)-10, REMOVAL, Intercooler.> 4) Remove clutch pipe and sealed cover from master cylinder. CAUTION: Plug up pipe connection to prevent clutch fluid from spilling out.
B: INSTALLATION
1. NON-TURBO MODEL
S504168A1101
1) Install master cylinder to body, and install clutch pipe to master cylinder. CAUTION: Check that pipe is routed properly. Tightening torque: T1: 15 Nm (1.5 kgf-m, 10.8 ft-lb) T2: 18 Nm (1.8 kgf-m, 13.0 ft-lb)
S2M1854A
(A) (B)
Clutch pipe Sealed cover
S2M0919C
5) Remove clutch pipe from master cylinder bracket clamp.
2) Connect push rod of master cylinder to clutch pedal, and install clevis pin and snap pin. NOTE: Apply grease to clevis pin.
CL-26
MASTER CYLINDER
Clutch System
2) Install clutch hose to master cylinder. CAUTION: Check that hose is routed properly. Tightening torque: T: 18 Nm (1.8 kgf-m, 13.0 ft-lb)
B4M1189C
(A) (B) (C)
Clevis pin Snap pin Push rod
3) After bleeding air from system, ensure that clutch operates properly. <Ref. to CL-34 Clutch Fluid Air Bleeding.> 4) Install air cleaner case and air intake duct.
S2M1213D
(A) (B)
Master cylinder Clutch hose
2. TURBO LHD MODEL

CAUTION: Always use a new gasket.
S504168A1102
1) Install master cylinder to body.
3) Connect push rod of master cylinder to clutch pedal, and install clevis pin and snap pin.
Tightening torque: T: 18 Nm (1.8 kgf-m, 13.0 ft-lb)
B4M1189C
(A) (B) (C)

S2M1219B
(A) (B)
Master cylinder Bracket
4) After installing master cylinder assembly, bleeding air from clutch system. <Ref. to CL-34, Clutch Fluid Air Bleeding.> 5) After bleeding air from system, ensure that clutch operates properly. 6) Install inter coder. <Ref. to IN(DOHC TURBO)10, INSTALLATION, Intercooler.>
CL-27
Clutch System
MASTER CYLINDER
S504168A1103
3. TURBO RHD MODEL
1) Slightly lift clutch pipe on master cylinder, then install master cylinder to body. CAUTION: Always use a new gasket. NOTE: Be careful not to bend clutch pipe when installing master cylinder. Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft-lb) 2) Insert clutch pipe into pipe bracket clamp.
4) Connect push rod of master cylinder to clutch pedal, and install clevis pin and snap pin.
B4M1189C
(A) (B) (C)
H2M1824B
5) After installing master cylinder assembly, bleeding air from clutch system. <Ref. to CL-34, Clutch Fluid Air Bleeding.> 6) After bleeding air from system, ensure that clutch operates properly. 7) Install intercooler. <Ref. to IN(DOHC TURBO)10, INSTALLATION, Intercooler.>
(A) (B) (C)
C: DISASSEMBLY
S504168A06
1. NON-TURBO MODEL
S504168A0601
3) Install clutch pipe to master cylinder. Tightening torque: T1: 15Nm (1.5 kgf-m, 10.8 ft-lb)
1) Remove straight pin and reservoir tank.
S2M0915A
S2M1854A
(A) (B)
Reservoir tank Straight pin
(A) (B)
CL-28
MASTER CYLINDER
2) Remove oil seal. 3) Remove oil seal.
Clutch System
S2M0916B
S2M1217B
(A) (B)
Oil seal Master cylinder
(A) (B)
Oil seal Master cylinder
3) Move the cylinder boot backward.
S2M0917B
S2M1218B
(A) (B)
Cylinder boot Master cylinder
(A) (B)
Cylinder boot Master cylinder
4) Remove snap ring. CAUTION: Be careful when removing the snap ring to prevent the rod, washer, piston and return spring from flying out.
2. TURBO LHD MODEL
S504168A0602
3. TURBO RHD MODEL
S504168A0603
1) Remove diaphragm spring and gasket. 2) Remove straight pin and reservoir tank.
1) Loose reservoir band, and remove reservoir tank and band.
S2M1216B
S2M0620B
(A) (B)
Reservoir tank Straight pin
(A) (B)
Reservoir tank Reservoir band
CL-29
Clutch System
MASTER CYLINDER E: INSPECTION

S504168A1001 S504168A10
1. LHD AND NON-TURBO RHD MODEL

If any damage, deformation, wear, swelling, rust or other faults are found on the cylinder, piston, push rod, fluid reservoir, return spring and seat, replace the faulty part.
S2M0621B
(A) (B)
Master cylinder boot Master cylinder
S2M0918A
D: ASSEMBLY
S504168A02
1) Apply a coat of grease to the contacting surfaces of the push rod and piston before installation. Grease: SILICONE GREASE G40M (Part No. 004404003)
(A) (B) (C) (D) (E)
Master cylinder body Return spring Piston Snap ring Rod ASSY
S504168A1002
2. TURBO RHD MODEL
If any damage, deformation, wear, swelling, rust or other faults are found on the cylinder, piston, push rod, fluid reservoir, return spring and seat, replace the faulty part.
S2M0918B
2) Assemble in the reverse order of disassembly.
S2M1855A
(A) (B)
Reservoir tank Piston
CL-30
CLUTCH PIPE AND HOSE
Clutch System
7. Clutch Pipe and Hose

A: REMOVAL
S504262A18
S504262
3) Remove connector bracket.
1. EXCEPT RHD TURBO MODEL
S504262A1801
1) Remove air cleaner case or intercooler. 2) Drain clutch fluid. <Ref. to CL-33 Clutch Fluid.> 3) Remove clutch pipe from the clutch hose and master cylinder. 4) Pull out clamp, then remove clutch hose from bracket.
H2M1825B
(A) (B)
Connector bracket Connector ASSY
4) Remove master cylinder. <Ref. to CL-28, TURBO RHD MODEL, INSTALLATION, Master Cylinder.>
B2M4113A
(A) (B)
Clamp Clutch hose
5) Remove hose from operating cylinder.
2. RHD TURBO MODEL
S504262A1802
1) Remove snap pin, clevis pin and separate push rod of master cylinder from clutch pedal.
H2M1824B
(A) (B) (C)
5) Remove clutch pipe bracket from body. 6) Remove clutch pipe from clutch pipe bracket. 7) Separate master cylinder and clutch pipe and connector assembly.
B: INSTALLATION
B4M1189E
S504262A11
1. EXCEPT RHD TURBO MODEL

S504262A1101
(A) (B) (C) (D)
NOTE: Bleed clutch fluid. <Ref. to CL-34 Clutch Fluid Air Bleeding.> Tightening torque: T1: 15 Nm (1.5 kgf-m, 10.8 ft-lb) T2: 18 Nm (1.8 kgf-m, 13.0 ft-lb)
2) Remove intercooler. <Ref. to IN(DOHC TURBO)-10, INSTALLATION, Intercooler.>
CL-31
Clutch System
CLUTCH PIPE AND HOSE
B2M4225A
(A) (B) (C) (D)
Clutch pipe (LHD model) Clip Clutch hose Clutch pipe (RHD model)
S504262A1102
2. RHD TURBO MODEL
1) Install clutch pipe to clutch pipe bracket. Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft-lb) 2) Install clutch pipe to master cylinder. Tightening torque: 15 Nm (1.5 kgf-m, 10.8 ft-lb)
S2M1854A
(A) (B)

S504262A10
C: INSPECTION
Check pipes and hoses for cracks, breakage, or damage. Check joints for fluid leakage. If any cracks, breakage, damage, or leakage is found, repair or replace the applicable pipe or hose.
CL-32
CLUTCH FLUID
Clutch System
8. Clutch Fluid
A: INSPECTION
S504261
S504261A10
1) Park vehicle on a level surface. 2) Check the clutch fluid for significant deterioration. If it is deteriorated, replace it. 3) Inspect the fluid level using the scale on the outside of the clutch master cylinder tank. If the level is below MIN, add clutch fluid to bring it up to MAX.
1) Remove air cleaner case and air duct. 2) Either jack-up vehicle and place a safety stand under it, or lift-up vehicle. 3) Draw out the brake fluid from reservoir tank with syringe. 4) Refill reservoir tank with recommended brake fluid. Recommended brake fluid: FMVSS No. 116, fresh DOT3 or 4 brake fluid 5) Drain fluid in the same method as the air bleeding. 6) Refill brake fluid before reservoir tank becomes empty, and drain contaminated fluid again. 7) Repeat the above procedure until the contaminated fluid is completely drained.
S2M0616B
(A)
Reservoir tank
S504261A20
B: REPLACEMENT
CAUTION: The FMVSS No. 116, fresh DOT3 or 4 brake fluid must be used. Cover bleeder with waste cloth, when loosening it, to prevent brake fluid from being splashed over surrounding parts. Avoid mixing different brands of brake fluid to prevent degrading the quality of the fluid. Be careful not to allow dirt or dust to get into the reservoir tank. NOTE: During bleeding operation, keep the clutch reservoir tank filled with brake fluid to eliminate entry of air. Clutch pedal operating must be very slow. For convenience and safety, it is advisable to have two men working. The amount of brake fluid required is approximately 70 m (2.4 US fl oz, 2.5 Imp fl oz) for total clutch system.
CL-33
Clutch System
CLUTCH FLUID AIR BLEEDING

S504260
9. Clutch Fluid Air Bleeding

A: PROCEDURE
S504260E4501 S504260E45
1. LHD AND NON-TURBO RHD MODEL

NOTE: Bleed air from oil line with the help of a co-worker. 1) Remove air cleaner case or intercooler. Non-turbo model: <Ref. to IN(SOHC)-7, REMOVAL, Air Cleaner Case.> Turbo model: <Ref. to IN(DOHC TURBO)-10, REMOVAL, Intercooler.> 2) Fit one end of a vinyl tube into the air bleeder of operating cylinder and put the other end into a brake fluid container.
3) Slowly depress the clutch pedal and keep it depressed. Then open the air bleeder to discharge air together with the fluid. Release the air bleeder for 1 or 2 seconds. Next, with the bleeder closed, slowly release the clutch pedal.
S2M1211B
(A) (B)
Operating cylinder Vinyl tube
4) Repeat these steps until there are no more air bubbles in the vinyl tube. CAUTION: Cover bleeder with waste cloth when loosening it, to prevent brake fluid from being splashed over surrounding parts.
S2M2000A
(A) (B) (C)
Clutch hose Air bleeder Operating cylinder
CL-34

5) Tighten air bleeder. Tightening torque: T: 8 Nm (0.8 kgf-m, 5.8 ft-lb)
Clutch System
2) Fit one end of a vinyl tube into the air bleeder of clutch pipe and connector assembly and put the other end into a clutch fluid container.
H2M1814B
(A) (B)
Air bleeder Connector ASSY
3) Slowly depress the clutch pedal and keep it depressed. Then open the air bleeder to discharge air together with the fluid. Release the air bleeder for 1 or 2 seconds. Next, with the bleeder closed, slowly release the clutch pedal.
S2M2000B
6) Repeat steps 2) through 4) using air bleeder on master cylinder. (Turbo LHD model)
H2M1815B
(A) (B)
Vinyl tube Connector ASSY
S2M1212B
4) Repeat these steps until there are no more air bubbles in the vinyl tube. CAUTION: Cover bleeder with waste cloth when loosening it, to prevent brake fluid from being splashed over surrounding parts.
(A) (B)
Master cylinder Vinyl tube
7) Tighten air bleeder. (Turbo LHD model) Tightening torque: 8 Nm (0.8 kgf-m, 5.8 ft-lb) 8) After depressing the clutch pedal, make sure that there are no evident leaks in the entire system.
2. TURBO RHD MODEL
S504260E4502
NOTE: Bleed air from oil line with the help of a co-worker. 1) Remove intercooler. <Ref. to TURBO)-10, REMOVAL, Intercooler.> IN(DOHC
CL-35
Clutch System
5) Tighten air bleeder. Tightening torque: 8 Nm (0.8 kgf-m, 5.8 ft-lb)
H2M1814B
(A) (B)
Air bleeder Connector ASSY
6) Repeat steps 2) through 4) using air bleeder on operating cylinder.
S2M1841A
(A) (B)
Vinyl tube Operating cylinder
7) Tighten air bleeder. Tightening torque: T: 8 Nm (0.8 kgf-m, 5.8 ft-lb)
S2M1842A
(A) (B)
8) After depressing the clutch pedal, make sure that there are no leaks evident in the entire system.
CL-36
CLUTCH PEDAL
Clutch System
10. Clutch Pedal

A: REMOVAL
1. LHD MODEL
S504256A18 S504256A1803
S504256
6) Remove cable clamp, and disconnect PHV cable from PHV. CAUTION: Carefully protect boot and inner cable from damage when disconnecting PHV cable.
1) Remove steering column. <Ref. to PS-30 REMOVAL, Tilt Steering Column.> 2) Disconnect connectors from stop light and clutch switches. 3) Remove snap pins which secure lever to push rod and operating rod. 4) Remove clevis pins which secure lever to push rod and operating rod.
S4M0242B
(A) (B)
PHV cable Clamp
7) Remove nut which secures clutch master cylinder.

B4M1743A
(A) (B) (C) (D)
Operating rod Push rod Snap pin Clevis pin
5) Remove PHV adjusting nut and lock nut.

B4M1744
8) Remove bolts and nuts which secure brake and clutch pedals, and remove pedal assembly.
2. RHD MODEL
S504256A1804
S4M0241B
(A) (B) (C)
Adjusting nut Lock nut PHV
1) Disconnect ground cable from battery. 2) Disconnect connector from clutch. (With cruise control) 3) Remove snap pin and clevis pin that join push rod and clutch pedal. 4) Remove master cylinder mounting nuts.
B4M1749B
(A)
Master cylinder
CL-37
Clutch System
CLUTCH PEDAL B: INSTALLATION

S504256A11
1) Install in the reverse order of removal. CAUTION: If cable clamp is damaged, replace it with a new one. Never fail to cover outer cable end with boot. Be careful not to kink accelerator cable. Always use new clevis pins. 2) Adjustment of clutch pedal and adjustment after pedal installation. <Ref. to CL-41 ADJUSTMENT, Clutch Pedal.>
S4M0241B
(A) (B) (C)
C: DISASSEMBLY
1. LHD MODEL
S504256A0601
S504256A06
6) Remove cable clamp and disconnect PHV cable from PHV. CAUTION: Carefully protect boot and inner cable from damage when disconnecting PHV cable.
1) Remove clutch switches. 2) Remove clips, assist spring, rod and bushing.
B2M4115A
S4M0242B
(A) (B)
PHV cable Clamp
(A) (B) (C) (D) (E)
Clip Assist spring Assist rod Bushing Clevis pin
7) Remove clutch pedal and bracket as a unit.
3) Remove spring pin and lever.
B4M1752B
B2M4116A
(A) (B)
Clutch pedal bracket Clutch pedal
(A) (B)
Pin Lever
CL-38
CLUTCH PEDAL
4) Remove clutch pedal and bushings.
Clutch System
4) Remove clutch pedal from clutch pedal bracket.
B2M4117A
B2M4227A
(A) (B)
Clutch pedal Bushing
(A) (B)
Clutch pedal bracket Clutch pedal
5) Remove stopper, clip, O-ring, rod S, and then remove spring and bushing S.
5) Remove following parts (B to H) from clutch pedal bracket (A) as shown in figure.
B2M4118A
B2M4228A
(A) (B) (C) (D) (E) (F)
Clip O-ring Bushing S Spring S Rod S Stopper
6) Remove stoppers from clutch pedal. 7) Remove clutch pedal pad.
(A) (B) (C) (D) (E) (F) (G) (H)
Clutch pedal bracket Bushing C Clip O-ring Bushing S Spring S Rod S Bushing
2. RHD MODEL
S504256A0602
1) Remove clutch switch. 2) Remove clip, pull out clevis pin.
B2M4226A
(A)
Clevis pin
3) Remove assist rod, spring and bushing.
CL-39
Clutch System
CLUTCH PEDAL
4) Install clutch pedal to pedal bracket. Tightening torque: T: 29 Nm (3.0 kgf-m, 21.7 ft-lb)
6) Remove spacer, bushing and pedal pad from clutch pedal.
B2M4229A
(A) (B) (C) (D) (E) (F)
Spacer Bushing Bushing Pedal pad Clutch pedal Bushing C

S504256A02
B4M1753B
5) Install assist rod, bushing and assist spring to clutch pedal and pedal bracket. 6) Install PHV cable to clutch pedal. (Vehicle with hill holder).
D: ASSEMBLY
1. LHD MODEL
E: INSPECTION
S504256A10
S504256A0201
1. CLUTCH PEDAL
S504256A1001
1) Attach clutch switch, etc. to pedal bracket temporarily. 2) Clean inside of bores of clutch pedal and brake pedal, apply grease, and set bushings into bores. 3) Align bores of pedal bracket, clutch pedal and brake pedal, attach brake pedal return spring, assist rods, and spring, and bushing. NOTE: Clean up inside of bushings and apply grease before installing spacer. 4) Install hill holder cable to the clutch pedal. (Vehicle with hill holder)
Move clutch pedal pads in the lateral direction with a force of approximately 10 N (1 kgf, 2 lb) to ensure pedal deflection is in specified range. CAUTION: If excessive deflection is noted, replace bushings with new ones. Deflection of clutch pedal: Service limit 5.0 mm (0.197 in) or less
2. RHD MODEL
S504256A0202
1) Clean and apply grease to hole of sliding portion between clutch pedal and bushing. 2) Install pad, stopper, bushing C, spacer and bushing to clutch pedal. 3) Install rod S, spring S, bushing S, O-ring, clip, bushing, clutch switch and bushing C to clutch pedal bracket.
B2M4119A
(A) (B)
Clutch pedal Brake pedal
CL-40
CLUTCH PEDAL F: ADJUSTMENT

1. CLUTCH PEDAL
S504256A01
Clutch System
S504256A0101
1) Turn clutch switch lock nuts until clutch pedal full stroke length is within specifications. CAUTION: Do not attempt to turn clutch switch to adjust clutch pedal full stroke length. NOTE: If lock nuts cannot adjust clutch pedal full stroke length to specifications, turn master cylinder push rod to adjust it. Specified clutch pedal full stroke: A 130 135 mm (5.12 5.31 in) Tightening torque (Clutch switch lock nut): T: 8 Nm (0.8 kgf-m, 5.8 ft-lb)
4) Measure clutch pedal full stroke length again to ensure that it is within specifications. If it is not, repeat adjustment procedures again from the beginning. Specified clutch pedal full stroke: 130 135 mm (5.12 5.31 in) 5) Move clevis pin to the left and then to the right. It should move without resistance while it is rattling. If resistance is felt, repeat adjustment procedures again from the beginning. 6) Push release lever until operating cylinder push rod retracts. Ensure that clutch fluid level in reservoir tank increases. If clutch fluid level increases, hydraulic clutch is properly adjusted; if fluid level does not increase or push rod does not retract, replace master cylinder with new one. <Ref. to CL-25 Master Cylinder.>
B4M1190C B4M1191B
2) Turn master cylinder push rod so that clevis pin moves to the left and then to the right. Clevis pin must move without resistance while it is rattling. Tightening torque (Push rod lock nut): T: 10 Nm (1.0 kgf-m, 7 ft-lb)
(1) (2) (3)
Push rod Release lever Operating cylinder
7) Push release lever until operating cylinder push rod retracts. Check that clutch fluid level in reservoir tank increases.
B4M1189G
(A) (B) (C) (D)
B4M1191B
3) Depress and release clutch pedal 2 to 3 times to ensure that clutch pedal and release fork operate smoothly. If clutch pedal and release fork do not operate smoothly, bleed air from clutch hydraulic system. <Ref. to CL-34 Clutch Fluid Air Bleeding.>
(1) (2) (3)
Push rod Release lever Operating cylinder
8) If clutch fluid level increases, hydraulic clutch play is correct. 9) If clutch fluid level does not increase or push rod does not retract, clutch pedal must be readjusted.
CL-41
Clutch System
CLUTCH PEDAL
10) Inspect the fluid level. <Ref. to CL-33, Clutch Fluid.>
CL-42
CLUTCH SWITCH
Clutch System
11. Clutch Switch

A: REMOVAL
S504258A18
S504258
2) Check clutch switch continuity. If continuity is not as specified, replace the switch.
Switch position Switch pin free Switch pin pushed in Tester connection 12 Specified condition Continuity No continuity
1) Remove battery ground terminal. 2) Disconnect connector from clutch switch. 3) Remove clutch switch.
B: INSTALLATION
S504258A11
1) Move clevis pin of the push rod right and left and hold where it moves smoothly, then measure stroke of clutch pedal. Specified clutch pedal full stroke:A 130 135 mm (5.12 5.31 in) Tightening torque: T: 8 Nm (0.8 kgf-m, 5.8 ft-lb)
Clutch switch (With cruise control)
B2M4122
B4M1190C
2) If clutch pedal stroke is out of specification, adjust the stroke. <Ref. to CL-41, ADJUSTMENT, Clutch Pedal.> 3) Connect clutch switch connector.
C: INSPECTION
S504258A10
1) If clutch switch does not operate properly (or if it does not stop at the specified position), replace with new one. Specified position: L 2+1.5/0mm (0.079+0.059/0 in)
G4M0327
CL-43
Clutch System

S504257
A: INSPECTION
1. CLUTCH
S504257A1002
S504257A10
Symptom 1. Clutch slippage. It is hard to perceive clutch slippage in the early stage, but pay attention to the following symptoms Engine speed up when shifting. High speed driving is impossible; especially rapid acceleration impossible and vehicle speed does not increase in proportion to an increase in engine speed. Power falls, particularly when ascending a slope, and there is a smell of burning of the clutch facing. Method of testing: Put the vehicle in stationary condition with parking brake fully applied. Disengage the clutch and shift the transmission gear into the first. Gradually allow the clutch to engage while gradually increasing the engine speed. The clutch function is satisfactory if the engine stalls. However, the clutch is slipping if the vehicle does not start off and the engine does not stall. 2. Clutch drags. As a symptom of this trouble, a harsh scratching noise develops and control becomes quite difficult when shifting gears. The symptom becomes more apparent when shifting into the first gear. However, because much trouble of this sort is due to defective synchronization mechanism, carry out the test as described after. Method of testing: <Ref. to CL-45 DIAGNOSTIC DIAGRAM OF CLUTCH DRAG, INSPECTION, General Diagnostic Table.> It may be judged as insufficient disengagement of clutch if any noise occurs during this test. 3. Clutch chatters. Clutch chattering is an unpleasant vibration to the whole body when the vehicle is just started with clutch partially engaged.
Possible cause (a) Clutch facing smeared by oil
Corrective Replace.
(b) Worn clutch facing
Replace.
(c) Deteriorated diaphragm spring
Replace.
(d) Distorted pressure plate or flywheel
Correct or replace.
(e) Defective release bearing holder
Correct or replace.
(a) Worn or rusty clutch disc hub spline
Replace clutch disc.
(b) Excessive deflection of clutch disc facing
Correct or replace.
(c) Seized crankshaft pilot needle bearing
Replace.
(d) Cracked clutch disc facing
Replace.
(e) Sticked clutch disc (smeared by oil or Replace. water)
(a) Adhesion of oil on the facing (b) Weak or broken torsion spring (c) Defective facing contact or excessive disc (d) Warped pressure plate or flywheel (e) Loose disc rivets (f) Loose engine mounting (g) Improper adjustment of pitching stopper
Replace clutch disc. Replace clutch disc. Replace clutch disc defection. Correct or replace. Replace clutch disc. Retighten or replace mounting. Adjustment.
CL-44

Symptom 4. Noisy clutch Examine whether the noise is generated when the clutch is disengaged, engaged, or partially engaged. Possible cause (a) Broken, worn or unlubricated release bearing (b) Insufficient lubrication of pilot bearing (c) Loose clutch disc hub (d) Loose torsion spring retainer (e) Deteriorated or broken torsion spring (a) Grease or oil on facing 5. Clutch grabs. When starting the vehicle with the clutch (b) Deteriorated cushioning spring partially engaged, the clutch engages (c) Worn or rusted spline of clutch disc suddenly and the vehicle jumps instead or main shaft of making a smooth start. (d) Deteriorated or broken torsion spring (e) Loose engine mounting (f) Deteriorated diaphragm spring Corrective Replace release bearing.
Clutch System
Apply grease. Replace clutch disc. Replace clutch disc. Replace clutch disc. Replace clutch disc. Replace clutch disc. Take off rust, apply grease or replace clutch disc or main shaft. Replace clutch disc. Retighten or replace mounting. Replace.
2. CLUTCH PEDAL
S504257A1003
Trouble Insufficient pedal play Clutch pedal free play insufficient Excessively worn and damaged pedal shaft and/or bushing
Corrective action Adjust pedal play. Adjust pedal free play. Replace bushing and/or shaft with new one.
S504257A1001
3. DIAGNOSTIC DIAGRAM OF CLUTCH DRAG

No. 1 Step CHECK GEAR NOISE. 1) Start the engine. 2) Disengage the clutch and shift quickly from neutral to reverse in idling condition. CHECK GEAR NOISE. With the engine idling, disengage the clutch and shift quickly (between 0.5 to 1.0 s) from neutral to reverse.
Check Yes Is an abnormal noise heard Go to step 2. from the transmission gears? Is an abnormal noise heard Go to step 3. from the transmission gears?
No Clutch is normal.
CHECK GEAR NOISE. With the engine idling, disengage the clutch and shift quickly (between 0.5 to 1.0 s) from neutral to reverse shift repeatedly between neutral and reverse with clutch disengaged.
Defective transmission or excessive clutch drag torque. Inspect pilot bearing, clutch disc, transmission and clutch disc hub spline. Is an abnormal noise heard Clutch is not dis- Clutch disc and from the transmission engaged properly. flywheel are locked together. gears? Inspect clutch disc, clutch cover, Inspect clutch disc and clutch disc clutch release hub spline. system, and clutch pedal free play.
CL-45
Clutch System
MEMO:
CL-46
AUTOMATIC TRANSMISSION (DIAGNOSTICS)
AT
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Page Basic Diagnostic Procedure ........................................................................2 Check List for Interview...............................................................................4 General Description.....................................................................................5 Electrical Components Location..................................................................8 Transmission Control Module (TCM) I/O Signal .......................................15 Subaru Select Monitor...............................................................................20 Read Diagnostic Trouble Code .................................................................22 Inspection Mode ........................................................................................24 Clear Memory Mode..................................................................................25 Power Indicator Light Display ...................................................................26 List of Diagnostic Trouble Code................................................................27 Diagnostic Procedure for Power Indicator Light .......................................28 Diagnostic Procedure for Select Monitor Communication ........................36 Diagnostic Procedure with Trouble Code .................................................42 Diagnostic Procedure for No-trouble Code.............................................107 Symptom Related Diagnostic..................................................................134
Automatic Transmission (Diagnostics)

S004501

A: PROCEDURE
No. 1
S004501E45
2 3
Step CHECK PRE-INSPECTION. 1) Ask the customer when and how the trouble occurred using interview checklist. <Ref. to AT-4, Check List for Interview.> 2) Before performing diagnosis, inspect the following items which might influence the AT problems. General inspection <Ref. to AT-5, INSPECTION, General Description.> Oil leak Stall speed test <Ref. to AT-13, Stall Test.> Line pressure test <Ref. to AT-16, Line Pressure Test.> Transfer clutch pressure test <Ref. to AT-18, Transfer Clutch Pressure Test.> Time lag test <Ref. to AT-15, Time Lag Test.> Road test <Ref. to AT-12, Road Test.> Inhibitor switch <Ref. to AT-28, Inhibitor Switch.> CHECK POWER INDICATOR LIGHT. Turn ignition switch to ON. CHECK POWER INDICATOR LIGHT. 1) Turn ignition switch to OFF. 2) Repair POWER indicator light circuit or power supply and ground line circuit. <Ref. to AT-28, Diagnostic Procedure for Power Indicator Light.> 3) Turn ignition switch to ON. CHECK INDICATION OF TROUBLE CODE. Calling up trouble code. Without SUBARU SELECT MONITOR <Ref. to AT-22, WITHOUT SUBARU SELECT MONITOR, OPERATION, Read Diagnostic Trouble Code.> With SUBARU SELECT MONITOR <Ref. to AT-23, WITH SUBARU SELECT MONITOR, OPERATION, Read Diagnostic Trouble Code.> NOTE: If the communication function of the select monitor cannot be executed normally, check the communication circuit. <Ref. to AT-36, COMMUNICATION FOR INITIALIZING IMPOSSIBLE, Diagnostic Procedure for Select Monitor Communication.>
Check Is unit that might influence the AT problem normal?
Yes Go to step 2.
No Repair or replace each item.
Does not the POWER indicator light light up? Is the POWER indicator light flashing?
Go to step 3. Go to step 4.
Is the trouble code displayed?
Go to step 6. NOTE: Record all trouble codes.
Go to step 5.
AT-2

No. 5 Step PERFORM THE GENERAL DIAGNOSTICS. 1) Inspect using Diagnostic Procedure for No-trouble Code.<Ref. to AT-107, Diagnostic Procedure for No-trouble Code.> 2) Inspect using Symptom Related Diagnostic. <Ref. to AT-134, Symptom Related Diagnostic.> 3) Perform the clear memory mode. With SUBARU SELECT MONITOR <Ref. to AT-25, WITH SUBARU SELECT MONITOR, OPERATION, Clear Memory Mode.> Without SUBARU SELECT MONITOR <Ref. to AT-25, WITHOUT SUBARU SELECT MONITOR, OPERATION, Clear Memory Mode.> 4) Perform the inspection mode. <Ref. to AT-24, Inspection Mode.> Calling up the trouble code. Without SUBARU SELECT MONITOR <Ref. to AT-22, WITHOUT SUBARU SELECT MONITOR, OPERATION, Read Diagnostic Trouble Code.> With SUBARU SELECT MONITOR <Ref. to AT-23, WITH SUBARU SELECT MONITOR, OPERATION, Read Diagnostic Trouble Code.> PERFORM THE DIAGNOSIS. 1) Inspect using Diagnostics Chart with Trouble Code.<Ref. to AT-42, Diagnostic Procedure with Trouble Code.> NOTE: For trouble code table, refer to List of Diagnostic Trouble Code.<Ref. to AT-27, List of Diagnostic Trouble Code.> 2) Repair trouble cause. 3) Perform the clear memory mode. With SUBARU SELECT MONITOR <Ref. to AT-25, WITH SUBARU SELECT MONITOR, OPERATION, Clear Memory Mode.> Without SUBARU SELECT MONITOR <Ref. to AT-25, WITHOUT SUBARU SELECT MONITOR, OPERATION, Clear Memory Mode.> 4) Perform the inspection mode. <Ref. to AT-24, Inspection Mode.> 5) Calling up the trouble code. Without SUBARU SELECT MONITOR <Ref. to AT-22, WITHOUT SUBARU SELECT MONITOR, OPERATION, Read Diagnostic Trouble Code.> With SUBARU SELECT MONITOR <Ref. to AT-23, WITH SUBARU SELECT MONITOR, OPERATION, Read Diagnostic Trouble Code.> Check Is the trouble code displayed?

Yes Go to step 6. No Complete the diagnosis.
Is the trouble code displayed?
Complete the Inspect using Diagnostics Chart diagnosis. with Diagnostic Connector. <Ref. to AT-42, Diagnostic Procedure with Trouble Code.>
AT-3

S004502

A: CHECK
S004502A04
Customer s name Data vehicle brought in Data of repair Trans. model Odometer reading Frequency Weather
TRANSMISSION ( (
VIN km/h or mile
Place
Outdoor temperature Vehicle speed Malfunction indicator lamp (MIL) Select lever position Driving condition
Continuous Intermittent ( times a day) Fine Cloudy Rainy Snowy Various/Others ) Highway Suburbs Inner city Uphill Others ) Hot Warm Cool Cold
Rough road
km/h (MPH) Continuously lit P R N D Not affected At racing While decelerating ( Not lit 3 2 1 At starting While accelerating While turning ( RH/ LH)
While idling While cruising
POWER switch HOLD switch Symptoms
ON OFF ON OFF No up-shift No down-shift No kick down Vehicle does not move ( Any position Lock-up malfunction Noise or vibration Shift shock or slip Select lever does not move Others )
Particular position)
AT-4
GENERAL DESCRIPTION

S004001A1003
A: CAUTION
S004001A03
S004001
3. ATF LEVEL
Make sure that ATF level is in the specification.
Supplemental Restraint System Airbag Airbag system wiring harness is routed near the transmission control module (TCM). CAUTION: All airbag system wiring harness and connectors are colored yellow. Do not use electrical test equipment on these circuit. Be careful not to damage airbag system wiring harness when performing diagnostics and servicing the TCM. Measurement When measuring voltage and resistance of the ECM, TCM or each sensor, use a tapered pin with a diameter of less than 0.64 mm (0.025 in) in order to avoid poor contact. Do not insert the pin more than 6.5 mm (0.256 in).
(A) (B) Upper level Lower level
B3M0173B
4. FRONT DIFFERENTIAL OIL LEVEL

S004001A1004
Make sure that front differential oil level is in the specification.
B: INSPECTION
1. BATTERY
S004001A1001
S004001A10
Measure battery voltage and specific gravity of electrolyte. Standard voltage: 12V or more Specific gravity: Above 1.260
2. TRANSMISSION GROUND
S004001A1002
Make sure that the ground terminal bolt is tightened securely. Chassis side Tightening torque: 13 Nm (1.3 kgf-m, 9.4 ft-lb)
B3M0174B
(A) (B)
Upper level Lower level
TR0373
AT-5
GENERAL DESCRIPTION
7. HOLD SWITCH
S004001A1007
5. OPERATION OF SHIFT SELECT LEVER

S004001A1005
WARNING: Stop the engine while checking operation of select lever. 1) Check that select lever does not move from N to R without pushing the button. 2) Check that select lever does not move from R to P without pushing the button. 3) Check that select lever does not move from P to R without pushing the button. 4) Check that select lever does not move from 3 to 2 without pushing the button.
Make sure that HOLD indicator light in combination meter comes ON, when turning hold switch to ON.
S3M0117
G3M0717
6. POWER SWITCH
S004001A1006
Make sure that POWER indicator light in combination meter comes ON, when turning power switch to ON.
S3M0449
AT-6
GENERAL DESCRIPTION C: PREPARATION TOOL

1. SPECIAL TOOLS
ILLUSTRATION
S004001A1701 S004001A17
B2M3876
22771AA030
SELECT MONITOR KIT
B2M3877

TOOL NAME Circuit Tester Oscilloscope
S004001A1702
REMARKS Used for measuring resistance, voltage and ampere. Used for measuring sensor.
AT-7

S004507

A: LOCATION
LHD MODEL
S004507A13
1. CONTROL MODULE FOR MODEL WITHOUT OBD
S004507A1304
S3M0134A
RHD MODEL
S3M0133A
(1) Engine control module (ECM) (2) Power indicator light (AT diagnostic indicator light)
(3) Transmission control module (TCM) (4) Data link connector
AT-8
S2M0533C
S3M0590A
B3M1592B
B3M1652A
S2M0258C
AT-9

S004507A1305
2. CONTROL MODULE FOR MODEL WITH OBD

LHD MODEL
S3M0240A
RHD MODEL
S3M0241A
(1) Engine control module (ECM) (2) Power indicator light (AT diagnostic indicator light)
(3) Transmission control module (TCM) (4) Data link connector
AT-10
B3M0183E
S3M0590A
B3M1592B
B3M1652A
S2M0258C
AT-11
3. SENSOR
S004507A1302
LHD MODEL
S3M0240C
RHD MODEL
S3M0241C
(1) Throttle position sensor (2) Front vehicle speed sensor (3) Inhibitor switch
(4) Rear vehicle speed sensor (5) Torque converter torbine speed sensor
(6) ATF temperature sensor
AT-12
S2M0262B
TR0387
TR0388
TR0390
TR0389
AT-13
4. SOLENOID
S004507A1303
B3M1186A
(1) Solenoid 1 (2) Solenoid 2 (3) Line pressure duty solenoid
(4) Low clutch timing solenoid (5) Lock-up duty solenoid (6) 2-4 brake duty solenoid
(7) 2-4 brake timing solenoid (8) Transfer duty solenoid
B2M2263D
B2M2264E
AT-14

S004506
5. Transmission Control Module (TCM) I/O Signal

S004506A08
TR0532
Check with ignition switch ON. Content Back-up power supply Ignition power supply Connector No. B56 B54 B54 B55 Terminal No. 1 23 24 1 Measuring conditions Ignition switch OFF Ignition switch ON (with engine OFF) Select lever in P range Select lever in any other than P range (except N range) Select lever in N range Select lever in any other than N range (except P range) Select lever in R range Select lever in any other than R range Select lever in D range Select lever in any other than D range Select lever in 3 range Select lever in any other than 3 range Select lever in 2 range Select lever in any other than 2 range Select lever in 1 range Select lever in any other than 1 range Brake pedal depressed. Brake pedal released. Voltage (V) 10 16 10 16 Less than 1 More than 8 Less than 1 More than 8 Less than 1 More than 8 Less than 1 More than 8 Less than 1 More than 8 Less than 1 More than 8 Less than 1 More than 8 More than 10.5 Less than 1 Resistance to body (ohms)
P range switch
N range switch
B55
14
R range switch Inhibitor switch D range switch 3 range switch 2 range switch 1 range switch Brake switch
B55
B55
B55
B55
B55
B55
12
AT-15

Check with ignition switch ON.
Content
Connector No. B55 B56 B54 B54
Terminal No.
Measuring conditions Throttle fully open. Throttle fully closed. Light ON Light OFF Throttle fully closed. Throttle fully open. Ignition switch ON (With engine OFF)
Voltage (V) Less than 1 More than 6.5 Less than 1 More than 9 0.3 0.7 4.0 4.6 4.8 5.3
Resistance to body (ohms) 2.1 k 2.9 k 275 375 450 650
Kick-down switch AT OIL TEMP warning light Throttle position sensor Throttle position sensor power supply (with OBD model) ATF temperature sensor
11 10 3 2
B54
11
Rear vehicle speed sensor
B55
24
Front vehicle speed sensor
B55
18
Torque converter turbine speed sensor Vehicle speed output signal (Waveform) Engine speed signal
B55
B56
17
B55
17
Cruise set signal
B55
22
Torque control signal 1 Torque control signal 2 Torque control cut signal Intake manifold pressure signal (Non-turbo model) Mass air flow signal (Turbo model) Shift solenoid 1 Shift solenoid 2
B56 B56 B55 B54 B54 B54 B54
5 14 10 1 1 22 5
ATF temperature 20C 1.6 2.0 (68F) ATF temperature 80C 0.4 0.9 (176F) Vehicle stopped. 0 Vehicle speed at least 20 More than 1 (AC range) km/h (12 MPH) Vehicle stopped. 0 Vehicle speed at least 20 More than 1 (AC range) km/h (12 MPH) Engine idling after warm0 up. (D range) Engine idling after warmMore than 1 (AC range) up. (N range) Vehicle speed at most 10 Less than 1 km/h (6 MPH) More than 4 Ignition switch ON (with More than 10.5 engine OFF) Ignition switch ON (with 8 11 engine ON) When cruise control is set Less than 1 (SET lamp ON) When cruise control is not More than 6.5 set (SET lamp OFF) Ignition switch ON (with More than 4 engine ON) Ignition switch ON (with More than 4 engine ON) Ignition switch ON 8 Engine idling after warm1.2 1.8 up. Engine idling after warm0.5 1.2 up. 1st or 4th gear More than 9 2nd or 3rd gear Less than 1 1st or 2nd gear More than 9 3rd or 4th gear Less than 1
450 650
450 650
10 16 10 16
AT-16

Check with ignition switch ON. Content Connector No. Terminal No. Measuring conditions Ignition switch ON (with engine OFF) Throttle fully closed after warm-up. Ignition switch ON (with engine OFF) Throttle fully open after warm-up. When lock up occurs. When lock up is released. Fuse on FWD switch Fuse removed from FWD switch (with throttle fully open and with select lever in 1st gear). Throttle fully closed (with engine OFF) after warmup. Throttle fully open (with engine OFF) after warmup. 1st gear 3rd gear 2nd gear 4th gear Hold switch ON Hold switch OFF Power switch ON Power switch OFF Light ON Light OFF Fuse removed Fuse installed Fused ON FWD switch Fuse removed from FWD switch ABS switch ON ABS switch OFF Ignition switch ON Voltage (V)
B54
B54
10 17
B54
10 17
1.5 4.0 2.0 4.5 Less than 0.5 Less than 1 More than 9 Less than 1 More than 9 Less than 1 More than 8 Less than 1 More than 10 Less than 1 More than 9 6 9.1 Less than 1 Less than 1 More than 9 Less than 1 6.5 15 0 0 0 0 0 Less than 1 More than 4 10 16 10 16 Less than 1 Less than 1 Less than 1 Less than 1 Less than 1
B54
18
2-4 brake timing solenoid Low clutch timing solenoid Hold switch Power switch Power indicator light FWD switch
B54 B54 B55 B55 B56 B55
16 15 16 23 11 20
FWD indicator light
B56
ABS signal Sensor ground line 1 Sensor ground line 2 System ground line Sensor ground line 3 Sensor ground line 4 AT diagnosis signal (Waveform) Data link signal (Subaru Select Monitor)
B55 B54 B55 B56 B54 B54 B54 B56 B56
21 20 9 19 21 10 19 21 15 6
AT-17

S004506A21
B: SCHEMATIC
S3M0620
AT-18

(1) Transmission control module (2) Data link connector (3) Cruise control module (Nonturbo model) (4) ABS control module (5) Ignition switch (6) Brake switch (7) Brake light (8) Battery (9) Combination meter (Speedometer circuit) (10) ATF temperature warning light (11) FWD indicator light (12) POWER indicator light (13) HOLD indicator light (14) FWD switch (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (29) (30) Kick-down switch Power switch Hold switch P range switch R range switch N range switch D range switch 3 range switch 2 range switch 1 range switch Throttle position sensor Engine speed signal Torque control cut signal Torque control signal 2 Torque control signal 1 AT load signal (31) (32) (33) (34) (35) (36) (37) (38) (39) (40) (41) (42) (43) (44)

AT diagnostic signal (with OBD) Engine control module ATF temperature sensor Torque converter turbine speed sensor Vehicle speed sensor 2 (Front) Vehicle speed sensor 1 (Rear) Shift solenoid 1 Shift solenoid 2 2-4 brake timing solenoid Line pressure duty solenoid 2-4 brake duty solenoid Lock-up duty solenoid Low clutch timing solenoid Transfer duty solenoid
AT-19

S004503

A: OPERATION
S004503A1601 S004503A16
1. READ DIAGNOSTIC TROUBLE CODE

S2M0288C S2M0285
(A)
Power switch
2) Connect diagnosis cable to Subaru Select Monitor. 3) Insert cartridge into Subaru Select Monitor. <Ref. to AT-7, PREPARATION TOOL, General Description.>
6) On the Main Menu display screen, select the {Each System Check} and press the [YES] key. 7) On the System Selection Menu display screen, select the {Transmission Control System} and press the [YES] key. 8) Press the [YES] key after displayed the information of transmission type. 9) On the Transmission Diagnosis display screen, select the {Diagnostic Code(s) Display} and press the [YES] key. 10) On the Diagnostic Code(s) Display display screen, select the {Latest Diagnostic Code(s)} or {Memorized Diagnostic Code(s)} and press the [YES] key. NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. For detailed concerning diagnostic trouble codes, refer to the DIAGNOSTIC TROUBLE CODE LIST. <Ref. to AT-27, List of Diagnostic Trouble Code.>
S2M0286
2. READ CURRENT DATA
S004503A1602
BR0033
(A)
Data link connector
1) On the Main Menu display screen, select the {Each System Check} and press the [YES] key. 2) On the System Selection Menu display screen, select the {Transmission Control System} and press the [YES] key. 3) Press the [YES] key after displayed the information of transmission type. 4) On the Transmission Diagnosis display screen, select the {Current Data Display & Save} and press the [YES] key. 5) On the Data Display Menu display screen, select the {Data Display} and press the [YES] key. 6) Using the scroll key, move the display screen up or down until the desired data is shown.
AT-20

Contents Battery voltage Rear vehicle speed sensor signal Front vehicle speed sensor signal Engine speed signal Automatic transmission fluid temperature signal Throttle position signal Gear position Line pressure control duty ratio Lock up clutch control duty ratio Transfer clutch control duty ratio Power supply for throttle position sensor Torque converter turbine speed signal 2-4 brake timing pressure control duty ratio Intake manifold pressure sensor voltage 2 wheel drive switch signal Stop lamp switch signal Anti lock brake system signal Cruise control system signal Neutral/Parking range signal Reverse range signal Drive range signal 3rd range signal 2nd range signal 1st range signal Shift control solenoid A Shift control solenoid B Torque control output signal #1 Torque control output signal #2 Torque control cut signal 2-4 brake timing control solenoid valve Low clutch timing control solenoid valve Automatic transmission diagnosis indicator lamp Power mode switch signal Hold mode switch signal Kick down switch signal Automatic transmission fluid temperature lamp
Display Battery Voltage Rear Wheel Speed Front Wheel Speed Engine Speed ATF Temp. Throttle Sensor Voltage Gear Position Line Pressure Duty Ratio Lock Up Duty Ratio Transfer Duty Ratio Throttle Sensor Power Turbine Revolution Speed Brake Clutch Duty Ratio Mani. Pressure Voltage FWD Switch Stop Light Switch ABS Signal Cruise Control Signal N/P Range Signal R Range Signal D Range Signal 3rd Range Signal 2nd Range Signal 1st Range Signal Shift Solenoid #1 Shift Solenoid #2 Torque Control Signal 1 Torque Control Signal 2 Torque Control Cut Sig. 2-4 Brake Timing Sol. Low Clutch Timing Sol. Diagnosis Lamp Power Mode Switch Hold Mode Switch Kick Down Switch ATF Temperature Lamp
Unit of measure V km/h or MPH km/h or MPH rpm C or F V % % % V rpm % V ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF ON or OFF
3. CLEAR MEMORY MODE
S004503A1603
1) On the Main Menu display screen, select the {2. Each System Check} and press the [YES] key. 2) On the System Selection Menu display screen, select the {Transmission Control System} and press the [YES] key. 3) Press the [YES] key after displayed the information of transmission type.
4) On the Transmission Diagnosis display screen, select the {Clear Memory} and press the [YES] key. 5) When the Done and Turn Ignition Switch OFF are shown on the display screen, turn the Subaru Select Monitor and ignition switch to OFF. NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.
AT-21

S004508

A: OPERATION
No. 1
S004508A16

Step PERFORM READ DIAGNOSTIC TROUBLE CODE. 1) Warm-up the engine. 2) Turn ignition switch to OFF. 3) Turn ignition switch to ON. 4) Start the engine. 5) Drive vehicle at speeds greater than 20 km/h (12 MPH). 6) Stop vehicle. 7) Brake pedal depressed and move select lever to 1 range. 8) Turn ignition switch to OFF. 9) Turn ignition switch to ON. 10) Move select lever 2 range. 11) Move select lever 1 range. 12) Move select lever 2 range. 13) Move select lever 3 range. 14) Move select lever D range. CHECK INDICATOR LIGHT.
S004508A1601
Check Does indicator light blinks at 4-Hz intervals? NOTE: Blinks every 0.125 (1/8) seconds (until ignition switch is turned OFF).
Yes No Repair power sup- Go to step 2. ply and ground circuit.<Ref. to AT-32, CHECK POWER SUPPLY AND GROUND LINE, Diagnostic Procedure for Power Indicator Light.>
CHECK INDICATOR LIGHT.
CHECK INDICATOR LIGHT.
AT system is norDoes indicator light blinks mal. at 2-Hz intervals? NOTE: Blinks every 0.25 (1/4) seconds (until ignition switch is turned OFF). Is trouble code outputted? Inspect problem corresponding with trouble code. NOTE: Record all trouble codes. Does indicator light Repair power indiremains illuminated? cator light circuit <Ref. to AT-28, Diagnostic Procedure for Power Indicator Light.>, or Inspect inhibitor switch, wiring, TCM, etc.
Go to step 3.
Go to step 4.
Calling up trouble code again.
AT-22
The power indicator light flashes the code corresponding to the faulty part. The long segment (1.2 sec on) indicates a ten, and the short segment (0.2 sec on) signifies a one.
B3M1199A

S004508A1602
Refer to SUBARU SELECT MONITOR for information about how to obtain and understand trouble codes. <Ref. to AT-20, OPERATION, Subaru Select Monitor.>
AT-23
INSPECTION MODE
8. Inspection Mode
A: OPERATION
S004510A16
S004510
B2M2969C
(A) (B)
Safety stand Free rollers
AT-24
CLEAR MEMORY MODE

A: OPERATION
S004513A1602 S004513A16
S004513

Current trouble codes shown on the display are cleared by turning the ignition switch OFF after conducting on-board diagnostics operation. Previous trouble codes, however, cannot be cleared since they are stored in the TCM memory which is operating on the back-up power supply. These trouble codes can be cleared by removing the specified fuse (located under the light or left lower position of the instrument panel). CLEAR MEMORY: Removal of No. 4 fuse (for at least one minute) The No. 4 fuse is located in the line to the memory back-up power supply of the TCM. Removal of this fuse clears the previous trouble codes stored in the TCM memory. Be sure to remove the No. 4 fuse for at least the specified length of time. Otherwise, trouble codes may not be cleared.

S004513A1601
Refer to SUBARU SELECT MONITOR for information about how to clear trouble codes. <Ref. to AT-21, CLEAR MEMORY MODE, OPERATION, Subaru Select Monitor.>
AT-25
POWER INDICATOR LIGHT DISPLAY

unit can be determined by a trouble code during on-board diagnostics operation. Problems which occurred previously can also be identified through the memory function. If the power indicator does not show a problem (although a problem is occurring), the problem can be determined by checking the performance characteristics of each sensor using the select monitor. Indicator signal is as shown in the figure.
10. Power Indicator Light Display

S004729
A: INSPECTION
S004729A10
When any on-board diagnostics item is malfunctioning, the display on the power indicator light blinks from the time the malfunction is detected after starting the engine until the ignition switch is turned OFF. The malfunctioning part or
S3M0062F
AT-26
LIST OF DIAGNOSTIC TROUBLE CODE
11. List of Diagnostic Trouble Code

A: LIST
S004511A12
S004511
Trouble code 11
Item Engine speed signal Mass air flow signal (Turbo model) ATF temperature sensor Throttle position sensor Front vehicle speed sensor Torque converter turbine speed sensor
Content of diagnosis Detects open or shorted input signal circuit. Detects open or shorted input signal circuit. Detects open or shorted input signal circuit. Detects open or shorted input signal circuit. Detects open or shorted input signal circuit. Detects open or shorted input signal circuit. Detects open or shorted input signal circuit. Detects open or shorted input signal circuit. Detects open or shorted output signal circuit. Detects open or shorted output signal circuit. Detects open or shorted output signal circuit. Detects open or shorted output signal circuit. Detects open or shorted output signal circuit. Detects open or shorted output signal circuit. Detects open or shorted output signal circuit. Detects open or shorted output signal circuit. Detects open or shorted input signal circuit.
23
27
31
33
36
38
Torque control signal Intake manifold pressure signal (Non-turbo model) Shift solenoid 1
Index <Ref. to AT-42, TROUBLE CODE 11 ENGINE SPEED SIGNAL , Diagnostic Procedure with Trouble Code.> <Ref. to AT-44, TROUBLE CODE 23 MASS AIR FLOW SIGNAL , Diagnostic Procedure with Trouble Code.> <Ref. to AT-46, TROUBLE CODE 27 ATF TEMPERATURE SENSOR , Diagnostic Procedure with Trouble Code.> <Ref. to AT-50, TROUBLE CODE 31 THROTTLE POSITION SENSOR , Diagnostic Procedure with Trouble Code.> <Ref. to AT-58, TROUBLE CODE 33 FRONT VEHICLE SPEED SENSOR , Diagnostic Procedure with Trouble Code.> <Ref. to AT-64, TROUBLE CODE 36 TORQUE CONVERTER TURBINE SPEED SENSOR , Diagnostic Procedure with Trouble Code.> <Ref. to AT-68, TROUBLE CODE 38 TORQUE CONTROL SIGNAL , Diagnostic Procedure with Trouble Code.> <Ref. to AT-70, TROUBLE CODE 45 INTAKE MANIFOLD PRESSURE SIGNAL , Diagnostic Procedure with Trouble Code.> <Ref. to AT-72, TROUBLE CODE 71 SHIFT SOLENOID 1 , Diagnostic Procedure with Trouble Code.> <Ref. to AT-76, TROUBLE CODE 72 SHIFT SOLENOID 2 , Diagnostic Procedure with Trouble Code.> <Ref. to AT-80, TROUBLE CODE 73 LOW CLUTCH TIMING SOLENOID , Diagnostic Procedure with Trouble Code.> <Ref. to AT-84, TROUBLE CODE 74 2-4 BRAKE TIMING SOLENOID , Diagnostic Procedure with Trouble Code.> <Ref. to AT-88, TROUBLE CODE 75 LINE PRESSURE DUTY SOLENOID , Diagnostic Procedure with Trouble Code.> <Ref. to AT-92, TROUBLE CODE 76 2-4 BRAKE DUTY SOLENOID , Diagnostic Procedure with Trouble Code.> <Ref. to AT-96, TROUBLE CODE 77 LOCK-UP DUTY SOLENOID , Diagnostic Procedure with Trouble Code.> <Ref. to AT-100, TROUBLE CODE 79 TRANSFER DUTY SOLENOID , Diagnostic Procedure with Trouble Code.> <Ref. to AT-104, TROUBLE CODE 93 REAR VEHICLE SPEED SENSOR , Diagnostic Procedure with Trouble Code.>
45
71
72
Shift solenoid 2 Low clutch timing solenoid 2-4 brake timing solenoid Line pressure duty solenoid 2-4 brake duty solenoid
73
74
75
76
77
79
Transfer duty solenoid Rear vehicle speed sensor
93
AT-27
DIAGNOSTIC PROCEDURE FOR POWER INDICATOR LIGHT

S004730
12. Diagnostic Procedure for Power Indicator Light
A: POWER INDICATOR LIGHT DOES NOT COME ON OR GO OFF
S004730G75
DIAGNOSIS: The POWER Indicator light circuit is open or shorted. TROUBLE SYMPTOM: When ignition switch is turned to ON (engine OFF), POWER indicator light does not illuminate. When on-board diagnostics is performed, POWER indicator light remains illuminated.
AT-28

WIRING DIAGRAM:
S3M0621
No. 1
Step CHECK POWER INDICATOR LIGHT. Turn ignition switch to ON (engine OFF).
Check Does POWER indicator light illuminate?
Yes Go to step 3.
No Go to step 2.
AT-29

No. 2

Check Is POWER indicator light bulb OK? Yes Go to step 4. No Replace POWER indicator light bulb.
Step CHECK POWER INDICATOR LIGHT. 1) Turn ignition switch to OFF. 2) Remove combination meter. 3) Remove POWER indicator light bulb from combination meter. CHECK POWER INDICATOR LIGHT. Perform Read Diagnostic Trouble Code. <Ref. to AT-22, WITHOUT SUBARU SELECT MONITOR OPERATION, Read Diagnostic Trouble Code.>
Does POWER indicator light blink?
CHECK FUSE (No. 5). Remove fuse (No. 5).
Is the fuse (No. 5) blown out?
CHECK HARNESS CONNECTOR BETWEEN COMBINATION METER AND IGNITION RELAY. 1) Turn ignition switch to ON (engine OFF). 2) Measure voltage between combination meter connector and chassis ground. Connector & terminal (i10) No. 2 (+) Chassis ground (): CHECK COMBINATION METER. Measure voltage between combination meter connector and chassis ground. Connector & terminal (i12) No. 6 (+) Chassis ground (): CHECK OPEN CIRCUIT OF HARNESS. 1) Turn ignition switch to OFF. 2) Disconnect TCM and combination meter connector. 3) Measure resistance of harness between combination meter. Connector & terminal (B56) No. 11 (i12) No. 6: CHECK INPUT SIGNAL FOR TCM. 1) Connect connector to TCM and combination meter. 2) Turn ignition switch to ON (engine OFF). 3) Measure voltage between TCM connector and chassis ground. Connector & terminal (B56) No. 11 (+) Chassis ground ():
Is voltage more than 9 V?
A temporary poor Go to step 9. contact of the connector or harness may be the cause. Repair harness or connector in TCM, inhibitor switch and combination meter. Replace fuse (No. Go to step 5. 5). If replaced fuse (No. 5) is blown out easily, repair short circuit in harness between fuse (No. 5) and combination meter. Go to step 6. Repair open or short circuit in harness between combination meter and battery.
Is voltage less than 1 V?
Go to step 7.
Go to step 8.
Repair combination meter. <Ref. to IDI-15, Combination Meter Assembly.> Repair open circuit in harness between TCM and combination meter, and poor contact in coupling connector. Replace TCM. <Ref. to AT-48, Transmission Control Module (TCM).>
CHECK SUBARU SELECT MONITOR.
Do you have SUBARU SELECT MONITOR?
Even if POWER indicator lights up, the circuit has returned to a normal condition at this time. A temporary poor contact of the connector or harness may be the cause. Repair harness or connector in TCM. Go to step 10.
Go to step 11.
AT-30

No. 10 Step CHECK INHIBITOR SWITCH. 1) Connect Subaru Select Monitor to data link connector. 2) Turn ignition switch to ON. 3) Subaru Select Monitor to ON. 4) Read data of range switch using Subaru Select Monitor. Range switch is indicated in ON OFF. CHECK SHORT CIRCUIT OF HARNESS. 1) Disconnect connector from TCM. 2) Remove combination meter. 3) Disconnect connector from combination meter. 4) Measure resistance of harness connector between TCM and chassis ground. Connector & terminal/specified resistance (B56) No. 11 (+) Chassis ground (): Check Yes Go to step 11. When each range is selected, does LED of Subaru Select Monitor light up?

No Check inhibitor switch circuit. <Ref. to AT-122, CHECK INHIBITOR SWITCH., Diagnostic Procedure for No-trouble Code.> Repair short circuit in harness between combination meter connector and TCM connector.
11
Is the resistance less than 1 M?
AT-31

S004730G86
B: CHECK POWER SUPPLY AND GROUND LINE

WIRING DIAGRAM: WITHOUT OBD MODEL
S3M0623
AT-32

WITH OBD MODEL
S3M0622
AT-33

No. 1 2 Step CHECK IGNITION SWITCH.

Check Is ignition switch ON? Is the voltage between 10 and 15 V? Yes Go to step 2. Go to step 3. No Turn ignition switch ON. Repair generator. <Ref. to SC-12, Generator.>
3 4
CHECK GENERATOR. 1) Start the engine. 2) Idle the engine. 3) Measure voltage between generator and chassis ground. Terminal Generator B terminal (+) Chassis ground (): CHECK BATTERY TERMINAL. Turn ignition switch to OFF. CHECK POWER SUPPLY OF TCM. 1) Disconnect connector from TCM. 2) Turn ignition switch to ON. 3) Measure voltage between TCM connector and chassis ground. Connector & terminal (B56) No. 1 (+) Chassis ground (): CHECK FUSE (NO. 4). Remove fuse (No. 4).
Is there poor contact at battery terminal? Is the voltage between 10 and 15 V?
Repair battery terminal. Go to step 6.
CHECK IGNITION POWER SUPPLY CIRCUIT. 1) Turn ignition switch to ON (engine OFF). 2) Measure ignition power supply voltage between TCM connector and chassis ground. Connector & terminal (B54) No. 23 (+) Chassis ground (): (B54) No. 24 (+) Chassis ground (): CHECK FUSE (NO. 11). Is the fuse (No. 11) blown Remove fuse (No. 11). out?
Replace fuse (No. 4). If replaced fuse (No. 4) has blown out easily, repair short circuit in harness between fuse (No. 4) and TCM. Is the voltage more than 10 Go to step 8. V?
Is the fuse (No. 4) blown out?
Repair open circuit in harness between fuse (No. 4) and TCM, or fuse (No. 4) and battery, and poor contact in coupling connector. Go to step 7.
Is the resistance less than CHECK HARNESS CONNECTOR 1 ? BETWEEN TCM AND TRANSMISSION. 1) Turn ignition switch to OFF. 2) Disconnect connector from TCM and transmission. 3) Measure resistance of harness between TCM and transmission connector. Connector & terminal (B56) No. 19 (B11) No. 16 (B54) No. 21 (B11) No. 16
Replace fuse (No. 11). If replaced fuse (No. 11) has blown out easily, repair short circuit in harness between fuse (No. 11) and TCM. Go to step 9.
Repair open circuit in harness between fuse (No. 11) and TCM, or fuse (No. 11) and battery, and poor contact in coupling connector. Repair open circuit in harness between TCM and transmission harness connector, and poor contact in coupling connector.
AT-34

No. 9 Step CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND TRANSMISSION GROUND. Measure resistance of harness between transmission and transmission ground. Connector & terminal (T4) No. 16 Transmission ground: CHECK POOR CONTACT IN CONNECTORS. Check Is the resistance less than 1 ? Yes Go to step 10.

No Repair open circuit in harness between transmission and transmission ground.
10
Is there poor contact in control module power supply and ground line?
Repair connector.
AT-35
DIAGNOSTIC PROCEDURE FOR SELECT MONITOR COMMUNICATION

S004782
13. Diagnostic Procedure for Select Monitor Communication

A: COMMUNICATION FOR INITIALIZING IMPOSSIBLE
DIAGNOSIS: Faulty harness connector TROUBLE SYMPTOM: Select monitor communication failure
S004782E34
AT-36

WIRING DIAGRAM: WITHOUT OBD
S3M0623
AT-37
WITH OBD
S3M0622
AT-38

No. 1 2 Step CHECK THE VEHICLE. CHECK MAIN RELAY. 1) Turn ignition switch to OFF. 2) Remove main relay. 3) Connect battery to main relay terminals No. 2 (+) and No. 1 (). 4) Measure resistance between main relay terminal. Terminal No. 4 No. 6 CHECK GROUND CIRCUIT OF ECM. <Ref. to AT-50, TROUBLE CODE 31 THROTTLE POSITION SENSOR , Diagnostic Procedure with Trouble Code.> CHECK HARNESS BETWEEN ECM AND MAIN RELAY. 1) Remove main relay connector. 2) Measure voltage between main relay and chassis ground. Connector & terminal (B47) No. 1 Chassis ground: CHECK INPUT VOLTAGE TO ECM. 1) Install main relay. 2) Disconnect ECM connector. 3) Measure voltage between ECM connector and chassis ground. Connector & terminal (B84) No. 5 (+) Chassis ground (): CHECK INPUT VOLTAGE TO SUBARU SELECT MONITOR. 1) Connect main relay connector. 2) Turn ignition switch to ON. 3) Measure voltage between data link connector and chassis ground. Connector & terminal (B40) No. 1 (+) Chassis ground (): CHECK SUBARU SELECT MONITOR GROUND CIRCUIT. 1) Turn ignition switch to OFF. 2) Disconnect ECM connector. 3) Measure resistance between data link connector and chassis ground. Connector & terminal (B40) No. 12 Chassis ground: (B40) No. 13 Chassis ground: CHECK HARNESS BETWEEN BATTERY AND MAIN RELAY. 1) Connect ECM connector. 2) Measure resistance of harness between data link connector and chassis ground. Connector & terminal (B40) No. 12 Chassis ground: (B40) No. 13 Chassis ground: Check Yes Is the target vehicle without Go to step 2. OBD? Is the resistance less than Go to step 3. 10 ?

No Go to step 10. Replace main relay.
Is there any trouble?
Repair ground terminal and/or ground circuit of ECM. Is the voltage more than 10 Go to step 5. V?
Go to step 4.
Repair short circuit in harness between battery and main relay connector.
Repair open or short circuit in harness between ECM and main relay connector, then replace ECM. Repair harness and connector between data link connector and battery.
Repair harness and connector between data link connector and ECM connector.
Go to step 9.
Replace ECM.
AT-39

No. 9

Step CHECK SUBARU SELECT MONITOR GROUND CIRCUIT. Measure resistance between data link connector and ECM connector. Connector & terminal (B40) No. 12 (B84) No. 15: (B40) No. 13 (B84) No. 15: CHECK SUBARU SELECT MONITOR POWER SUPPLY CIRCUIT. Measure voltage between data link connector and chassis ground. Connector & terminal (B40) No. 1 Chassis ground: Check Is the resistance less than 1 ? Yes Go to step 12. No Repair harness and connector between data link connector and ECM connector, or replace ECM. Repair harness and connector between battery and data link connector, and poor contact in coupling connector. Repair open circuit in harness between data link connector and ground terminal, and poor contact in coupling connector. Go to step 13.
10
11
CHECK SUBARU SELECT MONITOR GROUND CIRCUIT. Measure resistance of harness between data link connector and chassis ground. Connector & terminal (B40) No. 12 Chassis ground: (B40) No. 13 Chassis ground: CHECK COMMUNICATION OF SELECT MONITOR. 1) Connect ECM connector (Vehicle without OBD) 2) Turn ignition switch to ON. 3) Using the select monitor, check whether communication to other systems (such as engine, ABS etc.) can be executed normally. CHECK COMMUNICATION OF SELECT MONITOR. 1) Turn ignition switch to OFF. 2) Disconnect TCM connector. 3) Check whether communication to other systems (such as ABS etc.) can be executed normally. CHECK COMMUNICATION OF SELECT MONITOR. 1) Turn ignition switch to OFF. 2) Connect TCM connector. 3) Disconnect ECM connector. 4) Check whether communication to other systems (such as ABS etc.) can be executed normally. CHECK COMMUNICATION OF SELECT MONITOR. 1) Turn ignition switch to OFF. 2) Connect ECM connector. 3) Disconnect ABSCM&H/U connector. 4) Check whether communication to other systems (such as engine etc.) can be executed normally.
Go to step 12.
12
Are the name and year of the system displayed on the select monitor?
Go to step 17.
13
Go to step 19.
Go to step 14.
14
Inspect ECM.
Go to step 15.
15
Inspect ABSCM&H/U.
Go to step 16.
AT-40

No. 16 Step CHECK COMMUNICATION OF SELECT MONITOR. 1) Turn ignition switch to OFF. 2) Connect ABSCM&H/U module connector. 3) Disconnect cruise control module connector. 4) Check whether communication to other systems (such as engine etc.) can be executed normally. NOTE: If the vehicle is not equipped with cruise control, Go to step 17. CHECK HARNESS CONNECTOR BETWEEN EACH CONTROL MODULE AND DATA LINK CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect TCM, ECM, ABSCM&H/U and cruise control module connectors. 3) Measure resistance between data link connector and chassis ground. Connector & terminal (B40) No. 5 Chassis ground: (B40) No. 4 Chassis ground: CHECK OUTPUT SIGNAL FOR TCM. 1) Turn ignition switch to ON. 2) Measure voltage between data link connector and chassis ground. Connector & terminal (B40) No. 5 Chassis ground: (B40) No. 4 Chassis ground: CHECK HARNESS/CONNECTOR BETWEEN TCM AND DATA LINK CONNECTOR. Measure resistance between TCM connector and data link connector. Connector & terminal (B56) No. 6 (B40) No. 5: (B56) No. 15 (B40) No. 4: CHECK INSTALLATION OF TCM CONNECTOR. Turn ignition switch to OFF. CHECK POOR CONTACT IN CONNECTORS. Check Are the name and year of the system displayed on the select monitor? Yes Inspect cruise control module.

No Go to step 17.
17
Is the resistance more than Go to step 18. 1M ?
Repair harness and connector between each control module and data link connector.
18
Repair harness and connector between each control module and data link connector.
19
Is the resistance less than 0.5 ?
Go to step 20.
A temporary poor contact of the connector or harness may be the cause. Repair harness or connector in the circuit. Repair harness and connector between TCM and data link connector.
20
Is TCM connector inserted into TCM? Is there poor contact in control module and data link connector?
Go to step 21.
Insert TCM connector into TCM. Replace TCM. <Ref. to AT-48, Transmission Control Module (TCM).>
21
Repair poor contact.
AT-41
DIAGNOSTIC PROCEDURE WITH TROUBLE CODE

S004509
14. Diagnostic Procedure with Trouble Code

DIAGNOSIS: Engine speed input signal circuit is open or shorted. TROUBLE SYMPTOM: No lock-up (after engine warm-up). POWER indicator light remains on when vehicle speed is 0. WIRING DIAGRAM:
A: TROUBLE CODE 11 ENGINE SPEED SIGNAL
S004509C39
S3M0624
AT-42

No. 1 Step CHECK HARNESS CONNECTOR BETWEEN TCM AND ECM. 1) Turn ignition switch to OFF. 2) Disconnect connectors from TCM and ECM. 3) Measure resistance of harness between TCM and ECM connector. Connector & terminal SOHC model: (B55) No. 17 (B135) No. 30: SOHC without OBD: (B55) No. 17 (B84) No. 6: DOHC TURBO: (B55) No. 17 (B136) No. 9: CHECK HARNESS CONNECTOR BETWEEN TCM AND ECM. Measure resistance of harness between TCM connector and chassis ground. Connector & terminal (B55) No. 17 Chassis ground: PREPARE SUBARU SELECT MONITOR. CHECK INPUT SIGNAL FOR TCM. 1) Connect connectors to TCM and ECM. 2) Turn ignition switch to ON (engine OFF). 3) Measure voltage between TCM connector and chassis ground. Connector & terminal (B55) No. 17 (+) Chassis ground (): Check Is the resistance less than 1 ? Yes Go to step 2.

No Repair open circuit in harness between TCM and ECM connector.
Repair short circuit in harness between TCM and ECM connector.
3 4
Even if POWER Go to step 6. indicator lights up, the circuit has returned to a normal condition at this time. A temporary poor contact of the connector or harness may be the cause. Repair harness or connector in the TCM and ECM. Even if POWER Go to step 6. Is the revolution value the CHECK INPUT SIGNAL FOR TCM USING indicator lights up, same as the tachometer SUBARU SELECT MONITOR. reading shown on the com- the circuit has 1) Connect connectors to TCM and ECM. returned to a nor2) Connect Subaru Select Monitor to data link bination meter? mal condition at connector. this time. A tem3) Start the engine, and turn Subaru Select porary poor conMonitor switch to ON. tact of the con4) Warm-up the engine until engine coolant nector or harness temperature is above 80C (176F). may be the 5) Engine idling. cause. Repair 6) Read data of engine speed using Subaru harness or conSelect Monitor. nector in the TCM Display shows engine speed signal value and ECM. sent from ECM. Repair poor con- Go to step 7. CHECK POOR CONTACT. Is there poor contact in engine speed signal cirtact. cuit? Replace ECM. Replace TCM. CONFIRM TROUBLE CODE 11. Replace ECM with a new one. Does the trouble code <Ref. to AT-48, Transmission appear again, after the memory has been cleared? Control Module (TCM).>
Do you have a Subaru Select Monitor? Is the voltage more than 10.5 V?
Go to step 5.
Go to step 4.
AT-43

S004509I01
B: TROUBLE CODE 23 MASS AIR FLOW SIGNAL

DIAGNOSIS: Input signal circuit of TCM from ECM is open or shorted. TROUBLE SYMPTOM: Excessive shift shock. WIRING DIAGRAM:
S3M0625
No. 1
Step CHECK ENGINE GROUND TERMINALS AND GROUND CIRCUIT OF ECM <Ref. to AT-50, TROUBLE CODE 31 THROTTLE POSITION SENSOR -, Diagnostic Procedure with Trouble Code.> CHECK HARNESS CONNECTOR BETWEEN TCM AND ECM. 1) Turn ignition switch to OFF. 2) Disconnect connectors from TCM and ECM. 3) Measure resistance of harness between TCM and ECM connector. Connector & terminal (B54) No. 1 (B135) No. 28: CHECK HARNESS CONNECTOR BETWEEN TCM AND ECM. Measure resistance of harness between TCM connector and chassis ground. Connector & terminal (B54) No. 1 Chassis ground: PREPARE SUBARU SELECT MONITOR.
Check Is there any trouble?
Yes Repair ground terminal and/or ground circuit of ECM. Go to step 3.
No Go to step 2.
Repair open circuit in harness between TCM and ECM connector.
Do you have a Subaru Select Monitor?
Go to step 6.
Go to step 5.
AT-44

No. 5 Step CHECK INPUT SIGNAL FOR TCM. 1) Connect connectors to TCM and ECM. 2) Start the engine, and warm-up the transmission until ATF temperature is above 80C (176F). NOTE: If ambient temperature is below 0C (32F), drive the vehicle until the ATF reaches its operating temperature. 3) Engine idling. 4) Measure voltage between TCM connector and chassis ground. Connector & terminal (B54) No. 1 (+) Chassis ground (): CHECK INPUT SIGNAL FOR TCM USING SUBARU SELECT MONITOR. 1) Connect connectors to TCM and ECM. 2) Connect Subaru Select Monitor to data link connector. 3) Start the engine, and turn Subaru Select monitor switch to ON. 4) Warm-up the engine until engine coolant temperature is above 80C (176F). 5) Engine idling. 6) Read data of intake manifold pressure signal using Subaru Select Monitor. Display shows intake manifold pressure signal value sent from ECM. CHECK POOR CONTACT. Check Is the voltage between 0.4 and 1.8 V?

Yes Even if POWER indicator lights up, the circuit has returned to a normal condition at this time. A temporary poor contact of the connector or harness may be the cause. Repair harness or connector in the TCM and ECM. Even if POWER indicator lights up, the circuit has returned to a normal condition at this time. A temporary poor contact of the connector or harness may be the cause. Repair harness or connector in the TCM and ECM. Repair poor contact. No Go to step 7.
Is the value between 0.4 and 1.8 V?
Go to step 7.
Is there poor contact in intake manifold pressure signal circuit?
AT-45

S004509C76
C: TROUBLE CODE 27 ATF TEMPERATURE SENSOR

DIAGNOSIS: Input signal circuit of TCM to ATF temperature sensor is open or shorted. TROUBLE SYMPTOM: Excessive shift shock. WIRING DIAGRAM:
S3M0626
AT-46

No. 1 Step CHECK HARNESS CONNECTOR BETWEEN TCM AND ATF TEMPERATURE SENSOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from transmission and TCM. 3) Measure resistance of harness between TCM and transmission connector. Connector & terminal (B54) No. 20 (B11) No. 12: CHECK HARNESS CONNECTOR BETWEEN TCM AND ATF TEMPERATURE SENSOR. Measure resistance of harness between TCM and transmission connector. Connector & terminal (B54) No. 11 (B11) No. 11: CHECK HARNESS CONNECTOR BETWEEN TCM AND ATF TEMPERATURE SENSOR. Measure resistance of harness between TCM connector and chassis ground. Connector & terminal (B54) No. 20 Chassis ground: CHECK HARNESS CONNECTOR BETWEEN TCM AND ATF TEMPERATURE SENSOR. Measure resistance of harness between TCM connector and chassis ground. Connector & terminal (B54) No. 11 Chassis ground: CHECK ATF TEMPERATURE SENSOR. 1) Turn ignition switch to OFF. 2) Connect connectors to transmission and TCM. 3) Turn ignition switch to ON and start engine. 4) Warm-up the transmission until ATF temperature reaches to 80C (176F). NOTE: If ambient temperature is below 0C (32F), drive the vehicle until the ATF reaches its operating temperature. 5) Disconnect connector from transmission. 6) Measure resistance between transmission connector terminals. Connector & terminal (T4) No. 11 No. 12: CHECK ATF TEMPERATURE SENSOR. 1) Turn ignition switch to ON (engine OFF). 2) Measure resistance between transmission connector terminals. Connector & terminal (T4) No. 11 No. 12: PREPARE SUBARU SELECT MONITOR. Check Is the resistance less than 1 ? Yes Go to step 2.

No Repair open circuit in harness between TCM and transmission connector.
Go to step 3.
Repair open circuit in harness between TCM and transmission connector.
Repair short circuit in harness between TCM and transmission connector.
Repair short circuit in harness between TCM and transmission connector.
Go to step 6.
Go to step 11.
Does the resistance value increase while the ATF temperature decreases?
Go to step 7.
Go to step 11.
Go to step 9.
Go to step 8.
AT-47

No. 8

Check Is the voltage between 0.4 and 0.9 V? Yes Even if POWER indicator lights up, the circuit has returned to a normal condition at this time. Temporary poor contact of the connector or harness may be the case. Repair harness or contact in the ATF temperature sensor and transmission connector. Does the ATF temperature Even if POWER gradually decrease? indicator lights up, the circuit has returned to a normal condition at this time. Temporary poor contact of the connector or harness may be the case. Repair harness or contact in the ATF temperature sensor and transmission connector. Is there poor contact in ATF Repair poor contemperature sensor circuit? tact. No Go to step 10.
Step CHECK INPUT SIGNAL FOR TCM. 1) Connect connector to transmission. 2) Warm-up the transmission until ATF temperature is about 80C (176F). NOTE: If ambient temperature is below 0C (32F), drive the vehicle until the ATF reaches its operating temperature. 3) Measure voltage between TCM connector terminal. Connector & terminal (B54) No. 11 (+) No. 20 ():
CHECK INPUT SIGNAL FOR TCM USING SUBARU SELECT MONITOR. 1) Connect connector to transmission. 2) Turn ignition switch to ON (engine OFF).
Go to step 10.
10
CHECK POOR CONTACT.
11
CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND ATF TEMPERATURE SENSOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from transmission. 3) Remove transmission connector from bracket. 4) Lift-up the vehicle and place safety stand. CAUTION: On AWD models, raise all wheels off ground. 5) Drain automatic transmission fluid. CAUTION: Do not drain the automatic transmission fluid until it cools down. 6) Remove oil pan, and disconnect connector from ATF temperature sensor connector. 7) Measure resistance of harness between ATF temperature sensor and transmission connector. Connector & terminal (T4) No. 11 (AT1) No. 2:
Go to step 12.
Replace TCM. <Ref. to AT-48, Transmission Control Module (TCM).> Repair open circuit in harness between ATF temperature sensor and transmission connector.
AT-48

No. 12 Step CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND ATF TEMPERATURE SENSOR. Measure resistance of harness between ATF temperature sensor and transmission connector. Connector & terminal (T4) No. 12 (AT1) No. 1: CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND ATF TEMPERATURE SENSOR. Measure resistance of harness between transmission connector and transmission ground. Connector & terminal (T4) No. 11 Transmission ground: CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND ATF TEMPERATURE SENSOR. Measure resistance of harness between transmission connector and transmission ground. Connector & terminal (T4) No. 12 Transmission ground: Check Is the resistance less than 1 ? Yes Go to step 13.

No Repair open circuit in harness between ATF temperature sensor and transmission connector.
13
Repair short circuit in harness between ATF temperature sensor and transmission connector.
14
Is the resistance more than Replace ATF tem1 M? perature sensor. <Ref. to AT-41, Shift Solenoids, Duty Solenoids and ATF Temperature Sensor.>
Repair short circuit in harness between ATF temperature sensor and transmission connector.
AT-49

S004509C94
D: TROUBLE CODE 31 THROTTLE POSITION SENSOR
DIAGNOSIS: Input signal circuit of throttle position sensor is open or shorted. TROUBLE SYMPTOM: Shift point too high or too low; excessive shift shock; excessive tight corner braking. WIRING DIAGRAM: SOHC w/o OBD
S3M0627
AT-50

SOHC
S3M0628
AT-51
DOHC TURBO FOR LHD
S3M0647
AT-52

DOHC TURBO FOR RHD
S3M0648
AT-53

No. 1 2

Check Have engine ground terminals been tightened? Is the resistance less than 5 ? Yes Go to step 2. Go to step 3. No Tighten engine ground terminals. Repair open circuit in harness between ECM connector and engine grounding terminal.
Step CHECK ENGINE GROUND TERMINALS. CHECK GROUND CIRCUIT OF ECM. 1) Turn ignition switch to OFF. 2) Disconnect connector from ECM. 3) Measure resistance of harness between ECM and engine ground. Connector & terminal SOHC MODEL: (B134) No. 27 Engine ground: (B134) No. 8 Engine ground: (B134) No. 7 Engine ground: (B136) No. 21 Engine ground: (B136) No. 22 Engine ground: (B134) No. 35 Engine ground: (B134) No. 34 Engine ground: (B135) No. 6 Engine ground: SOHC w/o OBD MODEL (E22) No. 10 Engine ground: (E22) No. 11 Engine ground: (E22) No. 12 Engine ground: (E22) No. 21 Engine ground: DOHC TURBO MODEL: (B134) No. 7 Engine ground: (B134) No. 15 Engine ground: (B134) No. 22 Engine ground: (B136) No. 8 Engine ground: (B136) No. 17 Engine ground: (B136) No. 18 Engine ground: (B137) No. 8 Engine ground: (B137) No. 9 Engine ground: CHECK THROTTLE POSITION SENSOR. 1) Disconnect connector from throttle position sensor. 2) Measure resistance between throttle position sensor connector receptacles terminals. Terminals SOHC MODEL: No. 4 No. 2: EXCEPT SOHC MODEL: No. 1 No. 2: CHECK THROTTLE POSITION SENSOR. Measure resistance between throttle position sensor connector receptacles terminals. Terminals No. 2 No. 3: CHECK HARNESS CONNECTOR BETWEEN TCM AND THROTTLE POSITION SENSOR. 1) Disconnect connector from TCM. 2) Measure resistance of harness between TCM and throttle position sensor connector. Connector & terminal (B55) No. 3 (E13) No. 3:
Is the resistance between 3.0 and 4.2 k?
Go to step 4.
Replace throttle position sensor.
Go to step 5.
Replace throttle position sensor.
Go to step 6.
Repair open circuit in harness between TCM and throttle position sensor connector, and poor contact in coupling connector.
AT-54

No. 6 Step CHECK HARNESS CONNECTOR BETWEEN TCM AND THROTTLE POSITION SENSOR. Measure resistance of harness between TCM and throttle position sensor connector. Connector & terminal (B54) No. 2 (E13) No. 4: NOTE: If SOHC w/o OBD model, Go to step 7. CHECK HARNESS CONNECTOR BETWEEN TCM AND THROTTLE POSITION SENSOR. Measure resistance of harness between TCM connector and chassis ground. Connector & terminal (B54) No. 3 Chassis ground: CHECK HARNESS CONNECTOR BETWEEN TCM AND THROTTLE POSITION SENSOR. Measure resistance of harness between TCM connector and chassis ground. Connector & terminal (B54) No. 2 Chassis ground: CHECK HARNESS CONNECTOR BETWEEN TCM AND ECM. Measure resistance of harness between TCM and ECM connector. Connector & terminal SOHC w/o OBD MODEL: (B54) No. 3 (E22) No. 23: SOHC MODEL: (B54) No. 3 (B136) No. 17: DOHC TURBO: (B54) No. 3 (B135) No. 7: CHECK HARNESS CONNECTOR BETWEEN TCM AND ECM. Measure resistance of harness between TCM and ECM connector. Connector & terminal (B54) No. 2 (B136) No. 15: NOTE: If SOHC w/o OBD model, Go to step 11. PREPARE SUBARU SELECT MONITOR. CHECK INPUT SIGNAL FOR TCM. 1) Connect connectors to TCM, throttle position sensor and ECM. 2) Turn ignition switch to ON (engine OFF). 3) Close the throttle completely. 4) Measure voltage between TCM connector and chassis ground. Connector & terminal (B54) No. 3 (+) Chassis ground (): CHECK INPUT SIGNAL FOR TCM. 1) Open the throttle completely. 2) Measure voltage between TCM connector and chassis ground. Connector & terminal (B54) No. 3 (+) Chassis ground (): Check Is the resistance less than 1 ? Yes Go to step 7.

No Repair open circuit in harness between TCM and throttle position sensor connector, and poor contact in coupling connector. Repair short circuit in harness between TCM and throttle position sensor connector.
Repair short circuit in harness between TCM and throttle position sensor connector.
Go to step 10.
10
Go to step 11.
11 12
Do you have a Subaru Select Monitor? Is the voltage between 0.3 and 0.7 V in throttle fully closed?
13
Is the voltage between 4.0 and 4.6 V with throttle fully open?
Go to step 16.
Go to step 18.
AT-55

No. 14

Check Is the value voltage between 0.3 and 0.7 V? Yes Go to step 15. No Go to step 18.
15
16
Step CHECK INPUT SIGNAL FOR TCM USING SUBARU SELECT MONITOR. 1) Connect connectors to TCM, throttle position sensor and ECM. 2) Connect Subaru Select Monitor to data link connector. 3) Turn ignition switch to ON (engine OFF). 4) Turn Subaru Select Monitor switch to ON. 5) Throttle fully closed. 6) Read data of throttle position sensor using Subaru Select Monitor. Throttle position sensor input signal is indicated. CHECK INPUT SIGNAL FOR TCM USING SUBARU SELECT MONITOR. Throttle fully open. NOTE: Must be changed correspondingly with accelerator pedal operation (from released to depressed position). CHECK INPUT SIGNAL FOR TCM (THROTTLE POSITION SENSOR POWER SUPPLY). Measure voltage between TCM connector and chassis ground. Connector & terminal (B54) No. 2 (+) Chassis ground ():
Is the value voltage between 4.0 and 4.6 V?
Go to step 17.
Go to step 18.
17
CHECK INPUT SIGNAL FOR TCM USING SUBARU SELECT MONITOR (THROTTLE POSITION SENSOR POWER SUPPLY). Read data of throttle position sensor power supply using Subaru Select Monitor. Throttle position sensor power supply voltage is indicated.
Is the value voltage between 4.8 and 5.3 V?
18
CHECK POOR CONTACT.
Is there poor contact in throttle position sensor circuit?
Even if POWER indicator lights up, the circuit has returned to a normal condition at this time. A temporary poor contact of the connector or harness may be the cause. Repair harness or connector in throttle position sensor circuit. Even if POWER indicator lights up, the circuit has returned to a normal condition at this time. A temporary poor contact of the connector or harness may be the cause. Repair harness or connector in throttle position sensor circuit. Repair poor contact.
Go to step 18.
Go to step 18.
AT-56

MEMO:
AT-57

S004509F60
E: TROUBLE CODE 33 FRONT VEHICLE SPEED SENSOR

DIAGNOSIS: The vehicle speed signal is abnormal. The circuit in combination meter is faulty. The harness connector between TCM and vehicle speed sensor is in short or open. TROUBLE SYMPTOM: Erroneous idling. Engine stalls. Poor driving performance.
AT-58

WIRING DIAGRAM:
S3M0629
AT-59

No. 1

Check Is the resistance less than 1 ? Yes Go to step 2. No Repair open circuit in harness between TCM and transmission connector.
Step CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. 1) Turn ignition switch to OFF. 2) Disconnect connector from TCM and transmission. 3) Measure resistance of harness between TCM and transmission connector. Connector & terminal (B55) No. 18 (B11) No. 17: CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. Measure resistance of harness between TCM and transmission connector. Connector & terminal (B54) No. 10 (B11) No. 18:
Go to step 3.
CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. Measure resistance of harness between TCM and transmission connector. Connector & terminal (B54) No. 10 Chassis ground: CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. Measure resistance of harness between TCM and transmission connector. Connector & terminal (B55) No. 18 Chassis ground:
Repair open circuit in harness between TCM and transmission connector, and poor contact in coupling connector. Repair short circuit in harness between TCM and transmission connector. Repair short circuit in harness between TCM and transmission connector, and poor contact in coupling connector. Replace front vehicle speed sensor. <Ref. to AT-32, Front Vehicle Speed Sensor.> Go to step 7. Go to step 8.
CHECK FRONT VEHICLE SPEED SENSOR. Is the resistance between 450 and 650 ? Measure resistance between transmission connector receptacles terminals. Connector & terminal (T4) No. 17 No. 18: PREPARE OSCILLOSCOPE. PREPARE SUBARU SELECT MONITOR. Do you have oscilloscope? Do you have a Subaru Select Monitor?
Go to step 6.
6 7
AT-60

No. 8 Step CHECK INPUT SIGNAL FOR TCM. 1) Connect all connectors. 2) Lift-up or raise the vehicle and place safety stands. CAUTION: On AWD models, raise all wheels off floor. 3) Start the engine and set vehicle in 20 km/h (12 MPH) condition. NOTE: The speed difference between front and rear wheels may light the ABS warning light, but this indicates no malfunction. When AT control diagnosis is finished, perform the ABS memory clearance procedure of on-board diagnostics system. <Ref. to ABS-22, Clear Memory Mode.> 4) Measure voltage between TCM connector terminals. Connector & terminal (B55) No. 18 (+) (B54) No. 10 (): CHECK FRONT VEHICLE SPEED SENSOR USING OSCILLOSCOPE. 1) Connect all connectors. 2) Lift-up the vehicle and place safety stand. CAUTION: On AWD models, raise all wheels off ground. 3) Set oscilloscope to TCM connector terminals. Positive probe; (B55) No. 18 Earth lead; (B54) No. 10 4) Start the engine, and drive the wheels slowly. NOTE: The speed difference between front and rear wheels may light the ABS warning light, but this indicates no malfunctions. When AT control diagnosis is finished, perform the ABS memory clearance procedure of self-diagnosis system. <Ref. to ABS-22, Clear Memory Mode.> 5) Measure signal voltage indicated on oscilloscope. Check Is the voltage more than AC 1 V?

Yes No Even if POWER Go to step 11. indicator lights up, the circuit has returned to a normal condition at this time. A temporary poor connector or harness may be the case. Repair harness or connector in the front vehicle speed sensor circuit.
Is the voltage more than AC 4 V?
Even if POWER Go to step 11. indicator lights up, the circuit has returned to a normal condition at this time. A temporary poor connector or harness may be the case. Repair harness or connector in the front vehicle speed sensor circuit.
AT-61

No. 10

Check Does the speedometer indication increase as the Subaru Select Monitor data increases? Yes No Even if POWER Go to step 11. indicator lights up, the circuit has returned to a normal condition at this time. A temporary poor connector or harness may be the case. Repair harness or connector in the front vehicle speed sensor circuit.
11
Step CHECK INPUT SIGNAL FOR TCM USING SUBARU SELECT MONITOR. 1) Connect all connectors. 2) Connect Subaru Select Monitor to data link connector. 3) Lift-up or raise the vehicle and place safety stands. CAUTION: On AWD models, raise all wheels off floor. 4) Turn ignition switch to ON and turn Subaru Select Monitor switch to ON. 5) Start the engine. 6) Read data of vehicle speed using Subaru Select Monitor. Compare speedometer with Subaru Select Monitor indications. Vehicle speed is indicated in km/h or MPH. 7) Slowly increase vehicle speed to 60 km/h or 37 MPH. NOTE: The speed difference between front and rear wheels may light the ABS warning light, but this indicates no malfunction. When AT control diagnosis is finished, perform the ABS memory clearance procedure of on-board diagnostics system. <Ref. to ABS-22, Clear Memory Mode.> CHECK POOR CONTACT.
Is there poor contact in front vehicle speed sensor circuit?
AT-62

MEMO:
AT-63
F: TROUBLE CODE 36 TORQUE CONVERTER TURBINE SPEED SENSOR

S004509D17
DIAGNOSIS: Input signal circuit of TCM is open or shorted. TROUBLE SYMPTOM: Excessive shift shock. WIRING DIAGRAM:
S3M0630
AT-64

No. 1 Step CHECK TORQUE CONVERTER TURBINE SPEED SENSOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from transmission. 3) Measure resistance between transmission connector receptacles terminals. Connector & terminal (T4) No. 14 No. 15: CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. 1) Disconnect connector from TCM. 2) Measure resistance of harness between TCM and transmission connector. Connector & terminal (B55) No. 8 (B11) No. 14: CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. Measure resistance of harness between TCM and transmission connector. Connector & terminal (B55) No. 9 (B11) No. 15: Check Is the resistance between 450 and 650 ? Yes Go to step 2.

No Replace turbine speed sensor. <Ref. to AT-37, Torque Converter Turbine Speed Sensor.>
Go to step 3.
Go to step 4.
CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. Measure resistance of harness between TCM and chassis ground. Connector & terminal (B55) No. 9 Chassis ground: CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. Measure resistance of harness between TCM and chassis ground. Connector & terminal (B55) No. 8 Chassis ground:
Repair open circuit in harness between TCM and transmission connector, and poor contact in coupling connector. Repair short circuit in harness between TCM and transmission connector. Repair short circuit in harness between TCM and transmission connector, and poor contact in coupling connector. Go to step 7. Go to step 8.
6 7 8
PREPARE OSCILLOSCOPE. PREPARE SUBARU SELECT MONITOR. CHECK INPUT SIGNAL FOR TCM. 1) Connect connectors to TCM and transmission. 2) Start the engine and move select lever to P or N range. 3) Measure voltage between TCM connector terminals. Connector & terminal (B55) No. 8 (+) No. 9 ():
Do you have oscilloscope? Do you have a Subaru Select Monitor? Is the voltage more than AC 1 V?
Even if POWER Go to step 11. indicator lights up, the circuit has returned to a normal condition at this time. A temporary poor contact of the connector or harness may be the cause. Repair harness or connector in the TCM and transmission.
AT-65

No. 9

Check Is the revolution value same as the tachometer reading shown on the combination meter? Yes Even if POWER indicator lights up, the circuit has returned to a normal condition at this time. A temporary poor contact of the connector or harness may be the cause. Repair harness or connector in the TCM and transmission. Even if POWER indicator lights up, the circuit has returned to a normal condition at this time. A temporary poor contact of the connector or harness may be the cause. Repair harness or connector in the TCM and transmission. Repair poor contact. No Go to step 11.
10
Step CHECK INPUT SIGNAL FOR TCM USING SUBARU SELECT MONITOR. 1) Connect connectors to TCM and transmission. 2) Connect Subaru Select Monitor to data link connector. 3) Turn ignition switch to ON and turn Subaru Select Monitor switch to ON. 4) Start the engine. 5) Move select lever to P or N range. 6) Read data of turbine speed using Subaru Select Monitor. Compare tachometer with Subaru Select Monitor indications. CHECK INPUT SIGNAL FOR TCM USING OSCILLOSCOPE. 1) Connect connectors to TCM and transmission. 2) Set oscilloscope to TCM connector terminals. Positive probe; (B55) No. 8 Earth lead; (B55) No. 9 3) Start the engine and move select lever to P or N range.
Is the signal voltage more than AC 1 V?
Go to step 11.
11
CHECK POOR CONTACT.
Is there poor contact in torque converter turbine speed sensor circuit?
AT-66

MEMO:
AT-67

S004509D26
G: TROUBLE CODE 38 TORQUE CONTROL SIGNAL

DIAGNOSIS: The signal circuit is open or shorted. TROUBLE SYMPTOM: Excessive shift shock. WIRING DIAGRAM:
S3M0631
No. 1
Step CHECK HARNESS CONNECTOR BETWEEN TCM AND ECM. 1) Turn ignition switch to OFF. 2) Disconnect connectors from TCM and ECM. 3) Measure resistance of harness between TCM and ECM connector. Connector & terminal SOHC without OBD: (B56) No. 14 (B84) No. 7: (B56) No. 5 (B84) No. 18: SOHC: (B56) No. 14 (B135) No. 17: (B56) No. 5 (B135) No. 16: DOHC TURBO: (B56) No. 14 (B134) No. 18: (B56) No. 5 (B134) No. 19: CHECK HARNESS CONNECTOR BETWEEN TCM AND ECM. Measure resistance of harness between TCM connector and chassis ground. Connector & terminal (B56) No. 14 Chassis ground: (B56) No. 5 Chassis ground:
Check Is the resistance less than 1 ?
Yes Go to step 2.
No Repair open circuit in harness between TCM and ECM connector.
AT-68

No. 3 Step Check CHECK OUTPUT SIGNAL EMITTED FROM Is the voltage more than 4.8 V? TCM. 1) Connect connectors to TCM and ECM. 2) Turn ignition switch to ON (engine OFF). 3) Measure voltage between TCM connector terminals. Connector & terminal (B56) No. 14 (+) Chassis ground (): (B56) No. 5 (+) Chassis ground ():

Yes No Even if POWER Go to step 4. indicator lights up, the circuit has returned to a normal condition at this time. A temporary poor contact of the connector or harness may be the cause. Repair harness or connector in the TCM and ECM. Repair poor con- Go to step 5. tact. Go to step 6.
CHECK POOR CONTACT.
CHECK GROUND LINE BETWEEN TRANSMISSION AND BODY. Check installing condition of ground line in transmission and body. CHECK GROUND LINE BETWEEN TRANSMISSION AND BODY. Check installing condition of ground line in transmission and body. Tightening torque: 133 Nm (1.30.3 kgf-m, 9.42.2 ft-lb) CHECK GROUND LINE INSIDE TRANSMISSION. 1) Drain AT fluid and remove oil pan. 2) Check tightening torque value of ground line installing bolt. Tightening torque: T: 81 Nm (0.80.1 kgf-m, 5.80.7 ft-lb) CHECK GROUND CIRCUIT OF ECM. <Ref. to AT-50, TROUBLE CODE 31 THROTTLE POSITION SENSOR -, Diagnostic Procedure with Trouble Code.> RECHECK OUTPUT SIGNAL EMITTED FROM TCM. Measure voltage between TCM connector and chassis ground. Connector & terminal (B56) No. 14 (+) Chassis ground (): (B56) No. 5 (+) Chassis ground ():
Is there poor contact in torque control signal circuit? Is there any dirt or rust at Remove dirt and ground line installing point? rust.
Is tightening torque value within specification?
Go to step 7.
Tighten to specified torque.
Is tightening torque value within specification?
Go to step 9.
Tighten to specified torque.
Is there any trouble?
Is each voltage more than 4.8 V?
Repair ground terminal and/or ground circuit of ECM. Replace TCM. <Ref. to AT-48, Transmission Control Module (TCM).>
Go to step 9.
Replace ECM.
AT-69

S004509D48
H: TROUBLE CODE 45 INTAKE MANIFOLD PRESSURE SIGNAL

DIAGNOSIS: Input signal circuit of TCM from ECM is open or shorted. TROUBLE SYMPTOM: Excessive shift shock. WIRING DIAGRAM:
S3M0632
No. 1
Step CHECK ENGINE GROUND TERMINALS AND GROUND CIRCUIT OF ECM <Ref. to AT-50, TROUBLE CODE 31 THROTTLE POSITION SENSOR -, Diagnostic Procedure with Trouble Code.> CHECK HARNESS CONNECTOR BETWEEN TCM AND ECM. 1) Turn ignition switch to OFF. 2) Disconnect connectors from TCM and ECM. 3) Measure resistance of harness between TCM and ECM connector. Connector & terminal SOHC without OBD: (B54) No. 1 (B84) No. 29: SOHC: (B54) No. 1 (B136) No. 11: CHECK HARNESS CONNECTOR BETWEEN TCM AND ECM. Measure resistance of harness between TCM connector and chassis ground. Connector & terminal (B54) No. 1 Chassis ground:
Check Is there any trouble?
Yes Repair ground terminal and/or ground circuit of ECM. Go to step 3.
No Go to step 2.
AT-70

No. 4 5 Step PREPARE SUBARU SELECT MONITOR. Check Do you have a Subaru Select Monitor? Is the voltage between 0.4 and 1.8 V? Yes Go to step 6.

No Go to step 5. Go to step 7.
CHECK INPUT SIGNAL FOR TCM. 1) Connect connectors to TCM and ECM. 2) Start the engine, and warm-up the transmission until ATF temperature is above 80C (176F). NOTE: If ambient temperature is below 0C (32F), drive the vehicle until the ATF reaches its operating temperature. 3) Engine idling. 4) Measure voltage between TCM connector and chassis ground. Connector & terminal (B54) No. 1 (+) Chassis ground (): Is the value between 0.4 CHECK INPUT SIGNAL FOR TCM USING and 1.8 V? SUBARU SELECT MONITOR. 1) Connect connectors to TCM and ECM. 2) Connect Subaru Select Monitor to data link connector. 3) Start the engine, and turn Subaru Select monitor switch to ON. 4) Warm-up the engine until engine coolant temperature is above 80C (176F). 5) Engine idling. 6) Read data of intake manifold pressure signal using Subaru Select Monitor. Display shows intake manifold pressure signal value sent from ECM. CHECK POOR CONTACT. Is there poor contact in intake manifold pressure signal circuit?
Even if POWER indicator lights up, the circuit has returned to a normal condition at this time. A temporary poor contact of the connector or harness may be the cause. Repair harness or connector in the TCM and ECM. Even if POWER indicator lights up, the circuit has returned to a normal condition at this time. A temporary poor contact of the connector or harness may be the cause. Repair harness or connector in the TCM and ECM. Repair poor contact.
Go to step 7.
AT-71

S004509D91
I: TROUBLE CODE 71 SHIFT SOLENOID 1

DIAGNOSIS: Output signal circuit of shift solenoid 1 is open or shorted. TROUBLE SYMPTOM: Does not shift. WIRING DIAGRAM:
TR0410
No. 1
Step Check Is the resistance less than CHECK HARNESS CONNECTOR 1 ? BETWEEN TCM AND TRANSMISSION. 1) Turn ignition switch to OFF. 2) Disconnect connector from TCM and transmission. 3) Measure resistance of harness between TCM and shift solenoid 1 connector. Connector & terminal (B54) No. 22 (B11) No. 1:
Yes Go to step 2.
AT-72

No. 2 Step CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. Measure resistance of harness between TCM connector and chassis ground. Connector & terminal (B54) No. 22 Chassis ground: CHECK SHIFT SOLENOID 1. Measure resistance between transmission connector terminals. Connector & terminal (T4) No. 1 No. 16: CHECK OUTPUT SIGNAL EMITTED FROM TCM. 1) Connect connectors to TCM and transmission. 2) Turn ignition switch to ON (engine OFF). 3) Move select lever to D range. 4) Measure voltage between TCM connector and chassis ground. Connector & terminal (B54) No. 22 (+) Chassis ground (): CHECK OUTPUT SIGNAL EMITTED FROM TCM. 1) Hold switch to ON. 2) Measure voltage between TCM connector and chassis ground. Connector & terminal (B54) No. 22 (+) Chassis ground (): Check Yes Is the resistance more than Go to step 3. 1 M?

No Repair short circuit in harness between TCM and transmission connector. Go to step 7.
Go to step 4.
Go to step 5.
Go to step 6.
Is the voltage less than 1V?
CHECK POOR CONTACT.
Is there poor contact in shift solenoid 1 circuit?
CHECK SHIFT SOLENOID 1 (IN TRANSMIS- Is the resistance between 10 and 16 ? SION). 1) Remove transmission connector from bracket. 2) Lift-up or raise the vehicle and support with safety stand. CAUTION: On AWD models, raise all wheels off ground. 3) Drain automatic transmission fluid. CAUTION: Do not drain the automatic transmission fluid until it cools down. 4) Remove oil pan, and disconnect connector from shift solenoid 1. 5) Measure resistance between shift solenoid 1 connector and transmission ground. Terminal No. 1 Transmission ground:
Even if POWER Go to step 6. indicator lights up, the circuit has returned to a normal condition at this time. A temporary poor contact of the connector or harness may be the cause. Repair harness or contact in the TCM. Repair poor con- Replace TCM. tact. <Ref. to AT-48, Transmission Control Module (TCM).> Go to step 8. Replace shift solenoid 1. <Ref. to AT-48, Transmission Control Module (TCM).>
AT-73

No. 8

Check Is the resistance less than 1 ? Yes Go to step 9. No Repair open circuit in harness between shift solenoid 1 and transmission connector. Repair short circuit harness between shift solenoid 1 and transmission connector.
Step CHECK HARNESS CONNECTOR BETWEEN SHIFT SOLENOID 1 AND TRANSMISSION. Measure resistance of harness between shift solenoid 1 and transmission connector. Connector & terminal (AT5) No. 1 (T4) No. 1: CHECK HARNESS CONNECTOR BETWEEN SHIFT SOLENOID 1 AND TRANSMISSION. Measure resistance of harness between shift solenoid 1 connector and transmission ground. Connector & terminal (T4) No. 1 Transmission ground:
Is the resistance more than Even if POWER 1 M? indicator lights up, the circuit has returned to a normal condition at this time. A temporary poor contact of the connector or harness may be the cause. Repair harness or connector in shift solenoid 1 and transmission.
AT-74

MEMO:
AT-75

S004509D98
J: TROUBLE CODE 72 SHIFT SOLENOID 2

DIAGNOSIS: Output signal circuit of shift solenoid 2 is open or shorted. TROUBLE SYMPTOM: Does not shift. WIRING DIAGRAM:
TR0411
No. 1
Step Check Is the resistance less than CHECK HARNESS CONNECTOR 1 ? BETWEEN TCM AND TRANSMISSION. 1) Turn ignition switch to OFF. 2) Disconnect connector from TCM and transmission. 3) Measure resistance of harness between TCM and shift solenoid 2 connector. Connector & terminal (B54) No. 5 (B11) No. 2:
Yes Go to step 2.
AT-76

No. 2 Step CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. Measure resistance of harness between TCM connector and transmission ground. Connector & terminal (B54) No. 5 Transmission ground: CHECK SHIFT SOLENOID 2. Measure resistance between transmission connector terminals. Connector & terminal (T4) No. 2 No. 16: CHECK OUTPUT SIGNAL EMITTED FROM TCM. 1) Connect connectors to TCM and transmission. 2) Lift-up or raise the vehicle and support with safety stand. CAUTION: On AWD models, raise all wheels off ground. 3) Start the engine and warm-up the transmission until ATF temperature is above 80C (176F). NOTE: If ambient temperature is below 0C (32F), drive the vehicle until the ATF reaches its operating temperature. 4) Move selector lever to D, and slowly increase vehicle speed to 50 km/h (31 MPH). NOTE: The speed difference between front and rear wheels may light the ABS warning light, but this indicates no malfunction. When AT control diagnosis is finished, perform the ABS memory clearance procedure of on-board diagnostics system. <Ref. to ABS-22, Clear Memory Mode.> 5) Measure voltage between TCM connector and chassis ground. Connector & terminal (B54) No. 22 (+) Chassis ground (): CHECK POOR CONTACT. Check Yes Is the resistance more than Go to step 3. 1 M?

Go to step 4.
Is there poor contact in shift solenoid 2 circuit?
CHECK SHIFT SOLENOID 2 (IN TRANSMIS- Is the resistance between 10 and 16 ? SION). 1) Remove transmission connector from bracket. 2) Drain automatic transmission fluid. CAUTION: Do not drain the automatic transmission fluid until it cools down. 3) Remove oil pan, and disconnect connector from shift solenoid 2. 4) Measure resistance between shift solenoid 2 connector and transmission ground. Connector & terminal No. 1 Transmission ground:
Go to step 7.
Replace TCM. <Ref. to AT-48, Transmission Control Module (TCM).> Replace shift solenoid 2 assembly. <Ref. to AT-41, Shift Solenoids, Duty Solenoids and ATF Temperature Sensor.>
AT-77

No. 7

Check Is the resistance less than 1 ? Yes Go to step 8. No Repair open circuit in harness between shift solenoid 2 and transmission connector. Repair short circuit harness between shift solenoid 2 and transmission connector.
Step CHECK HARNESS CONNECTOR BETWEEN SHIFT SOLENOID 2 AND TRANSMISSION. Measure resistance of harness between shift solenoid 2 and transmission connector. Connector & terminal (AT6) No. 1 (T4) No. 2: CHECK HARNESS CONNECTOR BETWEEN SHIFT SOLENOID 2 AND TRANSMISSION. Measure resistance of harness between shift solenoid 2 connector and transmission ground. Connector & terminal (T4) No. 2 Transmission ground:
Is the resistance more than Even if POWER 1 M? indicator lights up, the circuit has returned to a normal condition at this time. A temporary poor contact of the connector or harness may be the cause. Repair harness or connector in shift solenoid 2 and transmission.
AT-78

MEMO:
AT-79

S004509E05
K: TROUBLE CODE 73 LOW CLUTCH TIMING SOLENOID

DIAGNOSIS: Output signal circuit of low clutch timing solenoid is open or shorted. TROUBLE SYMPTOM: Excessive shift shock. WIRING DIAGRAM:
TR0412
No. 1
Step Check Is the resistance less than CHECK HARNESS CONNECTOR 1 ? BETWEEN TCM AND TRANSMISSION. 1) Turn ignition switch to OFF. 2) Disconnect connector from TCM and transmission. 3) Measure resistance of harness between TCM and transmission connector. Connector & terminal (B54) No. 15 (B11) No. 3:
Yes Go to step 2.
AT-80

No. 2 Step CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. Measure resistance of harness between TCM connector and transmission ground. Connector & terminal (B54) No. 15 Chassis ground: CHECK LOW CLUTCH TIMING SOLENOID. Measure resistance between transmission connector terminals. Connector & terminal (T4) No. 3 No. 16: CHECK OUTPUT SIGNAL EMITTED FROM TCM. 1) Connect connectors to TCM and transmission. 2) Turn ignition switch to ON (engine OFF). 3) Move select lever to D range. 4) Measure voltage between TCM connector and chassis ground. Connector & terminal (B54) No. 15 (+) Chassis ground (): CHECK OUTPUT SIGNAL EMITTED FROM TCM. 1) Hold switch to ON. 2) Measure voltage between TCM connector and chassis ground. Connector & terminal (B54) No. 15 (+) Chassis ground (): Check Yes Is the resistance more than Go to step 3. 1 M?

Go to step 4.
Go to step 5.
Go to step 6.
Even if POWER Go to step 6. indicator lights up, the circuit has returned to a normal condition at this time. A temporary poor contact of the connector or harness may be the cause. Repair harness or contact in the TCM and transmission. CHECK POOR CONTACT. Is there poor contact in low Repair poor con- Replace TCM. clutch timing solenoid cirtact. <Ref. to AT-48, cuit? Transmission Control Module (TCM).> Go to step 8. Replace low CHECK LOW CLUTCH TIMING SOLENOID Is the resistance between 10 and 16 ? clutch timing sole(IN TRANSMISSION). noid. <Ref. to 1) Remove transmission connector from AT-41, Shift bracket. Solenoids, Duty 2) Lift-up or raise the vehicle and support with Solenoids and safety stand. ATF Temperature CAUTION: Sensor.> On AWD models, raise all wheels off ground. 3) Drain automatic transmission fluid. CAUTION: Do not drain the automatic transmission fluid until it cools down. 4) Remove oil pan, and disconnect connector from low clutch timing solenoid. 5) Measure resistance between low clutch timing solenoid connector and transmission ground. Terminal No. 1 Transmission ground: Is the voltage less than 1V?
AT-81

No. 8

Check Is the resistance less than 1 ? Yes Go to step 9. No Repair open circuit in harness between low clutch timing solenoid and transmission connector. Repair short circuit harness between low clutch timing solenoid and transmission connector.
Step CHECK HARNESS CONNECTOR BETWEEN LOW CLUTCH TIMING SOLENOID AND TRANSMISSION. Measure resistance of harness between low clutch timing solenoid and transmission connector. Connector & terminal (AT9) No. 1 (T4) No. 3: CHECK HARNESS CONNECTOR BETWEEN LOW CLUTCH TIMING SOLENOID AND TRANSMISSION. Measure resistance of harness between low clutch timing solenoid connector and transmission ground. Connector & terminal (T4) No. 3 Transmission ground:
Is the resistance more than Even if POWER 1 M? indicator lights up, the circuit has returned to a normal condition at this time. A temporary poor contact of the connector or harness may be the cause. Repair harness or connector in low clutch timing solenoid and transmission.
AT-82

MEMO:
AT-83

S004509E07
L: TROUBLE CODE 74 2-4 BRAKE TIMING SOLENOID

DIAGNOSIS: Output signal circuit of 2-4 brake timing solenoid is open or shorted. TROUBLE SYMPTOM: Excessive shift shock. WIRING DIAGRAM:
TR0413
No. 1
Yes Go to step 2.
AT-84

No. 2 Step CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. Measure resistance of harness between TCM connector and transmission ground. Connector & terminal (B54) No. 16 Chassis ground: CHECK 2-4 BRAKE TIMING SOLENOID. Measure resistance between transmission connector terminals. Connector & terminal (T4) No. 4 No. 16: CHECK OUTPUT SIGNAL EMITTED FROM TCM. 1) Connect connectors to TCM and transmission. 2) Lift-up or raise the vehicle and support with safety stand. CAUTION: On AWD models, raise all wheels off ground. 3) Start the engine and warm-up the transmission until ATF temperature is above 80C (176F). NOTE: If ambient temperature is below 0C (32F), drive the vehicle until the ATF reaches its operating temperature. 4) Move selector lever to 1, and slowly increase vehicle speed to 10 km/h (6 MPH). NOTE: The speed difference between front and rear wheels may light the ABS warning light, but this indicates no malfunction. When AT control diagnosis is finished, perform the ABS memory clearance procedure of on-board diagnostics system. <Ref. to ABS-22, Clear Memory Mode.> 5) Measure voltage between TCM connector and chassis ground. Connector & terminal (B54) No. 16 (+) Chassis ground (): CHECK OUTPUT SIGNAL EMITTED FROM TCM. 1) Move selector lever to D, and slowly increase vehicle speed to 65 km/h (40 MPH). NOTE: The speed difference between front and rear wheels may light the ABS warning light, but this indicates no malfunction. When AT control diagnosis is finished, perform the ABS memory clearance procedure of on-board diagnostics system. <Ref. to ABS-22, Clear Memory Mode.> 2) Measure voltage between TCM connector and chassis ground. Connector & terminal (B54) No. 16 (+) Chassis ground (): Check Yes Is the resistance more than Go to step 3. 1 M?

Go to step 4.
Go to step 5.
Go to step 6.
Even if POWER Go to step 6. indicator lights up, the circuit has returned to a normal condition at this time. A temporary poor contact of the connector or harness may be the cause. Repair harness or contact in the transmission.
AT-85

No. 6 Step CHECK POOR CONTACT.

Check Yes Is there poor contact in 2-4 Repair poor contact. brake timing solenoid circuit? No Replace TCM. <Ref. to AT-48, Transmission Control Module (TCM).> Replace 2-4 brake timing solenoid. <Ref. to AT-41, Shift Solenoids, Duty Solenoids and ATF Temperature Sensor.>
CHECK 2-4 BRAKE TIMING SOLENOID (IN TRANSMISSION). 1) Remove transmission connector from bracket. 2) Lift-up or raise the vehicle and support with safety stand. CAUTION: On AWD models, raise all wheels off ground. 3) Drain automatic transmission fluid. CAUTION: Do not drain the automatic transmission fluid until it cools down. 4) Remove oil pan, and disconnect connector from 2-4 brake timing solenoid. 5) Measure resistance between 2-4 brake timing solenoid connector and transmission ground. Terminal No. 1 Transmission ground: CHECK HARNESS CONNECTOR BETWEEN 2-4 BRAKE TIMING SOLENOID AND TRANSMISSION. Measure resistance of harness between 2-4 brake timing solenoid and transmission connector. Connector & terminal (AT8) No. 1 (T4) No. 4: CHECK HARNESS CONNECTOR BETWEEN 2-4 BRAKE TIMING SOLENOID AND TRANSMISSION. Measure resistance of harness between 2-4 brake timing solenoid connector and transmission ground. Connector & terminal (T4) No. 4 Transmission ground:
Go to step 8.
Go to step 9.
Repair open circuit in harness between 2-4 brake timing solenoid and transmission connector. Repair short circuit harness between 2-4 brake timing solenoid and transmission connector.
Is the resistance more than Even if POWER 1 M? indicator lights up, the circuit has returned to a normal condition at this time. A temporary poor contact of the connector or harness may be the cause. Repair harness or connector in 2-4 brake timing solenoid and transmission.
AT-86

MEMO:
AT-87

S004509E14
M: TROUBLE CODE 75 LINE PRESSURE DUTY SOLENOID

DIAGNOSIS: Output signal circuit of line pressure duty solenoid is open or shorted. TROUBLE SYMPTOM: Excessive shift shock. WIRING DIAGRAM:
TR0414
No. 1
Step CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. 1) Turn ignition switch to OFF. 2) Disconnect connector from transmission and TCM. 3) Measure resistance of harness between TCM and transmission connector. Connector & terminal (B54) No. 9 (B11) No. 5: CHECK HARNESS CONNECTOR BETWEEN TCM AND CHASSIS GROUND. Measure resistance of harness between TCM and chassis ground. Connector & terminal (B54) No. 9 Chassis ground: CHECK LINE PRESSURE DUTY SOLENOID. Measure resistance between transmission connector receptacles terminals. Terminal (T4) No. 5 No. 16: PREPARE SUBARU SELECT MONITOR.
Yes Go to step 2.
Repair short circuit in harness between TCM and transmission connector. Go to step 10.
Go to step 4.
Go to step 7.
Go to step 5.
AT-88

No. 5 Step CHECK OUTPUT SIGNAL EMITTED FROM TCM. 1) Connect all connectors. 2) Start the engine and warm-up the transmission until ATF temperature is above 80C (176F). NOTE: If ambient temperature is below 0C (32F), drive the vehicle until the ATF reaches its operating temperature. 3) Turn ignition switch to ON (engine OFF). 4) Move select lever to N. 5) Measure voltage between TCM connector and chassis ground. Connector & terminal (B54) No. 9 (+) Chassis ground (): CHECK OUTPUT SIGNAL EMITTED FROM TCM. Measure voltage between TCM connector and chassis ground. Connector & terminal (B54) No. 9 (+) Chassis ground (): Check Is the voltage between 1.5 and 5.0 V with throttle fully closed? Yes Go to step 6.

No Go to step 9.
CHECK OUTPUT SIGNAL EMITTED FROM TCM USING SUBARU SELECT MONITOR. 1) Connect connectors to TCM and transmission. 2) Connect Subaru Select Monitor to data link connector. 3) Start the engine, and turn Subaru Select Monitor switch to ON. 4) Warm-up the transmission until ATF temperature is above 80C (176F). NOTE: If ambient temperature is below 0C (32F), drive the vehicle until the ATF reaches its operating temperature. 5) Stop the engine and turn ignition switch to ON (engine OFF). 6) Move select lever to N. 7) Read data of line pressure duty solenoid using Subaru Select Monitor. Line pressure duty solenoid is indicated in %. 8) Throttle is fully closed.
Is the voltage less than 1 V Even if POWER Go to step 9. with throttle fully open? indicator lights up, the circuit has returned to a normal condition at this time. A temporary poor contact of the connector or harness may be the cause. Repair harness or connector in transmission. Is the value 100%? Go to step 8. Go to step 9.
AT-89

No. 8

Check Is the value less than 25%?
10
11
12
Yes No Even if POWER Go to step 9. indicator lights up, the circuit has returned to a normal condition at this time. A temporary poor contact of the connector or harness may be the cause. Repair harness or connector in transmission. CHECK POOR CONTACT. Is there poor contact in line Repair poor con- Replace TCM. pressure duty solenoid cirtact. <Ref. to AT-48, cuit? Transmission Control Module (TCM).> Go to step 11. Replace line presCHECK LINE PRESSURE DUTY SOLENOID Is the resistance between 2.0 and 4.5 ? sure duty sole(IN TRANSMISSION). noid. <Ref. to 1) Remove transmission connector from AT-41, Shift bracket. Solenoids, Duty 2) Drain automatic transmission fluid. Solenoids and CAUTION: ATF Temperature Do not drain the automatic transmission Sensor.> fluid until it cools down. 3) Remove oil pan, and disconnect connector from line pressure duty solenoid. 4) Measure resistance between line pressure duty solenoid connector and transmission ground. Terminal No. 1 Transmission ground: Is the resistance less than Go to step 12. Repair open cirCHECK HARNESS CONNECTOR 1 ? cuit in harness BETWEEN TRANSMISSION AND LINE between line presPRESSURE DUTY SOLENOID. sure duty solenoid Measure resistance of harness between line and transmission pressure duty solenoid and transmission conconnector. nector. Connector & terminal (T4) No. 5 (AT2) No. 1: Is the resistance more than Even if POWER Repair short cirCHECK HARNESS CONNECTOR 1 M? indicator lights up, cuit in harness BETWEEN TRANSMISSION AND LINE between line presthe circuit has PRESSURE DUTY SOLENOID. returned to a nor- sure duty solenoid Measure resistance of harness between and transmission mal condition at transmission connector and transmission connector. this time. A temground. porary poor conConnector & terminal tact of the con(T4) No. 5 Transmission ground: nector or harness may be the cause. Repair harness or connector in line pressure duty solenoid and transmission.
Step CHECK OUTPUT SIGNAL EMITTED FROM TCM USING SUBARU SELECT MONITOR. 1) Turn ignition switch to ON (Engine OFF). 2) Throttle is fully open.
AT-90

MEMO:
AT-91

S004509E15
N: TROUBLE CODE 76 24 BRAKE DUTY SOLENOID

DIAGNOSIS: Output signal circuit of 2-4 brake duty solenoid is open or shorted. TROUBLE SYMPTOM: Excessive shift shock. WIRING DIAGRAM:
TR0415
No. 1
Step CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. 1) Turn ignition switch to OFF. 2) Disconnect connector from transmission and TCM. 3) Measure resistance of harness between TCM and transmission connector. Connector & terminal (B54) No. 18 (B11) No. 9: CHECK HARNESS CONNECTOR BETWEEN TCM AND CHASSIS GROUND. Measure resistance of harness between TCM and chassis ground. Connector & terminal (B54) No. 18 Chassis ground: CHECK 2-4 BRAKE DUTY SOLENOID. Measure resistance between transmission connector receptacles terminals. Terminal (T4) No. 16 No. 9: PREPARE SUBARU SELECT MONITOR.
Yes Go to step 2.
Go to step 4.
Go to step 7.
Go to step 5.
AT-92

No. 5 Step CHECK OUTPUT SIGNAL EMITTED FROM TCM. 1) Connect all connectors. 2) Start the engine and warm-up the transmission until ATF temperature is above 80C (176F). NOTE: If ambient temperature is below 0C (32F), drive the vehicle until the ATF reaches its operating temperature. 3) Turn ignition switch to ON (engine OFF). 4) Move select lever to N. 5) Measure voltage between TCM connector and chassis ground. Connector & terminal (B54) No. 18 (+) Chassis ground (): CHECK OUTPUT SIGNAL EMITTED FROM TCM. Measure voltage between TCM connector and chassis ground. Connector & terminal (B54) No. 18 (+) Chassis ground (): Check Is the voltage between 1.5 and 5.0 V with throttle fully closed? Yes Go to step 6.

No Go to step 9.
CHECK OUTPUT SIGNAL EMITTED FROM TCM USING SUBARU SELECT MONITOR. 1) Connect all connectors. 2) Connect Subaru Select Monitor to data link connector. 3) Start the engine, and turn Subaru Select Monitor switch to ON. 4) Warm-up the transmission until ATF temperature is above 80C (176F). NOTE: If ambient temperature is below 0C (32F), drive the vehicle until the ATF reaches its operating temperature. 5) Stop the engine and turn ignition switch to ON (engine OFF). 6) Move select lever to N. 7) Read data of 2-4 brake duty solenoid using Subaru Select Monitor. 2-4 brake duty solenoid is indicated in %. 8) Throttle is fully closed.
Is the voltage less than 1 V Even if POWER Go to step 9. with throttle fully open? indicator lights up, the circuit has returned to a normal condition at this time. A temporary poor contact of the connector or harness may be the cause. Repair harness or connector in TCM and transmission. Is the value 100%? Go to step 8. Go to step 9.
AT-93

No. 8

Check Is the value less than 25%? Yes No Even if POWER Go to step 9. indicator lights up, the circuit has returned to a normal condition at this time. A temporary poor contact of the connector or harness may be the cause. Repair harness or connector in TCM and transmission. Is there poor contact in 2-4 Repair poor con- Replace TCM. brake duty solenoid circuit? tact. <Ref. to AT-48, Transmission Control Module (TCM).> Is the resistance between Go to step 11. Replace 2-4 brake 2.0 and 4.5 ? duty solenoid. <Ref. to AT-41, Shift Solenoids, Duty Solenoids and ATF Temperature Sensor.>
Step CHECK OUTPUT SIGNAL EMITTED FROM TCM USING SUBARU SELECT MONITOR. 1) Turn ignition switch to ON (Engine OFF). 2) Throttle is fully open.
CHECK POOR CONTACT.
10
11
12
CHECK 2-4 BRAKE DUTY SOLENOID (IN TRANSMISSION). 1) Remove transmission connector from bracket. 2) Drain automatic transmission fluid. CAUTION: Do not drain the automatic transmission fluid until it cools down. 3) Remove oil pan, and disconnect connector from 2-4 brake duty solenoid. 4) Measure resistance between 2-4 brake duty solenoid connector and transmission ground. Terminal No. 1 Transmission ground: CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND 2-4 BRAKE DUTY SOLENOID. Measure resistance of harness between 2-4 brake duty solenoid and transmission connector. Connector & terminal (T4) No. 9 (AT7) No. 1: CHECK HARNESS CONNECTOR BETWEEN TRANSMISSION AND 2-4 BRAKE DUTY SOLENOID. Measure resistance of harness between transmission connector and transmission ground. Connector & terminal (T4) No. 9 Transmission ground:
Go to step 12.
Repair open circuit in harness between 2-4 brake duty solenoid and transmission connector. Repair short circuit in harness between 2-4 brake duty solenoid and transmission connector.
Is the resistance more than Even if POWER 1 M? indicator lights up, the circuit has returned to a normal condition at this time. A temporary poor contact of the connector or harness may be the cause. Repair harness or connector in line pressure duty solenoid and transmission.
AT-94

MEMO:
AT-95

S004509E16
O: TROUBLE CODE 77 LOCK-UP DUTY SOLENOID

DIAGNOSIS: Output signal circuit of lock-up duty solenoid is open or shorted. TROUBLE SYMPTOM: No lock-up (after engine warm-up). WIRING DIAGRAM:
TR0416
No. 1
Step CHECK TROUBLE CODE.
Check Do multiple trouble codes appear in the on-board diagnostics test mode?
Yes Go to another trouble code.
No Go to step 2.
AT-96

No. 2 Step CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. 1) Turn ignition switch to OFF. 2) Disconnect connector from TCM and transmission. 3) Measure resistance of harness between TCM and transmission connector. Connector & terminal (B54) No. 7 (B11) No. 13: CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. Measure resistance of harness connector between TCM and chassis ground. Connector & terminal (B54) No. 7 Chassis ground: CHECK LOCK-UP DUTY SOLENOID. Measure resistance between transmission connector receptacles terminals. Connector & terminal (T4) No. 13 No. 16: PREPARE SUBARU SELECT MONITOR. CHECK OUTPUT SIGNAL EMITTED FROM TCM. 1) Connect connectors to TCM and transmission. 2) Lift-up the vehicle and place safety stand. CAUTION: On AWD models, raise all wheels off ground. 3) Start the engine and warm-up the transmission until ATF temperature is above 80C (176F). NOTE: If ambient temperature is below 0C (32F), drive the vehicle until the ATF reaches its operating temperature. 4) Move selector lever to D and slowly increase vehicle speed to 75 km/h (47 MPH). Wheels will lock-up. NOTE: The speed difference between front and rear wheels may light the ABS warning light, but this indicates no malfunction. When AT control diagnosis is finished, perform the ABS memory clearance procedure of on-board diagnostics system. <Ref. to ABS-22, Clear Memory Mode.> 5) Measure voltage between TCM connector and chassis ground. Connector & terminal (B54) No. 7 (+) Chassis ground (): Check Is the resistance less than 1 ? Yes Go to step 3.

Go to step 5.
5 6
Do you have a Subaru Select Monitor? Is the voltage more than 8.5 V?
AT-97

No. 7

Check Yes No Is the voltage less than 0.5 Even if POWER Go to step 10. V? indicator lights up, the circuit has returned to a normal condition at this time. A temporary poor contact of the connector or harness may be the cause. Repair harness or connector in TCM and transmission. Is the value 95%? Go to step 9. Go to step 10.
Step CHECK OUTPUT SIGNAL EMITTED FROM TCM. 1) Return the engine to idling speed and move select lever to N. 2) Measure voltage between TCM connector and chassis ground. Connector & terminal (B54) No. 7 (+) Chassis ground ():
CHECK OUTPUT SIGNAL EMITTED FROM TCM USING SUBARU SELECT MONITOR. 1) Connect connectors to TCM and transmission. 2) Lift-up the vehicle and place safety stand. CAUTION: On AWD models, raise all wheels off ground. 3) Connect Subaru Select Monitor to data link connector. 4) Start the engine, and turn Subaru Select Monitor switch to ON. 5) Start the engine and warm-up the transmission until ATF temperature is above 80C (176F). NOTE: If ambient temperature is below 0C (32F), drive the vehicle until the ATF reaches its operating temperature. 6) Read data of lock-up duty solenoid using Subaru Select Monitor. Lock-up duty solenoid is indicated in %. 7) Move selector lever to D and slowly increase vehicle speed to 75 km/h (47 MPH). Wheels will lock-up. NOTE: The speed difference between front and rear wheels may light the ABS warning light, but this indicates no malfunction. When AT control diagnosis is finished, perform the ABS memory clearance procedure of on-board diagnostics system. <Ref. to ABS-22, Clear Memory Mode.> CHECK OUTPUT SIGNAL EMITTED FROM Is the value 5%? TCM USING SUBARU SELECT MONITOR. Return the engine to idling speed and move selector lever to N. NOTE: The speed difference between front and rear wheels may light the ABS warning light, but this indicates no malfunction. When AT control diagnosis is finished, perform the ABS memory clearance procedure of on-board diagnostics system. <Ref. to ABS-22, Clear Memory Mode.>
Even if POWER Go to step 10. indicator lights up, the circuit has returned to a normal condition at this time. A temporary poor contact of the connector or harness may be the cause. Repair harness or connector in TCM and transmission.
AT-98

No. 10 Step CHECK POOR CONTACT. Check Is there poor contact in lock-up duty solenoid circuit? Yes Repair poor contact.

No Replace TCM. <Ref. to AT-48, Transmission Control Module (TCM).> Replace lock-up duty solenoid. <Ref. to AT-41, Shift Solenoids, Duty Solenoids and ATF Temperature Sensor.>
11
12
13
CHECK LOCK-UP DUTY SOLENOID (IN TRANSMISSION). 1) Remove transmission connector from bracket. 2) Drain automatic transmission fluid. CAUTION: Do not drain the automatic transmission fluid until it cools down. 3) Remove oil pan, and disconnect connector from lock-up duty solenoid. 4) Measure resistance between lock-up duty solenoid connector and transmission ground. Terminal No. 1 Transmission ground: CHECK HARNESS CONNECTOR BETWEEN LOCK-UP DUTY SOLENOID AND TRANSMISSION. Measure resistance of harness between lock-up duty solenoid and transmission connector. Connector & terminal (T4) No. 13 (AT3) No. 1: CHECK HARNESS CONNECTOR BETWEEN LOCK-UP DUTY SOLENOID AND TRANSMISSION. Measure resistance of harness between transmission connector and transmission ground. Connector & terminal (T4) No. 13 Transmission ground:
Go to step 12.
Go to step 13.
Is the resistance more than Even if POWER 1 M? indicator lights up, the circuit has returned to a normal condition at this time. A temporary poor contact of the connector or harness may be the cause. Repair harness or connector in lock-up duty solenoid and transmission.
Repair short circuit in harness between lock-up duty solenoid and transmission connector.
AT-99

S004509E17
P: TROUBLE CODE 79 TRANSFER DUTY SOLENOID

DIAGNOSIS: Output signal circuit of transfer duty solenoid is open or shorted. TROUBLE SYMPTOM: Excessive braking in tight corners. WIRING DIAGRAM:
TR0417
No. 1
Yes Go to step 2.
AT-100

No. 2 Step CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. Measure resistance harness connector between TCM and chassis ground. Connector & terminal (B54) No. 6 Chassis ground: CHECK TRANSFER DUTY SOLENOID. Measure resistance between transmission connector and transmission terminals. Connector & terminal (T4) No. 6 No. 16: PREPARE SUBARU SELECT MONITOR. Check Yes Is the resistance more than Go to step 3. 1 M?

Go to step 4.
4 5
CHECK OUTPUT SIGNAL EMITTED FROM TCM. 1) Connect connectors to TCM and transmission. 2) Turn ignition switch to ON (engine OFF). 3) Throttle is fully closed. 4) Measure voltage between TCM connector and chassis ground. Connector & terminal (B54) No. 6 (+) Chassis ground (): CHECK OUTPUT SIGNAL EMITTED FROM Is the voltage between 5 and 7 V in D range? TCM. Measure voltage between TCM connector and chassis ground. Connector & terminal (B54) No. 6 (+) Chassis ground ():
Do you have a Subaru Go to step 7. Select Monitor? Is the voltage less than 1 V Go to step 6. in P range?
CHECK OUTPUT SIGNAL EMITTED FROM TCM USING SUBARU SELECT MONITOR. 1) Connect connectors to TCM and transmission. 2) Connect Subaru Select Monitor to data link connector. 3) Turn ignition switch to ON (engine OFF) and turn Subaru Select Monitor switch to ON. 4) Move select lever to D with throttle fully open (vehicle speed 0 km/h or 0 MPH). 5) Read data of transfer duty solenoid using Subaru Select Monitor. Transfer duty solenoid is indicated in %.
Even if POWER Go to step 9. indicator lights up, the circuit has returned to a normal condition at this time. A temporary poor contact of the connector or harness may be the cause. Repair harness or connector in the TCM and transmission. Is the value between 5 and Go to step 8. Go to step 9. 10%?
AT-101

No. 8

Check Is the value between approx. 60% and approx. 70%? Yes No Even if POWER Go to step 9. indicator lights up, the circuit has returned to a normal condition at this time. A temporary poor contact of the connector or harness may be the cause. Repair harness or connector in the TCM and transmission. Repair poor con- Replace TCM. tact. <Ref. to AT-48, Transmission Control Module (TCM).> Go to step 11. Replace transfer duty solenoid.
Step CHECK OUTPUT SIGNAL EMITTED FROM TCM USING SUBARU SELECT MONITOR. 1) Move select lever to N with throttle fully closed (vehicle speed 0 km/h or 0 MPH). 2) Rear data of transfer duty solenoid using Subaru Select Monitor. Transfer duty solenoid is indicated in %.
CHECK POOR CONTACT.
Is there poor contact in transfer duty solenoid circuit?
10
11
12
CHECK TRANSFER DUTY SOLENOID (IN TRANSMISSION). 1) Lift-up the vehicle and place safety stand. CAUTION: On AWD models, raise all wheels off ground. 2) Drain automatic transmission fluid. CAUTION: Do not drain the automatic transmission fluid until it cools down. 3) Remove extension case, and disconnect connector from transfer duty solenoid. 4) Measure resistance between transfer duty solenoid connector and transmission ground. Connector & terminal (AT4) No. 1 Transmission ground: CHECK HARNESS CONNECTOR BETWEEN TRANSFER DUTY SOLENOID AND TRANSMISSION. Measure resistance of harness between transfer duty solenoid and transmission connector. Connector & terminal (T4) No. 6 (AT4) No. 1: CHECK HARNESS CONNECTOR BETWEEN TRANSFER DUTY SOLENOID AND TRANSMISSION. Measure resistance of harness between transmission connector and transmission ground. Connector & terminal (T4) No. 6 Transmission ground:
Go to step 12.
Repair open circuit in harness between transfer duty solenoid and transmission connector.
Is the resistance more than Even if POWER 1 M? indicator lights up, the circuit has returned to a normal condition at this time. A temporary poor contact of the connector or harness may be the cause. Repair harness or contact in the transfer duty solenoid and transmission.
Repair short circuit in harness between transfer duty solenoid and transmission connector.
AT-102

MEMO:
AT-103

S004509F61
Q: TROUBLE CODE 93 REAR VEHICLE SPEED SENSOR

DIAGNOSIS: Input signal circuit of TCM is open or shorted. TROUBLE SYMPTOM: No lock-up or excessive tight corner braking. WIRING DIAGRAM:
S3M0633
AT-104

No. 1 Step CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. 1) Turn ignition switch to OFF. 2) Disconnect connector from TCM and transmission. 3) Measure resistance of harness between TCM and transmission connector. Connector & terminal (B55) No. 24 (B11) No. 19: CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. Measure resistance of harness between TCM and transmission connector. Connector & terminal (B54) No. 19 (B11) No. 20: CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. Measure resistance of harness between TCM and chassis ground. Connector & terminal (B55) No. 24 Chassis ground: CHECK HARNESS CONNECTOR BETWEEN TCM AND TRANSMISSION. Measure resistance of harness between TCM and chassis ground. Connector & terminal (B54) No. 19 Chassis ground: CHECK REAR VEHICLE SPEED SENSOR. Measure resistance between transmission connector receptacles terminals. Connector & terminal (T4) No. 19 No. 20: PREPARE OSCILLOSCOPE. PREPARE SUBARU SELECT MONITOR. CHECK INPUT SIGNAL FOR TCM. 1) Connect connectors to TCM and transmission. 2) Lift-up or raise the vehicle and place safety stands. CAUTION: On AWD models, raise all wheels off floor. 3) Start the engine and set vehicle in 20 km/h (12 MPH) condition. NOTE: The speed difference between front and rear wheels may light the ABS warning light, but this indicates no malfunction. When AT control diagnosis is finished, perform the ABS memory clearance procedure of on-board diagnostics system. <Ref. to ABS-22, Clear Memory Mode.> 4) Measure voltage between TCM connector terminals. Connector & terminal (B55) No. 24 (+) (B54) No. 19 (): Check Is the resistance less than 1 ? Yes Go to step 2.

Go to step 3.
Repair open circuit in harness between TCM and transmission, and poor contact in coupling connector. Repair short circuit in harness between TCM and transmission connector. Repair short circuit in harness between TCM and transmission connector. Replace rear vehicle speed sensor. <Ref. to AT-36, Rear Vehicle Speed Sensor.> Go to step 7. Go to step 8.
Go to step 6.
6 7 8
Do you have oscilloscope? Do you have a Subaru Select Monitor? Is the voltage more than AC 1 V?
AT-105

No. 9

Check Does the speedometer indication increase as the Subaru Select Monitor data increases? Yes No Even if POWER Go to step 11. indicator lights up, the circuit has returned to a normal condition at this time. A temporary poor contact of the connector or harness may be the cause. Repair harness or connector in the TCM and transmission.
10
11
Step CHECK INPUT SIGNAL FOR TCM USING SUBARU SELECT MONITOR. 1) Connect connectors to TCM and transmission. 2) Connect Subaru Select Monitor to data link connector. 3) Lift-up or raise the vehicle and place safety stands. CAUTION: On AWD models, raise all wheels off floor. 4) Turn ignition switch to ON and turn Subaru Select Monitor switch to ON. 5) Start the engine. 6) Read data of vehicle speed using Subaru Select Monitor. Compare speedometer with Subaru Select Monitor indications. Vehicle speed is indicated in km/h or MPH. 7) Slowly increase vehicle speed to 60 km/h or 37 MPH. NOTE: The speed difference between front and rear wheels may light the ABS warning light, but this indicates no malfunction. When AT control diagnosis is finished, perform the ABS memory clearance procedure of on-board diagnostics system. <Ref. to ABS-22, Clear Memory Mode.> CHECK INPUT SIGNAL FOR TCM USING OSCILLOSCOPE. 1) Connect connectors to TCM and transmission. 2) Lift-up or raise the vehicle and place safety stands. CAUTION: On AWD models, raise all wheels off floor. 3) Set oscilloscope to TCM connector terminals. Positive probe; (B55) No. 24 Earth lead; (B54) No. 19 4) Start the engine and set vehicle in 20 km/h (12 MPH) condition. NOTE: The speed difference between front and rear wheels may light the ABS warning light, but this indicates no malfunction. When AT control diagnosis is finished, perform the ABS memory clearance procedure of on-board diagnostics system. <Ref. to ABS-22, Clear Memory Mode.> 5) Measure signal voltage indicated on oscilloscope. CHECK POOR CONTACT.
Is the signal voltage more than AC 1 V?
Is there poor contact in rear vehicle speed sensor circuit?
AT-106
DIAGNOSTIC PROCEDURE FOR NO-TROUBLE CODE

S004618
15. Diagnostic Procedure for No-trouble Code

A: CHECK GEAR POSITION.
No. 1
S004618F15
Step Check Does the transmission gear CHECK GEAR POSITION. correspond to the gear 1) Lift-up the vehicle and place safety stand. which is shown on display? CAUTION: On AWD models, raise all wheels off ground. 2) Start the engine. 3) Move select lever to D, and drive vehicle. 4) Read data of gear position using Subaru Select Monitor. Gear position is indicated. NOTE: The speed difference between front and rear wheels may light the ABS warning light, but this indicates no malfunction. When AT control diagnosis is finished, perform the ABS memory clearance procedure of on-board diagnostics system. <Ref. to ABS-22, Clear Memory Mode.>
Yes Go to step CHECK FWD SWITCH. <Ref. to AT-108, CHECK FWD SWITCH., Diagnostic Procedure for No-trouble Code.>
No Check shift solenoid 1 and shift solenoid 2 signal circuit. <Ref. to AT-72, TROUBLE CODE 71 - SHIFT SOLENOID 1 -, Diagnostic Procedure with Trouble Code.> and <Ref. to AT-76, TROUBLE CODE 72 - SHIFT SOLENOID 2 -, Diagnostic Procedure with Trouble Code.>
AT-107

S004618F16
B: CHECK FWD SWITCH.
DIAGNOSIS: LED does not come on even if FWD switch is ON. FWD switch circuit is open or short.
AT-108

WIRING DIAGRAM:
S3M0634
AT-109

No. 1 Step CHECK FWD SWITCH.

Check When fuse is inserted to FWD switch, does LED light up? Yes No Go to step 2. Go to step CHECK BRAKE SWITCH.<Ref. to AT-111, CHECK BRAKE SWITCH., Diagnostic Procedure for No-trouble Code.> Go to step 3. Replace FWD indicator light bulb. <Ref. to IDI15, Combination Meter Assembly.> Go to step 4. Repair open circuit in harness between TCM and FWD switch connector.
CHECK FWD INDICATOR LIGHT. 1) Turn ignition switch to OFF. 2) Remove combination meter. 3) Remove FWD indicator light bulb from combination meter. CHECK HARNESS CONNECTOR BETWEEN TCM AND FWD SWITCH. 1) Turn ignition switch to OFF. 2) Disconnect connector from TCM and FWD switch. 3) Measure resistance of harness between TCM and FWD switch connector. Connector & terminal (B55) No. 20 (F67) No. 30: CHECK HARNESS CONNECTOR BETWEEN FWD SWITCH AND CHASSIS GROUND. Measure resistance of harness between FWD switch and chassis ground. Connector & terminal (F67) No. 29 Chassis ground: CHECK HARNESS CONNECTOR BETWEEN TCM AND FWD SWITCH. Measure resistance of harness connector between TCM and body to make sure that circuit does not short. Connector & terminal (B55) No. 20 Chassis ground: CHECK INPUT SIGNAL FOR TCM. 1) Turn ignition switch to OFF. 2) Connect connector to TCM and FWD switch. 3) Turn ignition switch to ON. 4) Measure signal voltage for TCM while installing the fuse to FWD switch connector. Connector & terminal (B55) No. 20 (+) Chassis ground (): CHECK INPUT SIGNAL FOR TCM. Measure signal voltage for TCM while removing the fuse from FWD switch connector. Connector & terminal (B55) No. 20 (+) Chassis ground (): CHECK HARNESS CONNECTOR BETWEEN TCM AND COMBINATION METER. 1) Turn ignition switch to OFF. 2) Disconnect connector from TCM and combination meter. 3) Measure resistance of harness between TCM and diagnosis connector. Connector & terminal (B56) No. 2 (i11) No. 6:
Is FWD indicator light bulb OK?
Go to step 5.
Repair open circuit in harness between FWD switch connector and chassis ground. Repair short circuit in harness between TCM and FWD switch connector.
Is the voltage less than 1 V Go to step 7. in FWD switch while installing?
Go to step 11.
Is the voltage more than 6 V in FWD switch while removing?
Go to step 8.
Go to step 9.
Replace TCM. <Ref. to AT-48, Transmission Control Module (TCM).> Repair open circuit in harness between TCM and combination meter and poor contact in coupling connector.
AT-110

No. 9 Step CHECK HARNESS CONNECTOR BETWEEN TCM AND COMBINATION METER. Measure resistance of harness connector between TCM and chassis ground to make sure that circuit does not short. Connector & terminal (B56) No. 2 Chassis ground: CHECK OUTPUT SIGNAL EMITTED FROM TCM. 1) Turn ignition switch to OFF. 2) Connect connector to TCM and combination meter. 3) Turn ignition switch to ON. 4) Measure signal voltage for TCM while installing and removing the fuse to FWD switch connector. Connector & terminal (B56) No. 2 Chassis ground: CHECK OUTPUT SIGNAL EMITTED FROM TCM. Measure signal voltage for TCM while removing the fuse from FWD switch connector. Connector & terminal (B56) No. 2 Chassis ground: CHECK POOR CONTACT. Check Yes Is the resistance more than Go to step 10. 1 M?

No Repair short circuit in harness between TCM and combination meter connector.
10
Is the voltage less than 1 V Go to step 11. in FWD switch while installing?
Go to step 12.
11
Is the voltage more than 9 V in FWD switch while removing?
Go to step 12.
Replace TCM. <Ref. to AT-48, Transmission Control Module (TCM).> Replace TCM. <Ref. to AT-48, Transmission Control Module (TCM).>
12
Is there poor contact in FWD switch circuit?
C: CHECK BRAKE SWITCH.

No. 1 Step CHECK BRAKE SWITCH.
S004618F17
Check When the brake pedal is depressed, does LED light up?
Yes Go to step CHECK ABS SWITCH. <Ref. to AT-112, CHECK ABS SWITCH, Diagnostic Procedure for No-trouble Code.>
No Check brake switch circuit. <Ref. WI-58, A/T Control System.>
AT-111

S004618F18
D: CHECK ABS SWITCH.

No. 1 Step CHECK ABS SWITCH.
Check Does the LED of ABS switch light up?
Yes Check ABS switch circuit. <Ref. to ABS-134, TROUBLE CODE 44 - ABS-AT CONTROL (NON CONTROLLED) -, Diagnostics Chart with Subaru Select Monitor.> and <Ref. to ABS136, TROUBLE CODE 44 ABS-AT CONTROL (CONTROLLED) -, Diagnostics Chart with Subaru Select Monitor.>
No Go to step CHECK CRUISE CONTROL SWITCH. <Ref. to AT-112, CHECK CRUISE CONTROL SWITCH., Diagnostic Procedure for No-trouble Code.>
E: CHECK CRUISE CONTROL SWITCH.

No. 1 Step CHECK CRUISE CONTROL SWITCH.
S004618F19
Check When cruise control is set, does LED light up?
Yes Go to step CHECK KICKDOWN SWITCH. <Ref. to AT-114, CHECK KICKDOWN SWITCH., Diagnostic Procedure for No-trouble Code.>
No Check cruise control. <Ref. to CC-37, Diagnostics Chart with Trouble Code (Turbo Model).>, <Ref. to CC-57, Diagnostics Chart with Trouble Code (Non-Turbo Model).>
AT-112

MEMO:
AT-113

S004618G76
F: CHECK KICKDOWN SWITCH.
DIAGNOSIS: The kick-down switch is not ON when the throttle is fully open but is OFF when the throttle is partially open or fully closed. Kick-down switch circuit is open or short. TROUBLE SYMPTOM: No kick-down occurs (when the throttle is fully open). WIRING DIAGRAM:
B3M2169
AT-114

No. 1 Step Check Yes CHECK KICK-DOWN SWITCH OPERATION. When the accelerator pedal Go to step CHECK POWER is depressed, does ON MODE SWITCH. displayed? <Ref. to AT-118, CHECK POWER MODE SWITCH, Diagnostic Procedure for No-trouble Code.> Is the resistance less than Go to step 3. CHECK KICK-DOWN SWITCH GROUND 1 ? LINE. 1) Disconnect connector from kick-down switch. 2) Measure resistance of harness connector between kick-down switch and chassis ground. Connector & terminal (B129) No. 1 Chassis ground: Is the resistance less than Go to step 4. CHECK KICK-DOWN SWITCH. 1 ? Measure resistance for kick-down switch when depressing the accelerator pedal. Terminals No. 1 No. 2: Is the resistance more than Go to step 5. CHECK KICK-DOWN SWITCH. 1 M? Measure resistance for kick-down switch when pressing the accelerator pedal. Terminals No. 1 No. 2: Is the resistance less than Go to step 6. CHECK HARNESS CONNECTOR BETWEEN TCM AND KICK-DOWN SWITCH. 1 ? 1) Turn ignition switch OFF. 2) Disconnect connectors from kick-down switch. 3) Measure resistance of harness connector between TCM and kick-down switch. Connector & terminal (B55) No. 11 (B129) No. 2: Is the resistance more than Go to step 7. CHECK HARNESS CONNECTOR BETWEEN TCM AND KICK-DOWN SWITCH. 1 M? Measure resistance of harness connector between TCM and chassis ground. Connector & terminal (B55) No. 11 Chassis ground: Is the voltage less than 1 Go to step 8. CHECK INPUT SIGNAL FOR TCM. V? 1) Turn ignition switch to OFF. 2) Connect connector to kick-down switch. 3) Turn ignition switch ON (with engine OFF). 4) Measure signal voltage for TCM when depressing the accelerator pedal. Connector & terminal (B55) No. 11 (+) Chassis ground (): Is the voltage more than A temporary poor CHECK INPUT SIGNAL FOR TCM. contact of the Measure signal voltage for TCM when press- 6.5 V? connector and ing the accelerator pedal. harness may be Connector & terminal the cause. Repair (B55) No. 11 (+) Chassis ground (): harness and connector in the TCM.

No Go to step 2.
Repair open circuit in harness between kickdown switch and chassis ground.
Replace kickdown switch. <Ref. to SP-5, Accelerator Pedal.> Replace kickdown switch.
Repair open circuit in harness between TCM and kick-down switch.
Repair short circuit in harness between TCM and chassis ground.
Go to step 9.
Go to step 9.
AT-115

No. 9 Step CHECK POOR CONTACT.

Check Is there poor contact? Yes Repair poor contact. No Replace TCM. <Ref. to AT-48, Transmission Control Module (TCM).>
AT-116

MEMO:
AT-117

S004618G77
G: CHECK POWER MODE SWITCH.
DIAGNOSIS: LED does not come on when power switch is ON. Power switch circuit is open or shorted. TROUBLE SYMPTOM: No power mode occurs. WIRING DIAGRAM:
S3M0635
AT-118

No. 1 Step CHECK POWER SWITCH OPERATION. Check When power switch is turned OFF, does LED light up? When power switch is turned ON, does LED light up? Yes Go to step 5.

No Go to step 2.
CHECK POWER SWITCH OPERATION.
CHECK POWER INDICATOR LIGHT. 1) Turn ignition switch to OFF. 2) Remove combination meter. 3) Remove POWER indicator light bulb from combination meter. CHECK POWER SWITCH GROUND LINE. 1) Turn ignition switch to OFF. 2) Disconnect connector from power switch. 3) Measure resistance of harness connector between power switch and chassis ground. Connector & terminal (B116) No. 4 Chassis ground: CHECK POWER SWITCH. 1) Power switch turned ON. 2) Measure resistance between terminals of power switch. Terminals No. 3 No. 4: CHECK POWER SWITCH. 1) Power switch turned OFF. 2) Measure resistance between terminals of power switch. Terminals No. 3 No. 4: CHECK HARNESS CONNECTOR BETWEEN TCM AND POWER SWITCH. Measure resistance of harness connector between TCM and power switch. Connector & terminal (B55) No. 23 (B116) No. 3: CHECK HARNESS CONNECTOR BETWEEN TCM AND POWER SWITCH. Measure resistance of harness connector between TCM and chassis ground. Connector & terminal (B55) No. 23 Chassis ground: CHECK INPUT SIGNAL FOR TCM. 1) Connect connectors to TCM and power switch. 2) Turn ignition switch ON (with engine OFF). 3) Measure signal voltage for TCM while turning power switch OFF. Connector & terminal (B55) No. 23 (+) Chassis ground ():
Is POWER indicator light bulb OK?
Go to step 3. Go to step CHECK INHIBITOR SWITCH. <Ref. to AT-122, CHECK INHIBITOR SWITCH., Diagnostic Procedure for No-trouble Code.> Go to step 4. Replace POWER indicator light bulb. <Ref. to IDI15, Combination Meter Assembly.> Go to step 5. Repair open circuit in harness between power switch and chassis ground.
Go to step 6.
Repair power switch.
Repair power switch.
Go to step 8.
Repair open circuit in harness between TCM and power switch connector. Repair short circuit in harness between TCM and power switch connector. Replace TCM. <Ref. to AT-48, Transmission Control Module (TCM).>
AT-119

No. 10

Yes Go to step 11. No Replace TCM. <Ref. to AT-48, Transmission Control Module (TCM).> A temporary poor contact of the connector or harness in power switch circuit.
11
Step Check Is the voltage less than 1 CHECK INPUT SIGNAL FOR TCM. Measure signal voltage for TCM while turning V? power switch ON. Connector & terminal (B55) No. 23 (+) Chassis ground (): CHECK POOR CONTACT. Is there poor contact?
AT-120

MEMO:
AT-121

S004618F20
H: CHECK INHIBITOR SWITCH.
DIAGNOSIS: Input signal circuit of inhibitor switch is open or shorted. TROUBLE SYMPTOM: Shift characteristics are erroneous. Engine brake is not effected when selector lever is in 3 range. Engine brake is not effected when selector lever is in 2 range. Engine brake is not effected when selector lever is in 1 range.
AT-122

WIRING DIAGRAM:
S3M0636
No. 1
Step CHECK P RANGE SWITCH.
CHECK P RANGE SWITCH.
CHECK R RANGE SWITCH.
CHECK R RANGE SWITCH.
CHECK N RANGE SWITCH.
CHECK N RANGE SWITCH.
CHECK D RANGE SWITCH.
CHECK D RANGE SWITCH.
CHECK 3 RANGE SWITCH.
Check When P range is selected, does LED light up? When the R range is selected, does P range LED light up? When the R range is selected, does LED light up? When the N range is selected, does R range LED light up? When the N range is selected, does LED light up? When the D range is selected, does N range LED light up? When the D range is selected, does LED light up? When the 3 range is selected, does D range LED light up? When the 3 range is selected, does LED light up?
Yes Go to step 2.
No Go to step 15.
Go to step 19.
Go to step 3.
Go to step 4.
Go to step 20.
Go to step 23.
Go to step 5.
Go to step 6.
Go to step 24.
Go to step 27.
Go to step 7.
Go to step 8.
Go to step 28.
Go to step 31.
Go to step 9.
Go to step 10.
Go to step 32.
AT-123

No. 10

Check When the 2 range is selected, does 3 range LED light up? When the 2 range is selected, does LED light up? When the 1 range is selected, does 2 range LED light up? When the 1 range is selected, does LED light up? When the P range is selected, does 1 range LED light UP? Yes Go to step 35. No Go to step 11.
Step CHECK 3 RANGE SWITCH.
11
Go to step 12.
Go to step 36.
12
Go to step 39.
Go to step 13.
13
Go to step 14.
Go to step 40.
14
Go to step 43.
15
16
17
18
CHECK HARNESS CONNECTOR BETWEEN INHIBITOR SWITCH AND CHASSIS GROUND. 1) Turn ignition switch to OFF. 2) Disconnect connector from inhibitor switch. 3) Measure resistance of harness between inhibitor switch and chassis ground. Connector & terminal (T7) No. 5 Chassis ground: CHECK HARNESS CONNECTOR BETWEEN TCM AND INHIBITOR SWITCH. 1) Turn ignition switch to OFF. 2) Disconnect connectors from TCM and inhibitor switch. 3) Measure resistance of harness between TCM and inhibitor switch connector. Connector & terminal (B55) No. 1 (T7) No. 9 CHECK INPUT SIGNAL FOR TCM. 1) Turn ignition switch to OFF. 2) Connect connector to TCM and inhibitor switch. 3) Turn ignition switch to ON. 4) Measure voltage between TCM and chassis ground. Connector & terminal (B55) No. 1 (+) Chassis ground (): CHECK INPUT SIGNAL FOR TCM. Measure voltage between TCM and chassis ground. Connector & terminal (B55) No. 1 (+) Chassis ground ():
Go to step 16.
Go to step CHECK HOLD SWITCH. <Ref. to AT-130, CHECK HOLD SWITCH., Diagnostic Procedure for No-trouble Code.> Repair open circuit in harness between inhibitor switch connector and chassis ground, and poor contact in coupling connector. Repair open circuit in harness between TCM and inhibitor switch connector, and poor contact in coupling connector. Go to step 44.
Go to step 17.
Is the voltage less than 1 V Go to step 18. in P range?
Is the voltage more than 8 V in other ranges?
Go to step 44.
AT-124

No. 19 Step CHECK HARNESS CONNECTOR BETWEEN TCM AND INHIBITOR SWITCH. 1) Turn ignition switch to OFF. 2) Disconnect connectors from TCM, inhibitor switch and combination meter. 3) Measure resistance of harness between TCM and chassis ground. Connector & terminal (B55) No. 1 Chassis ground: CHECK HARNESS CONNECTOR BETWEEN TCM AND INHIBITOR SWITCH. 1) Turn ignition switch to OFF. 2) Disconnect connectors from TCM and inhibitor switch. 3) Measure resistance of harness between TCM and inhibitor switch connector. Connector & terminal (B55) No. 3 (T7) No. 8: CHECK INPUT SIGNAL FOR TCM. 1) Turn ignition switch to OFF. 2) Connect connector to TCM and inhibitor switch. 3) Turn ignition switch to ON. 4) Measure voltage between TCM and chassis ground. Connector & terminal (B55) No. 3 (+) Chassis ground (): CHECK INPUT SIGNAL FOR TCM. Measure voltage between TCM and chassis ground. Connector & terminal (B55) No. 3 (+) Chassis ground (): CHECK HARNESS CONNECTOR BETWEEN TCM AND INHIBITOR SWITCH. 1) Turn ignition switch to OFF. 2) Disconnect connectors from TCM, inhibitor switch and combination meter. 3) Measure resistance of harness between TCM and chassis ground. Connector & terminal (B55) No. 3 Chassis ground: CHECK HARNESS CONNECTOR BETWEEN TCM AND INHIBITOR SWITCH. 1) Turn ignition switch to OFF. 2) Disconnect connectors from TCM and inhibitor switch. 3) Measure resistance of harness between TCM and inhibitor switch connector. Connector & terminal (B55) No. 14 (T7) No. 10: CHECK INPUT SIGNAL FOR TCM. 1) Turn ignition switch to OFF. 2) Connect connector to TCM and inhibitor switch. 3) Turn ignition switch to ON. 4) Measure voltage between TCM and chassis ground. Connector & terminal (B55) No. 14 (+) Chassis ground (): Check Is the resistance less than 1 M? Yes Go to step 20.

No Repair ground short circuit in P range circuit.
20
Go to step 21.
Repair open circuit in harness between TCM and inhibitor switch connector, and poor contact in coupling connector. Go to step 44.
21
Is the voltage less than 1 V Go to step 22. in R range?
22
Go to step 44.
23
Replace TCM. <Ref. to AT-48, Transmission Control Module (TCM).> Repair ground short circuit in R range circuit.
24
Go to step 25.
25
Is the voltage less than 1 V Go to step 26. in N range?
AT-125

No. 26

Check Is the voltage more than 8 V in other ranges? Yes Go to step 44. No Replace TCM. <Ref. to AT-48, Transmission Control Module (TCM).> Repair ground short circuit in N range circuit.
27
28
29
30
31
32
Step CHECK INPUT SIGNAL FOR TCM. Measure voltage between TCM and chassis ground. Connector & terminal (B55) No. 14 (+) Chassis ground (): CHECK HARNESS CONNECTOR BETWEEN TCM AND INHIBITOR SWITCH. 1) Turn ignition switch to OFF. 2) Disconnect connectors from TCM, inhibitor switch and combination meter. 3) Measure resistance of harness between TCM and chassis ground. Connector & terminal (B55) No. 14 Chassis ground: CHECK HARNESS CONNECTOR BETWEEN TCM AND INHIBITOR SWITCH. 1) Turn ignition switch to OFF. 2) Disconnect connectors from TCM and inhibitor switch. 3) Measure resistance of harness between TCM and inhibitor switch connector. Connector & terminal (B55) No. 4 (T7) No. 3: CHECK INPUT SIGNAL FOR TCM. 1) Turn ignition switch to OFF. 2) Connect connector to TCM and inhibitor switch. 3) Turn ignition switch to ON. 4) Measure voltage between TCM and chassis ground. Connector & terminal (B55) No. 4 (+) Chassis ground (): CHECK INPUT SIGNAL FOR TCM. Measure voltage between TCM and chassis ground. Connector & terminal (B55) No. 4 (+) Chassis ground (): CHECK HARNESS CONNECTOR BETWEEN TCM AND INHIBITOR SWITCH. 1) Turn ignition switch to OFF. 2) Disconnect connectors from TCM, inhibitor switch and combination meter. 3) Measure resistance of harness between TCM and chassis ground. Connector & terminal (B55) No. 4 Chassis ground: CHECK HARNESS CONNECTOR BETWEEN TCM AND INHIBITOR SWITCH. 1) Turn ignition switch to OFF. 2) Disconnect connector from TCM and inhibitor switch. 3) Measure resistance of harness between TCM and inhibitor switch connector. Connector & terminal (B55) No. 5 (T7) No. 11:
Go to step 29.
Is the voltage less than 1 V Go to step 30. in D range?
Go to step 44.
Replace TCM. <Ref. to AT-48, Transmission Control Module (TCM).> Repair ground short circuit in D range circuit.
Go to step 33.
Repair open circuit in harness between TCM and inhibitor switch connector, and poor contact in coupling connector.
AT-126

No. 33 Step CHECK INPUT SIGNAL FOR TCM. 1) Turn ignition switch to OFF. 2) Connect connector to TCM and inhibitor switch. 3) Turn ignition switch to ON. 4) Measure voltage between TCM and chassis ground. Connector & terminal (B55) No. 5 (+) Chassis ground (): CHECK INPUT SIGNAL FOR TCM. Measure voltage between TCM and chassis ground. Connector & terminal (B55) No. 5 (+) Chassis ground (): CHECK HARNESS CONNECTOR BETWEEN TCM AND INHIBITOR SWITCH. 1) Turn ignition switch to OFF. 2) Disconnect connectors from TCM, inhibitor switch and combination meter. 3) Measure resistance of harness between TCM and chassis ground. Connector & terminal (B55) No. 5 Chassis ground: CHECK HARNESS CONNECTOR BETWEEN TCM AND INHIBITOR SWITCH. 1) Turn ignition switch to OFF. 2) Disconnect connector from TCM and inhibitor switch. 3) Measure resistance of harness between TCM and inhibitor switch connector. Connector & terminal (B55) No. 6 (T7) No. 4: CHECK INPUT SIGNAL FOR TCM. 1) Turn ignition switch to OFF. 2) Connect connector to TCM and inhibitor switch. 3) Turn ignition switch to ON. 4) Measure voltage between TCM and chassis ground. Connector & terminal (B55) No. 6 (+) Chassis ground (): CHECK INPUT SIGNAL FOR TCM. Measure voltage between TCM and chassis ground. Connector & terminal (B55) No. 6 (+) Chassis ground (): CHECK HARNESS CONNECTOR BETWEEN TCM AND INHIBITOR SWITCH. 1) Turn ignition switch to OFF. 2) Disconnect connectors from TCM, inhibitor switch and combination meter. 3) Measure resistance of harness between TCM and chassis ground. Connector & terminal (B55) No. 6 Chassis ground: Check Yes Is the voltage less than 1 V Go to step 34. in 3 range?

No Go to step 44.
34
Go to step 44.
35
Replace TCM. <Ref. to AT-48, Transmission Control Module (TCM).> Repair ground short circuit in 3 range circuit.
36
Go to step 37.
37
Is the voltage less than 1 V Go to step 38. in 2 range?
38
Go to step 44.
39
AT-127

No. 40

Check Is the resistance less than 1 ? Yes Go to step 41. No Repair open circuit in harness between TCM and inhibitor switch connector, and poor contact in coupling connector. Go to step 44.
41
42
43
44
Step CHECK HARNESS CONNECTOR BETWEEN TCM AND INHIBITOR SWITCH. 1) Turn ignition switch to OFF. 2) Disconnect connectors from TCM and inhibitor switch. 3) Measure resistance of harness between TCM and inhibitor switch connector. Connector & terminal (B55) No. 7 (T7) No. 6: CHECK INPUT SIGNAL FOR TCM. 1) Turn ignition switch to OFF. 2) Connect connector to TCM and inhibitor switch. 3) Turn ignition switch to ON. 4) Measure voltage between TCM and chassis ground. Connector & terminal (B55) No. 7 (+) Chassis ground (): CHECK INPUT SIGNAL FOR TCM. Measure voltage between TCM and chassis ground. Connector & terminal (B55) No. 7 (+) Chassis ground (): CHECK HARNESS CONNECTOR BETWEEN TCM AND INHIBITOR SWITCH. 1) Turn ignition switch to OFF. 2) Disconnect connectors from TCM, inhibitor switch and combination meter. 3) Measure resistance of harness between TCM and chassis ground. Connector & terminal (B55) No. 7 Chassis ground: CHECK POOR CONTACT.
Is the voltage less than 1 V Go to step 42. in 1 range?
Go to step 44.
Is there poor contact in inhibitor switch circuit?
Adjust inhibitor switch and select cable or replace TCM. <Ref. to AT-28, ADJUSTMENT , Inhibitor Switch.> and <Ref. to CS-10, Select Cable.> <Ref. to AT-48, Transmission Control Module (TCM).>
AT-128

MEMO:
AT-129

S004618G78
I: CHECK HOLD SWITCH.
DIAGNOSIS: LED does not come on when hold switch is ON. Hold switch circuit is open or shorted. TROUBLE SYMPTOM: 2nd gear is not held. Failure of vehicle to start in 2nd gear except 1st range.
AT-130

WIRING DIAGRAM:
S3M0637
AT-131

No. 1 2

Check Yes When hold switch is turned Go to step 5. OFF, does LED light up? When hold switch is turned Go to step SympON, does LED light up? tom Related Diagnostic. <Ref. 134, Symptom Related Diagnostic.> Is HOLD indicator light bulb Go to step 4. OK? No Go to step 2. Go to step 3.
Step CHECK HOLD SWITCH OPERATION. CHECK HOLD SWITCH OPERATION.
CHECK HOLD INDICATOR LIGHT. 1) Turn ignition switch to OFF. 2) Remove combination meter. 3) Remove HOLD indicator light bulb from combination meter. CHECK HOLD SWITCH GROUND LINE. 1) Turn ignition switch to OFF. 2) Disconnect connector from hold switch. 3) Measure resistance of harness connector between hold switch and chassis ground. Connector & terminal (B116) No. 4 Chassis ground: CHECK HOLD SWITCH. 1) Hold switch turned ON. 2) Measure resistance between terminals of hold switch. Terminals No. 4 No. 3: CHECK HOLD SWITCH. 1) Hold switch turned OFF. 2) Measure resistance between terminals of hold switch. Terminals No. 4 No. 3: CHECK HARNESS CONNECTOR BETWEEN TCM AND HOLD SWITCH. 1) Disconnect connector TCM and combination meter. 2) Measure resistance of harness connector between TCM and hold switch. Connector & terminal (B55) No. 16 (B116) No. 3: CHECK HARNESS CONNECTOR BETWEEN TCM AND COMBINATION METER. Measure resistance of harness connector TCM and combination meter. Connector & terminal (B55) No. 16 (i12) No. 5: CHECK HARNESS CONNECTOR BETWEEN TCM AND HOLD SWITCH. Measure resistance of harness connector between TCM and chassis ground to make sure that circuit does not short. Connector & terminal (B55) No. 16 Chassis ground:
Go to step 5.
Replace HOLD indicator light bulb. <Ref. to IDI15, Combination Meter Assembly.> Repair open circuit in harness between hold switch and chassis ground.
Go to step 6.
Repair hold switch.
Repair hold switch.
Go to step 8.
Repair open circuit in harness between TCM and hold switch connector and poor contact in coupling connector. Repair open circuit in harness between TCM and combination meter, and poor contact in coupling connector. Repair short circuit in harness between TCM, hold switch and combination meter connector.
Go to step 9.
AT-132

No. 10 Step CHECK INPUT SIGNAL FOR TCM. 1) Connect connectors to TCM and hold switch. 2) Turn ignition switch ON (with engine OFF). 3) Measure signal voltage for TCM while turning hold switch OFF. Connector & terminal (B55) No. 16 (+) Chassis ground (): CHECK INPUT SIGNAL FOR TCM. Measure signal voltage for TCM while turning hold switch ON. Connector & terminal (B55) No. 16 (+) Chassis ground (): CHECK POOR CONTACT. Check Is the voltage more than 8 V? Yes Go to step 11.

11
Go to step 12.
12
Is there poor contact?
Replace TCM. <Ref. to AT-48, Transmission Control Module (TCM).> A temporary poor contact of the connector or harness or connector in hold switch circuit.
AT-133
SYMPTOM RELATED DIAGNOSTIC

S004519
16. Symptom Related Diagnostic

A: INSPECTION
Symptom Starter does not rotate when select lever is in P or N; starter rotates when select lever is in R, D, 3 or 2.
S004519A10
Abnormal noise when select lever is in P or N.
Hissing noise occurs during standing start. Noise occurs while driving in D1. Noise occurs while driving in D2.
Noise occurs while driving in D3.
Noise occurs while driving in D4.
Engine stalls while shifting from one range to another.
Vehicle moves when select lever is in N.
Shock occurs when select lever is moved from N to D.
Excessive time lag occurs when select lever is moved from N to D.
Shock occurs when select lever is moved from N to R.
Excessive time lag occurs when select lever is moved from N to R.
Vehicle does not start in any shift range (engine stalls).
Problem parts Inhibitor switch Select cable Select lever Starter motor and harness Strainer Transfer duty solenoid Oil pump Drive plate ATF level too high or too low Strainer ATF level too high or too low Final gear Planetary gear Reduction gear Differential gear oil level too high or too low Final gear Low & reverse brake Reduction gear Differential gear oil level too high or too low Final gear Low & reverse brake Planetary gear Reduction gear Differential gear oil level too high or too low Control valve Lock-up damper Engine performance Input shaft TCM Low clutch TCM Harness Control valve ATF deterioration Control valve Low clutch Line pressure duty solenoid Seal ring Front gasket transmission case TCM Harness Control valve ATF deterioration Control valve Low & reverse clutch Reverse clutch Line pressure duty solenoid Seal ring Front gasket transmission case Parking brake mechanism Planetary gear
AT-134

Symptom
Vehicle does not start in any shift range (engine revving up).
Vehicle does not start in R range only (engine revving up).
Vehicle does not start in R range only (engine stalls).
Vehicle does not start in D, 3 range only (engine revving up). Vehicle does not start in D, 3 or 2 range only (engine rev Low clutch ving up). Vehicle does not start in D, 3 or 2 range only (engine Reverse clutch stalls). Vehicle starts in R range only (engine revving up). Control valve Control valve Low clutch Reverse clutch Acceleration during standing starts is poor (high stall rpm). ATF level too low Front gasket transmission case Differential gear oil level too high or too low Oil pump Acceleration during standing starts is poor (low stall rpm). Torque converter one-way clutch Engine performance TCM Control valve Acceleration is poor when select lever is in D, 3 or 2 High clutch range (normal stall rpm). 2-4 brake Planetary gear Control valve Acceleration is poor when select lever is in R (normal stall High clutch rpm). 2-4 brake Planetary gear TCM Rear vehicle speed sensor Front vehicle speed sensor Throttle position sensor No shift occurs from 1st to 2nd gear. Shift solenoid 1 Control valve 2-4 brake TCM Control valve No shift occurs from 2nd to 3rd gear. High clutch Shift solenoid 2
Problem parts Strainer Line pressure duty solenoid Control valve Drive pinion Hypoid gear Axle shaft Differential gear Oil pump Input shaft Output shaft Planetary gear Drive plate ATF level too low Front gasket transmission case Select cable Select lever Control valve Low & reverse clutch Reverse clutch Low clutch 2-4 brake Planetary gear Parking brake mechanism Low clutch One-way clutch
AT-135

Symptom

Problem parts TCM Shift solenoid 1 ATF temperature sensor Control valve 2-4 brake Inhibitor switch TCM Throttle position sensor Control valve Control valve Control valve Low & reverse brake Inhibitor switch TCM Front vehicle speed sensor Rear vehicle speed sensor Throttle position sensor Control valve Ground earth TCM Throttle position sensor ATF temperature sensor Control valve Lock-up facing Engine speed signal
No shift occurs from 3rd to 4th gear.
Engine brake is not effected when select lever is in 3 range. Engine brake is not effected when select lever is in 3 or 2 range. Engine brake is not effected when select lever is in 1 range.
Shift characteristics are erroneous.
No lock-up occurs.
Parking brake is not effected. Shift lever cannot be moved or is hard to move from P range. ATF spurts out. Differential oil spurts out. Differential oil level changes excessively.
Select cable Select lever Parking mechanism ATF level too high Differential gear oil too high Seal pipe Double oil seal High clutch 2-4 brake Low & reverse clutch Reverse clutch Lock-up facing ATF deterioration TCM Throttle position sensor 2-4 brake duty solenoid ATF temperature sensor Line pressure duty solenoid Control valve 2-4 brake ATF deterioration Engine performance 2-4 brake timing solenoid TCM Throttle position sensor 2-4 brake duty solenoid ATF temperature sensor Line pressure duty solenoid Control valve 2-4 brake 2-4 brake timing solenoid High clutch
Odor is produced from ATF supply pipe.
Shock occurs from 1st to 2nd gear.
Slippage occurs from 1st to 2nd gear.
AT-136

Symptom
Shock occurs from 2nd to 3rd gear.
Slippage occurs from 2nd to 3rd gear.
Shock occurs from 3rd to 4th gear.
Slippage occurs from 3rd to 4th gear.
Shock occurs when select lever is moved from 3 to 2 range.
Shock occurs when select lever is moved from D to 1 range.
Problem parts TCM Throttle position sensor 2-4 brake duty solenoid ATF temperature sensor Line pressure duty solenoid Control valve High clutch 2-4 brake ATF deterioration Engine performance 2-4 brake timing solenoid TCM Throttle position sensor 2-4 brake duty solenoid ATF temperature sensor Line pressure duty solenoid Control valve High clutch 2-4 brake 2-4 brake timing solenoid TCM Throttle position sensor 2-4 brake duty solenoid ATF temperature sensor Line pressure duty solenoid Control valve 2-4 brake timing solenoid 2-4 brake ATF deterioration Engine performance Low clutch timing solenoid Low clutch TCM Throttle position sensor 2-4 brake duty solenoid ATF temperature sensor Line pressure duty solenoid Control valve 2-4 brake 2-4 brake timing solenoid TCM Throttle position sensor ATF temperature sensor Line pressure duty solenoid Control valve 2-4 brake duty solenoid 2-4 brake ATF deterioration 2-4 brake timing solenoid TCM Throttle position sensor ATF temperature sensor Line pressure duty solenoid Control valve ATF deterioration 2-4 brake duty solenoid 2-4 brake timing solenoid Low clutch timing solenoid
AT-137

Symptom

Problem parts TCM Throttle position sensor ATF temperature sensor Line pressure duty solenoid Control valve Low & reverse clutch ATF deterioration 2-4 brake duty solenoid 2-4 brake timing solenoid Low clutch timing solenoid TCM Throttle position sensor ATF temperature sensor Line pressure duty solenoid Control valve Lock-up damper Engine performance 2-4 brake duty solenoid 2-4 brake timing solenoid Low clutch timing solenoid TCM Lock-up duty solenoid Lock-up facing Lock-up damper Hold switch TCM Front vehicle speed sensor Rear vehicle speed sensor Throttle position sensor ATF temperature sensor Transfer clutch Transfer valve Transfer duty solenoid ATF deterioration Harness Hold switch TCM Front vehicle speed sensor FWD switch Throttle position sensor ATF temperature sensor Control valve Transfer clutch Transfer valve Transfer pipe Transfer duty solenoid TCM FWD switch Transfer clutch Transfer valve Transfer duty solenoid Select cable Select lever Detent spring Manual plate Detent spring Manual plate
Shock occurs when select lever is moved from 2 to 1 range.
Shock occurs when accelerator pedal is released at medium speeds.
Vibration occurs during straight-forward operation.
Vibration occurs during turns (tight corner braking phenomenon).
Front wheel slippage occurs during standing starts.
Vehicle is not set in FWD mode.
Select lever is hard to move.
Select lever is too high to move (unreasonable resistance).
AT-138

Symptom Select lever slips out of operation during acceleration or while driving on rough terrain. Problem parts Select cable Select lever Detent spring Manual plate
AT-139
MEMO:
AT-140
FRONT SUSPENSION
FS
1. 2. 3. 4. 5. 6. 7. 8. Page General Description.....................................................................................2 Wheel Alignment .........................................................................................6 Front Transverse Link ...............................................................................14 Front Ball Joint ..........................................................................................17 Front Strut .................................................................................................18 Front Stabilizer ..........................................................................................22 Front Crossmember ..................................................................................23 General Diagnostic Table ..........................................................................24
Front Suspension
GENERAL DESCRIPTION
S202001
A: SPECIFICATIONS
1. STABILIZER
Model NON-TURBO TURBO
S202001E4901 S202001E49
Bar dia. Front Rear 19 mm (0.75 in) 13 mm (0.51 in) 20 mm (0.79 in) 15 mm (0.59 in)
S202001E4902
2. WHEEL ALIGNMENT
Model Camber (tolerance: 030) Caster (common difference: 045) Toe-in Kingpin angle Wheel arch height [tolerance: +12/24 mm (+0.47/0.94 in)
NON-TURBO 015 037 03 mm (00.12 in)* Each toe angle: 009 1325 432 mm (17.01 in)
TURBO 020 057
1340
422 mm (16.61 in)
*: When performing toe-in adjustment, align as close to 0 mm (0 in) as possible.
NOTE: Front and rear toe-ins and front camber can be adjusted. If toe-in or camber tolerance exceeds specifications, adjust toe-in and camber to the middle value of specification. The other items indicated in the specification table cannot be adjusted. If the other items exceeds specifications, check suspension parts and connections for deformities; replace with new ones as required.
B4M2250B
(1) Front A B = Positive: Toe-in, Negative: Toe-out = Each toe angle
FS-2

S202001A05
Front Suspension
S4M0317B
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16)
Front crossmember Bolt ASSY Housing Washer Stopper rubber (Rear) Rear bushing Stopper rubber (Front) Ball joint Transverse link Cotter pin Front bushing Stabilizer link Clamp (Non-Turbo model) Bushing (Non-Turbo model) Stabilizer Jack-up plate
(17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (29) (30) (31) (32)
Dust seal Strut mount Spacer Upper spring seat Rubber seat Dust cover Helper Coil spring Damper strut Adjusting bolt Castle nut Self-locking nut Adapter front crossmember Clip Clamp (Turbo model) Bushing (Turbo model)
Tightening torque: Nm (kgf-m, ft-lb) T1: 20 (2.0, 14.5) T2: 25 (2.5, 18.1) T3: 30 (3.1, 22) T4: 40 (4.1, 30) T5: 45 (4.6, 33) T6: 50 (5.1, 37) T7: 55 (5.6, 41) T8: 100 (10.2, 74) T9: 175 (17.8, 129) T10: 190 (19.4, 140) T11: 245 (25.0, 181)
FS-3
Front Suspension
GENERAL DESCRIPTION
S202001A03
C: CAUTION
Wear working clothing, including a cap, protective goggles, and protective shoes during operation. Remove contamination including dirt and corrosion before removal, installation or disassembly. Keep the disassembled parts in order and protect them from dust or dirt. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly, and replacement. Use SUBARU genuine grease etc. or the equivalent. Do not mix grease etc. with that of another grade or from other manufacturers. Be sure to tighten fasteners including bolts and nuts to the specified torque. Place shop jacks or safety stands at the specified points. Apply grease onto sliding or revolution surfaces before installation. Before installing O-rings or snap rings, apply sufficient amount of grease to avoid damage and deformation. Before securing a part on a vise, place cushioning material such as wood blocks, aluminum plate, or shop cloth between the part and the vise.
FS-4
GENERAL DESCRIPTION D: PREPARATION TOOL

1. SPECIAL TOOLS
ILLUSTRATION
S202001A1701 S202001A17
Front Suspension
DESCRIPTION ADAPTER
REMARKS Used as an adapter for camber & caster gauge when measuring camber and caster. (1) 28199AC000 PLATE (2) 28199AC010 BOLT
B4M2378A
927680000
INSTALLER & REMOVER SET
Used for replacing transverse link bushing.
B4M2385
927760000
STRUT MOUNT SOCKET
Used for disassembling and assembling strut and shock mount.
B4M2384

TOOL NAME Alignment Gauge Turning Radius Gauge Toe-in Gauge Dial Gauge
S202001A1702
Used Used Used Used
for for for for
REMARKS wheel alignment measurement. wheel alignment measurement. toe-in measurement. damper strut measurement.
FS-5
Front Suspension
WHEEL ALIGNMENT
S202116
2. Wheel Alignment
A: INSPECTION
S202116A10
Check, adjust and/or measure wheel alignment in accordance with procedures indicated in figure:
B4M1088A
FS-6
WHEEL ALIGNMENT
1. WHEEL ARCH HEIGHT
S202116A1006
Front Suspension
1) Adjust tire pressure to specifications. 2) Set vehicle under curb weight conditions. (Empty luggage compartment, install spare tire, jack, service tools, and top up fuel tank.) 3) Set steering wheel in a wheel-forward position. 4) Suspend thread from wheel arch (point A in figure below) to determine a point directly above center of spindle. 5) Measure distance between measuring point A and center of spindle.
S4M0086B
(1) Wheel arch height (2) Front fender (3) Outer rear quarter
(4) Front wheel arch height (5) Rear wheel arch height (6) Cross-section of arch
(7) Measuring point (8) End of spindle
Model Non-Turbo Turbo 432+12/24 422+12/24
Specified wheel arch height Front Rear mm (17.01+0.47/0.94 in) 435+12/24 mm (17.13+0.47/0.94 in) mm (16.61+0.47/0.94 in) 425+12/24 mm (16.73+0.47/0.94 in)
FS-7
Front Suspension
WHEEL ALIGNMENT
Front Camber Adjustment
1) Loosen two self-locking nuts located at lower front portion of strut. CAUTION: When adjusting bolt needs to be loosened or tightened, hold its head with a wrench and turn self-locking nut. Discard loosened self-locking nut and replace with a new one. When performing toe-in adjustment, align as close to 0 mm (0 in) as possible. 2) Turn camber adjusting bolt so that camber is set at the specification. NOTE: Moving the adjusting bolt by one scale graduation changes camber by approximately 010.
2. CAMBER Inspection
S202116A1002
1) Place front wheel on turning radius gauge. Make sure ground contacting surfaces of front and rear wheels are set at the same height. 2) Set ST into the center of the wheel, and then install the wheel alignment gauge. ST 927380002 ADAPTER
S4M0087C
(1) (2)
Alignment gauge Turning radius gauge
NOTE: Refer to the SPECIFICATIONS for the camber values. Front <Ref. to FS-2, SPECIFICATIONS, General Description.> Rear <Ref. to RS-2, SPECIFICATIONS, General Description.>
S4M0300B
(1) (2) (3) (4) (5) (6) (7)
Strut Adjusting bolt Housing Outer Inner Camber is increased. Camber is decreased.
FS-8
WHEEL ALIGNMENT
Left side Right side
Front Suspension
Camber is increased.
Rotate counterclockwise.
Rotate clockwise.
B4M0190
B4M0350
Camber is decreased.
Rotate clockwise.
B4M0350
B4M0190
3) Tighten the two self-locking nuts. Tightening torque: 175 Nm (17.8 kgf-m, 129 ft-lb)
4. FRONT WHEEL TOE-IN Inspection
S202116A1004
3. CASTER
1) Using a toe gauge, measure front wheel toe-in. Toe-in: 03 mm (00.12 in) 2) Mark rear sides of left and right tires at height corresponding to center of spindles and measure distance A between marks. 3) Move vehicle forward so that marks line up with front sides at height corresponding to center of spindles. 4) Measure distance B between left and right marks. Toe-in can then be obtained by the following equation: A B = Toe-in
S202116A1003
Inspection
1) Place front wheel on turning radius gauge. Make sure ground contacting surfaces of front and rear wheels are set at the same height. 2) Set ST into the center of the wheel, and then install the wheel alignment gauge. ST 927380002 ADAPTER
S4M0087C
(1) (2)
Alignment gauge Turning radius gauge

H4M1279B
NOTE: Refer to the SPECIFICATIONS for the caster values. <Ref. to FS-2 SPECIFICATIONS, General Description.>
FS-9
Front Suspension
WHEEL ALIGNMENT
B A = Toe-in
Adjustment
1) Loosen the left and right side steering tie-rods lock nuts. 2) Turn the left and right tie rods equal amounts until the toe-in is at the specification. Both the left and right tie-rods are right-hand threaded. To increase toe-in, turn both tie-rods clockwise equal amounts (as viewed from the inside of the vehicle).
M4A0059
Adjustment
1) Loosen self-locking nut on inner side of rear lateral link. CAUTION: When loosening or tightening adjusting bolt, hold bolt head and turn self-locking nut. Discard loosened self-locking nut and replace with a new one. When performing toe-in adjustment, align as close to 0 mm (0 in) as possible.
S4M0348A
(1)
Lock nut
3) Tighten tie-rod lock nut. Tightening torque: 83 Nm (8.5 kgf-m, 61.5 ft-lb) CAUTION: Correct tie-rod boot, if it is twisted. NOTE: Check the left and right wheel steering angle is within specifications.
5. REAR WHEEL TOE-IN Inspection
S202116A1007
S4M0349A
1) Using a toe-in gauge, measure rear wheel toein. Toe-in: 23 mm (0.080.12 in) 2) Mark rear sides of left and right tires at height corresponding to center of spindles and measure distance B between marks. 3) Move vehicle forward so that marks line up with front sides at height corresponding to center of spindles. 4) Measure distance A between left and right marks. Toe-in can then be obtained by the following equation:
(1) (2)
Adjusting scale Rear lateral link
2) Turn adjusting bolt head until toe-in is at the specification. NOTE: When left and right wheels are adjusted for toe-in at the same time, the movement of one scale graduation changes toe-in by approximately 3 mm (0.12 in).
FS-10
WHEEL ALIGNMENT
Left side Right side
Front Suspension
Toe-in is increased.
Rotate clockwise.
B4M0192
B4M0352
Toe-in is decreased.
Rotate clockwise.
B4M0352
B4M0192
3) Tighten self-locking nut. Tightening torque: 100 Nm (10.2 kgf-m, 74 ft-lb)
6. THRUST ANGLE Inspection
S202116A1008
1) Position vehicle on a level surface. 2) Move vehicle 3 to 4 meters directly forward. 3) Determine locus of both front and rear axles. 4) Measure distance L between center line of loci of the axles. Thrust angle: Less than 20 when L is equal to or less than 15 mm (0.59 in).
S4M0350B
(1) (2)
Center line of loci (front axle) Center line of loci (rear axle)
FS-11
Front Suspension
WHEEL ALIGNMENT
NOTE: Thrust angle refers to a mean value of left and right rear wheel toe angles in relation to vehicle body center line. Vehicle is driven straight in the thrust angle direction while swinging in the oblique direction depending on the degree of the mean thrust angle.
Adjustment
1) Make thrust angle adjustments by turning toe-in adjusting bolts of rear suspension equally in the same direction. 2) When one rear wheel is adjusted in a toe-in direction, adjust the other rear wheel equally in toe-out direction, in order to make thrust angle adjustment. 3) When left and right adjusting bolts are turned incrementally by one graduation in the same direction, the thrust angle will change approximately 10 [L is almost equal to 7.5 mm (0.295 in)]. Thrust angle: 020
B4M0193B
(1) (2) (3)
Front Thrust angle Body center line
Thrust angle: r = ( )/2 : Right rear wheel toe-in angle : Left rear wheel toe-in angle NOTE: Here, use only positive toe-in values from each wheel to substitute for and in the equation.
S4M0350B B4M0194B
(1) (2)
Center line of loci (front axle) Center line of loci (rear axle)
(1) (2)
Front Body center line
FS-12
WHEEL ALIGNMENT
7. STEERING ANGLE Inspection
1) Place vehicle on a turning radius gauge. 2) While depressing brake pedal, turn steering wheel fully to the left and right. With steering wheel held at each fully turned position, measure both the inner and outer wheel steering angle. Steering angle: Inner wheel 34.41.5 Outer wheel 30.21.5
S202116A1005
Front Suspension
Adjustment
Turn tie-rod to adjust steering angle of both inner and outer wheels. CAUTION: Check toe-in. Correct boot if it is twisted.
S4M0348A
(1)
Lock nut
FS-13
Front Suspension
FRONT TRANSVERSE LINK

S202113
3. Front Transverse Link

A: REMOVAL
S202113A18
B: INSTALLATION
S202113A11
1) Set the vehicle on the lift. 2) Disconnect ground terminal from the battery. 3) Lift-up the vehicle and remove the wheel. 4) Disconnect stabilizer link from transverse link. 5) Remove bolt securing ball joint of transverse link to housing.
1) Temporarily tighten the two bolts used to secure rear bushing of the transverse link to body. NOTE: These bolts should be tightened to such an extent that they can still move back and forth in the oblong shaped hole in the bracket (which holds the bushing). 2) Install bolts used to connect transverse link to crossmember and temporarily tighten with nut. CAUTION: Discard loosened self-locking nut and replace with a new one. 3) Insert ball joint into housing. 4) Connect stabilizer link to transverse link, and temporarily tighten bolts.
S4M0090
6) Remove nut (do not remove bolt.) securing transverse link to crossmember. 7) Remove two bolts securing bushing bracket of transverse link to vehicle body at rear bushing location.
CAUTION: Discard loosened self-locking nut and replace with a new one.
S4M0090
S4M0091
8) Extract ball joint from housing. 9) Remove bolt securing transverse link to crossmember and extract transverse link from crossmember.
5) Tighten the following points in the order shown below when wheels are in full contact with the ground and vehicle is curb weight. (1) Transverse link and stabilizer Tightening torque: 30 Nm (3.1 kgf-m, 22 ft-lb) (2) Transverse link and crossmember Tightening torque: 100 Nm (10.2 kgf-m, 74 ft-lb) (3) Transverse link rear bushing and body Tightening torque: 245 Nm (25 kgf-m, 181 ft-lb)
S4M0092
FS-14

NOTE: Move rear bushing back and forth until transverse link-to-rear bushing clearance is established (as indicated in figure.) before tightening. Check wheel alignment and adjust if necessary.
Front Suspension
S202113A06
C: DISASSEMBLY
1. FRONT BUSHING
S202113A0601
Using ST, press front bushing out of place. ST 927680000 INSTALLER & REMOVER SET
S4M0352A
G4M0494
(1)
Rear bushing
2. REAR BUSHING
S202113A0602
1) Scribe an aligning mark on transverse link and rear bushing. 2) Loosen nut and remove rear bushing.
G4M0495
FS-15
Front Suspension

S202113A02
D: ASSEMBLY
E: INSPECTION
S202113A10
1. FRONT BUSHING
S202113A0201
To reassemble, reverse disassembly procedures. CAUTION: Install front bushing in correct direction, as shown in figure.
1) Check transverse link for wear, damage and cracks, and correct or replace if defective. 2) Check bushings for cracks, fatigue or damage. 3) Check rear bushing for oil leaks.
S4M0351A
(1) (2)
Face bushing toward center of ball joint Ball joint

S202113A0202
2. REAR BUSHING
1) Install rear bushing to transverse link and align aligning marks scribed on the two. 2) Tighten self-locking nut. CAUTION: Discard loosened self-locking nut and replace with a new one. While holding rear bushing so as not to change position of aligning marks, tighten selflocking nut. Tightening torque: 190 Nm (19.4 kgf-m, 140 ft-lb)
FS-16
FRONT BALL JOINT
Front Suspension
S202114A10
4. Front Ball Joint

A: REMOVAL
S202114A18
S202114
C: INSPECTION
1) Set the vehicle on the lift. 2) Disconnect ground terminal from the battery. 3) Lift-up the vehicle and remove the wheel. 4) Pull out the cotter pin from the ball stud, remove the castle nut, and extract the ball stud from the transverse link. 5) Remove the bolt securing the ball joint to the housing.
1) Measure play of ball joint by the following procedures. Replace with a new one when the play exceeds the specified value. (1) With 690 N (70.4 kgf, 155 lb) loaded in the direction shown in the figure, measure dimension 1.
G4M0500
G4M0499
(2) With 690 N (70.4 kgf, 155 lb) loaded in the opposite direction shown in the figure, measure dimension 2.
6) Extract the ball joint from the housing.
B: INSTALLATION
S202114A11
1) Install ball joint onto housing. Torque (Bolt): 50 Nm (5.1 kgf-m, 37 ft-lb) CAUTION: Do not apply grease to tapered portion of ball stud. 2) Connect ball joint to transverse link. Torque (Castle nut): 40 Nm (4.1 kgf-m, 30 ft-lb) 3) Retighten castle nut further within 60 until a slot in castle nut is aligned with the hole in ball stud end, then insert new cotter pin and bend it around castle nut. 4) Install front wheel.
G4M0501
(3) Calculate plays from the following formula. S= 2 1 (4) When plays are larger than the following value, replace with a new one. FRONT BALL JOINT Specified play for replacement: S Less than 0.3 mm (0.012 in) 2) When play is smaller than the specified value, visually inspect the dust cover. 3) The ball joint and cover that have been removed must be checked for wear, damage or cracks, and any defective part must be replaced. 4) If the dust cover is damaged, replace with the new ball joint.
FS-17
Front Suspension
FRONT STRUT
S202115
5. Front Strut
A: REMOVAL
S202115A18
1) Set the vehicle on the lift. 2) Disconnect ground terminal from the battery. 3) Lift-up the vehicle and remove the wheel. 4) Depress brake pedal and hold it down using a wooden block etc. 5) Remove union bolts from caliper. CAUTION: Use brake hose cap to prevent brake fluid from escaping.
7) Scribe an alignment mark on the camber adjusting bolt which secures strut to housing. 8) Remove bolt securing the ABS sensor harness on models equipped with ABS.
B4M1442C
(1)
Sensor harness
9) Remove two bolts securing housing to strut. CAUTION: While holding head of adjusting bolt, loosen self-locking nut.
S4M0093
10) Remove the three nuts securing strut mount to body.
6) Remove brake hose clamp and disconnect brake hose from strut. Attach brake hose to body using gum tape.
S4M0094C
(1)
Clamp
G4M0505
FS-18
FRONT STRUT B: INSTALLATION

S202115A11
Front Suspension
S202115A06
C: DISASSEMBLY
1) Install strut mount at upper side of strut to body and tighten with nuts. Tightening torque: 20 Nm (2.0 kgf-m, 14.5 ft-lb) 2) Install ABS sensor harness to strut. (ABS equipped models) Tightening torque: 32 Nm (3.3 kgf-m, 24 ft-lb) 3) Position aligning mark on camber adjustment bolt with aligning mark on lower side of strut. CAUTION: While holding head of adjusting bolt, tighten self-locking nut. Be sure to use new self-locking nut. Tightening torque: 175 Nm (17.8 kgf-m, 129 ft-lb) 4) Install brake hose at lower side of strut with clamp. 5) Install union bolts which secure brake caliper to brake hose. Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft-lb)
1) Using a coil spring compressor, compress coil spring.
S4M0095
2) Using ST, remove self-locking nut. ST 927760000 STRUT MOUNT SOCKET
S4M0096A
3) Remove strut mount, upper spring seat and rubber seat from strut. 4) Gradually decreasing compression force, and remove coil spring. 5) Remove dust cover and helper spring.
S4M0093
CAUTION: Be sure to bleed air from brake system. 6) Install wheels. NOTE: Check wheel alignment and adjust if necessary.
FS-19
Front Suspension
FRONT STRUT
S202115A02
D: ASSEMBLY
1) Before installing coil spring, strut mount, etc., on the strut, check for the presence of air in the dampening force generating mechanism of the strut since air prevents proper dampening force from being produced. 2) Checking for the presence of air (1) Place the strut vertically with the piston rod facing up. (2) Move the piston rod to the center of its entire stroke. (3) While holding the piston rod end with fingertips, move the rod up and down. (4) If the piston rod moves at least 10 mm (0.39 in) in the former step, purge air from the strut. 3) Air purging procedure (1) Place the strut vertically with the piston rod facing up. (2) Fully extend the piston rod. (3) With the piston rod fully extended, place the piston rod side down. The strut must stand vertically. (4) Fully contract the piston rod. (5) Repeat 3 or 4 times from the first step. NOTE: After completely purging air from the strut, be sure to place the strut with the piston rod facing up. If it is laid down, check for entry of air in the strut as outlined under Checking for the presence of air. 4) Using a coil spring compressor, compress the coil spring. NOTE: Make sure that the vertical installing direction of coil spring is as shown in figure.
5) Set the coil spring correctly so that its end face fits well into the spring seat as shown.
S4M0353A
6) Install helper and dust cover to the piston rod. 7) Pull the piston rod fully upward, and install rubber seat and spring seat. NOTE: Ensure that upper spring seat is positioned as shown in figure.
S4M0097B
(1)
Outside of body
8) Install strut mount to the piston rod, and tighten the self-locking nut temporarily. CAUTION: Be sure to use a new self-locking nut. 9) Using hexagon wrench to prevent strut rod from turning, tighten self-locking nut with ST. ST 927760000 STRUT MOUNT SOCKET Tightening torque: 55 Nm (5.6 kgf-m, 41 ft-lb)
B4M0568B
(1) (2) (3)
Flat (top side) Identification paint Inclined (bottom side)
S4M0096A
10) Loosen the coil spring carefully.
FS-20
FRONT STRUT E: INSPECTION

S202115A10
Front Suspension
S202115A1005
5. HELPER
Check the disassembled parts for cracks, damage and wear, and replace with new parts if defective.
Replace it with new one if cracked or damaged.
1. DAMPER STRUT
S202115A1001
1) Check for oil leakage. 2) Move the piston rod up and down to check it operates smoothly without any binding. 3) Play of piston rod Measure the play as follows: Fix outer shell and fully extend the rod. Set a dial gauge at the end of the rod: L [10 mm (0.39 in)], then apply a force of W [20 N (2 kgf, 4 lb)] to threaded portion. With the force of 20 N (2 kgf, 4 lb) applied, read dial gauge indication: P1. Apply a force of 20 N (2 kgf, 4 lb) in the opposite direction of W, then read dial gauge indication: P2.
G4M0508
The free play is determined by the following equation: Play = P1, P2 Limit of play: Less than 0.8 mm (0.031 in) If the play is greater, replace the strut.
2. STRUT MOUNT
S202115A1002
Check rubber part for creep, cracks and deterioration, and replace it with new one if defective.
3. DUST COVER
S202115A1003
If any cracks or damage are found, replace it with a new one.
4. COIL SPRING
S202115A1004
One having permanent strain should be replaced with a new one. When vehicle posture is uneven, although there are no considerable reasons like tire puncture, uneven loading, etc., check coil spring for its free length referring to specifications, cracks, etc., and replace it with a new one if defective.
FS-21
Front Suspension
FRONT STABILIZER
S202119
6. Front Stabilizer
A: REMOVAL
S202119A18
B: INSTALLATION
S202119A11
1) Install in the reverse order of removal. NOTE: Install bushing (on front crossmember side) while aligning it with paint mark on stabilizer. Ensure that bushing and stabilizer have the same identification colors when installing.
1) Set the vehicle on the lift. 2) Disconnect ground terminal from the battery. 3) Jack-up the front part of the vehicle and support it with safety stand (rigid racks). 4) Remove jack-up plate from lower part of crossmember. 5) Remove bolts which secure stabilizer to crossmember.
S4M0356A
(1) (2)
B4M1846A
Mark stamped on stabilizer Bushing identification color
(1) (2)
Nut (Turbo model) Bolt
2) Always tighten rubber bushing location when wheels are in full contact with the ground and vehicle is curb weight. Tightening torque: Jack-up plate to crossmember: 20 Nm (2.0 kgf-m, 14 ft-lb) Stabilizer link to front transverse link: 30 Nm (3.1 kgf-m, 22 ft-lb) Stabilizer to crossmember: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
6) Remove bolts which secure stabilizer link to front transverse link.
C: INSPECTION
S202119A10
S4M0355
1) Check bushing for cracks, fatigue or damage. 2) Check stabilizer link for deformities, cracks, or damage, and bushing for protrusions from the hole of stabilizer link.
7) Remove front stabilizer.
FS-22
FRONT CROSSMEMBER
Front Suspension
7. Front Crossmember
A: REMOVAL
S202108A18
S202108
1) Set the vehicle on the lift. 2) Disconnect ground cable from the battery. 3) Lift-up vehicle and remove front tires and wheels. 4) Remove both stabilizer and jack-up plate.
12) Support crossmember with a jack, remove nuts securing crossmember to body and lower crossmember gradually along with steering gearbox. CAUTION: When removing crossmember downward, be careful that tie-rod end does not interfere with SFJ boot.
B: INSTALLATION
S202108A11
1) Install in the reverse order of removal. CAUTION: Always tighten rubber bushing when wheels are in full contact with the ground and vehicle is curb weight. Tightening torque: Transverse link bushing to crossmember: 100 Nm (10.2 kgf-m, 74 ft-lb) Stabilizer to bushing: 25 Nm (2.5 kgf-m, 18.1 ft-lb) Tie-rod end to housing: 27.0 Nm (2.75 kgf-m, 19.9 ft-lb) Front cushion rubber to crossmember: 85 Nm (8.7 kgf-m, 63 ft-lb) Universal joint to pinion shaft: 24 Nm (2.4 kgf-m, 17.4 ft-lb) Crossmember to body: 100 Nm (10.2 kgf-m, 74 ft-lb) 2) Purge air from power steering system. <Ref. to PS-102, INSTALLATION, Power Steering Fluid.> NOTE: Check wheel alignment and adjust if necessary.
S4M0354B
(1) (2) (3)
Front stabilizer Front crossmember Jack-up plate
5) Disconnect tie-rod end from housing. 6) Remove front exhaust pipe. (Non-turbo model) With OBD <Ref. to EX(SOHC)-5, REMOVAL, Front Exhaust Pipe.> Without OBD <Ref. to EX(SOHCw/oOBD)-6, REMOVAL, Front Exhaust Pipe.> 7) Remove front transverse link from front crossmember and body.
C: INSPECTION
S202108A10
Check crossmember for wear, damage and cracks, and correct or replace if defective.
S4M0092
8) Remove nuts attaching engine mount cushion rubber to crossmember. 9) Remove steering universal joint. <Ref. to PS-28, REMOVAL, Universal Joint.> 10) Disconnect power steering pipe from steering gear box. 11) Lift engine by approx. 10 mm (0.39 in) by using chain block.
FS-23
Front Suspension

S202121

A: INSPECTION
S202121A10
1. IMPROPER VEHICLE POSTURE OR IMPROPER WHEEL ARCH HEIGHT

(1) (2) (3) (4) Possible causes Permanent distortion or breakage of coil spring Unsmooth operation of damper strut and/or shock absorber Installation of wrong strut and/or shock absorber Installation of wrong coil spring
S202121A1002
S202121A1001
Countermeasures Replace. Replace. Replace with proper parts. Replace with proper parts.
2. POOR RIDE COMFORT
1) Large rebound shock 2) Rocking of vehicle continues too long after running over bump and/or hump. 3) Large shock in bumping
Possible causes (1) Breakage of coil spring (2) Overinflation pressure of tire (3) Improper wheel arch height (4) Fault in operation of damper strut and/or shock absorber (5) Damage or deformation of strut mount and/or shock absorber mount (6) Unsuitability of maximum and/or minimum length of damper strut and/or shock absorber (7) Deformation or loss of bushing (8) Deformation or damage of helper in strut assembly and/or shock absorber (9) Oil leakage of damper strut and/or shock absorber Countermeasures Replace. Adjust. Adjust or replace coil springs with new ones. Replace. Replace. Replace with proper parts. Replace. Replace. Replace.
3. NOISE
S202121A1003
Possible causes (1) Wear or damage of damper strut and/or shock absorber component parts (2) Loosening of suspension link installing bolt (3) Deformation or loss of bushing (4) Unsuitability of maximum and/or minimum length of damper strut and/or shock absorber (5) Breakage of coil spring (6) Wear or damage of ball joint (7) Deformation of stabilizer clamp
Countermeasures Replace. Retighten to the specified torque. Replace. Replace with proper parts. Replace. Replace. Replace.
FS-24
REAR SUSPENSION
RS
1. 2. 3. 4. 5. 6. 7. 8. Page General Description.....................................................................................2 Wheel Alignment .........................................................................................7 Rear Stabilizer.............................................................................................8 Rear Trailing Link ........................................................................................9 Lateral link .................................................................................................12 Rear Strut ..................................................................................................16 Rear Crossmember ...................................................................................20 General Diagnostic Table ..........................................................................21
Rear Suspension
GENERAL DESCRIPTION
S201001
A: SPECIFICATIONS
Item Camber (tolerance: 045) Toe-in Wheel arch height [tolerance: +12/24 mm (+0.47/0.94 in)] Thrust angle Diameter of stabilizer
S201001E49
Non-turbo 035 23 mm (0.080.12 in)* Each toe-in angle: 006009 435 mm (17.13 in) 020 13 mm (0.51 in)
Turbo 045
425 mm (16.73 in)
15 mm (0.59 in)
*: When performing toe-in adjustment, align as close to 2 mm (0.08 in) as possible.
NOTE: Front and rear toe-ins and front camber can be adjusted. If toe-in or camber tolerance exceeds specifications, adjust toe-in and camber to the middle value of specification. The other items indicated in the specification table cannot be adjusted. If the other items exceeds specifications, check suspension parts and connections for deformities; replace with new ones as required.
B4M2250C
(1) Front A B = Positive: Toe-in, Negative: Toe-out 1, 2: Each toe-in angle
RS-2

S201001A05
Rear Suspension
S4M0085B
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14)
Stabilizer Stabilizer bracket Stabilizer bushing Clamp Floating bushing Stopper Stabilizer link Rear lateral link Bushing (C) Bushing (A) Front lateral link Bushing (B) Trailing link rear bushing Trailing link
(15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28)
Trailing link front bushing Trailing link bracket Cap (Protection) Washer Rear crossmember Strut mount cap Strut mount Rubber seat upper Dust cover Coil spring Helper Rubber seat lower Damper strut Self-locking nut
Tightening torque: Nm (kgf-m, ft-lb) T1: 20 (2.0, 14.5) T2: 25 (2.5, 18.1) T3: 45 (4.6, 33) T4: 60 (6.1, 44) T5: 100 (10.2, 74) T6: 115 (11.7, 85) T7: 130 (13.3, 96) T8: 140 (14.3, 103) T9: 200 (20.4, 148)
RS-3
Rear Suspension
GENERAL DESCRIPTION
S201001A03
C: CAUTION
Wear working clothing, including a cap, protective goggles, and protective shoes during operation. Remove contamination including dirt and corrosion before removal, installation or disassembly. Keep the disassembled parts in order and protect them from dust or dirt. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly, and replacement. Use SUBARU genuine grease etc. or the equivalent. Do not mix grease etc. with that of another grade or from other manufacturers. Be sure to tighten fasteners including bolts and nuts to the specified torque. Place shop jacks or safety stands at the specified points. Apply grease onto sliding or revolution surfaces before installation. Before installing O-rings or snap rings, apply sufficient amount of grease to avoid damage and deformation. Before securing a part on a vise, place cushioning material such as wood blocks, aluminum plate, or shop cloth between the part and the vise. Before disposing shock absorbers, be sure to bleed gas completely. Also, do not throw away in fire.
RS-4

1. SPECIAL TOOL
ILLUSTRATION
S201001A1701 S201001A17
Rear Suspension
DESCRIPTION ADAPTER
REMARKS Used as an adapter for camber & caster gauge when measuring camber and caster. (1) 28199AC000 PLATE (2) 28199AC010 BOLT
B4M2378A
927690000
Used for replacing lateral link bushing (12 dia.).
H5M0979
927700000
Used for replacing lateral link bushing (14 dia.).
H5M0979
927720000
Used for replacing trailing link bushing.
H5M0980
RS-5
Rear Suspension
ILLUSTRATION
GENERAL DESCRIPTION
TOOL NUMBER 927730000 DESCRIPTION INSTALLER & REMOVER SET REMARKS Used for replacing rear housing bushing.
H5M0979
927760000
STRUT MOUNT SOCKET
Used for disassembling and assembling strut mount.
B4M2384
2. GENERAL TOOL
Alignment Gauge Turning Radius Gauge Toe-in Gauge Transmission Jack Bearing Puller
S201001A1704
TOOL NAME Used Used Used Used Used for for for for for
REMARKS wheel alignment measurement. wheel alignment measurement. toe-in measurement. suspension assembly/disassembly. removing bushings.
RS-6
WHEEL ALIGNMENT
Rear Suspension
2. Wheel Alignment
A: INSPECTION
S201116A10
S201116
NOTE: The front and rear wheel alignment must be measured and/or adjusted at once to obtain accuracy. Measure and/or adjust the rear wheel alignment together with the front. Follow the procedure in FS section Wheel Alignment for measurement and/or adjustment of wheel alignment. <Ref. FS-6, INSPECTION, Wheel Alignment.>
RS-7
Rear Suspension
REAR STABILIZER
S201118
3. Rear Stabilizer
A: REMOVAL
S201118A18
B: INSTALLATION
S201118A11
1) Install in the reverse order of removal. NOTE: Install bushing while aligning it with paint mark on stabilizer. Ensure that bushing and stabilizer have the same identification colors when installing.
1) Set vehicle on a lift. 2) Disconnect ground terminal from battery. 3) Jack-up the rear part of the vehicle, support it with safety stands (rigid racks). 4) Remove bolts which secure stabilizer link to rear lateral link.
S4M0356A S4M0525
5) Remove bolts which secure stabilizer to stabilizer bracket.
(1) (2)
Mark stamped on stabilizer Bushing identification color
2) Always tighten rubber bushing location when wheels are in full contact with the ground and vehicle is curb weight. 3) Tightening torque: Stabilizer to stabilizer link: 45 Nm (4.6 kgf-m, 33 ft-lb) Stabilizer link to rear lateral link: 45 Nm (4.6 kgf-m, 33 ft-lb) Stabilizer to stabilizer bracket: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
S4M0526
C: INSPECTION
S201118A10
6) Separate rear stabilizer and stabilizer link.
1) Check bushing for cracks, fatigue or damage. 2) Check stabilizer links for deformities, cracks, or damage, and bushing for protrusions from the hole of stabilizer link.
RS-8
REAR TRAILING LINK
Rear Suspension
S201107A11
4. Rear Trailing Link

A: REMOVAL
S201107A18
S201107
B: INSTALLATION
Install in the reverse order of removal. CAUTION: Always tighten rubber bushing location when wheels are in full contact with the ground and vehicle is at curb weight condition. NOTE: Check wheel alignment and adjust if necessary.
1) Set vehicle on a lift. 2) Disconnect ground terminal from battery. 3) Loosen rear wheel nuts. 4) Jack-up vehicle, and remove rear wheels. 5) Remove both rear parking brake clamp and ABS sensor harness. (Models equipped with ABS)
C: DISASSEMBLY
1. FRONT BUSHING
S201107A06
S201107A0601
Using ST, press front bushing out of place. ST 927720000 INSTALLER & REMOVER SET
S4M0527A
(1) (2)
Parking brake cable ABS sensor harness
6) Remove bolt which secure trailing link to trailing link bracket.
S4M0103B
(1)
Trailing link (1) (2) Press Trailing link
S4M0358A
7) Remove bolt which secure trailing link to rear housing.
RS-9
Rear Suspension
REAR TRAILING LINK

S201107A0602
2. REAR BUSHING
D: ASSEMBLY
S201107A02
1) Remove housing. <Ref. to DS-23, REMOVAL, Rear Axle.> for removal procedures. 2) Using ST, press rear bushing out of place. ST 927730000 INSTALLER & REMOVER SET
Assemble in the reverse order of disassembly.
1. FRONT BUSHING
S201107A0201
Using ST, press bushing into trailing link. ST 927720000 INSTALLER & REMOVER SET CAUTION: When installing bushing, turn ST plunger upside down and press it until plunger end surface contacts trailing link end surface.
S4M0359A
(1) (2)
Press Housing
S4M0360A
(1) (2) (3)
Press Front bushing Trailing link
CAUTION: Install front bushing in the proper direction, as shown in figure.
S4M0361A
(1)
Front
RS-10
REAR TRAILING LINK

2. REAR BUSHING
S201107A0202
Rear Suspension
S201107A10
E: INSPECTION
1) Using ST, press bushing into trailing link. ST 927730000 INSTALLER & REMOVER SET NOTE: If it is difficult to press bushing into trailing link, apply water-diluted TIRE LUBE to the inner surface of ST as a lubricant. Specified lubricant: TIRE LUBE : water = 1 : 3
Check trailing links for bends, corrosion or damage.
B4M0224B
(1)
Press
2) Install housing. <Ref. INSTALLATION, Rear Axle.>
to
DS-26,
RS-11
Rear Suspension
LATERAL LINK
S201576
5. Lateral link
A: REMOVAL
S201576A18
8) Remove DOJ from rear differential using ST. (Except Non-TURBO AT model) ST 28099PA100 DRIVE SHAFT REMOVER NOTE: The side spline shaft circlip comes out together with the shaft.
1) Set vehicle on a lift. 2) Disconnect battery ground terminal from battery. 3) Loosen wheel nuts. Jack-up vehicle and remove wheel. 4) Remove stabilizers. <Ref. to RS-8, REMOVAL, Rear Stabilizer.> 5) Remove ABS sensor harness from trailing link. (Models equipped with ABS)
S4M0362A
(1) (2)
Bolt DOJ
S4M0527A
6) Remove bolt securing trailing link to housing.
CAUTION: Be careful not to damage side bearing retainer. Always use bolt as shown in figure, as supporting point for ST during removal. 9) Remove DOJ from rear differential using tire lever. (Non-TURBO AT model) NOTE: The side spline shaft circlip comes out together with the shaft.
B4M0573B
(1) (2)
Rear housing Trailing link
7) Remove bolts which secure lateral link assembly to rear housing.

(1) Tire lever
S4M0363A
RS-12
LATERAL LINK
CAUTION: When removing the DOJ from the rear differential, fit tire lever to the bolt as shown in figure so as not to damage the axle shaft holder.
Rear Suspension
S4M0364A
(1)
Axle shaft holder
10) Scribe an alignment mark on rear lateral link adjusting bolt and crossmember. 11) Remove bolts securing front and rear lateral links to crossmember, detach lateral links. CAUTION: To loosen adjusting bolt, always loosen nut while holding the head of adjusting bolt.
(1) (2) (3) (4) (5) Bushing A Bushing B Bushing C Front Outside of body
S4M0100B
B: INSTALLATION
S201576A11
Install in the reverse order of removal, observing the following instructions. NOTE: Installation of DOJ to differential; <Ref. to DS-39, INSTALLATION, Rear Drive Shaft.> CAUTION: Always tighten rubber bushing when wheels are in full contact with the ground and vehicle is curb weight. Tighten nut when installing adjusting bolt. Replace self-locking nut. NOTE: Check wheel alignment and adjust if necessary.
C: DISASSEMBLY
S201576A06
Using ST, press bushing out of place. NOTE: Using the following table as a guide, verify the type of bushings. Select ST according to the type of bushings used.
Bushing Bushing A Bushing B Bushing C ST: INSTALLER & REMOVER SET 927700000 927690000 927700000 (1) (2) Press Lateral link
S4M0365A
RS-13
Rear Suspension
LATERAL LINK
S201576A02
D: ASSEMBLY
1) Using ST, press bushing into place. CAUTION: Select ST according to the type of bushings used. NOTE: Use the same ST as that used during disassembly. If it is difficult to press bushing into trailing link, apply water-diluted TIRE LUBE to the inner surface of ST as a lubricant. Specified lubricant: TIRE LUBE : water = 1 : 3
2) Press ST plunger until bushing flange protrudes beyond lateral link. NOTE: Use the same ST as that used during disassembly.
B4M0197B
(1) (2) (3) (4)
Press Plunger Lateral link Flange
S4M0366A
(1) (2) (3)
Press Bushing Lateral link
RS-14
LATERAL LINK
3) Turn lateral link upside down. Press ST plunger in the direction opposite that outlined in the former procedure until bushing is correctly positioned in trailing link. NOTE: Use the same ST as that used during disassembly.
Rear Suspension
S201576A10
E: INSPECTION
Visually check lateral links for damage or bends.
B4M0198B
(1) (2) (3)
Press Plunger Lateral link
RS-15
Rear Suspension
REAR STRUT
S201132
6. Rear Strut
A: REMOVAL
10) Use a garage jack to support the rear housing.
S201132A18
1) Set vehicle on a lift. 2) Disconnect ground terminal from battery. 3) Depress brake pedal and secure it in that position using a wooden block, etc. 4) Remove strut cap of rear quarter trim.
S4M0104
11) Remove nuts securing strut mount to body.
S4M0105B
(1)
Strut cap
5) Loosen rear wheel nuts. 6) Jack-up vehicle, and remove rear wheels. 7) Remove brake hose clip.
S4M0102
12) Remove bolts which secure rear strut to housing.
S4M0528A
(1)
Clip
G4M0539
8) Models equipped with rear disc brakes: Remove union bolt from brake caliper.
13) Remove strut mount.
S4M0106
9) Models equipped with rear drum brakes: Disconnect brake hose and brake pipe from strut, and disconnect brake pipe from drum brake.
RS-16
REAR STRUT B: INSTALLATION

S201132A11
Rear Suspension
S201132A06
C: DISASSEMBLY
1) Install strut mount cap. 2) Tighten self-locking nut used to secure strut mount to vehicle body. CAUTION: Use a new self-locking nut. NOTE: Tighten strut mount and cap as a unit. Tightening torque: 20 Nm (2.0 kgf-m, 14.5 ft-lb) 3) Tighten bolts securing rear strut to housing. Tightening torque: 200 Nm (20.4 kgf-m, 148 ft-lb) CAUTION: Use a new self-locking nut. 4) Models with rear disc brakes: Tighten brake hose union bolt on brake caliper. Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft-lb) Models with rear drum brakes: Connect brake hose to brake pipe. Tightening torque: 15 Nm (1.5 kgf-m, 10.8 ft-lb) 5) Insert brake hose clip between brake hose and lower side of strut. CAUTION: Check that hose clip is positioned properly. Check brake hose for twisting, or excessive tension. Models equipped with ABS: Do not subject ABS sensor harness to excessive tension. 6) Be sure to bleed air from brake system. 7) Lower vehicle and tighten wheel nut. Tightening torque: 88 Nm (9 kgf-m, 65 ft-lb) 8) Install strut cap of rear quarter trim. NOTE: Check wheel alignment and adjust if necessary.
For disassembly of rear strut, refer to procedures outlined under front strut as a guide. <Ref. to FS-19, DISASSEMBLY, Front Strut.>
D: ASSEMBLY
S201132A02
Refer to Front Strut as a guide for assembly procedures. <Ref. to FS-20, ASSEMBLY, Front Strut.> CAUTION: Install rear strut with 4WD mark on strut mount facing outside of vehicle body. Insert the protrusion of lower rubber seat into the strut spring seat hole.
S4M0184B
(1) (2)
Front of vehicle 4WD mark
RS-17
Rear Suspension
REAR STRUT
S201132A10
E: INSPECTION
1) Refer to Front Strut as a guide for inspection procedures. <Ref. to FS-21, INSPECTION, Front Strut.> 2) For models equipped with self leveling struts: Inspect the following.
No. 1 Step CHECK WHEEL ARCH HEIGHT. 1) Remove all cargo from the vehicle. 2) Fill gasoline tank completely. 3) Drive vehicle (only the driver aboard) for at least 1 km (0.6 mile). 4) Measure the rear wheel arch height. This is value A in the equation. <Ref. to FS-6, Wheel Alignment.> 5) Put 4 people in the vehicle. NOTE: The total weight of the 4 people should be approximately 300 kg (662 lb). 6) Drive the vehicle for at least 5 km (3 miles). 7) Stop the vehicle. With the 4 people in the vehicle, measure the rear wheel arch height. This value is B in the equation. 8) A B = C CHECK WHEEL ARCH HEIGHT. 1) Let the 4 people get off of the vehicle. 2) Drive the vehicle (only the driver aboard) for at least 1 km (0.6 mile). 3) Measure the rear wheel arch height. This is value D in the equation. 4) A D = E CHECK VEHICLE. CHECK WHEEL ARCH HEIGHT. CHECK WHEEL ARCH HEIGHT. Check Yes Is C less than 30 mm (1.18 Go to step 2. in)? No Replace damper strut.
Is E less than 10 mm (0.39 in)?
Go to step 3.
Replace damper strut.
3 4 5
Is it a non-turbo vehicle? Is E less than 435+12/24 mm (17.13+0.47/0.94 in)? Is E less than 425+12/24 mm (16.73+0.47/0.94 in)?
Go to step 4. Correct. Correct.
Go to step 5. Replace coil spring. Replace coil spring.
RS-18
REAR STRUT F: DISPOSAL

S201132A07
Rear Suspension
CAUTION: Completely discharge the gas from the green-painted struts on outer housings, before disposal. Follow the disposal procedure outlined below. Do not disassemble strut damper or place into a fire. Drill holes before disposing of self leveling struts. Before handling self leveling struts, be sure to wear goggles to protect eyes from gas, oil and/or filings. 1) Place self leveling strut upside-down (the opposite of its installation position on the vehicle) on a flat surface. 2) Using a 2 to 3 mm (0.08 to 0.12 in) dia. drill, drill 30 mm (1.18 in) deep holes in areas shown in the figure.
S4M0229B
(1)
Self leveling strut
RS-19
Rear Suspension
REAR CROSSMEMBER
S201133
7. Rear Crossmember
A: REMOVAL
S201133A18
B: INSTALLATION
S201133A11
CAUTION: Do not subject ABS sensor harness to excessive tension. (Models equipped with ABS) 1) Set vehicle on a lift. 2) Disconnect ground terminal from battery. 3) Loosen wheel nuts. Jack-up vehicle and remove wheels. 4) Separate front exhaust pipe and rear exhaust pipe. (Non-turbo model) 5) Separate center exhaust pipe (rear) and rear exhaust pipe. (Turbo model) 6) Remove rear exhaust pipe and muffler. 7) Remove rear differential. T-Type: <Ref. to DI-25, Rear Differential for T-type.> VA-Type: <Ref. to DI-42, Rear Differential for VAtype.> 8) Place transmission jack under rear crossmember.
1) Install in the reverse order of removal. 2) For installation and tightening torque of rear differential, always tighten rubber bushing when wheels are in full contact with the ground and vehicle is curb weight. NOTE: Check wheel alignment and adjust if necessary.
C: INSPECTION
S201133A10
Check removed parts for wear, damage and cracks, and correct or replace if defective.
G4M0544
9) Remove bolts securing crossmember to vehicle body, and remove crossmember.
G4M0545
10) Scribe an alignment mark on rear lateral link cam bolt and crossmember. 11) Remove front and rear lateral links by loosening nuts.
RS-20
Rear Suspension

A: INSPECTION
S201257A10
S201257
1. IMPROPER VEHICLE POSTURE OR IMPROPER WHEEL ARCH HEIGHT

(1) (2) (3) (4) Possible causes Permanent distortion or breakage of coil spring Unsmooth operation of damper strut Installation of wrong strut Installation of wrong coil spring
S201257A1002
S201257A1001
Countermeasures Replace. Replace. Replace with proper parts. Replace with proper parts.
2. POOR RIDE COMFORT
1) Large rebound shock 2) Rocking of vehicle continues too long after running over bump and/or hump. 3) Large shock in bumping
Possible causes (1) Breakage of coil spring (2) Overinflation pressure of tire (3) Improper wheel arch height (4) Fault in operation of damper strut (5) Damage or deformation of strut mount (6) Unsuitability of maximum and/or minimum length of damper strut (7) Deformation or loss of bushing (8) Deformation or damage of helper in strut assembly (9) Oil leakage of damper strut Countermeasures Replace. Adjust. Adjust or replace coil springs with new ones. Replace. Replace. Replace with proper parts. Replace. Replace. Replace.
3. NOISE
S201257A1003
Possible causes (1) Wear or damage of damper strut component parts (2) Loosening of suspension link installing bolt (3) Deformation or loss of bushing (4) Unsuitability of maximum and/or minimum length of damper strut (5) Breakage of coil spring (6) Wear or damage of ball joint (7) Deformation of stabilizer clamp
Countermeasures Replace. Retighten to the specified torque. Replace. Replace with proper parts. Replace. Replace. Replace.
RS-21
Rear Suspension
MEMO:
RS-22
WHEEL AND TIRE SYSTEM
WT
1. 2. 3. 4. 5. 6. Page General Description.....................................................................................2 Tire ..............................................................................................................4 Steel Wheel .................................................................................................5 Aluminum Wheel .........................................................................................6 Wheel Balancing .........................................................................................7 General Diagnostics Table ..........................................................................8
Wheel and Tire System
GENERAL DESCRIPTION
S204001
A: SPECIFICATIONS
S204001E49
S4M0367A
(1) (2)
Offset P.C.D. Model Australia model Tire size P205/70R15 95S P215/60R16 94H 205/70R15 95H 215/60R16 95V Rim size 15 6J 16 6 1/2JJ 15 6J 16 6 1/2JJ Rim offset 48 mm (1.89 in) 100 mm (3.94 in) dia. 48 mm (1.89 in) Tire inflation pressure Light load Ft: 200 kPa (2.0 kg/cm2, 29 psi) Rr: 190 kPa (1.9 kg/cm2, 28 psi) Full load Ft: 200 kPa (2.0 kg/cm2, 29 psi) Rr: 250 kPa (2.5 kg/cm2, 36 psi) P.C.D.
Front and Rear Except Australia model
Model Australia model Except Australia model
Tire size P205/70R15 95S P215/60R16 94H 205/70R15 95H 215/60R16 95V
NOTE: Spare tires are the same for both front and rear. At trailer towing, rear inflation pressure is 280 kPa (2.8 kg/cm2, 41 psi).
WT-2
GENERAL DESCRIPTION
1. SERVICE DATA
Item Steel wheel Aluminum wheel
S204001E4901

S204001A17
B: PREPARATION TOOL
Axial runout Radial runout 1.5 mm (0.059 in) 1.0 mm (0.039 in)
S204001E4902
S204001A1701
2. ADJUSTING PARTS
Wheel balancing Dynamic unbalance
TOOL NAME REMARKS Air Pressure Gauge Used for measuring tire air pressure. Dial Gauge Used for measuring wheel runout.
Standard Service limit Less than 5 g (0.18 oz) Weight 5 g (0.18 oz) 10 g (0.35 oz) 15 g (0.53 oz) 20 g (0.71 oz) 25 g (0.88 oz) 30 g (1.06 oz) 35 g (1.23 oz) 40 g (1.41 oz) 45 g (1.59 oz) 50 g (1.76 oz) 55 g (1.94 oz) 60 g (2.12 oz) Weight 5 g (0.18 oz) 10 g (0.35 oz) 15 g (0.53 oz) 20 g (0.71 oz) 25 g (0.88 oz) 30 g (1.06 oz) 35 g (1.23 oz) 40 g (1.41 oz) 45 g (1.59 oz) 50 g (1.76 oz) 55 g (1.94 oz) 60 g (2.12 oz)
Balance weight part number (For steel wheel) 28101FC000 28101FC010 28101FC020 723141320 723141330 723141340 723141350 723141360 723141370 723241380 723241580 723241590 Balance weight part number (For aluminum wheel) 23141GA462 23141GA472 23141GA482 23141GA492 23141GA502 23141GA512 23141GA522 23141GA532 23141GA542 23141GA552 23141GA572
WT-3
TIRE
2. Tire
S204125
A: INSPECTION
S204125A10
1) Take stone, glass, nail etc. off the tread groove. 2) Replace tire: CAUTION: When replacing a tire, make sure to use only the same size, construction and load range as originally installed. Avoid mixing radial, belted bias or bias tires on the vehicle. (1) when large crack on side wall, damage or crack on tread is found. (2) when the tread wear indicator appears as a solid band across the tread.
S4M0377A
(1) (2)
Tread wear indicator Tire tread

S204125A1001
1. TIRE ROTATION
If tires are maintained at the same positions for a long period of time, uneven wear results. Therefore, they should be periodically rotated. This lengthens service life of tires. CAUTION: When rotating tires, replace unevenly worn or damaged tires with new ones.
B4M1765
WT-4
STEEL WHEEL

S204131A10
3. Steel Wheel
A: REMOVAL
S204131
C: INSPECTION
S204131A18
1) Apply parking brake, and position select lever to P or LOW. 2) Set shop jacks or a lift to the specified point, and support the vehicle with its wheels slightly contacting the floor. 3) Loosen wheel nuts. 4) Raise the vehicle until its wheels take off the ground using a jack or a lift. 5) Remove wheel nuts and wheels. NOTE: While removing wheels, prevent hub bolts from damage. Place wheels with their outer sides facing upward to prevent wheels from damage.
1) Deformation or damage on the rim can cause air leakage. Check the rim flange for deformation, crack, or damage, and repair or replace as necessary. 2) Jack-up vehicle until wheels clear the floor. 3) Slowly rotate wheel to check rim runout using a dial gauge.
B: INSTALLATION
S204131A11
G4M0298
1) Attach the wheel to the hub by aligning the wheel bolt hole with the hub bolt. 2) Temporarily attach the wheel nuts to the hub bolts. (In the case of aluminum wheel, use SUBARU genuine wheel nut for aluminum wheel.) 3) Manually tighten the nuts making sure the wheel hub hole is aligned correctly to the guide portion of hub. 4) Tighten the wheel nuts in a diagonal selection to the specified torque. Use a wheel nut wrench. Wheel nut tightening torque: 88 Nm (9 kgf-m, 65 ft-lb) CAUTION: Tighten the wheel nuts in two or three steps by gradually increasing the torque and working diagonally, until the specified torque is reached. For drum brake models, excess tightening of wheel nuts may cause wheels to judder. Do not depress the wrench with a foot; Always use both hands when tightening. Make sure the bolt, nut and the nut seating surface of the wheel are free from oils. 5) If a wheel is removed for replacement or for repair of a puncture, retighten the wheel nuts to the specified torque after running 1,000 km (600 miles).
Axial runout limit Radial runout limit 1.5 mm (0.059 in)
G4M0299
4) If rim runout exceeds specifications, remove tire from rim and check runout while attaching dial gauge to positions shown in figure. 5) If measured runout still exceeds specifications, replace the wheel.
WT-5
ALUMINUM WHEEL
S204130
4. Aluminum Wheel
A: REMOVAL
S204130A18
Refer to Steel Wheel for removal procedure of aluminum wheels. <Ref. to WT-5 REMOVAL Steel Wheel.>
B: INSTALLATION
A204130A11
Refer to Steel Wheel for installation procedure of aluminum wheels. <Ref. to WT-5 INSTALLATION, Steel Wheel.>
C: INSPECTION
S204130A10
Refer to Steel Wheel for inspection procedure of aluminum wheels. <Ref. to WT-5 INSPECTION, Steel Wheel.> Rim runout:
Axial runout limit Radial runout limit 1.0 mm (0.039 in)
D: CAUTION
S204130A03
Aluminum wheels are easily scratched. To maintain their appearance and safety, do the following: 1) Do not damage aluminum wheels during removal, disassembly, installation, wheel balancing, etc. After removing aluminum wheels, place them on a rubber mat, etc. 2) While vehicle is being driven, be careful not to ride over sharp obstacles or allow aluminum wheels to contact the shoulder of the road. 3) When installing tire chain, be sure to install it properly not to have a slack; otherwise it may hit wheel while driving. 4) When washing aluminum wheel, use neutral synthetic detergent and water. Avoid using the cleanser including abrasive, hard brushes or an automatic car washer.
WT-6
WHEEL BALANCING

S204127A10
5. Wheel Balancing
A: REPLACEMENT
S204127
B: INSPECTION
S204127A20
1) Remove balance weights. 2) Using dynamic balancing, measure wheel balance. 3) Select a weight close to the value measured by dynamic balancing.
Balance weight part number (For steel wheel) 28101FC000 28101FC010 28101FC020 723141320 723141330 723141340 723141350 723141360 723141370 723241380 723241580 723241590 Balance weight part number (For aluminum wheel) 23141GA462 23141GA472 23141GA482 23141GA492 23141GA502 23141GA512 23141GA522 23141GA532 23141GA542 23141GA552 23141GA572 Weight 5 g (0.18 oz) 10 g (0.35 oz) 15 g (0.53 oz) 20 g (0.71 oz) 25 g (0.88 oz) 30 g (1.06 oz) 35 g (1.23 oz) 40 g (1.41 oz) 45 g (1.59 oz) 50 g (1.76 oz) 55 g (1.94 oz) 60 g (2.12 oz) Weight 5 g (0.18 oz) 10 g (0.35 oz) 15 g (0.53 oz) 20 g (0.71 oz) 25 g (0.88 oz) 30 g (1.06 oz) 35 g (1.23 oz) 40 g (1.41 oz) 45 g (1.59 oz) 50 g (1.76 oz) 55 g (1.94 oz) 60 g (2.12 oz)
1) Proper wheel balance may be lost if the tire is repaired or if it wears. Check the tire for dynamic balance, and repair as necessary. 2) To check for dynamic balance, use a dynamic balancer. Drive in the balance weight on both the top and rear sides of the rim. 3) Some types of balancer can cause damage to the wheel. Use an appropriate balancer when adjusting the wheel balance. 4) Use genuine balance weights. CAUTION: 55 g (1.94 oz) weight used with aluminum wheel is not available. Balance weights are available for use with any of 14- to 16-inch wheels.
B4M0053B
4) Install the selected weight to the point designated by dynamic balancing. 5) Using dynamic balancing, measure wheel balance again. Check that wheel balance is correctly adjusted.
(1) (2)
Weight for aluminum wheel Weight for steel wheel
Service limit: A Weight for steel wheel; 1.8 2.0 mm (0.071 0.079 in) Weight for aluminum wheel; 4.6 5.4 mm (0.181 0.213 in)
WT-7
GENERAL DIAGNOSTICS TABLE

S204121
6. General Diagnostics Table

A: INSPECTION
Symptom Front wheel shimmy Abnormal tire wear Sways/pitches Wander/pulls
S204121A10
Possible cause Worn or improperly inflated of tire. Wheel is out of balance. Improperly inflated of tire. Worn or improperly inflated of tire. Worn or improperly inflated of tire.
Remedy Replace Adjustment Replace Replace Replace
WT-8
DIFFERENTIALS
DI
1. 2. 3. 4. 5. 6. 7. 8. 9. Page General Description.....................................................................................2 Differential Gear Oil...................................................................................22 Front Differential........................................................................................24 Rear Differential for T-type ........................................................................25 Rear Differential for VA-type .....................................................................42 Rear Differential Front Oil Seal.................................................................59 Rear Differential Side Oil Seal ..................................................................61 Rear Differential Member ..........................................................................66 General Diagnostic Table ..........................................................................67
Differentials
GENERAL DESCRIPTION
S303001
A: SPECIFICATIONS
Model
S303001E49
Non-Turbo MT T type Rear differential type Gear Gear ratio Oil capacity Rear differential gear oil T2 AT VA type XH Europe
Turbo Except Europe MT AT T type (with LSD) JP
4.111 (37/9)
HP (with oil temCF perature sensor) Hypoid gear 4.444 (40/9) 0.8 L (0.8 US qt, 0.7 Imp qt) GL-5
Identification When replacing a rear differential assembly, select the correct one according to the following table. CAUTION: Using the different rear differential assembly causes the drive line and tires to drag or emit abnormal noise when AWD is selected.
S3M0613
DI-2
GENERAL DESCRIPTION
Rear differential gear oil Recommended oil CAUTION: Each oil manufacturer has its base oil and additives. Thus, do not mix two or more brands.
Differentials
H3M1272A
1. SERVICE DATA
S303001E4901
Front and rear bearing preload at companion New bearing flange bolt hole N (kgf, lb) Used bearing Side gear backlash mm (in) mm (in) mm (in) mm (in)
T-type VA-type T-type T-type VA-type T-type VA-type
Side bearing standard width
Crown gear to drive pinion backlash
Crown gear runout on its back surface
19.6 28.4 (2.0 2.9, 4.4 6.4) 12.7 32.4 (1.3 3.3, 2.9 7.3) 8.34 16.67 (0.85 1.7, 1.87 3.75) 0.10 0.20 (0.0039 0.0079) 0.05 0.15 (0.0020 0.0059) 20.00 (0.7874) 0.10 0.20 (0.0039 0.0079) 0.10 0.15 (0.0039 0.0059) Less than 0.05 (0.0020)
DI-3
Differentials
GENERAL DESCRIPTION
S303001E4902
2. ADJUSTING PARTS
VA-type
Item
Preload adjusting spacer
Preload adjusting washer
Pinion height adjusting shim
Part No. 32288AA040 32288AA050 31454AA100 32288AA060 31454AA110 32288AA070 31454AA120 32288AA080 32288AA090 38336AA000 38336AA120 38336AA010 38336AA130 38336AA020 38336AA140 38336AA030 38336AA150 38336AA040 38336AA160 38336AA050 38336AA170 38336AA060 38336AA180 38336AA070 38336AA190 38336AA080 38336AA200 38336AA090 38336AA210 38336AA100 38336AA220 38336AA110 32295AA200 32295AA210 32295AA220 32295AA230 32295AA240 32295AA250 803135011 803135012
Side gear thrust washer
803135013 803135014 803135015
Length or thickness 52.3 mm (2.059 in) 52.5 mm (2.067 in) 52.6 mm (2.071 in) 52.7 mm (2.075 in) 52.8 mm (2.079 in) 52.9 mm (2.083 in) 53.0 mm (2.087 in) 53.1 mm (2.091 in) 53.3 mm (2.098 in) 1.500 mm (0.0591 in) 1.513 mm (0.0596 in) 1.525 mm (0.0600 in) 1.538 mm (0.0606 in) 1.550 mm (0.0610 in) 1.563 mm (0.0615 in) 1.575 mm (0.0620 in) 1.588 mm (0.0625 in) 1.600 mm (0.0630 in) 1.613 mm (0.0635 in) 1.625 mm (0.0640 in) 1.638 mm (0.0645 in) 1.650 mm (0.0650 in) 1.663 mm (0.0655 in) 1.675 mm (0.0659 in) 1.688 mm (0.0665 in) 1.700 mm (0.0669 in) 1.713 mm (0.0674 in) 1.725 mm (0.0679 in) 1.738 mm (0.0684 in) 1.750 mm (0.0689 in) 1.763 mm (0.0694 in) 1.775 mm (0.0699 in) 0.150 mm (0.0059 in) 0.175 mm (0.0069 in) 0.200 mm (0.0079 in) 0.225 mm (0.0089 in) 0.250 mm (0.0098 in) 0.275 mm (0.0108 in) 0.925 0.950 mm (0.0364 0.0374 in) 0.950 0.975 mm (0.0374 0.0384 in) 0.975 1.000 mm (0.0384 0.0394 in) 1.000 1.025 mm (0.0394 0.0404 in) 1.025 1.050 mm (0.0404 0.0413 in)
DI-4
GENERAL DESCRIPTION
T-type
Item Part No. 383695201 383695202 383695203 383695204 383695205 383695206 383705200 383715200 383725200 383735200 383745200 383755200 383765200 383775200 383785200 383795200 383805200 383815200 383825200 383835200 383845200 383495200 383505200 383515200 383525200 383535200 383545200 383555200 383565200 383575200 383585200 383595200 383605200 383615200 383625200 383635200 383645200 383655200 383665200 383675200 383685200 383445201 383445202 383445203 383445204 383445205
Differentials
Side gear thrust washer
Length or thickness 56.2 mm (2.213 in) 56.4 mm (2.220 in) 56.6 mm (2.228 in) 56.8 mm (2.236 in) 57.0 mm (2.244 in) 57.2 mm (2.252 in) 2.59 mm (0.1020 in) 2.57 mm (0.1012 in) 2.55 mm (0.1004 in) 2.53 mm (0.0996 in) 2.51 mm (0.0988 in) 2.49 mm (0.0980 in) 2.47 mm (0.0972 in) 2.45 mm (0.0965 in) 2.43 mm (0.0957 in) 2.41 mm (0.0949 in) 2.39 mm (0.0941 in) 2.37 mm (0.0933 in) 2.35 mm (0.0925 in) 2.33 mm (0.0917 in) 2.31 mm (0.0909 in) 3.09 mm (0.1217 in) 3.12 mm (0.1228 in) 3.15 mm (0.1240 in) 3.18 mm (0.1252 in) 3.21 mm (0.1264 in) 3.24 mm (0.1276 in) 3.27 mm (0.1287 in) 3.30 mm (0.1299 in) 3.33 mm (0.1311 in) 3.36 mm (0.1323 in) 3.39 mm (0.1335 in) 3.42 mm (0.1346 in) 3.45 mm (0.1358 in) 3.48 mm (0.1370 in) 3.51 mm (0.1382 in) 3.54 mm (0.1394 in) 3.57 mm (0.1406 in) 3.60 mm (0.1417 in) 3.63 mm (0.1429 in) 3.66 mm (0.1441 in) 0.75 0.80 mm (0.0295 0.0315 in) 0.80 0.85 mm (0.0315 0.0335 in) 0.85 0.90 mm (0.0335 0.0354 in) 0.90 0.95 mm (0.0354 0.0374 in) 0.95 1.0 mm (0.0374 0.0394 in)
DI-5
Differentials
Item
GENERAL DESCRIPTION
Part No. 383475201 383475202 383475203 383475204 383475205 Length or thickness 0.20 mm (0.0079 in) 0.25 mm (0.0098 in) 0.30 mm (0.0118 in) 0.40 mm (0.0157 in) 0.50 mm (0.0197 in)
Side bearing retainer shim
DI-6

S303001A05
Differentials
1. REAR DIFFERENTIAL FOR T-TYPE WITHOUT LSD
S303001A0501
B3M0130C
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12)
Pinion crown gear set Pinion height adjusting washer Rear bearing Bearing preload adjusting spacer Bearing preload adjusting washer Differential carrier Front bearing Spacer Pilot bearing Front oil seal Companion flange Self-locking nut
(13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25)
Side bearing O-ring Side bearing retainer shim Side bearing retainer Side oil seal Side gear thrust washer Side gear Pinion mate gear Pinion mate gear washer Pinion shaft lock pin Circlip Pinion mate shaft Air breather cap
(26) (27) (28) (29) (30)
Stud bolt Oil filler plug Oil drain plug Rear cover Differential case
Tightening torque: Nm (kgf-m, ft-lb) T1: 10.3 (1.05, 7.6) T2: 29.4 (3.00, 21.7) T3: 49.0 (5.0, 36.2) T4: 103.0 (10.50, 75.9) T5: 181.4 (18.50, 133.8)
DI-7
Differentials
GENERAL DESCRIPTION
2. REAR DIFFERENTIAL FOR T-TYPE WITH LSD S303001A0502
S3M0643A
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)
Pinion crown gear set Pinion height adjusting shim Rear bearing Bearing preload adjusting spacer Bearing preload adjusting washer Differential carrier Front bearing Collar Pilot bearing Front oil seal Companion flange
(12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22)
Self-locking nut Side bearing O-ring Side bearing retainer shim Side bearing retainer Side oil seal Gasket Differential case Rear cover Air breather cap Stud bolt
(23) Oil filler plug (With oil temperature sensor) (24) Oil filler plug (Without oil temperature sensor) (25) Oil drain plug
Tightening torque: Nm (kgf-m, ft-lb) T1: 10.3 (1.05, 7.6) T2: 29 (3.0, 21.7) T3: 49.0 (5.0, 36.2) T4: 103 (10.5, 76) T5: 181 (18.5, 134)
DI-8
GENERAL DESCRIPTION
3. REAR DIFFERENTIAL FOR VA-TYPE
S303001A0503
Differentials
H3M1663A
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12)
Pinion crown gear set Pinion height adjusting shim Rear bearing Bearing preload adjusting spacer Bearing preload adjusting washer Differential carrier Front bearing Collar Pilot bearing Front oil seal Companion flange Self-locking nut
(13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25)
Lock plate Side bearing O-ring Axle shaft holder Side oil seal Side gear thrust washer Side gear Pinion mate gear Pinion shaft lock pin Differential case Pinion mate shaft Air breather cap Stud bolt
(26) (27) (28) (29)
Gasket Oil filler plug Oil drain plug Rear cover
Tightening torque: Nm (kgf-m, ft-lb) T1: 25 (2.5, 18.1) T2: 25 (2.5, 18.1) T3: 34 (3.5, 25.3) T4: 62 (6.3, 45.6) T5: 188 (19.2, 139)
DI-9
Differentials
GENERAL DESCRIPTION
4. REAR DIFFERENTIAL MOUNTING SYSTEM S303001A0504
S3M0231A
(1) (2) (3) (4) (5)
Differential front member Plate Crossmember Rear bushing Differential mount lower bracket (Non-Turbo model) (6) Differential mount lower bracket (Turbo model) (7) Stopper
(8) (9) (10) (11)
Differential mount bracket Dynamic damper A Mass damper (Turbo model) Dynamic damper B (Non-Turbo model) (12) Differential mount front cover
Tightening torque: Nm (kgf-m, ft-lb) T1: 20 (2.0, 14.5) T2: 32 (3.3, 23.9) T3: 40 (4.1, 30) T4: 64 (6.5, 47.0) T5: 69 (7.0, 50.6) T6: 69 (7.0, 50.6) T7: 88 (9.0, 65) T8: 98 (10.0, 72)
DI-10

S303001A03
Differentials
Wear working clothing, including a cap, protective goggles, and protective shoes during operation. Remove contamination including dirt and corrosion before removal, installation or disassembly. Keep the disassembled parts in order and protect them from dust or dirt. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly, and replacement. Be careful not to burn your hands, because each part on the vehicle is hot after running. Use SUBARU genuine gear oil, grease etc. or the equivalent. Do not mix gear oil, grease etc. with that of another grade or from other manufacturers. Be sure to tighten fasteners including bolts and nuts to the specified torque. Place shop jacks or safety stands at the specified points. Apply gear oil onto sliding or revolution surfaces before installation. Before installing O-rings or snap rings, apply sufficient amount of gear oil to avoid damage and deformation. Before securing a part on a vise, place cushioning material such as wood blocks, aluminum plate, or shop cloth between the part and the vise. Avoid damaging the mating face of the case.
DI-11
Differentials
GENERAL DESCRIPTION
S303001A17
D: PREPARATION TOOL
1. SPECIAL TOOLS
ILLUSTRATION
S303001A1701
DESCRIPTION HANDLE
REMARKS Used for installing front and rear bearing cone.
B3M1893
398477702
DRIFT
Used press-fitting the bearing cone of differential carrier (rear).
B3M1894
398217700
ATTACHEMENT SET
Stand for rear differential carrier disassembly and assembly.
B3M1895
498447120
OIL SEAL INSTALLER
Used for installing front oil seal.
B3M1896
DI-12
GENERAL DESCRIPTION
ILLUSTRATION TOOL NUMBER 498427200 DESCRIPTION FLANGE WRENCH
Differentials
REMARKS Used for stopping rotaiotn of companion flange when loosening and tightening self-lock nut.
B3M1897
398467700
DRIFT
Used for removing pinion, pilot bearing and front bearing cone.
B3M1898
399780104
WEIGHT
Used for installing front bearing cone, pilot bearing companion flange.
B3M1899
899580100
INSTALLER
Used for press-fitting the front bearing cone, pilot bearing.
B3M1900
899904100
STRAIGHT PIN REMOVER
Used for driving out differential pinion shaft lock pin.
B3M1901
DI-13
Differentials
ILLUSTRATION
GENERAL DESCRIPTION
TOOL NUMBER 399703600 DESCRIPTION PULLEY ASSY REMARKS Used for removing companion flange.
B3M1930
498247001
MAGENT BASE
Used for measuring backlash between side gear and pinion, and hypoid gear.. Used with DIAL GAUGE (498247100).
B3M1902
498247100
DAIL GAUGE
Used measurng backlash between side gear and pinion, hypoid gear. Used with MAGNET BASE (498247001).
B3M1903
398507704
BLOCK
Used for adjusting pinion height and preload.
B3M1904
DI-14
GENERAL DESCRIPTION
Differentials
REMARKS Used for installing rear bearing cone. For T-type.
B3M1905
398457700
ATTACHMENT
Used for removing side bearing retainer. For T-type.
B3M1906
398477703
DRIFT2
Used forpress-fitting the bearing race (rear) of differential carrier. For T-type.
B3M1907
398437700
DRIFT
Used for installing said oil seal. For T-type.
B3M1908
DI-15
Differentials
ILLUSTRATION
GENERAL DESCRIPTION
TOOL NUMBER 398507702 DESCRIPTION DUMMY SHAFT REMARKS Used for adjusting pinion height and preload. For T-type.
B3M1909
398507703
DUMMY COLLAR
Used for adjusting pinion height and preload. For T-type.
B3M1910
398517700
REPLACER
Used for removing rear bearing cone. For T-type.
B3M1911
398487700
DRIFT
Used for press-fitting the side bearing cone. For T-type.
B3M1912
398507701
GAUGE
Used for adjusting pinion height. For T-type.
B3M1913
DI-16
GENERAL DESCRIPTION
ILLUSTRATION TOOL NUMBER 398527700 DESCRIPTION PULLER ASSY
Differentials
REMARKS Used for removing oil seal and side bearing cup. For T-type.
B3M1914
399527700
PULLER SET
Used for extracking side bearing cone. (1) BOLT (899521412) (2) PULLER (399527702) (3) HOLDER (399527703) (4) ADAPTER (398497701) (5) BOLT (899520107) (6) NUT (021008000) For T-type.
B3M1915A
28099PA090
OIL SEAL PROTEC- Used for installing rear drive shaft into rear TOR differential. For protecting oil seal. For T-type.
B3M1917
28099PA100
DRIVE SHAFT REMOVER
Used for removing rear drive shaft from rear differential. For T-type.
B3M1919
DI-17
Differentials
ILLUSTRATION
GENERAL DESCRIPTION
TOOL NUMBER 498175500 DESCRIPTION INSTALLER REMARKS Used for installing rear bearing cone. For VA-type.
B3M1920
399780111
WRENCH ASSY
Used for removing and installing side oil seal holder. For VA-type.
B3M1921
498447100
INSTALLER
Used for installing oil seal. For VA-type.
B3M1922
399520105
SEAT
Used for removing side bearing cone. Used with PULLER SET (899524100). For VA-type.
B3M1923
DI-18
GENERAL DESCRIPTION
ILLUSTRATION TOOL NUMBER 498485400 DESCRIPTION DRIFT
Differentials
REMARKS UUsed for installing side bearing cone. For VA-type.
B3M1924
498505501
GAUGE
Used for adjusting pinion height. For VA-type.
B3M1925
498447110
BEARING OUTER RACE DRIFT
Used for press-fitting the bearing race (front) of differential carrier. For VA-type.
B3M1926
498447150
DUMMY SHAFT
Used for adjusting pinion height and Preload. For VA-type.
B3M1927
DI-19
Differentials
ILLUSTRATION
GENERAL DESCRIPTION
TOOL NUMBER 32285AA000 DESCRIPTION DUMMY COLLAR REMARKS Used for adjusting pinion height and Preload. For VA-type.
B3M1928
499705404
SEAT
Used for removing side bearing race. Used with PULLEY ASSY (499705401). For VA-type.
B3M1929
499705401
PULLEY ASSY
Used for removing side bearing race. Used with SEAT (499705404). For VA-type.
B3M1930
899874100
INSTALLER
Used for installing companion flange. For VA-type.
B3M1931
899524100
DIFFERENTIAL BEARING PULLER SET
Used for removing side bearing cone of differential. For VA-type. (1) Puller (2) Cap Used with SEAT (399520105)
B3M1932A
DI-20
GENERAL DESCRIPTION
TOOL NAME Transmission Jack Puller Thickness Gauge Tire Lever
S301001A1702
Differentials
REMERKS Used for assembly/disassembly of rear differential. Used for removal of side bearing retainer. (T-type) Used for measuring clearance. Used for removal of rear drive shaft. (VA-type)
DI-21
Differentials

S303150
2. Differential Gear Oil

A: INSPECTION
S303150A10
B: REPLACEMENT
S303150A20
1) Set vehicle on a lift. 2) Disconnect ground terminal from battery. 3) Lift vehicle. 4) Disconnect oil temperature sensor connector (Turbo model for Europe).
1) Disconnect ground terminal from battery. 2) Jack-up vehicle and support it with sturdy racks. 3) Disconnect oil temperature sensor connector (Turbo model for Europe).
S3M0615A S3M0615A
(A)
Connector
(A)
Connector
5) Take out filler plug, and replace gear oil if it is contaminated or deteriorated. <Ref. to DI-22 REPLACEMENT, Differential Gear Oil.> 6) Check gear oil level is up to the bottom part of filler bolt. If the level is low, refill up to the bottom of filler bolt.
4) Remove the oil drain plug and filler plug, and drain the gear oil. CAUTION: Be careful not to burn your hands, because gear oil becomes extremely hot after running.
B3M0136B
S3M0527A
(A) (B)
Filler plug Drain plug
(A) (B)
5) Tighten oil drain plug. CAUTION: Apply fluid packing to drain plug in T-type. VA-type uses a new aluminum gasket. Fluid packing: THREE BOND 1105 or equivalent Tightening torque: T-type; 49.0 Nm (5.0 kgf-m, 36.2 ft-lb) VA-type; 34 Nm (3.5 kgf-m, 25.3 ft-lb)
DI-22

6) Fill differential carrier with gear oil to the upper plug level. CAUTION: Carefully refill oil while watching the level. Excess or insufficient oil must be avoided. Oil capacity: 0.8 (0.8 US qt, 0.7 Imp qt)
Differentials
S3M0527A
(A) (B)
7) Install filler plug. CAUTION: Apply fluid packing to drain plug in T-type. VA-type uses a new aluminum gasket. Fluid packing: THREE BOND 1105 or equivalent Tightening torque: T-type; 49.0 Nm (5.0 kgf-m, 36.2 ft-lb) VA-type; 34 Nm (3.5 kgf-m, 25.3 ft-lb) 8) Connect oil temperature sensor connector.
DI-23
Differentials
FRONT DIFFERENTIAL
S303152
3. Front Differential
A: NOTE
S303152A15
1. AT MODEL
S303152A1501
Refer to AUTOMATIC TRANSMISSION in separate publication AUTOMATIC TRANSMISSION for Front Differential. (Pub No. G0853ZE)
2. MT MODEL
S303152A1502
For front differential of manual transmission, refer to MT section. <Ref. to MT-92, Front Differential Assembly.>
DI-24
REAR DIFFERENTIAL FOR T-TYPE
Differentials
4. Rear Differential for T-type

S303145
12) Remove heat sealed cover.
A: REMOVAL
S303145A18
1) Set vehicle on a lift. 2) Disconnect ground terminal from battery. 3) Move select lever or gear shift lever to N. 4) Release the parking brake. 5) Loosen wheel nuts. 6) Jack-up vehicle and support it with sturdy racks. 7) Remove wheels. 8) Remove rear exhaust pipe and muffler. Non-turbo model with OBD: <Ref. to EX(SOHC)-9, REMOVAL, Rear Exhaust Pipe.> and <Ref. to EX(SOHC)-11, REMOVAL, Muffler.> Non-turbo model without OBD: <Ref. to EX(SOHCw/oOBD)-10, REMOVAL, Rear Exhaust Pipe.> and <Ref. to EX(SOHCw/oOBD)12, REMOVAL, Muffler.> Turbo model: <Ref. to EX(DOHC TURBO)-14, REMOVAL, Rear Exhaust Pipe.> and <Ref. to EX(DOHC TURBO)15, REMOVAL, Muffler.> 9) Remove front exhaust cover. (Non-Turbo model)
S2M0166
13) Remove clamps and bracket of parking brake cable.
S2M0191
14) Disconnect connector from oil temperature sensor. (Turbo model for Europe)
S3M0502
10) Remove front cover of rear differential mount.

(A) Connector
S3M0615A
S3M0503
11) Remove propeller shaft. <Ref. to DS-14, REMOVAL, Propeller Shaft.>
DI-25
Differentials

18) Support rear differential with transmission jack.
15) Remove DOJ of rear drive shaft from rear differential using ST. <Ref. to DS-38, REMOVAL, Rear Drive Shaft.> ST 28099PA100 DRIVE SHAFT REMOVER
S3M0505
H3M1179B
19) Remove self-locking nuts connecting rear differential to rear crossmember.
(A) (B)
Bolt DOJ
16) Secure rear drive shaft to rear crossmember using wire.
G3M1028
20) Remove bolts which secure rear differential front member to body. (1) Loosen bolt A first, then remove bolts B.
S3M0500
17) Remove lower differential bracket.
NOTE: Support front member with a help of an assistant to prevent it from dropping.
S3M0529 B3M0657C
(A) (B)
Bolt A Bolt B
(2) Remove bolt A.
DI-26

21) While slowly lowering transmission jack, move rear differential forward and remove bolts from rear crossmember. 22) Remove front member from body.
Differentials
S303145A11
B: INSTALLATION
To install, reverse the removal sequence. 1) Install the air breather cap tapping with a plastic hammer. CAUTION: Be sure to install new air breather cap. 2) Position front member on body by passing it under parking brake cable and securing to rear differential. NOTE: When installing rear differential front member, do not confuse the installation sequence of the upper and lower stoppers. 3) Install DOJ of rear drive shaft into rear differential. ST 28099PA090 SIDE OIL SEAL PROTECTOR
G3M1029
23) Remove rear differential from body.
G3M1030
G3M1026
4) Install in the reverse order of removal. 5) After installing rear differential carrier on vehicle, remove filler plug and replenish gear oil up. <Ref. to DI-22, Differential Gear Oil.> 6) Connect connector to rear differential temperature sensor. (Turbo model for Europe) 7) If the results of the following inspections are not satisfactory, check rear differential temperature sensor and circuit. Then repair or replace if necessary. (1) Check that rear differential temperature sensor warning light lights up when ignition switch is turned to on (engine stopped). (2) Start engine, then check that the warning light goes off after a few seconds.
DI-27
Differentials

S303145A06
C: DISASSEMBLY
To detect real cause of trouble, inspect the following items before disassembling. Tooth contact of crown gear and pinion, and backlash Runout of crown gear at its back surface Turning resistance of drive pinion 1) Set ST on vise and install the differential assembly to ST. ST 398217700 ATTACHMENT SET
4) Remove rear cover by loosening retaining bolts.
S3M0531A
(A) (B)
Rear cover Differential carrier
G3M1031
5) Make right and left side bearing retainers in order to identify them at reassembly. Remove side bearing retainer attaching bolts, set ST to differential case, and extract right and left side bearing retainers with a puller. CAUTION: Each shim, which is installed to adjust the side bearing preload, should be kept together with its mating retainer. ST 398457700 ATTACHMENT
2) Drain gear oil by removing plug. 3) Remove the air breather cap. NOTE: Do not attempt to replace the air breather cap unless necessary.
S3M0532A S3M0530A
(A) (B)
Air breather cap Rear cover
6) Pull out differential case assembly from differential carrier. CAUTION: Be careful not to hit the teeth against the case.
S3M0533
DI-28

7) When replacing side bearing, pull bearing cup from side bearing retainer using ST. ST 398527700 PULLER ASSY
Differentials
10) Drive out pinion shaft lock pin from crown gear side. NOTE: The lock pin is staked at the pin hole end on the differential carrier; do not drive it out forcibly before unstaking it. ST 899904100 STRAIGHT PIN REMOVER
S3M0534A
8) Extract bearing cone with ST. CAUTION: Do not attempt to disassemble the parts unless necessary. NOTE: Set puller so that its claws catch the edge of the bearing cone. Never mix up the right and left hand bearing races and cones. ST 399527700 PULLER SET
B3M0133
11) Draw out pinion mate shaft and remove pinion mate gears, side gears and thrust washers. NOTE: The gears as well as thrust washers should be marked or kept separated left and right, and front and rear.
G3M0068
S3M0510A
9) Remove crown gear by loosening crown gear bolts. CAUTION: Further disassembling is not allowed.
(A) (B) (C) (D) (E)
Side gear Pinion mate gear Thrust washer Differential case Pinion mate shaft
S3M0509
DI-29
Differentials

15) Remove rear bearing cone from drive pinion by supporting cone with ST. NOTE: Place the replacer so that its center-recessed side faces the pinion gear. ST 398517700 REPLACER
12) Hold companion flange with ST and remove drive pinion nut. ST 498427200 FLANGE WRENCH
G3M1052
13) Extract the companion flange with a puller.

S3M0512A
16) Remove front oil seal from differential carrier using ST. ST 398527700 PULLER ASSY
S3M0511
14) Press the end of drive pinion shaft and extract it together with rear bearing cone, preload adjusting spacer and washer. NOTE: Hold the drive pinion so as not to drop it. ST 398467700 DRIFT
S3M0513
17) Remove pilot bearing together with front bearing cone using ST. ST 398467700 DRIFT
G3M0074
S3M0514A
(A) (B) (C)
Pinion bearing Front bearing Rear bearing cup
DI-30

18) When replacing bearings, tap front bearing cup and rear bearing cup in this order out of case by using a brass bar.
Differentials
2) Adjusting preload for front and rear bearings Adjust the bearing preload with spacer and washer between front and rear bearings. Pinion height adjusting washer are not affected by this adjustment. The adjustment must be carried out without oil seal inserted. (1) Press rear bearing race into differential carrier with ST1 and ST2. ST1 398477701 HANDLE ST2 398477703 DRIFT 2
S3M0515A
(A) (B)
2 cutouts along diagonal lines Tap alternately with brass bar.

S303145A02
D: ASSEMBLY
1) Precautions for assembling Assemble in the reverse order of disassembling. Check and adjust each part during assembly. For correct installation, keep the shims and washers in order. Thoroughly clean the surfaces on which the shims, washers and bearings are to be installed. Apply gear oil when installing the bearings and thrust washers. Be careful not to mix up the right and left hand races of the bearings. Replace the oil seal with new one at every disassembly. Apply chassis grease between the lips when installing the oil seal.
G3M1037
(2) Insert ST1 into carrier with pinion height adjusting washer and rear bearing cone fitted onto it. CAUTION: Re-use the used washer if not deformed. Use a new rear bearing cone. (3) Then install preload adjusting spacer and washer, front bearing cone, ST2, companion flange, and washer and drive pinion nut. ST1 398507702 DUMMY SHAFT ST2 398507703 DUMMY COLLAR
G3M0079 S3M0516A
(A) (B) (C)
Pinion height adjusting shim Preload adjusting spacer Preload adjusting washer
DI-31
Differentials

Part No. 383705200 383715200 383725200 383735200 383745200 383755200 383765200 383775200 383785200 383795200 383805200 383815200 383825200 383835200 383845200 Part No. 383695201 383695202 383695203 383695204 383695205 383695206 Thickness mm (in) 2.59 (0.1020) 2.57 (0.1012) 2.55 (0.1004) 2.53 (0.0996) 2.51 (0.0988) 2.49 (0.0980) 2.47 (0.0972) 2.45 (0.0965) 2.43 (0.0957) 2.41 (0.0949) 2.39 (0.0941) 2.37 (0.0933) 2.35 (0.0925) 2.33 (0.0917) 2.31 (0.0909) Length mm (in) 56.2 (2.213) 56.4 (2.220) 56.6 (2.228) 56.8 (2.236) 57.0 (2.244) 57.2 (2.252)
(4) Turn ST1 with hand to make it seated, and tighten drive pinion nut while measuring the preload with spring balance. Select preload adjusting washer and spacer so that the specified preload is obtained when nut is tightened to the specified torque. CAUTION: Use a new lock nut. NOTE: Be careful not to give excessive preload. When tightening the drive pinion nut, lock ST1 with ST2 as shown in the figure. ST1 ST2 398507704 398507702 BLOCK DUMMY SHAFT
Tightening torque: 181 Nm (18.5 kgf-m, 134 ft-lb)
G3M1038
Front and rear bearing preload For new bearing: 19.6 28.4 N (2.0 2.9 kgf, 4.4 6.4 lb) at companion flange bolt hole For used bearing: 8.34 16.67 N (0.85 1.7 kgf, 1.87 3.75 lb) at companion flange bolt hole
3) Adjusting drive pinion height Adjust drive pinion height with shim installed between rear bearing cone and the back of pinion gear. (1) Install ST1, ST2 and ST3, as shown in the figure, and apply the specified preload on the bearings.
Front and rear bearing preload For new bearing: 19.6 28.4 N (2.0 2.9 kgf, 4.4 6.4 lb) at companion flange bolt hole For used bearing: 8.34 16.67 N (0.85 1.7 kgf, 1.87 3.75 lb) at companion flange bolt hole
Adjusting preload for front and rear bearings NOTE: At this time, install a pinion height adjusting shim which is temporarily selected or the same as that used before. Measure and record the thickness. ST1 398507702 DUMMY SHAFT ST2 398507701 GAUGE ST3 398507703 DUMMY COLLAR
S3M0518A
DI-32
Differentials
(Example of calculation) To = 2.20 + 1.20 = 3.40 mm N = 0.23 mm H = + 1, T = 3.40 + 0.23 0.01 0.20 = 3.42 Result: Thickness = 3.42 mm Therefore use the shim 383605200.
Pinion height adjusting shim Part No. Thickness mm (in) 383495200 3.09 (0.1217) 383505200 3.12 (0.1228) 383515200 3.15 (0.1240) 383525200 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) 383615200 3.45 (0.1358) 383625200 3.48 (0.1370) 383635200 3.51 (0.1382) 383645200 3.54 (0.1394) 383655200 3.57 (0.1406) 383665200 3.60 (0.1417) 383675200 3.63 (0.1429) 383685200 3.66 (0.1441)
S3M0518B
(A)
(2) Measure the clearance N between the end of ST2 and the end surface of ST1 by using a thickness gauge. NOTE: Make sure there is no clearance between the case and ST2. ST1 ST2 398507702 398507701 DUMMY SHAFT GAUGE
H3M1309B
(3) Obtain the thickness of pinion height adjusting shim to be inserted from the following formula, and replace the temporarily installed shim with this one. T = To + N (H x 0.01) 0.20 mm (0.0079 in) NOTE: Use copies of this page.
T To N H Memo: Thickness of shim temporarily inserted mm (in) Thickness of pinion height adjusting shim mm (in) Reading of thickness gauge mm (in) Figure marked on drive pinion head
4) Install the selected pinion height adjusting shim on drive pinion, and press the rear bearing cone into position with ST. ST 398177700 INSTALLER
S3M0519A
DI-33
Differentials

8) Fit a new oil seal with ST. NOTE: Press-fit until end of oil seal is 1 mm (0.04 in) inward from end of carrier. Apply grease between the oil seal lips. ST 498447120 INSTALLER
5) Insert drive pinion into differential carrier, install the previously selected bearing preload adjusting spacer and washer.
B3M0560B
(A) (B) (C) (D)
Drive pinion Bearing adjusting spacer Washer Differential carrier
G3M0087
6) Press-fit front bearing cone into case with ST1, ST2 and ST3. ST1 398507703 DUMMY COLLAR ST2 399780104 WEIGHT ST3 899580100 INSTALLER
9) Press-fit companion flange with ST1 and ST2. CAUTION: Be careful not to damage bearing. ST1 ST2 899874100 399780104 INSTALLER WEIGHT
G3M0085
S3M0521A
7) Insert spacer, then press-fit pilot bearing with ST1 and ST2. ST1 399780104 WEIGHT ST2 899580100 INSTALLER
10) Install self-locking nut. Then tighten it with ST. ST 498427200 FLANGE WRENCH Tightening torque: 181 Nm (18.5 kgf-m, 134 ft-lb)
S3M0520A G3M1052
DI-34

11) Assembling differential case Install side gears and pinion mate gears, with their thrust washers and pinion mate shaft, into differential case. CAUTION: Apply gear oil on both sides of the washer and on the side gear shaft before installing. Insert the pinion mate shaft into the differential case by aligning the lock pin holes.
Differentials
(1) Measure the side gear backlash. Side gear back clearance: 0.10 0.20 mm (0.0039 0.0079 in)
B3M1933
(2) Adjust the backlash as specified by selecting side gear thrust washer.
Part No. 383445201 383445202 383445203 383445204 383445205 Side gear thrust washer Thickness mm (in) 0.75 0.80 (0.0295 0.0315) 0.80 0.85 (0.0315 0.0335) 0.85 0.90 (0.0335 0.0354) 0.90 0.95 (0.0354 0.0374) 0.95 1.00 (0.0374 0.0394)
G3M0089
(3) Check the condition of rotation after applying oil to the gear tooth surfaces and thrust surfaces. (4) After inserting pinion shaft lock pin into differential case, stake the both sides of the hole to prevent pin from falling off. 12) Install crown gear on differential case. CAUTION: Before installing bolts, apply Lock Tite to bolt threads. Lock Tite: THREE BOND 1324 or equivalent NOTE: Tighten diagonally while tapping the bolt heads. Tightening torque: 103 Nm (10.5 kgf-m, 76 ft-lb)
S3M0509
DI-35
Differentials

(4) Align arrow marked on differential carrier with that marked on side retainer during installation. CAUTION: Be careful that side bearing outer race is not damaged by bearing roller.
13) Press side bearing cone onto differential case with ST. ST 398487700 DRIFT
G3M0091
14) Adjusting side bearing retainer shims (1) The driven gear backlash and side bearing preload can be determined by the side bearing retainer shim thickness. (2) Install the differential case assembly into differential carrier in the reverse order of disassembly.
S3M0172B
(A)
Arrow mark
(5) Tighten side bearing retainer bolts. CAUTION: Before tightening the two side bearing retainer bolts, apply Lock Tite to bolt threads. Lock Tite: THREE BOND 1105 or equivalent Tightening torque: 10.3 Nm (1.05 kgf-m, 7.6 ft-lb)
S3M0533
(3) Install side retainer shims and O-rings to the left and right retainers from which they were removed. NOTE: Replace broken or cracked O-ring with new one. Replace broken or corroded side retainer shim with new one of same thickness.
Side bearing retainer shim Part No. Thickness mm (in) 383475201 0.20 (0.0079) 383475202 0.25 (0.0098) 383475203 0.30 (0.0118) 383475204 0.40 (0.0157) 383475205 0.50 (0.0197)
S3M0173
DI-36

(6) Measure the crown gear-to-drive pinion backlash. Set magnet base on differential carrier. Align contact point of dial gauge with tooth face of crown gear, and move crown gear while holding drive pinion still. Read value indicated on dial gauge. Backlash: 0.10 0.20 mm (0.0039 0.0079 in)
Differentials
16) Check the crown gear runout on its back surface, and make sure pinion and crown gear rotate smoothly. Limit of runout: Less than 0.05 mm (0.0020 in)
S3M0525
G3M1047
(7) At the same time, measure the turning resistance of drive pinion. Compared with the resistance when differential case is not installed, if the increase of the resistance is not within the specified range, readjust side bearing retainer shims. Turning resistance increase: 2.9 10.8 N (0.3 1.1 kgf, 0.7 2.4 lb) 15) Re-check crown gear-to-pinion backlash. Backlash: 0.10 0.20 mm (0.0039 0.0079 in)
17) Checking and adjusting tooth contact of crown gear (1) Apply an even coat of red lead on both sides of three or four teeth on the crown gear. Check the contact pattern after rotating crown gear several revolutions back and forth until a definite contact pattern appears on the crown gear. (2) When the contact pattern is incorrect, readjust according to the instructions given in TOOTH CONTACT PATTERN. NOTE: Be sure to wipe off red lead completely after adjustment is completed. 18) If proper tooth contact is not obtained, once again adjust the drive pinion height changing RH and LH side bearing retainer shims and the hypoid gear backlash.
G3M1047
DI-37
Differentials

(2) Hypoid gear backlash Backlash: 0.10 0.20 mm (0.0039 0.0079 in)
(1) Drive pinion height ST1 398507702 DUMMY SHAFT ST2 398507701 GAUGE
H3M1309B G3M1047
T = To + N (H x 0.01) 0.20 (mm) Where: T = Thickness of pinion height adjusting shim (mm) To = Thickness of shim temporarily inserted (mm) N = Reading of thickness gauge (mm) H = Figure marked on drive pinion head
DI-38

TOOTH CONTACT PATTERN Contact pattern
Differentials
Condition Correct tooth contact Tooth contact pattern slightly shifted towards toe under no load rotation. (When loaded, contact pattern moves toward heel.)
Adjustment
G3M0098A
Face contact Backlash is too large.
This may cause noise and chipping at tooth ends.
Increase thickness of drive pinion height adjusting shim in order to bring drive pinion closer to crown gear center.
G3M0098B G3M0098F
Flank contact Backlash is too small.
This may cause noise and stepped wear Reduce thickness of drive pinion height on surfaces. adjusting shim in order to move drive pinion away from crown gear.
G3M0098C G3M0098G
Toe contact Contact area is small.
This may cause chipping at toe ends.
Adjust as for flank contact.
G3M0098D
G3M0098G
Heel contact Contact area is small.
This may cause chipping at heel ends.
Adjust as for face contact.
G3M0098E
G3M0098F
: Adjusting direction of drive pinion : Adjusting direction of crown gear
DI-39
Differentials

9) Rear differential oil temperature sensor (Turbo model for Europe) If the results of the following inspections are not satisfactory, replace rear differential temperature sensor. (1) At room temperature, check for continuity between the sensor terminal and body. (2) Soak the sensor in oil, then raise the oil temperature. Check that the continuity is cut off when the oil temperature is between 144C (291F) and 156C (313F). Then, check that the continuity resumes by the time the oil temperature drops to 135C (275F). CAUTION: The oil is hot, so be careful not to burn yourself when inspecting.
19) Install rear cover and tighten bolts to specified torque. CAUTION: Securely connect ground terminal of rear differential temperature sensor. Tightening torque: 29 Nm (3.0 kgf-m, 21.7 ft-lb)
1. SIDE GEAR BACKLASH

G3M1050
S303145A1001
Using a dial gauge, check the backlash of the side gear. Side gear backlash: 0.1 0.2 mm (0.004 0.008 in) If side gear backlash is not within the specification, adjust clearance as specified by selecting side gear thrust washer.
E: INSPECTION
S303145A10
Wash all the disassembled parts clean, and examine them for wear, damage, or other defects. Repair or replace defective parts as necessary. 1) Crown gear and drive pinion If abnormal tooth contact is evident, find out the cause and adjust to give correct tooth contact at assembly. Replace the gear if excessively worn or incapable of adjustment. If crack, score, or seizure is evident, replace as a set. Slight damage of tooth can be corrected by oil stone or the like. 2) Side gear and pinion mate gear Replace if crack, score, or other defects are evident on tooth surface. Replace if thrust washer contacting surface is worn or seized. Slight damage of the surface can be corrected by oil stone or the like. 3) Bearing Replace if seizure, peeling, wear, rust, dragging during rotation, abnormal noise or other defect is evident. 4) Thrust washers of side gear and pinion mate gear Replace if seizure, flaw, abnormal wear or other defect is evident. 5) Oil seal Replace if deformed or damaged, and at every disassembling. 6) Differential carrier Replace if the bearing bores are worn or damaged. 7) Differential case Replace if its sliding surfaces are worn or cracked. 8) Companion flange Replace if the oil seal lip contacting surfaces have flaws.
B3M1934
DI-40

2. CROWN GEAR BACKLASH
S303145A1002
Differentials
S303145A1005
5. TOTAL PRELOAD
Using a dial gauge, check the backlash of the crown gear. Crown gear backlash: 0.1 0.2 mm (0.004 0.008 in) If crown gear backlash is not within the specification, adjust the side bearing preload or repair if necessary.
Using a gauge, check the turning resistance increase. Total preload: 2.9 10.8 N (0.3 1.1 kgf, 0.7 2.4 lb) If the increase of the resistance is not within the specification, adjust the side bearing retainer shims.
G3M1047
B3M1935
3. CROWN GEAR RUNOUT
S303145A1003
F: ADJUSTMENT
S303145A01
Using a dial gauge, check the crown gear runout. Crown gear runout: Less than 0.05 mm (0.0020 in) If the crown gear runout exceeds 0.05 mm (0.0020 in), replace the crown gear.
A303145A0101
Adjust side gear backlash. <Ref. to DI-31 ASSEMBLY, Differential for T-type.>
A303145A0102
Adjust crown gear backlash. <Ref. to DI-31 ASSEMBLY, Differential for T-type.>
3. TOOTH CONTACT BETWEEN CROWN GEAR AND DRIVE PINION A303145A0103

Adjust the tooth contact between crown gear and drive pinion gear. <Ref. to DI-31 ASSEMBLY, Differential for T-type.>
4. TOTAL PRELOAD
S3M0525
A303145A0104
Adjust side bearing shim. <Ref. to DI-31 ASSEMBLY, Differential for T-type.>
4. TOOTH CONTACT BETWEEN CROWN GEAR AND DRIVE PINION S303145A1004

Inspect tooth contact between crown gear and driven pinion. <Ref. to DI-31 ASSEMBLY, Differential for T-type.>
DI-41
Differentials
REAR DIFFERENTIAL FOR VA-TYPE

12) Remove heat sealed cover.
5. Rear Differential for VA-type

S303151
A: REMOVAL
S303151A18
1) Set vehicle on a lift. 2) Disconnect ground terminal from battery. 3) Move select lever or gear shift lever to N. 4) Release the parking brake. 5) Loosen wheel nuts. 6) Jack-up vehicle and support it with sturdy racks. 7) Remove wheels. 8) Remove rear exhaust pipe and muffler. With OBD: <Ref. to EX(SOHC)-9, REMOVAL, Rear Exhaust Pipe.> and <Ref. to EX(SOHC)-11, REMOVAL, Muffler.> Without OBD: <Ref. to EX(SOHCw/oOBD)-10, REMOVAL, Rear Exhaust Pipe.> and <Ref. to EX(SOHCw/oOBD)12, REMOVAL, Muffler.> 9) Remove front exhaust cover.
S2M0166
13) Remove clamps and bracket of parking brake cable.
S2M0191
14) Remove DOJ of rear drive shaft from rear differential. <Ref. to DS-38, REMOVAL, Rear Drive Shaft.>
S3M0502
10) Remove front cover of rear differential mount.
S3M0504A
(A) (B)
DOJ Tire lever
S3M0503
11) Remove propeller shaft. <Ref. to DS-14, REMOVAL, Propeller Shaft.>
DI-42

Differentials
19) Remove bolts which secure rear differential front member to body. (1) Loosen bolt A first, then remove bolts B. NOTE: Support front member with a help of an assistant to prevent it from dropping.
S3M0500
16) Remove lower differential bracket.

B3M0657C
(A) (B)
Bolt A Bolt B
H3M1273B
(2) Remove bolt A. 20) While slowly lowering transmission jack, move rear differential forward and remove bolts from rear crossmember. 21) Remove front member from body.
(A) (B)
Lower differential bracket Rear differential
17) Support rear differential with transmission jack.
G3M0058
22) Remove rear differential from body.
S3M0505
18) Remove self-locking nuts connecting rear differential to rear crossmember.
G3M0059
B: INSTALLATION
S303151A11
B3M0131
To install, reverse the removal sequence. 1) Position front member on body by passing it under parking brake cable and securing to rear differential.
DI-43
Differentials

3) Remove rear cover by loosening retaining bolts.
NOTE: When installing rear differential front member, do not confuse the installation sequence of the upper and lower stoppers. 2) Install DOJ of rear drive shaft into rear differential. ST 28099PA090 SIDE OIL SEAL PROTECTOR
S3M0506
4) Replace air breather cap. NOTE: Do not attempt to replace the air breather cap unless necessary.
G3M0049
3) Install in the reverse order of removal. 4) After installation, fill differential carrier with gear oil. <Ref. to DI-22, Differential Gear Oil.>
C: DISASSEMBLY
S303151A06
To detect real cause of trouble, inspect the following items before disassembling. Tooth contact of crown gear and pinion, and backlash Runout of crown gear at its back surface Turning resistance of drive pinion 1) Set ST on vise and install the differential assembly to ST. ST 398217700 ATTACHMENT
S3M0507A
(A) (B)
Air breather cap Rear cover
5) Remove right and left lock plates.
G3M0063 G3M0060
2) Drain gear oil by removing plug.
DI-44

6) Remove right and left holders with ST. ST 399780111 WRENCH
Differentials
9) Remove oil seal from right and left holders with screwdriver. CAUTION: Perform this operation only when changing oil seal.
G3M0064
7) Pull out differential assembly from differential case. CAUTION: Be careful not to hit the teeth against the case.
B3M0132
10) Extract bearing cone with ST1 and ST2. CAUTION: Do not attempt to disassemble the parts unless necessary. NOTE: Set Puller so that its claws catch the edge of the bearing cone. Never mix up the right and left hand bearing races and cones.
G3M0065
ST1 ST2
899524100 399520105
PULLER SET SEAT
8) Remove bearing race from right and left holders with ST1 and ST2. ST1 499705401 PULLER ASSY ST2 499705404 OUTER RACE PULLER SEAT
H3M1970A
11) Remove crown gear by loosening crown gear bolts.
S3M0508A
(A) (B)
Bearing race Holder
S3M0509
DI-45
Differentials

14) Hold companion flange with ST and remove self-locking nut. ST 498427200 FLANGE WRENCH
12) Drive out pinion shaft lock pin from crown gear side. NOTE: The lock pin is staked at the pin hole end on the differential case; do not drive it out forcibly before unstaking it. ST 899904100 STRAIGHT PIN REMOVER
G3M0072
15) Extract the companion flange with a puller.
B3M0133
13) Draw out pinion mate shaft and remove pinion mate gears, side gears and thrust washers. NOTE: The gears as well as thrust washers should be marked or kept separated left and right, and front and rear.
S3M0511A
(A) (B)
Companion Puller
16) Press the end of drive pinion shaft and extract it together with rear bearing cone, preload adjusting spacer and washer. NOTE: Hold the drive pinion so as not to drop it.
S3M0510A
ST
398467700
DRIFT
(A) (B) (C) (D) (E)
Side gear Pinion mate gear Thrust washer Differential case Pinion mate shaft
G3M0074
DI-46

17) Remove rear bearing cone from drive pinion by supporting cone with ST. NOTE: Place the replacer so that its center-recessed side faces the pinion gear. ST 498515500 REPLACER
Differentials
20) When replacing bearings, tap front bearing cup and rear bearing cup in this order out of case by using a brass bar.
S3M0515A
(A) (B)
S3M0512A
2 cutouts along diagonal lines Tap alternately with brass bar.

S303151A02
D: ASSEMBLY
18) Remove front oil seal from differential carrier using ST. ST 398527700 PULLER ASSY
S3M0513A
1) Precautions for assembling Assemble in the reverse order of disassembling. Check and adjust each part during assembly. Keep the shims and washers in order, so that they are not misinstalled. Thoroughly clean the surfaces on which the shims, washers and bearings are to be installed. Apply gear oil when installing the bearings and thrust washers. Be careful not to mix up the right and left hand races of the bearings. Replace the oil seal with new one at every disassembly. Apply chassis grease between the lips when installing the oil seal.
(A) (B)
Differential carrier Front oil seal
19) Remove pilot bearing together with front bearing cone using ST. ST 398467700 DRIFT
G3M0079
S3M0514A
2) Adjust preload for front and rear bearings. Adjust the bearing preload with spacer and washer between front and rear bearings. Pinion height adjusting washer are not affected by this adjustment. The adjustment must be carried out without oil seal inserted.
(A) (B) (C)
Pilot bearing Front bearing Rear bearing cup
DI-47
Differentials

CAUTION: Use a new self-locking nut. NOTE: Be careful not to give excessive preload. When tightening the drive pinion nut, lock ST1 with ST2 as shown in the figure. ST1 ST2 398507704 498447150 BLOCK DUMMY SHAFT
(1) Press rear bearing race into differential carrier with ST1 and ST2. ST1 398477701 HANDLE ST2 398477702 DRIFT (2) Press front bearing race into differential carrier with ST1 and ST2. ST1 398477701 HANDLE ST2 498447110 DRIFT
G3M0080
(3) Insert front bearing cone. CAUTION: Use a new front bearing cone. (4) Insert ST1 into case with pinion height adjusting shim and rear bearing cone fitted onto it. CAUTION: Re-use the used washer if not deformed. Use a new rear bearing cone. (5) Then install preload adjusting spacer and washer, front bearing cone, ST2, companion flange, and washer and self-locking nut. ST1 498447150 DUMMY SHAFT ST2 32285AA000 DUMMY COLLAR
Front and rear bearing preload For new bearing: 12.7 32.4 N (1.3 3.3 kgf, 2.9 7.3 lb) at companion flange bolt hole
G3M1038
S3M0517
S3M0516A
(A) (B) (C)
Pinion height adjujusting shim Preload adjusting spacer Preload adjusting washer
(6) Turn ST1 with hand to make it seated, and tighten drive pinion nut while measuring the preload with spring balance. Select preload adjusting washer and spacer so that the specified preload is obtained when nut is tightened to the specified torque.
DI-48

Part No. 38336AA000 38336AA120 38336AA010 38336AA130 38336AA020 38336AA140 38336AA030 38336AA150 38336AA040 38336AA160 38336AA050 38336AA170 38336AA060 38336AA180 38336AA070 38336AA190 38336AA080 38336AA200 38336AA090 38336AA210 38336AA100 38336AA220 38336AA110 Part No. 32288AA040 32288AA050 31454AA100 32288AA060 31454AA110 32288AA070 31454AA120 32288AA080 32288AA090 Thickness mm (in) 1.500 (0.0591) 1.513 (0.0596) 1.525 (0.0600) 1.538 (0.0606) 1.550 (0.0610) 1.563 (0.0615) 1.575 (0.0620) 1.588 (0.0625) 1.600 (0.0630) 1.613 (0.0635) 1.625 (0.0640) 1.638 (0.0645) 1.650 (0.0650) 1.663 (0.0655) 1.675 (0.0659) 1.688 (0.0665) 1.700 (0.0669) 1.713 (0.0674) 1.725 (0.0679) 1.738 (0.0684) 1.750 (0.0689) 1.763 (0.0694) 1.775 (0.0699) Length mm (in) 52.3 (2.059) 52.5 (2.067) 52.6 (2.071) 52.7 (2.075) 52.8 (2.079) 52.9 (2.083) 53.0 (2.087) 53.1 (2.091) 53.3 (2.098)
Differentials
ST3
498505501
DIFFERENTIAL CARRIER GAUGE
S3M0518A
(A)
(2) Measure the clearance N between the end of ST3 and the end surface of ST1 by using a thickness gauge. NOTE: Make sure there is no clearance between the case and ST3. ST1 ST2 498447150 498505501 DUMMY SHAFT DIFFERENTIAL CARRIER GAUGE
H3M1309B
3) Adjusting drive pinion height Adjust drive pinion height with shim installed between rear bearing cone and the back of pinion gear. (1) Install ST1, ST2 and ST3, as shown in the figure, and apply the specified preload on the bearings
Front and rear bearing preload For new bearing: 12.7 32.4 N (1.3 3.3 kgf, 2.9 7.3 lb) at companion flange bolt hole
Adjusting preload for front and rear bearings NOTE: At this time, install an original pinion height adjusting shim. ST1 498447150 DUMMY SHAFT ST2 32285AA000 DUMMY COLLAR
DI-49
Differentials

5) Insert drive pinion into differential carrier, install the previously selected bearing preload adjusting spacer and washer.
(3) Obtain the thickness of pinion height adjusting washer to be inserted from the following formula, and replace the temporarily installed shim with this one. NOTE: Use 1 to 3 shims as required for adjustment. T = To + N 0.05 (mm) where T = Thickness of pinion height adjusting shim (mm) To = Thickness of shim originally installed (mm) N = Reading of thickness gauge (mm) H = Figure marked on drive pinion head (Example of calculation) To = 0.15 mm N = 0.1 mm T = 0.15 + 0.1 0.05 = 0.2 mm Result: Thickness = 0.2 mm Therefore use the 32295AA220.
Pinion height adjusting shim Part No. Thickness mm (in) 32295AA200 0.150 (0.0059) 32295AA210 0.175 (0.0069) 32295AA220 0.200 (0.0079) 32295AA230 0.225 (0.0089) 32295AA240 0.250 (0.0098) 32295AA250 0.275 (0.0108)
H3M1666A
(A) (B) (C) (D)
Drive pinion Bearing preload adjusting spacer Bearing preload adjusting washer Differential carrier
6) Press-fit front bearing cone into carrier with ST1, ST2 and ST3. ST1 32285AA000 DUMMY COLLAR ST2 399780104 WEIGHT ST3 899580100 INSTALLER
4) Install the selected pinion height adjusting shim on drive pinion, and press the rear bearing cone into position with ST. ST 498175500 INSTALLER
G3M0085
7) Insert spacer, then press-fit pilot bearing with ST1 and ST2. ST1 399780104 WEIGHT ST2 899580100 INSTALLER
S3M0519A
S3M0520A
DI-50

8) Fit a new oil seal with ST. NOTE: Press-fit until end of oil seal is 1 mm (0.04 in) inward from end of carrier. Apply grease between the oil seal lips. ST 498447120 OIL SEAL INSTALLER
Differentials
11) Assembling differential case Install side gears and pinion mate gears, with their thrust washers and pinion mate shaft, into differential case. NOTE: Apply gear oil on both sides of the washer and on the side gear shaft before installing. Insert the pinion mate shaft into the differential case by aligning the lock pin holes.
G3M0087
9) Press-fit companion flange with ST1 and ST2. CAUTION: Be careful not to damage bearing. ST1 ST2 899874100 399780104 INSTALLER WEIGHT
G3M0089
S3M0521A
10) Install self-locking nut. Then tighten it with ST. ST 398427200 FLANGE WRENCH Tightening torque: 188 Nm (19.2 kgf-m, 139 ft-lb)
G3M0721
DI-51
Differentials

12) Press side bearing cone onto differential case with ST. ST 498485400 DRIFT
(1) Measure the side gear backlash. Side gear back clearance: 0.05 0.15 mm (0.0020 0.0059 in)
B3M1933
G3M0091
(2) Adjust the side gear backlash as specified by selecting side gear thrust washer.
Part No. 803135011 803135012 803135013 803135014 803135015 Side gear thrust washer Thickness mm (in) 0.925 0.950 (0.0364 0.0374) 0.950 0.975 (0.0374 0.0384) 0.975 1.000 (0.0384 0.0394) 1.000 1.025 (0.0394 0.0404) 1.025 1.050 (0.0404 0.0413)
13) Assemble holders. (1) Install oil seal into right and left holders. ST 498447100 INSTALLER
(3) Check the condition of rotation after applying oil to the gear tooth surfaces and thrust surfaces. (4) After driving in pinion shaft lock pin, stake the both sides of the hole to prevent pin from falling off. (5) Install crown gear on differential case. CAUTION: Before installing bolts, apply Lock Tite to bolt threads. Lock Tite THREE BOND 1324 or equivalent NOTE: Tighten diagonally while tapping the bolt heads. Tightening torque: 62 Nm (6.3 kgf-m, 45.6 ft-lb)
S3M0522A
(2) Install bearing race into right and left holders. ST 398477702 DRIFT
G3M0093
S3M0509
DI-52

(3) Install the differential case assembly into differential carrier in the reverse order of disassembly. (4) Temporarily tighten lock plate.
Differentials
NOTE: Turn over lock plate to displace holder 1/2 tooth.
G3M0065
G3M0063
14) Perform adjustment of backlash of pinion crown gear set and adjustment of preload of differential side bearing. (1) Turn drive pinion with ST for better fitting of differential side bearing. ST 498427200 FLANGE WRENCH
(5) Measure the crown gear-to-drive pinion backlash. Set magnet base on differential carrier. Align contact point of dial gauge with tooth face of crown gear, and move crown gear while holding drive pinion still. Read value indicated on dial gauge. NOTE: If measured backlash is not within specified range, repeat procedures for pinion crown gear set backlash adjustment and differential side bearing preload adjustment. Backlash: 0.10 0.15 mm (0.0039 0.0059 in)
G3M0094
(2) Screw in side (left-side) holder until light contact is made with ST. ST 399780111 WRENCH
S3M0523
G3M0064
(3) Back off side (left-side) holder approximately 1 1/2 teeth of holder, and tighten left-side holder by approximately 2 teeth (approximately 1 1/2 + 1/2 teeth). [Back off amount of side (left-side) holder + 1/2 tooth.] This + 1/2 tooth gives preload.
DI-53
Differentials

18) Check the crown gear runout on its back surface, and make sure pinion and crown gear rotate smoothly. Limit of runout: 0.05 mm (0.0020 in)
15) Draw a matching mark on both differential carrier and holder. Remove holder one side at a time. Replace in the original position after inserting an O-ring and applying grease to threaded portion.
S3M0524A
(A) (B)
Matching mark Holder
S3M0525
16) Tighten bolt of lock plate to specified torque. Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
19) Checking and adjusting tooth contact of crown gear. (1) Apply an even coat of red lead on both sides of three or four teeth on the crown gear. Check the contact pattern after rotating crown gear several revolutions back and forth until a definite contact pattern appears on the crown gear. (2) When the contact pattern is incorrect, readjust according to the instructions given in TOOTH CONTACT PATTERN. NOTE: Be sure to wipe off red lead completely after adjustment is completed.
G3M0063
17) Re-check crown gear-to-pinion backlash. Backlash: 0.10 0.15 mm (0.0039 0.0059 in)
20) If proper tooth contact is not obtained, once again adjust the drive pinion height and the differential side bearing preload (already mentioned) and the hypoid gear backlash. (1) Drive pinion height ST1 498447150 DUMMY SHAFT ST2 498505501 DIFFERENTIAL GAUGE
S3M0523 H3M1309B
T = To + N 0.05 (mm) where T = Thickness of pinion height adjusting shim (mm) To = Thickness of shim originally installed (mm)
DI-54

N = Reading of thickness gauge (mm) (2) Differential side bearing preload Screw in side (left-side) holder until light contact is made with ST. Back off side (left-side) holder approximately 1 1/2 teeth of holder, and tighten left-side holder by approximately 2 teeth (approximately 1 1/2 + 1/2 teeth). [Back off amount of side (left-side) holder + 1/2 tooth.] This + 1/2 tooth gives preload. ST 399780111 WRENCH (3) Hypoid gear backlash
Differentials
Backlash: 0.10 0.15 mm (0.0039 0.0059 in)
S3M0523
G3M0064
DI-55
Differentials

TOOTH CONTACT PATTERN Contact pattern
Condition Correct tooth contact Tooth contact pattern slightly shifted towards toe under no load rotation. (When loaded, contact pattern moves toward heel.)
Adjustment
G3M0098A
Face contact Backlash is too large.
This may cause noise and chipping at tooth ends.
Increase thickness of drive pinion height adjusting washer in order to bring drive pinion closer to crown gear center.
G3M0098B G3M0098F
Flank contact Backlash is too small.
This may cause noise and stepped wear Reduce thickness of drive pinion height on surfaces. adjusting washer in order to move drive pinion away from crown gear.
G3M0098C G3M0098G
Toe contact
Contact area is small. This may cause chipping at toe ends.
Adjust as for flank contact.
G3M0098G G3M0098D
Heel contact
Contact area is small. This may cause chipping at heel ends.
Adjust as for face contact.
G3M0098F G3M0098E
: Adjusting direction of drive pinion : Adjusting direction of crown gear
DI-56

21) Install rear cover and tighten bolts to specified torque. Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
Differentials
S303151A1001
Using a dial gauge, check the backlash of the side gear. Side gear backlash: 0.05 0.15 mm (0.0020 0.0059 in) If side gear backlash is not within the specification, adjust clearance as specified by selecting side gear trust washer.
S3M0526A
(A)
Rear cover
S303151A10
E: INSPECTION
Wash all the disassembled parts clean, and examine them for wear, damage, or other defects. Repair or replace defective parts as necessary. 1) Crown gear and drive pinion If abnormal tooth contact is evident, find out the cause and adjust to give correct tooth contact at assembly. Replace the gear if excessively worn or incapable of adjustment. If crack, score, or seizure is evident, replace as a set. Slight damage of tooth can be corrected by oil stone or the like. 2) Side gear and pinion mate gear Replace if crack, score, or other defects are evident on tooth surface. Replace if thrust washer contacting surface is worn or seized. Slight damage of the surface can be corrected by oil stone or the like. 3) Bearing Replace if seizure, peeling, wear, rust, dragging during rotation, abnormal noise or other defect is evident. 4) Thrust washers of side gear and pinion mate gear Replace if seizure, flaw, abnormal wear or other defect is evident. 5) Oil seal Replace if deformed or damaged, and at every disassembling. 6) Differential carrier Replace if the bearing bores are worn or damaged. 7) Differential case Replace if its sliding surfaces are worn or cracked. 8) Companion flange Replace if the oil seal lip contacting surfaces have flaws.
B3M1934
S303151A1002
Using a dial gauge, check the backlash of the crown gear. Crown gear backlash: 0.10 0.15 mm (0.0039 0.0059 in) If crown gear backlash is not within the specification, adjust the side bearing preload or repair if necessary.
G3M1047
DI-57
Differentials

S303151A1003
3. CROWN GEAR RUNOUT
Using a dial gauge, check the crown gear runout. Crown gear runout: Less than 0.05 mm (0.0020 in) If the crown gear runout exceeds 0.05 mm (0.0020 in), replace the crown gear.
S3M0525
4. TOOTH CONTACT BETWEEN CROWN GEAR AND DRIVE PINION S303151A1004

Inspect tooth contact between crown gear and drive pinion. <Ref. to DI-47 ASSEMBLY Rear Differential for VAtype.>
F: ADJUSTMENT
S303151A01
A303151A0101
Adjust side gear backlash. <Ref. to DI-47 ASSEMBLY Rear Differential for VAtype.>
A303151A0102
Adjust crown gear backlash. <Ref. to DI-47 ASSEMBLY Rear Differential for VAtype.>
3. TOOTH CONTACT BETWEEN CROWN GEAR AND DRIVE PINION A303151A0103

Adjust the tooth contact between crown gear and drive pinion gear. <Ref. to DI-47 ASSEMBLY Rear Differential for VAtype.>
DI-58
REAR DIFFERENTIAL FRONT OIL SEAL
Differentials
6. Rear Differential Front Oil Seal

S303139
10) Remove self-locking nut while holding companion flange with ST. ST 498427200 FLANGE WRENCH
A: INSPECTION
S303139A10
Check front oil seal portion for oil leakage, if any leak is found, replace the oil seal and inspect propeller shaft.
B: REPLACEMENT
1) 2) 3) 4) 5) 6)
S303139A20
Set vehicle on a lift. Disconnect ground cable from battery. Move select lever or gear shift lever to N. Release the parking brake. Lift the vehicle. Remove oil drain plug, and drain gear oil.
S3M0031A
11) Extract companion flange using ST. ST 399703600 PULLEY ASSY
B3M0136B
B3M1644B
(A) (B)
Drain plug Filler plug
12) Remove oil seal using ST. ST 499705401 PULLER ASSY
7) Install oil drain plug. CAUTION: Apply fluid packing to drain plug in T-type. VA-type uses a new aluminum gasket. Tightening torque: T-type; 49 Nm (5.0 kgf-m, 36.2 ft-lb) VA-type; 34 Nm (3.5 kgf-m, 25.3 ft-lb) 8) Remove rear exhaust pipe and muffler. 9) Remove propeller shaft from body. <Ref. to DS-17 REMOVAL, Propeller Shaft.>
B3M1609B
13) Fit a new oil seal using ST. ST 498447120 OIL SEAL INSTALLER
G3M0037
14) Install companion flange.
DI-59
Differentials
REAR DIFFERENTIAL FRONT OIL SEAL
NOTE: Use a plastic hammer to install companion flange. 15) Tighten self-locking nut within the specified torque range so that the turning resistance of companion flange becomes the same as that before replacing oil seal. ST 498427200 FLANGE WRENCH CAUTION: Use a new self-locking nut. Tightening torque: 181.4 Nm (18.50 kgf-m, 133.8 ft-lb)
S3M0031A
16) Install in the reverse order of removal. 17) Fill differential carrier with gear oil. <Ref. to DI-22 Differential Gear Oil.>
DI-60
REAR DIFFERENTIAL SIDE OIL SEAL
Differentials
7. Rear Differential Side Oil Seal

S303137
(2) Remove the ABS sensor cable clamp from the trailing link.
A: INSPECTION
S303137A10
Check side oil seal portion for oil leakage, if any leak is found, replace the side oil seal and inspect propeller shaft.
B: REPLACEMENT
1. VA-TYPE
S303137A2002
S303137A20
1) Set vehicle on a lift. 2) Disconnect ground terminal from battery. 3) Move select lever or gear shift lever to N. 4) Release the parking brake. 5) Loosen both wheel nuts. 6) Jack-up the vehicle and support it with rigid racks. 7) Remove wheels. 8) Remove rear exhaust pipe and muffler. With OBD: <Ref. to EX(SOHC)-9, REMOVAL, Rear Exhaust Pipe.> and <Ref. to EX(SOHC)-11, REMOVAL, Muffler.> Without OBD: <Ref. to EX(SOHCw/oOBD)-10, REMOVAL, Rear Exhaust Pipe.> and <Ref. to EX(SOHCw/oOBD)12, REMOVAL, Muffler.> 9) Remove the DOJ of rear drive shaft from rear differential. (1) Remove the ABS sensor cable clamp and parking brake cable guide from bracket.
H3M1398
(3) Remove the ABS sensor cable clamp and parking brake cable guide from the trailing link.
H3M1399B
(A) (B)
Parking brake cable guide ABS sensor cable clamp
(4) Remove the rear stabilizer link.
H3M1396
H3M1397B
(5) Remove the bolts which secure the trailing link to the rear housing.
(A) (B)
ABS sensor cable clamp Parking brake cable guide
G3M0042
DI-61
Differentials

(6) Remove the bolts which secure the front and rear lateral link to the rear housing.
G3M0043
S3M0500
(7) Remove the DOJ from the rear differential with tire lever. CAUTION: When removing the DOJ from the rear differential, fit tire lever to the bolt as shown in figure so as not to damage the axle shaft holder. NOTE: The side spline shaft circlip comes out together with the shaft.
11) Remove oil seal with screwdriver.
S3M0501A
(A) (B)
Side oil seal Screwdriver
12) Drive in a new side oil seal with ST. CAUTION: Apply chassis grease between the oil seal lips. ST 498447100 OIL SEAL INSTALLER
G3M0048
H3M1664B
13) Insert the DOJ into rear differential. CAUTION: Before inserting, replace the circlip at the end of the spline shaft with a new one.
(A) (B)
Tire lever Axle shaft holder
DI-62

ST (1) Install ST to rear differential. 28099PA090 SIDE OIL SEAL PROTECTOR
Differentials
G3M0256
(2) Insert the spline shaft until the spline portion is inside the side oil seal.
6) Jack-up the vehicle and support it with rigid racks. 7) Remove wheels. 8) Remove rear exhaust pipe and muffler. Non-turbo model with OBD: <Ref. to EX(SOHC)-9, REMOVAL, Rear Exhaust Pipe.> and <Ref. to EX(SOHC)-11, REMOVAL, Muffler.> Non-turbo model without OBD: <Ref. to EX(SOHCw/oOBD)-10, REMOVAL, Rear Exhaust Pipe.> and <Ref. to EX(SOHCw/oOBD)12, REMOVAL, Muffler.> Turbo model: <Ref. to EX(DOHC TURBO)-14, REMOVAL, Rear Exhaust Pipe.> and <Ref. to EX(DOHC TURBO)15, REMOVAL, Muffler.> 9) Remove the DOJ of rear drive shaft from rear differential. (1) Remove the ABS sensor cable clamp and parking brake cable guide from bracket.
G3M0049
ST
(3) Remove ST. 28099PA090 SIDE OIL SEAL PROTECTOR (4) Completely insert DOJ into rear differential by pressing rear housing.
H3M1397B
(A) (B)
NOTE: Make sure that oil seal lip is not folded over inward.
(2) Remove the ABS sensor cable clamp from the trailing link.
H4M1095
H3M1398
2. T-TYPE
1) 2) 3) 4) 5)
S303137A2001
Set vehicle on a lift. Disconnect ground terminal from battery. Move select lever or gear shift lever to N. Release the parking brake. Loosen both wheel nuts.
DI-63
Differentials

(7) Remove the DOJ from the rear differential by using ST. CAUTION: When removing the DOJ from the rear differential, fit ST to the bolt as shown in figure so as not to damage the side bearing retainer. ST 208099PA100 DRIVE SHAFT REMOVER
(3) Remove the ABS sensor cable clamp and parking brake cable guide from the trailing link.
H3M1399B
(A) (B)
(4) Remove the rear stabilizer link.
S3M0528
(5) Remove the bolts which secure the trailing link to the rear housing.
(A) (B) Bolt DOJ
H3M1667C
G3M0042
(6) Remove the bolts which secure the front and rear lateral link to the rear housing.
S3M0500
G3M0043
DI-64

11) Remove side oil seal with ST. ST 398527700 PULLER ASSY
Differentials
(2) Insert the spline shaft until the spline portion is inside the side oil seal. (3) Remove ST. ST 28099PA090 SIDE OIL SEAL PROTECTOR
G3M1023
12) Drive in a new side oil seal with ST. CAUTION: Apply chassis grease between the oil seal lips. ST 398437700 DRIFT
G3M1026
(4) Completely insert DOJ into rear differential by pressing rear housing. NOTE: Make sure that oil seal lip is not folded over inward.
G3M1024
13) Insert the DOJ into rear differential. (1) Install ST to rear differential. ST 28099PA090 SIDE OIL SEAL PROTECTOR
G3M0050
G3M1025
DI-65
Differentials
REAR DIFFERENTIAL MEMBER

S303135
8. Rear Differential Member

A: REMOVAL
S303135A18
1) Set vehicle on a lift. 2) Disconnect ground terminal from battery. 3) Move select lever or gear shift lever to N. 4) Release the parking brake. 5) Loosen wheel nuts. 6) Jack-up vehicle and support it with sturdy racks. 7) Remove wheels. 8) Remove rear exhaust pipe and muffler. Non-turbo model with OBD: <Ref. to EX(SOHC)-9, REMOVAL, Rear Exhaust Pipe.> and <Ref. to EX(SOHC)-11 REMOVAL, Muffler.> Non-turbo model without OBD: <Ref. to EX(SOHCw/oOBD)-10, REMOVAL, Rear Exhaust Pipe.> and <Ref. to EX(SOHCw/oOBD)12, REMOVAL, Muffler.> Turbo model: <Ref. to EX(DOHC TURBO)-14, REMOVAL, Rear Exhaust Pipe.> and <Ref. to EX(DOHC TURBO)15, REMOVAL, Muffler.> 9) Remove rear differential front member. VA-type: <Ref. to DI-42, REMOVAL, Rear Differential for VA-type.> T-type: <Ref. to DI-25, REMOVAL, Rear Differential for T-type.> NOTE: When removing rear differential front member, work the removal procedure as rear differential.
NOTE: When installing rear differential front member, do not confuse the installation sequence of the stopper.
H3M1402B
(A) (B)
Stopper Differential mount bracket
2) Insert DOJ of rear drive shaft into rear differential. ST 28099PA090 SIDE OIL SEAL PROTECTOR CAUTION: Before inserting, replace the differential side oil seal and the circlip at the end of the spline shaft with a new one.
B: INSTALLATION
S303135A11
G3M0049
To install, reverse the removal sequence. 1) Position front member on body by passing it under parking brake cable and securing to rear differential.
C: INSPECTION
S303135A10
1) Check rear differential member for damage, bend, or corrosion. If damage, bend, or corrosion is excessive, replace rear differential member. 2) Check bushings of rear differential member for cracking, hardening, or damage. If cracking, hardening, or damage is excessive, replace rear differential member.
G3M0058
DI-66
Differentials

A: INSPECTION
S303257A10
S303257
Symptom or trouble 1. Oil leakage
2. Seizure NOTE: Seized or damaged parts should be replaced, and also other parts should be thoroughly checked for any defect and should be repaired or replaced as required. 3. Damage NOTE: Damaged parts should be replaced, and also other parts should be thoroughly checked for any defect and should be repaired or replaced as required.
Possible cause Worn, scratched, or incorrectly seated front or side oil seal. Scored, battered, or excessively worn sliding surface of companion flange. Clogged or damaged air breather. Loose bolts on differential spindle or side retainer, or incorrectly fitted O-ring. Loose rear cover attaching bolts or damaged gasket. Loose oil filler or drain plug. Wear, damage or incorrectly fitting for spindle, side retainer and oil seal. Insufficient backlash for hypoid gear. Excessive preload for side, rear, or front bearing. Insufficient or improper oil used. Improper backlash for hypoid gear. Insufficient or excessive preload for side, rear, or front bearing. Excessive backlash for differential gear. Loose bolts and nuts such as crown gear bolt. Damage due to overloading. Excessive backlash for hypoid gear. Excessive backlash for differential gear. Insufficient preload for front or rear bearing. Loose drive pinion nut. Loose bolts and nuts such as side bearing retainer attaching bolt. Damaged differential gear. Excessive wear or damage of thrust washer. Broken pinion mate shaft. Seized or damaged side bearing. Improper tooth contact of hypoid gear. Improper backlash for hypoid gear. Scored or chipped teeth of hypoid gear. Seized hypoid gear. Improper preload for front or rear bearings. Seized, scored, or chipped front or rear bearing. Seized, scored, or chipped side bearing. Vibrating differential carrier.
Remedy Repair or replace.
Clean, repair or replace. Tighten bolts to specified torque. Replace O-ring. Tighten bolts to specified torque. Replace gasket and apply liquid packing. Retighten and apply liquid packing. Repair or replace. Readjust or replace. Readjust or replace. Replace seized part and fill with specified oil to specified level. Replace. Readjust or replace. Replace gear or thrust washer. Retighten. Replace. Readjust. Replace gear or thrust washer. Readjust. Tighten to specified torque. Tighten to specified torque. Replace. Replace. Replace. Replace. Readjust or replace hypoid gear set. Readjust. Replace hypoid gear set. Replace hypoid gear set. Readjust. Replace. Replace. Replace.
4. Noises when starting or shifting gears NOTE: Noises may be caused by differential assembly, universal joint, wheel bearing, etc. Find out what is actually making noise before disassembly. 5. Noises when cornering
6. Gear noises NOTE: Since noises from engine, muffler, transmission, propeller shaft, wheel bearings, tires, and body are sometimes mistaken for noises from differential assembly, be careful in checking them. Inspection methods to locate noises include coasting, accelerating, cruising, and jacking-up all four wheels. Perform these inspections according to condition of trouble. When listening to noises, shift gears into four wheel drive and fourth speed position, trying to pick up only differential noise.
DI-67
Differentials
MEMO:
DI-68
TRANSFER CASE
TC
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Page General Description.....................................................................................2 Transfer Case and Extension for MT..........................................................3 Transfer Clutch and Extension for AT .........................................................4 Oil Seal........................................................................................................5 Transfer Drive Gear (MT)............................................................................6 Transfer Driven Gear (MT)..........................................................................7 Reduction Drive Gear without VTD.............................................................8 Reduction Driven Gear without VTD...........................................................9 Center Differential .....................................................................................10 Oil Pump....................................................................................................11 Transfer Clutch Pressure Test...................................................................12 Transfer Duty Solenoid and Valve Body ...................................................13
Transfer Case
GENERAL DESCRIPTION
S302001
A: NOTE
S302001A15
For removal, installation and inspection work, refer to AT section or MT section. AT model: <Ref. to AT-2, General Description.> MT model: <Ref. to MT-2, General Description.>
TC-2
TRANSFER CASE AND EXTENSION FOR MT
Transfer Case
2. Transfer Case and Extension for MT

S302138
A: NOTE
S302138A15
For removal, installation and inspection work, refer to MT section. <Ref. to MT-46, Transfer Case and Extension Case Assembly.>
TC-3
Transfer Case
TRANSFER CLUTCH AND EXTENSION FOR AT
3. Transfer Clutch and Extension for AT

S302142
A: NOTE
S302142A15
For removal, installation and inspection work, refer to AUTOMATIC TRANSMISSION (a separate publication: Pub. No. G0853ZE).
TC-4
OIL SEAL
Transfer Case
4. Oil Seal
A: NOTE
S302143
S302143A15
For removal, installation and inspection work, refer to AT section or MT section. AT model: <Ref. to AT-27, Extension Case Oil Seal.> MT model: <Ref. to MT-41, Oil Seal.>
TC-5
Transfer Case
TRANSFER DRIVE GEAR (MT)

S302146
5. Transfer Drive Gear (MT)

A: NOTE
S302146A15
For removal, installation and inspection work, refer to MT section. <Ref. to MT-52, Transfer Drive Gear.>
TC-6
TRANSFER DRIVEN GEAR (MT)
Transfer Case
6. Transfer Driven Gear (MT)

A: NOTE
S302141A15
S302141
For removal, installation and inspection work, refer to MT section. <Ref. to MT-54, Transfer Driven Gear .>
TC-7
Transfer Case
REDUCTION DRIVE GEAR WITHOUT VTD
7. Reduction Drive Gear without VTD

S302144
A: NOTE
S302144A15
TC-8
REDUCTION DRIVEN GEAR WITHOUT VTD
Transfer Case
8. Reduction Driven Gear without VTD

S302147
A: NOTE
S302147A15
TC-9
Transfer Case
CENTER DIFFERENTIAL
S302158
9. Center Differential
A: NOTE
S302158A15
For removal, installation and inspection work, refer to AUTOMATIC TRANSMISSION (a separate publication: Pub. No. G0853ZE) or MT section. <Ref. to MT-56, Center Differential.>
TC-10
OIL PUMP
Transfer Case
10. Oil Pump

A: NOTE
S302070A15
S302070
For removal, installation and inspection work, refer to MTsection. <Ref. to MT-50, Oil Pump.>
TC-11
Transfer Case
TRANSFER CLUTCH PRESSURE TEST
11. Transfer Clutch Pressure Test

S302159
A: NOTE
S302159A15
For removal, installation and inspection work, refer to AT section <Ref. to AT-18, Transfer Clutch Pressure Test.>
TC-12
TRANSFER DUTY SOLENOID AND VALVE BODY
Transfer Case
12. Transfer Duty Solenoid and Valve Body

S302161
A: NOTE
S302161A15
For removal, installation and inspection work, refer to AT section. <Ref. to AT-41, TRANSFER DUTY SOLENOID AND TRANSFER VALVE BODY, REMOVAL, Shift Solenoids, Duty Solenoids and ATF Temperature Sensor.>
TC-13
Transfer Case
TRANSFER DUTY SOLENOID AND VALVE BODY
MEMO:
TC-14
DRIVE SHAFT SYSTEM
DS
1. 2. 3. 4. 5. 6. 7. 8. 9. Page General Description.....................................................................................2 Propeller Shaft...........................................................................................14 Front Axle ..................................................................................................17 Rear Axle...................................................................................................23 Front Drive Shaft .......................................................................................32 Front Drive Shaft Boot ..............................................................................37 Rear Drive Shaft........................................................................................38 Rear Drive Shaft Boot ...............................................................................44 General Diagnostic Table ..........................................................................46
Drive Shaft System
GENERAL DESCRIPTION
S301001
A: SPECIFICATIONS
1. PROPELLER SHAFT
Propeller shaft type Front propeller shaft Joint-to-joint length: mm (in) Rear propeller shaft Joint-to-joint length: mm (in) Outside dia. of tube mm (in)
S301001E49 S301001E4901
Non-Turbo model UJ type AT L1 MT 585 (23.03) 644 (25.35) 707 (27.83) D1 D2 63.5 (2.500) 57.0 (2.244)
Turbo model DOJ type 580 (22.83) 639 (25.16) 712 (28.03)
L2
S3M0021E
DS-2
GENERAL DESCRIPTION
2. FRONT DRIVE SHAFT ASSEMBLY
Model Non-TURBO MT (With ABS) Non-TURBO MT (Without ABS) Non-TURBO AT (With ABS) TURBO Non-TURBO AT (Without ABS)
S301001E4902
Drive Shaft System
Tone wheel k k
Type of drive shaft assembly BJ87L+SFJ82 BJ87L+SFJ82 BJ87L+SFJ82 BJ87L+SFJ82
SHAFT Shaft diameter 28 mm (1.10 in) 28 mm (1.10 in) 26 mm (1.02 in) 26 mm (1.02 in)
Boot band identification color Pink Purple Brown
B4M2218C
(1) Measuring point
(2) Boot band identification color
(3) Tone wheel
DS-3
Drive Shaft System
GENERAL DESCRIPTION
S301001E4903
3. REAR DRIVE SHAFT ASSEMBLY

Model TURBO NON-TURBO MT NON-TURBO AT
Type of axle shaft assembly 82AC-RH, 82AC-LH 79AC-RH, 79AC-LH 79AC
SHAFT No. of identification grooves on shaft 2 (Two) 1 (One) None
Boot band identification color Auburn White Orange
S4M0521A
(1) Indication mark of RH
(2) Identification padding
(3) Boot band Identification
DS-4

S301001A05
Drive Shaft System
1. PROPELLER SHAFT
S301001A0501
S4M0522A
(1) Propeller shaft (Turbo model) (2) Propeller shaft (Non-Turbo model) (3) Rear differential (VA-type)
(4) Rear differential (T-type)
DS-5
Drive Shaft System
GENERAL DESCRIPTION
S301001A0502
2. FRONT AXEL
B4M2213B
(1) (2) (3) (4) (5) (6) (7) (8) (9)
Baffle plate (SFJ) Spring pin Outer race (SFJ) Snap ring Trunnion Free ring Circlip Boot band Boot (SFJ)
(10) (11) (12) (13) (14) (15) (16) (17) (18)
Boot (BJ) BJ ASSY Tone wheel Baffle plate Oil seal (IN) Snap ring Bearing Housing Oil seal (OUT)
(19) Hub bolt (20) Hub (21) Axle nut

Tightening torque: Nm (kgf-m, ft-lb) T: 186 (19, 137)
DS-6
GENERAL DESCRIPTION
3. REAR AXLE
S301001A0503
Drive Shaft System
S4M0523A
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
Circlip (Non-turbo AT vehicle) Baffle plate (DOJ) Outer race (DOJ) Snap ring Inner race Ball Cage Circlip Boot band Boot (DOJ)
(11) (12) (13) (14) (15) (16) (17) (18) (19) (20)
Boot (BJ or EBJ) BJ or EBJ ASSY Oil seal (IN. No. 2) Baffle plate Oil seal (IN) Housing Bearing Snap ring Oil seal (OUT) Tone wheel
(21) Hub bolt (22) Hub (23) Axle nut

Tightening torque: Nm (kgf-m, ft-lb) T1: 13 (1.3, 9.4) T2: 186 (19, 137)
DS-7
Drive Shaft System
GENERAL DESCRIPTION
S301001A03
C: CAUTION
Wear working clothing, including a cap, protective goggles, and protective shoes during operation. Remove contamination including dirt and corrosion before removal, installation or disassembly. Keep the disassembled parts in order and protect them from dust or dirt. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly, and replacement. Be careful not to burn your hands, because each part on the vehicle is hot after running. Use SUBARU genuine grease etc. or the equivalent. Do not mix grease etc. with that of another grade or from other manufacturers. Be sure to tighten fasteners including bolts and nuts to the specified torque. Place shop jacks or safety stands at the specified points. Apply grease onto sliding or revolution surfaces before installation. Before installing O-rings or snap rings, apply sufficient amount of grease to avoid damage and deformation. Before securing a part on a vise, place cushioning material such as wood blocks, aluminum plate, or shop cloth between the part and the vise.
DS-8

1. SPECIAL TOOLS
ILLUSTRATION
S301001A1701 S301001A17
Drive Shaft System
DESCRIPTION AXLE SHAFT INSTALLER
REMARKS Used for installing axle shaft into housing. Used with ADAPTER (927390000).
B4M2386
925091000
BAND TIGHTENING Used for tightening boot band. Except front TOOL axle housing side) (A) Jig for band (B) Ratchet wrench
B4M2387A
926470000
AXLE SHAFT PULLER
Used for removing axle shaft.
B4M2388
927060000
HUB REMOVER
Used for removing front hub. Used with HUB STAND (927080000).
B4M2389
DS-9
Drive Shaft System

ILLUSTRATION
GENERAL DESCRIPTION
TOOL NUMBER 927080000 DESCRIPTION HUB STAND REMARKS Used for disassembling and assembling hub bolt in hub.
B4M2390
927100000
BEARING REMOVER
Used for disassembling and assembling front housing bearing. Used with HOUSING STAND (927400000).
B4M2391
927140000
PLATE
Same as plate 2 included in AXLE SHAFT PULLER (926470000).
B4M2392
927390000
ADAPTER
Used as an adapter for AXLE SHAFT INSTALLER (922431000).
B4M2393
927400000
HOUSING STAND
Used for disassembling and assembling front housing bearing. Used with BEARING PULLER (927100000).
B4M2394
DS-10
GENERAL DESCRIPTION
ILLUSTRATION TOOL NUMBER 927410000 DESCRIPTION OIL SEAL INSTALLER
Drive Shaft System
REMARKS Used for installing oil seal into front housing. Used with HOUSING STAND (927400000).
B4M2395
927120000
HUB INSTALLER
Used for installing hub.
B4M2399
927420000
HUB REMOVER
Used for removing rear hub. Used with HUB STAND (927080000).
H5M0981
927430000
HOUSING STAND
Used for disassembling and assembling rear housing bearing. Used with BEARING PULLER (927440000).
H5M0982
DS-11
Drive Shaft System

ILLUSTRATION
GENERAL DESCRIPTION
TOOL NUMBER 927440000 DESCRIPTION BEARING REMOVER REMARKS Used for disassembling and assembling rear housing bearing. Used with HOUSING STAND (927430000).
H5M0983
927460000
OIL SEAL INSTALLER
Used for installing outer bearing and sub bearing into housing. Used with HOUSING STAND (927430000).
H5M0984
927450000
HUB INSTALLER
Used for installing rear hub into hub ASSY. Used with HUB STAND (927080000).
B4M2400
28099PA090
OIL SEAL PROTEC- Used for installing rear drive shaft into rear TOR differential. For protecting oil seal.
B4M2401
DS-12
GENERAL DESCRIPTION
ILLUSTRATION TOOL NUMBER 28099PA100 DESCRIPTION DRIVE SHAFT REMOVER
Drive Shaft System
REMARKS Used for removing rear drive shaft from rear differential.
B4M2402
28099AC000
BOOT BAND PLIERS
Used for tightening front BJ boot band. (Front axle housing side)
B4M2403

TOOL NAME Puller Dial Gauge Snap Ring Pliers
S301001A1702
REMARKS Used for removing ball joint from knuckle arm. Used for inspecting propeller shaft run-out. Used for installing and removing snap ring.
DS-13
Drive Shaft System
PROPELLER SHAFT
S301160
2. Propeller Shaft
A: REMOVAL
S301160A18
8) Remove the four bolts which hold propeller shaft to rear differential. NOTE: Put matching mark on affected parts before removal. Remove all but one bolt.
NOTE: Before removing propeller shaft, wrap metal parts with a cloth or rubber material. In case of DOJ type, before removing propeller shaft, wrap metal parts (installed at the rubber boot of center DOJ) with a cloth or rubber material, as shown in the figure. Rubber boot may be damaged due to interference with adjacent metal parts while bending the DOJ during removal.
S3M0027
9) Remove the two bolts which hold center bearing to car body.
S3M0030
1) Set vehicle on a lift. 2) Disconnect ground terminal from battery. 3) Move select lever or gear shift lever to N. 4) Release the parking brake. 5) Jack-up vehicle and support it with sturdy racks. 6) Remove front exhaust cover. (Non-Turbo model)
S3M0028
S3M0025
7) Remove differential mount front cover.
S3M0026
DS-14
PROPELLER SHAFT
10) Remove propeller shaft from transmission. CAUTION: Be sure not to damage oil seals and the frictional surface of sleeve yoke. Cover the center exhaust pipe with a cloth to keep off any ATF or oil spilled from transmission when removing propeller shaft. NOTE: Be sure to use an empty oil can to catch oil flowing out when removing propeller shaft. Be sure to plug the opening in transmission after removal of propeller shaft.
Drive Shaft System

S301160A11
B: INSTALLATION
1) Insert sleeve yoke into transmission and attach center bearing to body. Tightening torque: 52 Nm (5.3 kgf-m, 38.3 ft-lb)
B3M1606
2) Align matching marks and connect flange yoke and rear differential. Tightening torque: 31 Nm (3.2 kgf-m, 23.1 ft-lb)
S3M0029B
(A) (B)
Propeller shaft Cloth
11) Install the extension cap to transmission. NOTE: If extension cap is not available, place vinyl bag over opening and fasten with string to prevent gear oil or ATF from leaking.
B3M1587C
(A)
Matching mark
3) Install front exhaust cover. (Non-turbo model) 4) Install differential mount front cover. Tightening torque: 88 Nm (9.0 kgf-m, 65 ft-lb)
S3M0498A
(A)
Extension cap
S3M0026
DS-15
Drive Shaft System
PROPELLER SHAFT
S301160A10
C: INSPECTION
3. RUNOUT OF PROPELLER SHAFT

S301160A1003
NOTE: Do not disassemble propeller shaft. Check the following and replace if necessary. 1) Tube surfaces for dents or cracks 2) Splines for deformation or abnormal wear 3) Joints for non-smooth operation or abnormal noise 4) Center bearing for free play, noise or nonsmooth operation 5) Oil seals for abnormal wear or damage 6) Center bearing for breakage Check the following points with propeller shaft installed in vehicle.
1) Remove front exhaust cover. (Non-turbo model) 2) Turn rear wheels by hand to check for runout of propeller shaft. NOTE: Measure runout with a dial gauge at the center of front and rear propeller shaft tubes. Runout: Limit 0.6 mm (0.024 in)
1. JOINTS AND CONNECTIONS
S301160A1001
1) Remove center exhaust pipes. 2) Remove heat shield cover. 3) Check for any looseness of yoke flange connecting bolts and center bearing retaining bolts.
B3M1603A
2. SPLINES AND BEARING LOCATIONS

S301160A1002
(A) (B)
Propeller shaft Dial gauge

S301160A1004
1) Remove front exhaust cover. (Non-turbo model) 2) Turn propeller shaft by hand to see if abnormal free play exists at splines. Also move yokes to see if abnormal free play exists at spiders and bearings.
4. CENTER BEARING FREE PLAY
1) Remove front exhaust cover. (Non-turbo model) 2) While holding propeller shaft near center bearing with your hand, move it up and down, and left and right to check for any abnormal bearing free play.
B3M1602 B3M1604
DS-16
FRONT AXLE
Drive Shaft System
3. Front Axle
A: REMOVAL
S301148
8) Remove cotter pin and castle nut which secure tie-rod end to housing knuckle arm.
S301148A18
1) Disconnect ground terminal from battery. 2) Jack-up vehicle, support it with safety stands, and remove front wheels. 3) Unlock axle nut.
B4M2214A
(A) (B) (C)

G4M0214
Cotter pin Castle nut Tie-rod
9) Using a puller, remove tie-rod ball joint from knuckle arm.
4) Remove axle nut using a socket wrench. CAUTION: Be sure to loose and retighten axle nut after removing wheel from vehicle. Failure to follow this rule may damage wheel bearings. 5) Remove stabilizer link.
B4M2215
10) Remove ABS sensor assembly and harness in advance. (ABS equipped model)
G4M0215
6) Remove disc brake caliper from housing, and suspend it from strut using a wire. 7) Remove disc rotor from hub. If disc rotor seizes up within hub, drive disc rotor out by installing an 8-mm bolt in screw hole on the rotor.
B4M2209
B4M1678
DS-17
Drive Shaft System
FRONT AXLE
15) After scribing an alignment mark on camber adjusting bolt head, remove bolts which connect housing and strut, and disconnect housing from strut.
11) Remove bolt which secures sensor harness to strut. (ABS equipped model)
B4M1442
12) Remove transverse link ball joint from housing.
B4M1970
B: INSTALLATION
S301148A11
1) Install transverse link ball joint to housing. Tightening torque: 49 Nm (5.0 kgf-m, 36 ft-lb) 2) While aligning alignment mark on camber adjusting bolt head, connect housing and strut. CAUTION: Use a new self-locking nut. Tightening torque: 155 Nm (15.8 kgf-m, 114 ft-lb) 3) Install ABS sensor on housing. Tightening torque: 32 Nm (3.3 kgf-m, 23.9 ft-lb) 4) Install ABS sensor harness on strut. 5) Install disc rotor on hub. 6) Install disc brake caliper on housing. Tightening torque: 78 Nm (8 kgf-m, 57.9 ft-lb) 7) Install front drive shaft. <Ref. to DS-32 INSTALLATION, Front Drive Shaft.> 8) Connect stabilizer link.
B4M2216
13) Remove SFJ from transmission spindle. 14) Remove front drive shaft assembly from hub. If it is hard to remove, use STs. ST1 926470000 AXLE SHAFT PULLER ST2 927140000 PLATE CAUTION: Be careful not to damage oil seal lip and tone wheel when removing front drive shaft. When replacing front drive shaft, also replace inner oil seal.
S4M0108A
DS-18
FRONT AXLE
9) Connect tie-rod end ball joint and knuckle arm with a castle nut, and insert cotter pin into tie-rod end. Castle nut tightening torque: Tighten to 27.0 Nm (2.75 kgf-m, 19.9 ft-lb), and tighten further within 60 until cotter pin hole is aligned with a slot in the nut. CAUTION: When connecting, do not hit cap at the bottom of tie-rod end with hammer. Tightening torque: 88 Nm (9 kgf-m, 65 ft-lb)
Drive Shaft System
C: DISASSEMBLY
S301148A06
1) Using ST1, support housing and hub securely. 2) Attach ST2 to housing and drive hub out. ST1 927060000 HUB REMOVER ST2 927080000 HUB STAND
B4M2214A
(A) (B) (C)
Cotter pin Castle nut Tie-rod
10) While depressing brake pedal, tighten axle nut and lock it securely. Tightening torque: 186 Nm (19 kgf-m, 137 ft-lb) CAUTION: Use a new axle nut. Always tighten axle nut before installing wheel on vehicle. If wheel is installed and comes in contact with ground when axle nut is loose, wheel bearings may be damaged. Be sure to tighten axle nut to specified torque. Do not overtighten it as this may damage wheel bearing. 11) After tightening axle nut, lock it securely.
G4M0223
If inner bearing race remains in the hub, remove it with a suitable tool (commercially available). CAUTION: Be careful not to scratch polished area of hub. Be sure to install inner race on the side of outer race from which it was removed.
G4M0224
G4M0238
12) Install wheel and tighten wheel nuts to specified torque.
DS-19
Drive Shaft System
FRONT AXLE
8) Using ST and a hydraulic press, drive hub bolts out. ST 927080000 HUB STAND CAUTION: Be careful not to hammer hub bolts. This may deform hub.
3) Remove disc cover from housing.
G4M0225
4) Using a standard screwdriver, remove outer and inner oil seals. CAUTION: Do not use old oil seals. 5) Using flat bladed screwdriver, remove snap ring. CAUTION: Remove without scratching axle housing.
G4M0228
D: ASSEMBLY
S301148A02
1) Attach hub to ST securely. ST 927080000 HUB STAND
H4M1001 G4M0230
6) Using ST1, support housing securely. 7) Using ST2, press inner race to drive out outer bearing. ST1 927400000 HOUSING STAND ST2 927100000 BEARING REMOVER CAUTION: Do not remove outer race unless it is faulty. Discard outer race after removal. Do not replace inner or outer race separately; always replace as a unit.
2) Using a hydraulic press, press new hub bolts into place. CAUTION: Be sure to press hub bolts until their seating surfaces contact the hub. NOTE: Use 12 mm (0.47 in) dia. holes in HUB STAND to prevent bolts from tilting. 3) Clean dust or foreign particles from inside the housing. 4) Using ST1 and ST2, press a new bearing into place. ST1 927400000 HOUSING STAND ST2 927100000 BEARING REMOVER
G4M0227
DS-20
FRONT AXLE
CAUTION: Always press outer race when installing bearing. Be careful not to remove plastic lock from inner race when installing bearing. Charge bearing with new grease when outer race is not removed. Specified grease: SHELL 6459N
Drive Shaft System
8) Using ST1 and ST2, press outer oil seal until it contacts the bottom of housing. ST1 927410000 OIL SEAL INSTALLER ST2 927400000 HOUSING STAND
G4M0233
9) Apply sufficient grease to oil seal lip. Specified grease SHELL 6459N
G4M0232
5) Using pliers, install snap ring in its groove. CAUTION: Make sure to install it firmly to groove. Install without scratching axle housing.
CAUTION: If specified grease is not available, remove bearing grease and apply Auto Rex A instead. Do not mix different types of grease. 10) Install disc cover to housing the three bolts. Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft-lb) 11) Attach hub to ST1 securely. 12) Clean dust or foreign particles from the polished surface of hub. 13) Using ST2, press bearing into hub by driving inner race. ST1 927080000 HUB STAND ST2 927120000 HUB INSTALLER
B4M2253
6) Using ST1 and ST2, press inner oil seal until it contacts circlip. ST1 927410000 OIL SEAL INSTALLER ST2 927400000 HOUSING STAND
G4M0235
G4M0234
7) Invert ST and housing. ST 927400000 HOUSING STAND
DS-21
Drive Shaft System
FRONT AXLE
S301148A10
E: INSPECTION
1) Moving front tire up and down by hand, check that there is no backlash in the bearing. And check that wheel rotates smoothly.
S4M0572
2) Inspect the removed parts for wear and damage. If defective, replace with new ones. CAUTION: If bearing is faulty, replace it as the bearing set. Be sure to replace oil seal at every overhaul.
H4M1002C
(A)
Replace as a set.
DS-22
REAR AXLE
Drive Shaft System
4. Rear Axle
A: REMOVAL
1. DISC BRAKE
S301154
8) Disconnect parking brake cable end.
S301154A18
S301154A1802
1) Disconnect ground cable from battery. 2) Jack-up vehicle, and remove rear wheel cap and wheels. CAUTION: Be sure to loosen and retighten axle nut after removing wheel from vehicle. Failure to follow this rule may damage wheel bearings. 3) Unlock axle nut. 4) Remove axle nut using a socket wrench. 5) Return parking brake lever and loosen adjusting nut.
(1) Cable end
S4M0368A
9) Disconnect rear stabilizer from rear lateral link. 10) Remove bolts which secure trailing link assembly to rear housing. CAUTION: Discard old self-locking nut. Replace with a new one.
S4M0520A
(1) (2) (3)
Parking brake lever Lock nut Adjusting nut
S4M0109
6) Remove disc brake caliper from back plate, and suspend it from strut using a piece of wire.
11) Remove bolts which secure lateral link assembly to rear housing. CAUTION: Discard old self-locking nut. Replace with a new one.
G4M0240
7) Remove disc rotor from hub. NOTE: If disc rotor seizes up within hub, drive it out by installing an 8-mm bolt into bolt hole in disc rotor.
S4M0110
DS-23
Drive Shaft System
REAR AXLE
2. DRUM BRAKE
S301154A1803
12) Disengage BJ from housing splines, and remove rear drive shaft assembly. If it is hard to remove, use STs. ST1 926470000 AXLE SHAFT PULLER ST2 927140000 PLATE CAUTION: Be careful not to damage oil seal lip when removing rear drive shaft. When rear drive shaft is to be replaced, also replace inner oil seal with a new one.
1) Disconnect ground cable from battery. 2) Jack-up vehicle, and remove rear wheel cap and wheels. CAUTION: Be sure to loosen and retighten axle nut after removing wheel from vehicle. Failure to follow this rule may damage wheel bearings. 3) Unlock axle nut. 4) Remove axle nut using a socket wrench. 5) Return parking brake lever and loosen adjusting nut.
G4M0247
13) Remove rear ABS sensor from back plate (only vehicle equipped with ABS).
(1) (2) (3) Parking brake lever Lock nut Adjusting nut
S4M0520A
6) Remove brake drum from hub. 7) If it is difficult to remove brake drum, remove adjusting hole cover from back plate, and then turn adjusting screw using a slot-type screwdriver until brake shoe separates from the drum.
H4M1139B
(1)
ABS sensor
14) Remove bolts which secure rear housing to strut, and separate the two.
S4M0369A
G4M0249
(1) (2) (3) (4) (5) (6)
Back plate Wheel cylinder Adjuster ASSY pawls Adjusting lever Tightening direction Push
DS-24
REAR AXLE
NOTE: If brake drum is difficult to remove, drive it out by installing an 8-mm bolt into bolt hole in brake drum.
Drive Shaft System
11) Remove bolts which secure trailing link assembly to rear housing. CAUTION: Discard old self-locking nut. Replace with a new one.
G4M0243
8) Using a flare-nut wrench, disconnect brake pipe from wheel cylinder. CAUTION: Cover open end of wheel cylinder to prevent entry of foreign particles.
S4M0109
12) Remove bolts which secure lateral link assembly to rear housing. CAUTION: Discard old self-locking nut. Replace with a new one.
G4M0244
9) Disconnect parking brake cable end.

S4M0110
13) Disengage BJ from housing splines, and remove rear drive shaft assembly. If it is hard to remove, use STs. ST1 926470000 AXLE SHAFT PULLER ST2 927140000 PLATE CAUTION: Be careful not to damage oil seal lip when removing rear drive shaft. When rear drive shaft is to be replaced, also replace inner oil seal with a new one.
S4M0368A
(1)
Cable end
10) Disconnect rear stabilizer from rear lateral link.
G4M0247
DS-25
Drive Shaft System
REAR AXLE
3) Connect rear housing assembly to lateral link assembly. CAUTION: Use a new self-locking nut. Tightening torque: 137 Nm (14 kgf-m, 101 ft-lb)
14) Remove rear ABS sensor from back plate (only vehicle equipped with ABS).
H4M1139B
(1)
ABS sensor
15) Remove bolts which secure rear housing to strut, and separate the two.
S4M0110
4) Connect rear housing assembly to trailing link assembly. CAUTION: Use a new self-locking nut. Tightening torque: 113 Nm (11.5 kgf-m, 83 ft-lb)
G4M0249
B: INSTALLATION
1. DISC BRAKE
S301154A11
S301154A1102
1) Connect rear housing assembly and strut assembly. CAUTION: Use a new self-locking nut. Tightening torque: 196 Nm (20 kgf-m, 145 ft-lb) 2) Fit BJ (bell joint) to rear housing splines. CAUTION: Be careful not to damage inner oil seal lip.
S4M0109
5) Connect rear stabilizer to rear lateral link. CAUTION: Use a new self-locking nut. Tightening torque: 44 Nm (4.5 kgf-m, 32.5 ft-lb) 6) Connect parking brake cable to parking brake. 7) Install disc rotor on rear housing assembly.
DS-26
REAR AXLE
8) Install disc brake caliper on back plate. Tightening torque: 52 Nm (5.3 kgf-m, 38.3 ft-lb)
Drive Shaft System

S301154A1103
2. DRUM BRAKE
1) Connect rear housing assembly and strut assembly. CAUTION: Use a new self-locking nut. Tightening torque: 196 Nm (20 kgf-m, 145 ft-lb) 2) Fit BJ (bell joint) to rear housing splines. CAUTION: Be careful not to damage inner oil seal lip.
G4M0240
3) Connect rear housing assembly to lateral link assembly. CAUTION: Use a new self-locking nut. Tightening torque: 137 Nm (14 kgf-m, 101 ft-lb)
9) Install rear ABS sensor to back plate (only vehicle equipped with ABS).
H4M1139B
(1)
ABS sensor
S4M0110
10) Bleed air from brake system. <Ref. to BR-47, Air Bleeding.> 11) Adjust parking brake lever stroke by turning adjuster. 12) Move brake lever back to apply brakes. While depressing brake pedal, tighten axle nut using a socket wrench. Lock axle nut after tightening. Tightening torque: 186 Nm (19 kgf-m, 137 ft-lb) CAUTION: Use a new axle nut. Always tighten axle nut before installing wheel on vehicle. If wheel is installed and comes in contact with ground when axle nut is loose, wheel bearings may be damaged. Be sure to tighten axle nut to specified torque. Do not overtighten it as this may damage wheel bearing. 13) Install wheel and tighten wheel nuts to specified torque. Tightening torque: 88 Nm (9 kgf-m, 65 ft-lb)
4) Connect rear housing assembly to trailing link assembly. CAUTION: Use a new self-locking nut. Tightening torque: 113 Nm (11.5 kgf-m, 83 ft-lb)
S4M0109
5) Connect rear stabilizer to rear lateral link. CAUTION: Use a new self-locking nut. Tightening torque: 44 Nm (4.5 kgf-m, 32.5 ft-lb) 6) Connect parking brake cable to parking brake.
DS-27
Drive Shaft System
REAR AXLE C: DISASSEMBLY

S301154A06
7) Clean brake pipe connection. Using a flare-nut wrench, connect brake pipe to wheel cylinder. 8) Connect rear ABS sensor to back plate (only vehicle equipped with ABS).
1) Using ST1 and ST2, remove hub from rear housing. ST1 927080000 HUB STAND ST2 927420000 HUB REMOVER
H4M1139B
(1)
ABS sensor
G4M0250
9) Connect parking brake cable to lever. 10) Install brake drum on rear housing assembly. 11) Bleed air from brake system. <Ref. to BR-47, Air Bleeding.> 12) Adjust parking brake lever stroke by turning adjuster. 13) Move brake lever back to apply brakes. While depressing brake pedal, tighten axle nut using a socket wrench. Lock axle nut after tightening. Tightening torque: 186 Nm (19 kgf-m, 137 ft-lb) CAUTION: Use a new axle nut. Always tighten axle nut before installing wheel on vehicle. If wheel is installed and comes in contact with ground when axle nut is loose, wheel bearings may be damaged. Be sure to tighten axle nut to specified torque. Do not overtighten it as this may damage wheel bearing. 14) Install wheel and tighten wheel nuts to specified torque. Tightening torque: 88 Nm (9 kgf-m, 65 ft-lb)
2) Remove back plate from rear housing. 3) Using a standard screwdriver, remove outer and inner oil seals. CAUTION: Use new oil seals. 4) Using flat bladed screwdriver, remove snap ring. CAUTION: Remove without scratching axle housing.
H4M1003
DS-28
REAR AXLE
5) Using ST1 and ST2, remove bearing by pressing inner race. ST1 927430000 HOUSING STAND ST2 927440000 BEARING REMOVER CAUTION: Do not remove bearing unless damaged. Do not re-use bearing after removal.
Drive Shaft System

S301154A02
D: ASSEMBLY
1) Using ST, press new hub bolt into place. CAUTION: Ensure hub bolt closely contacts hub. Use a 12 mm (0.47 in) hole in the ST to prevent hub bolt from tilting during installation. ST 927080000 HUB STAND
G4M0252
6) Remove tone wheel bolts and remove tone wheel from hub (only vehicle equipped with ABS). 7) Using ST, press hub bolt out. ST 927080000 HUB STAND CAUTION: Be careful not to hammer hub bolts. This may deform hub.
G4M0230
2) Remove foreign particles (dust, rust, etc.) from mating surfaces of hub and tone wheel, and install tone wheel to hub (only vehicle equipped with ABS). CAUTION: Ensure tone wheel closely contacts hub. Be careful not to damage tone wheel teeth.
G4M0228 S4M0370A
(1)
Tone wheel
DS-29
Drive Shaft System
REAR AXLE
5) Using ST1 and ST2, press outer oil seal until it comes in contact with snap ring. ST1 927430000 HOUSING STAND ST2 927460000 OIL SEAL INSTALLER
3) Clean housing interior completely. Using ST1 and ST2, press bearing into housing. ST1 927430000 HOUSING STAND ST2 927440000 BEARING REMOVER CAUTION: Always press outer race when installing bearing. Be careful not to remove plastic lock from inner race when installing bearing. Charge bearing with new grease when outer race is not removed.
S4M0267B
(1)
Snap ring
S4M0266A
6) Invert both ST1 and housing. 7) Using ST2, press inner oil seal into housing until it touches bottom. ST1 927430000 HOUSING STAND ST2 927460000 OIL SEAL INSTALLER
4) Using plier, install snap ring. CAUTION: Ensure snap ring fits in groove properly. Install without scratching axle housing.
S4M0268A
8) Using ST1 and ST2, press sub seal into place. ST1 927430000 HOUSING STAND ST2 927460000 OIL SEAL INSTALLER
S4M0371A
(1)
Plier
S4M0269A
9) Apply sufficient grease to oil seal lip. Specified grease: SHELL 6459N CAUTION: If specified grease is not available, remove bearing grease and apply Auto Rex A instead. Do not mix different types of grease.
DS-30
REAR AXLE
10) Install back plate to rear housing. Tightening torque: 52 Nm (5.3 kgf-m, 38 ft-lb) 11) Using ST1 and ST2, press bearing into hub. ST1 927080000 HUB STAND ST2 927450000 HUB INSTALLER
Drive Shaft System
S4M0270B
(1)
Back plate
S301154A10
E: INSPECTION
1) Check that there is no backlash in the rear bearing as well as front. And check that wheel rotates smoothly. <Ref. to DS-22, INSPECTION, Front Axle.> 2) Inspect the removed parts for wear and damage. If defective, replace with a new one. CAUTION: If a bearing is faulty, replace it as the bearing set. Be sure to replace oil seal at every overhaul.
H4M1002B
(A)
Replace as a set.
DS-31
Drive Shaft System
FRONT DRIVE SHAFT

S301153
5. Front Drive Shaft

A: REMOVAL
S301153A18
B: INSTALLATION
S301153A11
1) Insert BJ into hub splines. CAUTION: Be careful not to damage inner oil seal lip and tone wheel. 2) Using ST1 and ST2, pull drive shaft into place. ST1 922431000 AXLE SHAFT INSTALLER ST2 927390000 ADAPTER CAUTION: Do not hammer drive shaft when installing it.
1) Disconnect ground terminal from battery. 2) Jack-up vehicle, support it with safety stands (rigid rocks), and remove front wheel cap and wheels. 3) Unlock axle nut. 4) Depress brake pedal and remove axle nut using a socket wrench. CAUTION: Be sure to loosen and retighten axle nut after removing wheel from vehicle. Failure to follow this rule may damage wheel bearings. 5) Remove stabilizer link from transverse link. 6) Disconnect transverse link from housing. 7) Remove spring pin which secures transmission spindle to SFJ. CAUTION: Use a new spring pin.
G4M0291
3) Tighten axle nut temporarily. 4) Install SFJ on transmission spindle and drive spring pin into place. CAUTION: Always use a new spring pin.
G4M0279
8) Remove front drive shaft assembly. If it is hard to remove, use ST1 and ST2. ST1 926470000 AXLE SHAFT PULLER ST2 927140000 PLATE CAUTION: Be careful not to damage oil seal lip and tone wheel when removing front drive shaft. When front drive shaft is to be replaced, also replace inner oil seal.
G4M0279
5) Connect transverse link to housing. Tightening torque (self-locking nut): 49 Nm (5.0 kgf-m, 36 ft-lb) CAUTION: Use a new self-locking nut. 6) Install stabilizer bracket. 7) While depressing brake pedal, tighten axle nut to the specified torque.
S4M0108A
Tightening torque: 186 Nm (19 kgf-m, 137 ft-lb)
DS-32
FRONT DRIVE SHAFT

CAUTION: Use a new axle nut. Always tighten axle nut before installing wheel on vehicle. If wheel is installed and comes in contact with ground when axle nut is loose, wheel bearings may be damaged. Be sure to tighten axle nut to specified torque. Do not overtighten it as this may damage wheel bearing. 8) After tightening axle nut, lock it securely.
Drive Shaft System
CAUTION: The grease is a special grease. Do not confuse with other greases. 6) Place alignment mark on free ring and trunnion.
C: DISASSEMBLY
S301153A06
1) Place alignment marks on shaft and outer race.
B4M0774
2) Remove SFJ boot band and boot. CAUTION: Be careful not to damage boot. 7) Remove free ring from trunnion.
B4M0777
CAUTION: Be careful with the free ring position. 8) Place alignment mark on trunnion and shaft.
B4M0775
3) Remove circlip from SFJ outer race using screwdriver. 9) Remove snap ring and trunnion.
B4M0778
B4M0776
4) Remove SFJ outer race from shaft assembly. 5) Wipe off grease.
B4M0779
DS-33
Drive Shaft System
FRONT DRIVE SHAFT D: ASSEMBLY

S301153A02
CAUTION: Be sure to wrap shaft splines with vinyl tape to prevent boot from scratches. 10) Remove SFJ boot. 11) Place drive shaft in a vise between wooden blocks. CAUTION: Do not place drive shaft directly in the vise; use wooden block. 12) Raise boot band claws by means of screwdriver and hammer.
CAUTION: Use specified grease. BJ side: NTG2218 (Part No. 28093AA000) SFJ side: SSG6003 (Part No. 28093TA000) 1) Place BJ boot and small boot band on BJ side of shaft. CAUTION: Be sure to wrap shaft splines with vinyl tape to prevent boot from scratches. 2) Place drive shaft in a vise. CAUTION: Do not place drive shaft directly in the vise; use wooden blocks. 3) Apply a coat of specified grease [60 to 70 g (2.12 to 2.47 oz)] to BJ. 4) Apply an even coat of specified grease [20 to 30 g (0.71 to 1.06 oz)] to the entire inner surface of boot. Also apply grease to shaft. NOTE: The inside of the larger end of BJ boot and the boot groove shall be cleaned so as to be free from grease and other substances. 5) Install boot projecting portion to BJ groove.
B4M2220B
(A)
Boot band claws
13) Cut and remove the boot. CAUTION: The boot must be replaced with a new one whenever it is removed.
(A) (B) (C) BJ Lorge boot band Boot
B4M2217B
6) Set large boot band in place.
B4M0690
14) Thus, disassembly of axle is completed, but BJ cannot be disassembled.
DS-34
FRONT DRIVE SHAFT

7) Install boot projecting portion to shaft groove. 11) Install snap ring to shaft.
Drive Shaft System
CAUTION: Confirm that the snap ring is completely fitted in the shaft groove. 12) Fill 100 to 110 g (3.53 to 3.88 oz) of specified grease into the interior of SFJ outer race. 13) Apply a coat of specified grease to free ring and trunnion. 14) Align alignment marks on free ring and trunnion and install free ring.
B4M1297C
(A) (B) (C)
Boot Small boot band Shaft
CAUTION: Be careful with the free ring position.
8) Tighten boot bands using ST, torque wrench and socket flex handle. ST 28099AC000 BOOT BAND PLIER
B4M0693C
(A) (B) (C) (D) (E)
Large boot band Boot Torque wrench Socket flex handle BJ
B4M0777
Tightening torque: Large boot band 157 Nm (16.0 kgf-m, 116 ft-lb) or more Small boot band 133 Nm (13.6 kgf-m, 98 ft-lb) or more 9) Place SFJ boot at the center of shaft. 10) Align alignment marks and install trunnion on shaft.
15) Align alignment marks on shaft and outer race, and install outer race.
B4M0774
16) Install circlip in the groove on SFJ outer race. CAUTION: Pull the shaft lightly and assure that the circlip is completely fitted in the groove.
B4M0778
DS-35
Drive Shaft System
FRONT DRIVE SHAFT

23) Cut off band with an allowance of about 10 mm (0.39 in) left from the clip and bend this allowance over the clip. CAUTION: Be careful so that the end of the band is in close contact with clip. 24) Fix up boot on BJ in the same manner. NOTE: Extend and retract SFJ to provide equal grease coating.
17) Apply an even coat of the specified grease 30 to 40 g (1.06 to 1.41 oz) to the entire inner surface of boot. 18) Install SFJ boot taking care not to twist it. CAUTION: The inside of the larger end of SFJ boot and the boot groove shall be cleaned so as to be free from grease and other substances. When installing SFJ boot, position outer race of SFJ at center of its travel. 19) Put a band through the clip and wind twice in alignment with band groove of boot. CAUTION: Use a new band. 20) Pinch the end of band with pliers. Hold the clip and tighten securely. NOTE: When tightening boot, exercise care so that the air within the boot is appropriate. 21) Tighten band by using ST. ST 925091000 BAND TIGHTENING TOOL NOTE: Tighten band until it cannot be moved by hand.
E: INSPECTION
S301153A10
Check the removed parts for damage, wear, corrosion etc. If faulty, repair or replace. 1) DOJ (Double Offset Joint) Check seizure, corrosion, damage, wear and excessive play. 2) SFJ (Shudder-less Freering tripod Joint) Check seizure, corrosion, damage and excessive play. 3) Shaft Check excessive bending, twisting, damage and wear. 4) BJ (Bell Joint) Check seizure, corrosion, damage and excessive play. 5) Boot Check for wear, warping, breakage or scratches. 6) Grease Check for discoloration or fluidity.
G4M0289
22) Tap on the clip with the punch provided at the end of ST. ST 925091000 BAND TIGHTENING TOOL CAUTION: Tap to an extent that the boot underneath is not damaged.
G4M0290
DS-36
FRONT DRIVE SHAFT BOOT
Drive Shaft System
6. Front Drive Shaft Boot

A: INSPECTION
S301755A10
S301755
Check boot for deterioration, deform and damage. If any fault is found, replace the boot.
B: REPLACEMENT
S301755A20
1) Set vehicle on a lift. 2) Disconnect ground terminal from battery. 3) Jack-up vehicle, support it with safety stands (rigid rocks), and remove front wheel cap and wheels. NOTE: Do not remove axle nut. 4) Remove stabilizer link. 5) Disconnect transverse link from housing. 6) Remove spring pin which secures transmission spindle to SFJ. CAUTION: Use a new spring pin.
G4M0279
7) Remove BJ and SFJ boots from drive shaft. <Ref. to DS-33, DISASSEMBLY, Front Drive Shaft.> 8) Install BJ and SFJ boots to drive shaft. <Ref. to DS-34, ASSEMBLY, Front Drive Shaft.> 9) Install SFJ on transmission spindle and drive spring pin into place. CAUTION: Always use a new spring pin.
G4M0279
10) Connect transverse link to housing. 11) Install stabilizer link.
DS-37
Drive Shaft System
REAR DRIVE SHAFT

S301156
7. Rear Drive Shaft

A: REMOVAL
S301156A18
1) Set vehicle on a lift. 2) Disconnect ground cable from battery. 3) Lift vehicle. Remove rear wheel cap and wheels. CAUTION: Be sure to loosen and retighten axle nut after removing wheel from vehicle. Failure to follow this rule may damage wheel bearings. 4) Unlock axle nut. 5) Loosen axle nut using a socket wrench. CAUTION: Do not remove axle nut. 6) Remove ABS sensor clamps and parking brake cable bracket. 7) Remove bolts which secure lateral link assembly to rear housing. CAUTION: Discard old self-locking nut. Replace with a new one. 8) Remove bolts which secure trailing link assembly to rear housing. CAUTION: Discard old self-locking nut. Replace with a new one. 9) Remove DOJ from rear differential using ST. (Except Non-TURBO AT vehicle) ST 28099PA100 DRIVE SHAFT REMOVER CAUTION: Do not remove circlip attached to inside of differential.
CAUTION: Be careful not to damage side bearing retainer. Always use bolt as shown in figure, as supporting point for ST during removal. ST 28099PA100 DRIVE SHAFT REMOVER
S4M0373A
(1)
Side bearing retainer
10) Remove DOJ from rear differential using tire lever. (Non-TURBO AT vehicles) NOTE: The side spline shaft circlip comes out together with the shaft.
S4M0374A
(1)
Tire lever
CAUTION: When removing the DOJ from the rear differential, fit tire lever to the bolt as shown in figure so as not to damage the axle shaft holder.
S4M0372A
(1) (2)
Bolt DOJ
S4M0375A
(1)
Axle shaft holder
DS-38
REAR DRIVE SHAFT

11) Remove axle nut and drive shaft. If it is hard to remove, use ST1 and ST2. ST1 926470000 AXLE SHAFT PULLER ST2 927140000 PLATE CAUTION: Be careful not to damage oil seal lip when removing rear drive shaft. When rear drive shaft is to be replaced, also replace inner oil seal with a new one.
Drive Shaft System
5) Using ST, install DOJ into differential. ST 28099PA090 SIDE OIL SEAL PROTECTOR
B4M0549A
6) Insert DOJ spline end into bore of side oil seal, and remove ST. CAUTION: Do not allow DOJ splines to damage side oil seal.
G4M0247
ST
28099PA090
SIDE OIL SEAL PROTECTOR
B: INSTALLATION
S301156A11
1) Insert BJ into rear housing splines. CAUTION: Be careful not to damage inner oil seal lip. 2) Using ST1 and ST2, pull drive shaft into place. ST1 922431000 AXLE SHAFT INSTALLER ST2 927390000 ADAPTER CAUTION: Do not hammer drive shaft when installing it.
B4M0550A
7) Align DOJ and differential splines. 8) Push housing to insert DOJ into differential. NOTE: Make sure DOJ is inserted properly.
G4M0293
3) Tighten axle nut temporarily. 4) Replace circlips from DOJ spline with new one.
G3M0050
9) Connect rear housing assembly to trailing link assembly, and tighten self-locking nut. Tightening torque: 113 Nm (11.5 kgf-m, 83 ft-lb) 10) Connect rear housing assembly to lateral link assembly, and tighten self-locking nut.
DS-39
Drive Shaft System
REAR DRIVE SHAFT

6) Take out DOJ outer race from shaft assembly. 7) Wipe off grease and take out balls. CAUTION: The grease is a special grease (grease for constant velocity joint). Do not confuse with other greases. NOTE: Disassemble exercising care not to lose balls (6 pcs).
Tightening torque: 137 Nm (14 kgf-m, 101 ft-lb) 11) Install stabilizer bracket. 12) While depressing brake pedal, tighten axle nut using a socket wrench. Tightening torque: 186 Nm (19 kgf-m, 137 ft-lb) CAUTION: Use a new axle nut. Always tighten axle nut before installing wheel on vehicle. If wheel is installed and comes in contact with ground when axle nut is loose, wheel bearings may be damaged. Be sure to tighten axle nut to specified torque. Do not overtighten it as this may damage wheel bearing. 13) After tightening axle nut, lock it securely.
C: DISASSEMBLY
S301156A06
B4M0227E
1) Straighten bent claw of larger end of DOJ boot. 2) Loosen band by means of screwdriver or pliers with care of not damaging boot.
(A) (B)
Outer race Grease
8) To remove the cage from the inner race, turn the cage by a half pitch to the track groove of the inner race and shift the cage. 9) Remove snap ring, which fixes inner race to shaft, by using pliers. 10) Take out DOJ inner race. 11) Take off DOJ cage from shaft and remove DOJ boot. CAUTION: Be sure to wrap shaft splines with vinyl tape to prevent boot from scratches. 12) Remove BJ boot in the same procedure as DOJ boot. 13) Thus, disassembly of axle is completed, but BJ is unable to be disassembled.
G4M0281
3) Remove boot band on the small end of DOJ boot in the same manner. 4) Remove the larger end of DOJ boot from DOJ outer race. 5) Pry and remove round circlip located at the neck of DOJ outer race with a screwdriver.
D: ASSEMBLY
S301156A02
CAUTION: Use specified grease. BJ side (Non-turbo model): Molylex No. 2 (Part No. 723223010) EBJ side (Turbo model): NTG 2218 (Part No. 28093AA000) DOJ side: VU-3A702 (Yellow) (Part No. 23223GA050)
G4M0282
1) Install BJ or EBJ boot in specified position, and fill it with 60 to 70 g (2.12 to 2.47 oz) of specified grease. 2) Place DOJ boot at the center of shaft.
DS-40
REAR DRIVE SHAFT

CAUTION: Be sure to wrap shaft splines with vinyl tape to prevent boot from scratches. 3) Insert DOJ cage onto shaft. NOTE: Insert the cage with the cut-out portion facing the shaft end, since the cage has an orientation.
Drive Shaft System
5) Install cage, which was previously fitted, to inner race fixed upon shaft. NOTE: Fit the cage with the protruded part aligned with the track on the inner race and then turn by a half pitch.
B4M0228E S4M0376B
(A) (B)
Cage Cut-out portion
(A) (B)
Inner race Cage
4) Install DOJ inner race on shaft and fit snap ring with pliers. NOTE: Confirm that the snap ring is completely fitted in the shaft groove.
6) Fill 80 to 90 g (2.82 to 3.17 oz) of specified grease into the interior of DOJ outer race. 7) Apply a coat of specified grease to the cage pocket and six balls. 8) Insert six balls into the cage pocket. 9) Align the outer race track and ball positions and place in the part where shaft, inner race, cage and balls are previously installed, and then fit outer race.
G4M0285
B4M0227E
(A) (B)
Outer race Grease
DS-41
Drive Shaft System
REAR DRIVE SHAFT

15) Tighten band by using ST. ST 925091000 BAND TIGHTENING TOOL NOTE: Tighten band until it cannot be moved by hand.
10) Install circlip in the groove on DOJ outer race. NOTE: Assure that the balls, cage and inner race are completely fitted in the outer race of DOJ. Exercise care not to place the matched position of circlip in the ball groove of outer race. Pull the shaft lightly and assure that the circlip is completely fitted in the groove.
G4M0289
16) Tap on the clip with the punch provided at the end of ST. ST 925091000 BAND TIGHTENING TOOL
G4M0282
11) Apply an even coat of the specified grease [20 to 30 g (0.71 to 1.06 oz)] to the entire inner surface of boot. Also apply grease to shaft. 12) Install DOJ boot taking care not to twist it. NOTE: The inside of the larger end of DOJ boot and the boot groove shall be cleaned so as to be free from grease and other substances. When installing DOJ boot, position outer race of DOJ at center of its travel. 13) Put a band through the clip and wind twice in alignment with band groove of boot. CAUTION: Use a new band. 14) Pinch the end of band with pliers. Hold the clip and tighten securely. NOTE: When tightening boot, exercise care so that the air within the boot is appropriate.
CAUTION: Tap to an extent that the boot underneath is not damaged.
G4M0290
17) Cut off band with an allowance of about 10 mm (0.39 in) left from the clip and bend this allowance over the clip. CAUTION: Be careful so that the end of the band is in close contact with clip. 18) Fix up boot on BJ or EBJ in the same manner. NOTE: Extend and retract DOJ to provide equal grease coating.
DS-42
REAR DRIVE SHAFT E: INSPECTION

S301156A10
Drive Shaft System
Check the removed parts for damage, wear, corrosion etc. If faulty, repair or replace. 1) DOJ (Double Offset Joint) Check seizure, corrosion, damage, wear and excessive play. 2) SFJ (Shudder-less Freering tripod Joint) Check seizure, corrosion, damage and excessive play. 3) Shaft Check excessive bending, twisting, damage and wear. 4) BJ (Bell Joint) or EBJ (High efficiency compact ball fixed joint) Check seizure, corrosion, damage and excessive play. 5) Boot Check for wear, warping, breakage or scratches. 6) Grease Check for discoloration or fluidity.
DS-43
Drive Shaft System
REAR DRIVE SHAFT BOOT

S301756
8. Rear Drive Shaft Boot

A: INSPECTION
S301756A10
Check boot for deterioration, deform and damage. If any fault is found, replace the boot.
CAUTION: Be careful not to damage side bearing retainer. Always use bolt as shown in figure, as supporting point for ST during removal. ST 28099PA100 DRIVE SHAFT REMOVER
B: REPLACEMENT
S301756A20
1) Set vehicle on a lift. 2) Disconnect ground cable from battery. 3) Lift vehicle. Remove rear wheel cap and wheels. NOTE: Axle nut need not be removed. 4) Remove ABS sensor clamps and parking brake cable bracket. 5) Disconnect stabilizer link from lateral link. 6) Remove bolts which secure lateral link assembly to rear housing. 7) Remove bolts which secure trailing link assembly to rear housing. 8) Remove DOJ from rear differential using ST. ST 28099PA100 DRIVE SHAFT REMOVER NOTE: The side spline shaft circlip comes out together with the shaft.
S4M0373A
(1)
Side bearing retainer
9) Remove DOJ and BJ or EBJ boots from drive shaft. <Ref. to DS-40, DISASSEMBLY, Front Drive Shaft.> 10) Install DOJ and BJ or EBJ boots to drive shaft. <Ref. to DS-40, ASSEMBLY, Rear Drive Shaft.> 11) Using ST, install DOJ into differential. ST 28099PA090 SIDE OIL SEAL PROTECTOR
S4M0372A
B4M0549A
(1) (2)
Bolt DOJ
DS-44
REAR DRIVE SHAFT BOOT

12) Insert DOJ spline end into bore of side oil seal, and remove ST. CAUTION: Do not allow DOJ splines to damage side oil seal. ST 28099PA090 SIDE OIL SEAL PROTECTOR
Drive Shaft System
B4M0550A
13) Align DOJ and differential splines. 14) Push housing to insert DOJ into differential. NOTE: Make sure DOJ is inserted properly.
G3M0050
CAUTION: Discard old self-locking nut. Replace with a new one. 15) Connect rear housing assembly to trailing link assembly, and tighten self-locking nut. 16) Connect rear housing assembly to lateral link assembly, and tighten self-locking nut. 17) Connect stabilizer link to lateral link. 18) Install ABS sensor clamps and parking brake cable bracket.
DS-45
Drive Shaft System

S301257

A: INSPECTION
S301257A10
NOTE: Vibration while cruising may be caused by an unbalanced tire, improper tire inflation pressure, improper wheel alignment, etc.
Symptom 1. Vibration of propeller shaft NOTE: Vibration is caused by propeller shaft during operation and is transferred to vehicle body. Generally vibration increase in proportion to vehicle speed. 2. Tapping when starting and noise while cruising, caused by propeller shaft. Possible cause (1) Worn or damaged universal joint. (2) Unbalanced propeller shaft due to bend or dent. (3) Loose installation of propeller shaft. (4) Worn or damaged center bearing and damaged center mounting rubber. (1) Worn or damaged universal joint. (2) Worn spline of sleeve yoke. (3) Loose installation of propeller shaft. (4) Loose installation of joint. (5) Worn or damaged center bearing and damaged center mounting rubber. (1) Worn or damaged hub bearing (1) Worn or damaged hub bearing Remedy Replace. Replace. Retighten. Replace. Replace. Replace. Retighten. Replace. Replace. Repair or replace. Repair or replace.
3. Front wheel shimmy 4. Wander or pulling
DS-46
ABS
ABS
1. 2. 3. 4. 5. 6. 7. 8. Page General Description.....................................................................................2 ABS Control Module and Hydraulic Control Unit (ABSCM&H/U)...............7 ABS Sequence Control .............................................................................11 Front ABS Sensor .....................................................................................14 Rear ABS Sensor ......................................................................................18 Front Tone Wheel......................................................................................21 Rear Tone Wheel ......................................................................................22 G Sensor ...................................................................................................23
ABS
GENERAL DESCRIPTION
S401001
A: SPECIFICATIONS
S401001E49
Item ABS sensor gap ABS sensor resistance ABS sensor Marks of the harness Front Rear Front Rear Front LH Front RH Rear LH Rear RH
G sensor ABS control module and hydraulic control unit (ABSCM&H/U) marks
G sensor voltage AT MT
Standard or remarks 0.3 0.8 mm (0.012 0.031 in) 0.7 1.2 mm (0.028 0.047 in) 1.250.25 k 1.00.2 k Brown Blue Yellow White 2.30.2 V C7 C8
ABS-2

1. SENSOR
S401001A0501 S401001A05
ABS
H4M1386A
(1) (2) (3) (4)
G sensor Rear ABS sensor RH ABS spacer Rear ABS sensor LH
(5) Front ABS sensor LH (6) Front ABS sensor RH
Tightening torque: Nm (kgf-m, ft-lb) T1: 18 (1.8, 13.0) T2: 32 (3.3, 24)
ABS-3
ABS
GENERAL DESCRIPTION
S401001A0502
2. ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U)
B4M2462A
(1) Stud bolt (2) Damper (3) ABS control module and hydraulic control unit (4) Front-LH outlet (5) Secondary inlet
(6) (7) (8) (9) (10)
Front-RH outlet Primary inlet Rear-LH outlet Rear-RH outlet Bracket
Tightening torque: Nm (kgf-m, ft-lb) T1: 18 (1.8, 13.06) T2: 32 (3.3, 24) T3: 38 (3.8, 28)
ABS-4

S401001A03
ABS
ABS-5
ABS
GENERAL DESCRIPTION
S401001A17
D: PREPARATION TOOL
1. SPECIAL TOOLS
ILLUSTRATION
S401001A1701
TOOL NUMBER DESCRIPTION 24082AA150 CARTRIDGE (Newly adapted tool)
B2M3876
22771AA030
SELECT MONITOR KIT
B2M3877

TOOL NAME Circuit Tester Pressure Gauge Oscilloscope
S401001A1702
REMARKS Used for measuring resistance, voltage and ampere. Used for measuring oil pressure. Used for measuring sensor.
ABS-6
ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U)
ABS
2. ABS Control Module and Hydraulic Control Unit (ABSCM&H/U)

S401543
A: REMOVAL
S401543A18
1) Disconnect ground terminal from battery. 2) Remove air intake duct from engine compartment to facilitate removal of ABSCM&H/U. 3) Use an air gun to get rid of water around the ABSCM&H/U. CAUTION: The contact will be insufficient if the terminal gets wet. 4) Pull off the lock of the ABSCM&H/U connector to remove it.
B4M1222
B4M1224
5) Disconnect connector from ABSCM&H/U. CAUTION: Be careful not to let water or other foreign matter contact the ABSCM&H/U terminal. 6) Unlock cable clip. 7) Disconnect brake pipes from ABSCM&H/U. CAUTION: Wrap brake pipes with vinyl bag to avoid spilling brake fluid on vehicle body. 8) Remove ABSCM&H/U ground terminal from bracket. 9) Remove ABSCM&H/U from engine compartment. CAUTION: ABSCM&H/U cannot be disassembled. Do not attempt to loosen bolts and nuts. Do not drop or bump ABSCM&H/U. Do not turn the ABSCM&H/U upside down or place it on its side. Be careful to prevent foreign particles from getting into ABSCM&H/U. Apply a coat of rust-preventive wax (Nippeco LT or GB) to bracket attaching bolt after tightening. Do not pull harness when disconnecting connector.
ABS-7
ABS

S401543A11
B: INSTALLATION
1) Install ABSCM&H/U.
C: INSPECTION
S401543A10
CAUTION: Confirm that the specifications of the ABSCM&H/U conforms to the vehicle specifications. Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft-lb) 2) Install ABSCM&H/U ground terminal to bracket. Tightening torque: 32 Nm (3.3 kgf-m, 24 ft-lb) 3) Connect brake pipes ABSCM&H/U connections. to their correct
1) Check connected and fixed condition of connector. 2) Check specifications of the mark with ABSCM&H/U.
Mark C7 C8 Model AT MT
S4M0289C
(1)
Mark
1. CHECKING THE HYDRAULIC UNIT ABS OPERATION BY PRESSURE GAUGE

S401543A1001
B4M1222
4) Using cable clip, secure ABSCM&H/U harness to bracket. 5) Connect connector to ABSCM&H/U. CAUTION: Be sure to remove all foreign matter from inside the connector before connecting. Ensure that the ABSCM&H/U connector is securely locked. 6) Install air intake duct. 7) Connect ground terminal to battery. 8) Bleed air from the brake system.
1) Lift-up vehicle and remove wheels. 2) Disconnect the air bleeder screws from the FL and FR caliper bodies. 3) Connect two pressure gauges to the FL and FR caliper bodies. CAUTION: Pressure gauges used exclusively for brake fluid must be used. Do not employ pressure gauge previously used for transmission since the piston seal is expanded which may lead to malfunction of the brake. NOTE: Wrap sealing tape around the pressure gauge.
B4M1732
ABS-8

4) Bleed air from the pressure gauges. 5) Perform ABS sequence control. <Ref. to ABS-11 ABS Sequence Control.> 6) When the hydraulic unit begins to work, and first the FL side performs decompression, holding, and compression, and then the FR side performs decompression, holding, and compression. 7) Read values indicated on the pressure gauge and check if the fluctuation of the values between decompression and compression meets the standard values. Also check if any irregular brake pedal tightness is felt.
Front wheel 3,432 kPa (35 kg/cm2, 498 psi) 490 kPa (5 kg/cm2, 71 psi) or less 3,432 kPa (35 kg/cm2, 498 psi) or more Rear wheel 3,432 kPa (35 kg/cm2, 498 psi) 490 kPa (5 kg/cm2, 71 psi) or less 3,432 kPa (35 kg/cm2, 498 psi) or more
ABS
2. CHECKING THE HYDRAULIC UNIT ABS OPERATION WITH BRAKE TESTER S401543A1002
1) In the case of AWD AT vehicles, install a spare fuse with the FWD connector in the main fuse box to simulate FWD vehicles.
Initial value When decompressed When compressed
S4M0127B
(1) (2)
Main fuse box FWD connector
8) Remove pressure gauges from FL and FR caliper bodies. 9) Remove air bleeder screws from the RL and RR caliper bodies. 10) Connect the air bleeder screws to the FL and FR caliper bodies. 11) Connect two pressure gauges to the RL and RR caliper bodies. 12) Bleed air from the pressure gauges and the FL and FR caliper bodies. 13) Perform ABS sequence control. <Ref. to ABS-11 ABS Sequence Control.> 14) When the hydraulic unit begins to work, at first the RR side performs decompression, holding, and compression, and then the RL side performs decompression, holding, and compression. 15) Read values indicated on the pressure gauges and check if they meet the standard value. 16) After checking, remove the pressure gauges from caliper bodies. 17) Connect the air bleeder screws to RL and RR caliper bodies. 18) Bleed air from brake line.
2) Prepare for operating ABS sequence control. <Ref. to ABS-11 ABS Sequence Control.> 3) Set the front wheels or rear wheels on the brake tester and set the select lever s position at neutral.
B4M1733B
B4M1730B
(1)
Brake tester
4) Operate the brake tester. 5) Perform ABS sequence control. <Ref. to ABS-11 ABS Sequence Control.>
ABS-9
ABS
6) Hydraulic unit begins to work; and check the following working sequence. (1) The FL wheel performs decompression, holding, and compression in sequence, and subsequently the FR wheel repeats the cycle. (2) The RR wheel performs decompression, holding, and compression in sequence, and subsequently the RL wheel repeats the cycle. 7) Read values indicated on the brake tester and check if the fluctuation of values, when decompressed and compressed, meet the standard values.
Front wheel 981 N (100 kgf, 221 lb) 490 N (50 kgf, 110 lb) or less 981 N (100 kgf, 221 lb) or more Rear wheel 981 N (100 kgf, 221 lb) 490 N (50 kgf, 110 lb) or less 981 N (100 kgf, 221 lb) or more
Initial value When decompressed When compressed
8) After checking, also check if any irregular brake pedal tightness is felt.
ABS-10
ABS SEQUENCE CONTROL
ABS
3. ABS Sequence Control

A: OPERATION
S401187A16
S401187
2. ABS SEQUENCE CONTROL WITH SELECT MONITOR S401187A1602

NOTE: In the event of any trouble, the sequence control may not be operative. In such a case, activate the sequence control, referring to ABS SEQUENCE CONTROL WITH DIAGNOSIS CONNECTOR. <Ref. to ABS-11 ABS SEQUENCE CONTROL WITH DIAGNOSIS CONNECTOR, OPERATION, ABS Sequence Control.> When the diagnosis terminal is connected to the diagnosis connector, the sequence control will not operate. 1) Connect select monitor to data link connector under driver s seat instrument panel lower cover. 2) Turn ignition switch ON. 3) Turn select monitor switch ON. 4) Put select monitor to BRAKE CONTROL mode. 5) When Function check sequence is selected, ABS sequence control will start. 6) The message Press Brake Pedal Firmly is displayed as follows: (1) When using the brake tester, depress brake pedal with braking force of 981 N (100 kg, 221 lb). (2) When using the pressure gauge, depress brake pedal so as to make the pressure gauge indicate 3,432 kPa (35 kg/cm2, 498 psi). CAUTION: Do not depress the clutch pedal. 7) When the message Press YES is displayed, press YES key. 8) Operation points will be displayed on select monitor.
1) Under the ABS sequence control, after the hydraulic unit solenoid valve is driven, the operation of the hydraulic unit can be checked by means of the brake tester or pressure gauge. 2) ABS sequence control can be started by diagnosis connector or select monitor.
1. ABS SEQUENCE CONTROL WITH DIAGNOSIS CONNECTOR S401187A1601

1) Connect diagnosis terminals to terminals No. 5 and No. 8 of the diagnosis connector beside driver s seat heater unit.
B4M0082E
(1) (2) (3) (4)
Diagnosis connector Diagnosis terminals 3 terminal 6 terminal
2) Set the speed of all wheels at 2.75 km/h (2 MPH) or less. 3) Turn ignition switch OFF. 4) Within 0.5 seconds after the ABS warning light goes out, depress the brake pedal and hold it immediately after ignition switch is turned to ON. CAUTION: Do not depress the clutch pedal. NOTE: When the ignition switch is set to on, the brake pedal must not be depressed. Engine must not operate. 5) After completion of ABS sequence control, turn ignition switch OFF.
ABS-11
ABS

S401187A1603
3. CONDITIONS FOR ABS SEQUENCE CONTROL
B4M1001C
NOTE: When select monitor is used, control operation starts at point A. The patterns from IGN key ON to the point A show that operation is started by diagnosis connector. HIGH means high voltage. LOW means low voltage.
ABS-12

4. CONDITIONS FOR COMPLETION OF ABS SEQUENCE CONTROL S401187A1604
When the following conditions develop, the ABS sequence control stops and ABS operation is returned to the normal control mode. 1) When the speed of at least one wheel reaches 10 km/h (6 MPH). 2) When terminal No. 5 or No. 8 are separated from diagnosis terminals. (When select monitor is not used.) 3) When the brake pedal is released during sequence control and the braking lamp switch is set to off. 4) When brake pedal is depressed after ignition key is turned to ON, and before ABS warning light goes out. (When select monitor is not used.) 5) When brake pedal is not depressed after ignition key is turned to ON, and within 0.5 seconds after ABS warning light goes out. (When select monitor is not used.) 6) After completion of the sequence control. 7) When malfunction is detected. (When select monitor is used.)
ABS
ABS-13
ABS
FRONT ABS SENSOR

S401190
4. Front ABS Sensor

A: REMOVAL
S401190A18
8) Remove bolts which secure front ABS sensor to housing, and remove front ABS sensor. CAUTION: Be careful not to damage pole piece located at tip of the sensor and teeth faces during removal. Do not pull sensor harness during removal.
1) Set vehicle on a lift. 2) Disconnect battery ground terminal. 3) Loosen the wheel nuts. 4) Lift vehicle and remove wheels. 5) Disconnect front ABS sensor connector located next to front strut mounting house in engine compartment. 6) Remove bolts which secure sensor harness to strut.
B4M2209
B4M1442
7) Remove bolts which secure sensor harness to body.
B4M1181B
(1) (2)
To front ABS sensor connector Bracket
ABS-14
FRONT ABS SENSOR B: INSTALLATION

S401190A11
ABS
1) Temporarily install front ABS sensor on housing. CAUTION: Be careful not to strike ABS sensor s pole piece and tone wheels teeth against adjacent metal parts during installation.
3) Place a thickness gauge between ABS sensor s pole piece and tone wheels tooth face. After standard clearance is obtained over the entire perimeter, tighten ABS sensor on housing to specified torque. ABS sensor standard clearance: 0.3 0.8 mm (0.012 0.031 in) Tightening torque: 32 Nm (3.3 kgf-m, 24 ft-lb)
B4M2209
2) Install front ABS sensor on strut and wheel apron bracket. Tightening torque: 32 Nm (3.3 kgf-m, 24 ft-lb)
B4M2209
CAUTION: Check the marks on the harness to make sure that no distortion exists.
Mark LH Brown RH Light blue
NOTE: If the clearance is outside specifications, readjust. 4) After confirmation of the ABS sensor clearance, connect connector to ABS sensor. 5) Install the wheels. 6) Connect connector to battery ground terminal.
B4M1181B
(1) (2)
To front ABS sensor connector Bracket
ABS-15
ABS
FRONT ABS SENSOR

S401190A10
C: INSPECTION
1. ABS SENSOR
S401190A1001
2) Measure the distance B between surface where the front axle housing meets the ABS sensor, and the tone wheel. NOTE: Measure so that the gauge touches the tone wheel teeth top.
1) Check pole piece of ABS sensor for foreign particles or damage. If necessary, clean pole piece or replace ABS sensor. 2) Measure ABS sensor resistance.
S4M0510A B4M0248
Terminal No. 1 and 2
Standard 1.250.25 k
(1) (2)
Axle housing Tone wheel
CAUTION: If resistance is outside the standard value, replace ABS sensor with new one. NOTE: Check ABS sensor cable for discontinuity. If necessary, replace with a new one.
3) Find the gap between the ABS sensor pole face and the surface of the tone wheel teeth by putting the measured valves in the formula below and calculating. ABS sensor clearance = B A ABS sensor standard clearance: 0.3 0.8 mm (0.012 0.031 in) NOTE: If the clearance is outside specifications, readjust.
2. SENSOR GAP
S401190A1002
1) Measure the distance A between ABS sensor surface and sensor pole face.
B4M2482A
ABS-16
FRONT ABS SENSOR

3. OUTPUT VOLTAGE
S401190A1003
ABS
S401190A01
D: ADJUSTMENT
Output voltage can be checked by the following method. Install resistor and condenser, then rotate wheel about 2.75 km/h (2 MPH) or equivalent. NOTE: Regarding terminal No., please refer to item 1. ABS SENSOR.
Adjust the gap using spacer (Part No. 26755A000).
B4M0118B
ABS-17
ABS
REAR ABS SENSOR

S401185
5. Rear ABS Sensor

A: REMOVAL
S401185A18
B: INSTALLATION
S401185A11
1) Set vehicle on a lift. 2) Disconnect battery ground terminal. 3) Loosen wheel nuts. 4) Lift vehicle, and remove wheels. 5) Remove rear seat and disconnect rear ABS sensor connector. 6) Remove rear sensor harness bracket from rear trailing link and bracket. 7) Remove rear ABS sensor from rear back plate.
1) Temporarily install rear ABS sensor on back plate. CAUTION: Be careful not to strike ABS sensor s pole piece and tone wheels teeth against adjacent metal parts during installation.
B4M1182B
(1)
B4M1182B
Rear ABS sensor
2) Install rear sensor harness on rear trailing link.

(1) Rear ABS sensor
S4M0299B
(1) (2)
Rear sensor harness Trailing link
3) Place a thickness gauge between ABS sensor s pole piece and tone wheels tooth face. After standard clearance is obtained over the entire perimeter, tighten ABS sensor on back plate to specified torque. ABS sensor standard clearance: 0.7 1.2 mm (0.028 0.047 in) Tightening torque: 32 Nm (3.3 kgf-m, 24 ft-lb) CAUTION: Check the marks on the harness to make sure that no distortion exists.
Mark LH Blue RH Pink
ABS-18
REAR ABS SENSOR

NOTE: If the clearance is outside specifications, readjust. 4) 5) 6) 7) Connect rear ABS sensor connector. Install rear seat. Install wheels. Connect battery ground terminal.
ABS
S401185A10
C: INSPECTION
1. ABS SENSOR
S401185A1001
1) Check pole piece of ABS sensor for foreign particles or damage. If necessary, clean pole piece or replace ABS sensor. 2) Measure ABS sensor resistance.
B4M0248
Terminal No. 1 and 2
Standard 1.00.2 k
CAUTION: If resistance is outside the standard value, replace ABS sensor with new one. NOTE: Check ABS sensor cable for discontinuity. If necessary, replace with a new one.
2. SENSOR GAP
S401185A1002
Clearances (sensor gaps) should be measured one by one to ensure tone wheel and speed sensor are installed correctly.
S4M0515A
(1) (2) (3)
Rear ABS sensor Rear tone wheel Sensor gap
ABS sensor clearance: 0.7 1.2 mm (0.028 0.047 in) NOTE: If clearance is narrow, adjust by using a spacer (Part No. 26755AA000). If clearance is wide, check the outputted voltage then replace ABS sensor or tone wheel if the outputted voltage is outside the specification.
ABS-19
ABS
REAR ABS SENSOR

S401185A1003
3. OUTPUT VOLTAGE
D: ADJUSTMENT
Adjust the gap 26755AA000).
S401185A01
Output voltage can be checked by the following method. Install resistor and condenser, then rotate wheel about 2.75 km/h (2 MPH) or equivalent. NOTE: Regarding terminal No., refer to item 1. ABS SENSOR.
using
spacer
(Part
No.
B4M0118B
ABS-20
FRONT TONE WHEEL
ABS
6. Front Tone Wheel

A: REMOVAL
S401184A18
S401184
Refer to Front Drive Shaft, because front tone wheel is integrated with front drive shaft. <Ref. to DS-32 REMOVAL, Front Drive Shaft.>
B: INSTALLATION
S401184A11
Refer to Front Drive Shaft, because front tone wheel is integrated with front drive shaft. <Ref. to DS-32 INSTALLATION, Front Drive Shaft.>
C: INSPECTION
S401184A10
Visually check tone wheels teeth (44 pieces) for cracks or dents. If necessary, replace tone wheel with a new one. NOTE: Replace BJ assembly with new one as a single unit if there are any defects found on tone wheel is unitized with BJ assembly of drive shaft.
ABS-21
ABS
REAR TONE WHEEL

S401182
7. Rear Tone Wheel

A: REMOVAL
S401182A18
For removal procedures of rear tone wheel, refer to Rear Axle. <Ref. to DS-23, Rear Axle.>
B: INSTALLATION
S401182A11
For installation procedures of rear tone wheel, refer to Rear Axle. <Ref. to DS-23, Rear Axle.>
C: INSPECTION
S401182A10
Visually check tone wheels teeth (44 pieces) for cracks or dents. If necessary, replace tone wheel with a new one.
ABS-22
G SENSOR
ABS
S401183A11
8. G Sensor
A: REMOVAL
S401183
B: INSTALLATION
S401183A18
Install in the reverse order of removal. Tightening torque (G sensor): 18 Nm (1.8 kgf-m, 13.0 ft-lb)
1) Disconnect battery ground terminal.
G6M0095
2) Remove console cover. <Ref. to EI-30 Console Box.> 3) Disconnect connector from G sensor. 4) Remove G sensor from body. CAUTION: Do not drop or bump G sensor.
H4M1324
ABS-23
ABS
G SENSOR
S401183A10
C: INSPECTION
No. 1 2
Step CHECK SUBARU SELECT MONITOR. CHECK G SENSOR. 1) Turn ignition switch to OFF. 2) Remove G sensor from vehicle. 3) Connect connector to G sensor. 4) Turn ignition switch to ON. 5) Measure voltage between G sensor connector terminals. Connector & terminal: (R70) No. 2 (+) No. 3 () CHECK G SENSOR. Measure voltage between G sensor connector terminals. Connector & terminal: (R70) No. 2 (+) No. 3 () CHECK G SENSOR. Measure voltage between G sensor connector terminals. Connector & terminal: (R70) No. 2 (+) No. 3 () CHECK G SENSOR. 1) Turn ignition switch to OFF. 2) Connect select monitor connector to data link connector. 3) Turn select monitor into {BRAKE CONTROL} mode. 4) Set the display in the {Current Data Display & Save} mode. 5) Read the G sensor output voltage. CHECK G SENSOR. 1) Remove console box. 2) Remove G sensor from vehicle. (Do not disconnect connector.) 3) Read the select monitor display. CHECK G SENSOR. Read the select monitor display.
Check Do you have SUBARU SELECT MONITOR? Is the voltage 2.30.2 V when G sensor is horizontal?
Yes Go to step 5. Go to step 3.
No Go to step 2. Replace G sensor.
Is the voltage 3.90.2 V when G sensor is inclined forwards to 90?
Go to step 4.
Replace G sensor.
Is the voltage 0.70.2 V when G sensor is inclined backwards to 90?
G sensor is normal.
Replace G sensor.
Is the indicated reading Go to step 6. 2.30.2 V when the vehicle is in horizontal position?
Replace G sensor.
Is the indicated reading Go to step 7. 3.90.2 V when G sensor is inclined forwards to 90?
Replace G sensor.
Is the indicated reading 0.70.2 V when G sensor is inclined backwards to 90?
G sensor is normal.
Replace G sensor.
ABS-24
BRAKE
BR
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. Page General Description.....................................................................................2 Front Brake Pad ........................................................................................20 Front Disc Rotor ........................................................................................22 Front Disc Brake Assembly.......................................................................23 Rear Brake Pad.........................................................................................26 Rear Disc Rotor.........................................................................................27 Rear Disc Brake Assembly .......................................................................29 Rear Drum Brake Shoe.............................................................................32 Rear Drum Brake Drum ............................................................................34 Rear Drum Brake Assembly......................................................................35 Master Cylinder .........................................................................................38 Brake Booster............................................................................................40 Proportioning Valve ...................................................................................44 Brake Fluid ................................................................................................45 Air Bleeding ...............................................................................................47 Brake Hose................................................................................................49 Brake Pipe.................................................................................................50 Hill Holder..................................................................................................51 Brake Pedal...............................................................................................54 Stop Light Switch ......................................................................................60 General Diagnostics ..................................................................................62
Brake
GENERAL DESCRIPTION
S405001
A: SPECIFICATIONS
S405001E49
Engine (cc) Driving system Model Type Effective disc diameter Disc thickness Outer diameter Effective cylinder diameter Pad dimensions (length width thickness*) Clearance adjustment Type Effective disc diameter Disc thickness Outer diameter Effective cylinder diameter Pad dimensions (length width thickness*) Clearance adjustment Type Rear drum brake Effective drum diameter Effective cylinder diameter Lining dimensions (length width thickness) Clearance adjustment Type Effective diameter Reservoir type Brake fluid reservoir capacity Type Effective diameter mm (in) mm (in) mm (in) Others
Front disc brake
mm (in) mm (in) mm (in) mm (in)
2000 AWD Non-TURBO Australia Disc (Floating type, ventilated) 228 (8.98) 24 277 (0.94 10.91) 42.8 (1.685) 2
TURBO
112.3 50.0 17.0 (4.42 1.969 0.669) Automatic adjustment Disc (Floating type) 230 (9.06) 10 266 (0.39 10.47) 38.1 (1.500) 82.4 33.7 14.0 (3.244 1.327 0.551) Automatic adjustment
Rear disc brake
mm (in) mm (in) mm (in) mm (in)
Drum (Leading-Trailing type) 228.6 (9) 19.0 (0.748) 218.8 35.0 4.1 (8.61 1.378 0.161) Automatic adjustment
Master cylinder Brake booster
mm (in) cm3 (cu in) mm (in) kPa (kg/cm2, psi)
Tandem 26.99 (1-1/16) Sealed type 205 (12.51) Vacuum suspended 205 + 230 (8.07 + 9.06) 3,678 (37.5, 533) 0.3
ProporSplit point tioning Reducing ratio valve Brake line ABS Brake fluid *: Including back metal
Dual circuit system OP FMVSS No. 116, DOT3 or DOT4
STD
NOTE: Refer to PB section for parking brake SPECIFICATIONS. <Ref. to PB-2, General Description.>
BR-2
GENERAL DESCRIPTION
ITEM Pad thickness (including back metal) Disc thickness Disc runout Pad thickness (including back metal) Disc thickness Disc runout Inside diameter Lining thickness Inside diameter Lining thickness Lever stroke STANDARD 17 mm (0.67 in) 24 mm (0.94 in) 14 mm (0.55 in) SERVICE LIMIT 7.5 mm (0.295 in)
Brake
Front brake
22 mm (0.87 in) 0.075 mm (0.0030 in) 6.5 mm (0.256 in)
Rear brake (Disc type)
Rear brake (Drum type) Rear brake (Disc type parking) Parking brake
10 mm (0.39 in) 8.5 mm (0.335 in) 0.070 mm (0.0028 in) 228.6 mm (9 in) 230.6 mm (9.08 in) 4.1 mm (0.161 in) 1.5 mm (0.059 in) 170 mm (6.69 in) 171 mm (6.73 in) 3.2 mm (0.126 in) 1.5 mm (0.059 in) 7 to 8 notches/196 N (20 kgf, 44 lb) Brake pedal force 147 N (15 kgf, 33 lb) 294 N (30 kgf, 66 lb) 147 N (15 kgf, 33 lb) 294 N (30 kgf, 66 lb) Fluid pressure 588 kPa (6 kg/cm2, 85 psi) 1,667 kPa (17 kg/cm2, 242 psi) 5,394 kPa (55 kg/cm2, 782 psi) 10,003 kPa (102 kg/cm2, 1,450 psi)
Brake booster
Brake fluid pressure without engine running Brake fluid pressure with engine running and vacuum at 66.7 kPa (500 mmHg, 19.69 inHg)
Brake pedal
Free play
1 3 mm (0.04 0.12 in) [Depress brake pedal pad with a force of less than 10 N (1 kgf, 2 lb).]
BR-3
Brake
GENERAL DESCRIPTION
S405001A05
B: COMPONENT
1. FRONT DISC BRAKE
S405001A0511
B4M1151C
(1) (2) (3) (4) (5) (6) (7) (8)
Caliper body Air bleeder screw Guide pin (Green) Pin boot Piston seal Piston Piston boot Boot ring
(9) (10) (11) (12) (13) (14) (15) (16)
Lock pin (Yellow) Support Pad clip Outer shim (For Australia) Inner shim (For Australia) Pad (Outside) Pad (Inside) Disc rotor
(17) Disc cover

Tightening torque: Nm (kgf-m, ft-lb) T1: 8 (0.8, 5.8) T2: 18 (1.8, 13.0) T3: 39 (4.0, 28.9) T4: 78 (8.0, 58)
BR-4
GENERAL DESCRIPTION
2. REAR DISC BRAKE
S405001A0503
Brake
H4M1355A
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13)
Caliper body Air bleeder screw Guide pin (Green) Pin boot Piston seal Piston Piston boot Boot ring Lock pin (Yellow) Support Pad clip Inner pad Outer pad
(14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26)
Shim Shoe hold-down pin Cover Back plate Retainer Spring washer Parking brake lever Parking brake shoe (Secondary) Parking brake shoe (Primary) Strut Strut shoe spring Shoe guide plate Secondary shoe return spring
(27) (28) (29) (30) (31) (32)
Primary shoe return spring Adjusting spring Adjuster Shoe hold-down cup Shoe hold-down spring Disc rotor
BR-5
Brake
GENERAL DESCRIPTION
S405001A0504
3. REAR DRUM BRAKE
B4M1120A
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10)
Air bleeder cap Air bleeder screw Boot Piston Cup Spring Wheel cylinder body Pin Plug Back plate
(11) (12) (13) (14) (15) (16) (17) (18) (19) (20)
Upper shoe return spring Retainer Washer Parking brake lever Brake shoe (Trailing) Brake shoe (Leading) Shoe hold-down spring Cup Adjusting lever Adjuster
(21) (22) (23) (24)
Lower shoe return spring Adjusting spring Drum Plug
BR-6
GENERAL DESCRIPTION
4. MASTER CYLINDER LHD model
S405001A0505
Brake
S4M0325B
(1) (2) (3) (4) (5)
Cap Filter Reservoir tank Piston retainer Primary piston
(6) (7) (8) (9) (10)
Secondary piston Cylinder body Cylinder pin (With ABS) Seal Pin
BR-7
Brake
GENERAL DESCRIPTION
RHD model
B4M1155D
(1) (2) (3) (4) (5)
Cap Filter Reservoir tank Bracket Piston retainer
(6) (7) (8) (9) (10)
Primary piston Secondary piston Cylinder body Cylinder pin (With ABS) Seal
(11) Pin
BR-8
GENERAL DESCRIPTION
5. HILL HOLDER
S405001A0510
Brake
S4M0240A
(1) (2) (3) (4)
Clamp PHV cable PHV (Pressure hold valve) Adjusting nut
(5) Lock nut
BR-9
Brake
GENERAL DESCRIPTION
S405001A0506
6. BRAKE PIPES AND HOSE
Front brake pipe for model with ABS (LHD)
S4M0533A
(1) (2) (3) (4) (5) (6)
Front brake pipe assembly Proportioning valve Front brake hose RH Front brake hose LH Clamp Gasket
(7) ABS control module and hydraulic control unit (8) Bracket (9) Master cylinder (10) Hill holder (11) Adapter pipe
Front brake pipe for model with ABS (RHD)
S4M0534A
(1) (2) (3) (4) (5) (6)
Front brake pipe assembly Proportioning valve Front brake hose RH Front brake hose LH Clamp Gasket
(7) ABS control module and hydraulic control unit (8) Bracket (9) Master cylinder (10) Hill holder (11) Adapter pipe
BR-10
GENERAL DESCRIPTION
Front brake pipe for model without ABS (LHD)
Brake
S4M0535A
(1) (2) (3) (4) (5)
Front brake pipe assembly Proportioning valve Front brake hose RH Front brake hose LH Clamp
(6) (7) (8) (9) (10)
Gasket Bracket Master cylinder Hill holder Adapter pipe
Front brake pipe for model without ABS (RHD)
S4M0536A
(1) (2) (3) (4) (5)
Front brake pipe assembly Proportioning valve Front brake hose RH Front brake hose LH Clamp
(6) (7) (8) (9) (10)
Gasket Bracket Master cylinder Hill holder Adapter pipe
BR-11
Brake
GENERAL DESCRIPTION
Center and rear brake pipe
S4M0537A
(1) (2) (3) (4) (5)
Center brake pipe assembly Clamp Rear brake hose RH (With ABS) Gasket Rear brake pipe RH (Without ABS) (6) Rear brake hose RH (Without ABS)
(7) (8) (9) (10)
Rear brake pipe assembly Two-way connector Rear brake hose LH (With ABS) Rear brake hose LH (Without ABS) (11) Rear brake pipe LH (Without ABS)
BR-12
GENERAL DESCRIPTION
7. BRAKE BOOSTER LHD model
S405001A0507
Brake
S4M0538A
RHD model
S4M0539A
(1) (2) (3) (4) (5) (6)
Brake master cylinder Vacuum hose Clip Brake booster assembly Seal Clevis pin
(7) (8) (9) (10) (11) (12)
Snap pin Brake pedal Bracket Vacuum hose (Non-turbo model) Vacuum hose (Turbo model) Vacuum pipe (Turbo model)
BR-13
Brake
GENERAL DESCRIPTION
S405001A0508
8. BRAKE PEDAL FOR MT MODEL LHD model
B4M2467A
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)
Stopper Bushing Spring pin Snap pin Brake pedal pad Brake pedal Clevis pin Brake pedal spring Clutch pedal pad Clutch pedal Bushing C
(12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22)
Clutch clevis pin Assist rod A Clip Assist spring Assist bushing Assist rod B Spring S Rod S Bushing S O-ring Clip
(23) Clutch switch (With cruise control) (24) Stop light switch (25) Pedal bracket (26) Clutch master cylinder bracket (27) Lever
BR-14
GENERAL DESCRIPTION
RHD model
Brake
S4M0544A
(1) (2) (3) (4) (5) (6) (7) (8)
Bushing Accelerator pedal Accelerator pedal spring Spring pin Accelerator pedal pad Stopper Spacer Clevis pin
(9) (10) (11) (12) (13) (14) (15) (16)
Brake pedal pad Brake pedal Snap pin Brake pedal spring Brake spacer Clip Pedal bracket Stop light switch
(17) Accelerator spring

BR-15
Brake
GENERAL DESCRIPTION
S405001A0509
9. BRAKE PEDAL FOR AT MODEL LHD model
B4M2346A
(1) (2) (3) (4) (5) (6)
Stopper Bushing Plug Pedal bracket Stop light switch Spacer
(7) (8) (9) (10) (11) (12)
Snap pin Brake pedal pad Brake pedal Clevis pin Brake spacer Brake pedal spring
BR-16
GENERAL DESCRIPTION
RHD model
Brake
S4M0321A
(1) (2) (3) (4) (5) (6) (7) (8)
Accelerator pedal Accelerator pedal spring Spring pin Accelerator pedal pad Stopper Bushing Kick-down switch Pedal bracket
(9) (10) (11) (12) (13) (14) (15) (16)
Clip Stop light switch Accelerator spring Brake pedal spring Brake spacer Brake pedal Spacer Clevis pin
(17) Brake pedal pad (18) Snap pin

BR-17
Brake
GENERAL DESCRIPTION
S405001A03
C: CAUTION
Wear working clothing, including a cap, protective goggles, and protective shoes during operation. Remove contamination including dirt and corrosion before removal, installation or disassembly. Keep the disassembled parts in order and protect them from dust or dirt. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly, and replacement. Be careful not to burn your hands, because each part in the vehicle is hot after running. Use SUBARU genuine grease etc. or the equivalent. Do not mix grease etc. with that of another grade or from other manufacturers. Be sure to tighten fasteners including bolts and nuts to the specified torque. Place shop jacks or safety stands at the specified points. Apply grease onto sliding or revolution surfaces before installation. Before installing O-rings or snap rings, apply sufficient amount of grease to avoid damage and deformation. Before securing a part on a vise, place cushioning material such as wood blocks, aluminum plate, or shop cloth between the part and the vise. Do not put fluid on body. If the body is tainted, wash away with water.
BR-18

1. SPECIAL TOOLS
ILLUSTRATION
S405001A1701 S405001A17
Brake
DESCRIPTION WHEEL CYLINDER 3/4 ADAPTER
REMARKS Used for installing cup onto wheel cylinder piston (Size 3/4 in).
B4M2406

TOOL NAME Snap Ring Pliers
S405001A1702
REMARKS Used for removing and installing snap ring.
BR-19
Brake
FRONT BRAKE PAD

S405178
2. Front Brake Pad

A: REMOVAL
S405178A18
1) Loosen wheel nuts, jack-up vehicle, support it with safety stands, and remove wheel. 2) Remove lock pin. 3) Raise caliper body. 4) Remove pad.
(4) Attach a rod of less than 12 mm (0.47 in) dia. to the shaded area of brake pad, and strike the rod with a hammer to drive brake pad out of place.
B4M2231
B: INSTALLATION
B4M1167
S405178A11
NOTE: If brake pad is difficult to remove, proceed as follows: (1) Remove caliper body and fasten it provisionally to coil spring. (2) Remove support. (3) Place a support in a vise between wooden blocks.
1) Apply thin coat of Molykote AS880N (Part No. 26298AC000) to the frictional portion between pad and pad clip. 2) Apply thin coat of Molykote AS880N (Part No. 26298AC000) to the frictional portion between pad and pad inner shim. (Australia model)
B4M1169A
3) Install pads on support. 4) Install caliper body on support. Tightening torque: 39 Nm (4.0 kgf-m, 28.9 ft-lb)
B4M2230B
(1) (2)
Support Wooden blocks
NOTE: If it is difficult to push piston during pad replacement, loosen air bleeder to facilitate work.
BR-20
FRONT BRAKE PAD C: INSPECTION

S405178A10
Brake
Check pad thickness A.
B4M1168A
Pad thickness (including back metal)
Standard value Wear limit
17 mm (0.67 in) 7.5 mm (0.295 in)
CAUTION: Always replace the pads for both the left and right wheels at the same time. Also replace pad clips if they are twisted or worn. A wear indicator is provided on the inner disc brake pad. If the pad wears down to such an extent that the end of the wear indicator contacts the disc rotor, a squeaking sound is produced as the wheel rotates. If this sound is heard, replace the pad. Replace pad if there is oil or grease on it.
BR-21
Brake
FRONT DISC ROTOR

S405173
3. Front Disc Rotor

A: REMOVAL
S405173A18
C: INSPECTION
S405173A10
1) Loosen wheel nuts, jack-up vehicle, support it with safety stands, and remove wheel. 2) Remove caliper body from housing, and suspend it from strut using a wire.
1) Install disc rotor by tightening the five wheel nuts. 2) Set a dial gauge on the disc rotor. Turn disc rotor to check runout.
B4M2353 BR0076
3) Remove the disc rotor. NOTE: If disc rotor seizes up within the hub, drive disc rotor out by installing an 8-mm bolt in holes B on the rotor.
NOTE: Make sure that dial gauge is set 5 mm (0.20 in) inward of rotor outer perimeter. If disc rotor runout is above standard value, inspect play of hub bearing axial direction and runout of axle hub. <Ref. to DS-22, INSPECTION, Front Axle.> If bearing and hub are normal, replace disc rotor. Disc rotor runout limit: 0.075 mm (0.0030 in) 3) Measure disc rotor thickness. If thickness of disc rotor is outside the standard value, replace disc rotor.
G4M0365
4) Clean mud and foreign particles from caliper body assembly and support.
B: INSTALLATION
S405173A11
1) Install the disc rotor. 2) Install the caliper body to housing. Tightening torque: 78 Nm (8 kgf-m, 58 ft-lb)
G4M0365
NOTE: Make sure that micrometer is set 5 mm (0.20 in) inward of rotor outer perimeter.
Standard value 24.0 mm (0.945 in) Service limit 22.0 mm (0.866 in) Disc outer dia. 277 mm (10.91 in)
Disc rotor thickness A
BR-22
FRONT DISC BRAKE ASSEMBLY
Brake
4. Front Disc Brake Assembly

S405176
6) Remove disc rotor from hub. NOTE: If disc rotor seizes up within hub, drive disc rotor out by installing an 8-mm bolt in holes B on the rotor.
A: REMOVAL
S405176A18
1) Loosen wheel nuts, jack-up vehicle, support it with safety stands, and remove wheel. 2) Remove union bolt and disconnect brake hose from caliper body assembly.
G4M0365
7) Clean mud and foreign particles from caliper body assembly and support.
B4M1844
3) Remove bolt securing lock pin to caliper body.
B4M1845
4) Raise caliper body and move it toward vehicle center to separate it from support. 5) Remove support from housing. NOTE: Remove support only when replacing it or the rotor. It need not be removed when servicing caliper body assembly.
B4M1192
BR-23
Brake

S405176A11
B: INSTALLATION
C: DISASSEMBLY
S405176A06
1) Install disc rotor on hub. 2) Install support on housing. Tightening torque: 78 Nm (8 kgf-m, 58 ft-lb) CAUTION: Always replace the pads for both the left and right wheels at the same time. Also replace pad clips if they are twisted or worn. A wear indicator is provided on the inner disc brake pad. If the pad wears down to such an extent that the end of the wear indicator contacts the disc rotor, a squeaking sound is produced as the wheel rotates. If this sound is heard, replace the pad. When replacing the pads, replace pads of the right and left wheels at the same time. 3) Apply thin coat of Molykote AS880N (Part No. 26298AC000) to the frictional portion between pad and pad clip. 4) Apply thin coat of Molykote AS880N (Part No. 26298AC000) to the frictional portion between pad and inner shim. (Australia model)
1) Clean mud and foreign particles from caliper body assembly and support. CAUTION: Be careful not to allow foreign particles to enter inlet (at brake hose connector). 2) Using a standard screwdriver, remove boot ring from piston.
B4M1164C
(1)
Boot ring
3) Remove boot from piston end. 4) Gradually supply compressed air via caliper body brake hose to force piston out. CAUTION: Place a wooden block as shown in Figure to prevent damage to piston.
B4M1169A
5) Install pads on support. 6) Install caliper body on support. Tightening torque: 39 Nm (4.0 kgf-m, 28.9 ft-lb) 7) Connect brake hose. Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft-lb) CAUTION: Replace brake hose gaskets with new ones. 8) Bleed air from brake system. <Ref. to BR-47, Air Bleeding.>
(1)
B4M1165C
Place a 30 mm (1.18 in) wide wooden block here.
5) Remove piston seal from caliper body cylinder.
B4M1172B
(1)
Piston pin
BR-24

6) Remove lock pin boot and guide pin boot.
Brake
D: ASSEMBLY
S405176A02
8) Apply a coat of specified grease to lock pin and guide pin, outer surface, cylinder inner surface, and boot grooves. Grease: NIGLUBE RX-2 (Part No. 003606000)
1) Clean caliper body interior using brake fluid. 2) Apply a coat of brake fluid to piston seal and fit piston seal in groove on caliper body. 3) Apply a coat of brake fluid to the entire inner surface of cylinder and outer surface of piston. 4) Insert piston into cylinder. CAUTION: Do not force piston into cylinder.
B4M1176B
(1) (2) (3)
Pin boot Lock pin or guide pin Apply grease.
9) Install lock pin boot and guide pin boot on support.

B4M0771
5) Apply a coat of specified grease to boot and fit in groove on ends of cylinder and piston. Grease: NIGLUBE RX-2 (Part No. 003606000) To facilitate installation, fit boot starting with piston end.
E: INSPECTION
S405176A10
NOTE: Repair or replace faulty parts. 1) Check caliper body and piston for uneven wear, damage or rust. 2) Check rubber parts for damage or deterioration.
S4M0448A
(1) (2) (3) (4)
Piston boot Boot ring Piston seal Caliper body
6) Position boot in grooves on cylinder and piston. 7) Install boot ring. Be careful not scratch boot.
BR-25
Brake
REAR BRAKE PAD

S405175
5. Rear Brake Pad

A: REMOVAL
S405175A18
C: INSPECTION
S405175A10
Check pad thickness (including back metal). Pad thickness: A Standard value 14.0 mm (0.551 in) Wear limit 6.5 mm (0.256 in)
1) Loosen wheel nuts, jack-up vehicle, support it with safety stands, and remove wheel. 2) Remove lock pin.
S4M0115
3) Raise caliper body. 4) Remove pad from support. NOTE: If brake pad is difficult to remove, use the same procedure as for front disc brake pad. <Ref. to BR-20 REMOVAL, Front Brake Pad.>
S4M0187A
CAUTION: Always replace the pads for both the left and right wheels at the same time. Also replace pad clips if they are twisted or worn. A wear indicator is provided on the inner disc brake pad. If the pad wears down to such an extent that the end of the wear indicator contacts the disc rotor, a squeaking sound is produced as the wheel rotates. If this sound is heard, replace the pad. Replace pad if there is oil or grease on it.
S4M0116
B: INSTALLATION
S405175A11
1) Apply thin coat of Molykote AS880N (Part No. 26298AC000) to the frictional portion between pad and pad clip. 2) Install pad on support. 3) Install caliper body on support. Tightening torque: 39 Nm (4.0 kgf-m, 28.9 ft-lb) NOTE: If it is difficult to push piston during pad replacement, loosen air bleeder to facilitate work.
BR-26
REAR DISC ROTOR
Brake
6. Rear Disc Rotor

A: REMOVAL
S405177A18
S405177
(2) If disc rotor seizes up within hub, drive disc rotor out by installing an 8-mm bolt in holes B on the rotor.
1) Disconnect battery ground terminal from battery. 2) Loosen wheel nuts, jack-up vehicle, support it with safety stands, and remove wheel. 3) Remove the two mounting bolts and remove the disc brake assembly.
G4M0383
B: INSTALLATION
S405177A11
S4M0459A
1) Install in the reverse order of removal. 2) Adjust parking brake. <Ref. to PB-11 ADJUSTMENT, Parking Brake Assembly (Rear Disc Brake).>
(1)
Disc brake
4) Suspend the disc brake assembly so that the hose is not stretched. 5) Pull down and release parking brake. 6) Remove the disc rotor. NOTE: If the disc rotor is difficult to remove try the following two methods in order. (1) Turn adjusting screw using a slot-type screwdriver until brake shoe gets away enough from the disc rotor.
S4M0569A
(1) (2) (3) (4)
Adjusting screw Cover Slot-type screwdriver Back plate
BR-27
Brake
REAR DISC ROTOR

S405177A10
C: INSPECTION
1) Secure disc rotor by tightening the five wheel nuts. 2) Set a dial gauge on the disc rotor. Turn disc rotor to check runout. CAUTION: Securely adjust disc rotor to hub.
B4M1771
NOTE: Make sure that dial gauge is set 5 mm (0.20 in) inward of rotor outer perimeter. If disc rotor runout is above standard value, inspect play of hub bearing axial direction and runout of axle hub. <Ref. to DS-31, INSPECTION, Rear Axle.> Disc rotor runout limit: 0.070 mm (0.0028 in) 3) Measure disc rotor thickness. If thickness of disc rotor is outside the standard value, replace disc rotor.
G4M0383
NOTE: Make sure that micrometer is set 5 mm (0.20 in) inward of rotor outer perimeter. Disc rotor thickness: A Standard value 10 mm (0.39 in) Service limit 8.5 mm (0.335 in)
BR-28
REAR DISC BRAKE ASSEMBLY
Brake
S405172A11
7. Rear Disc Brake Assembly

S405172
B: INSTALLATION
A: REMOVAL
S405172A18
1) Install disc rotor on hub. 2) Install support on back plate. Tightening torque: 78 Nm (8.0 kgf-m, 58 ft-lb) CAUTION: Always replace the pads for both the left and right wheels at the same time. Also replace pad clips if they are twisted or worn. A wear indicator is provided on the inner disc brake pad. If the pad wears down to such an extent that the end of the wear indicator contacts the disc rotor, a squeaking sound is produced as the wheel rotates. If this sound is heard, replace the pad. Replace pads if there is oil or grease on them. 3) Apply thin coat of Molykote AS880N (Part No. 26298AC000) to the frictional portion between pad and pad clip. 4) Install pads on support. 5) Install caliper body on support.
S4M0119
1) Loosen wheel nuts, jack-up vehicle, support it with safety stands, and remove wheel. 2) Disconnect brake hose from caliper body assembly. CAUTION: Do not allow brake fluid to come in contact with vehicle body; wipe off completely if spilled. 3) Remove lock pin.
4) Raise caliper body and move it toward vehicle center to separate it from support. 5) Remove support from back plate. NOTE: Remove support only when replacing it or the rotor. It need not be removed when servicing caliper body assembly. 6) Clean mud and foreign particles from caliper body assembly and support. CAUTION: Be careful not to allow foreign particles to enter inlet (at brake hose connector).
Tightening torque: 39 Nm (4.0 kgf-m, 28.9 ft-lb) 6) Connect brake hose. Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft-lb) CAUTION: The brake hose must be connected without any twist. Replace brake hose gaskets with new ones. 7) Bleed air from brake system. <Ref. to BR-47, Air Bleeding.>
BR-29
Brake
REAR DISC BRAKE ASSEMBLY

S405172A06
C: DISASSEMBLY
1) Remove the boot ring.
4) Remove piston seal from caliper body cylinder.
S4M0122 S4M0120B
(1)
Boot ring
5) Remove lock pin sleeve and boot from caliper body. 6) Remove guide pin boot.
2) Remove the piston boot.
S4M0121
3) Gradually supply compressed air via inlet of caliper body to force piston out. CAUTION: Place a wooden block as shown in Figure to prevent damage to piston. Do not apply excessively high-pressure.
B4M1174C
(1)
Place a 30 mm (1.18 in) wide wooden block here.
BR-30
REAR DISC BRAKE ASSEMBLY D: ASSEMBLY

S405172A02
Brake
S405172A10
E: INSPECTION
1) Clean caliper body interior using brake fluid. 2) Apply a coat of brake fluid to piston seal and fit piston seal in groove on caliper body. 3) Apply a coat of brake fluid to the entire inner surface of cylinder and outer surface of piston. 4) Insert piston into cylinder. CAUTION: Do not force piston into cylinder. 5) Apply a coat of specified grease to boot and fit in groove on ends of cylinder and piston. Grease: NIGLUBE RX-2 (Part No. 003606000) 6) Install the piston boot to the caliper body, and attach boot ring.
NOTE: Repair or replace faulty parts. 1) Check caliper body and piston for uneven wear, damage or rust. 2) Check rubber parts for damage or deterioration.
S4M0448A
(1) (2) (3) (4)
Piston boot Boot ring Piston seal Caliper body
7) Apply a coat of specified grease to guide pin, outer surface, sleeve outer surface, cylinder inner surface, and boot grooves. Grease: NIGLUBE RX-2 (Part No. 003606000)
B4M1176B
(1) (2) (3)
Pin boot Lock pin or guide pin Apply grease.
8) Install guide pin boot on caliper body. 9) Install lock pin boot on caliper body and insert lock pin sleeve into place.
BR-31
Brake
REAR DRUM BRAKE SHOE

S405174
8. Rear Drum Brake Shoe

A: REMOVAL
S405174A18
4) Hold hold-down pin by securing rear of back plate with your hand.
1) Loosen wheel nuts, jack-up vehicle, support it with safety stands, and remove wheel. 2) Release parking brake. 3) Remove brake drum from brake assembly. NOTE: If it is difficult to remove brake drum, remove adjusting hole cover from drum, and then turn adjuster assembly pawls using a slot-type screwdriver until brake shoe separates from the drum.
(1) (2) Hold-down cup Hold-down pin
S4M0451A
5) Disconnect hold-down cup from hold-down pin by rotating hold-down cup. 6) Disconnect lower shoe return spring from shoes.
S4M0369A
(1) (2) (3) (4) (5) (6)
Back plate Wheel cylinder Adjuster ASSY pawls Adjusting lever Tightening direction Push.
S4M0452
If brake drum is difficult to remove, drive it out by installing an 8-mm bolt into bolt hole in brake drum.
7) Remove shoes one by one from back plate with adjuster. CAUTION: Be careful not to bend parking brake cable excessively when removing brake shoes.
B4M0243
S4M0453A
(1) (2) (3) (4) (5) (6)
Wheel cylinder Adjuster Back plate Lower shoe return spring Parking lever Trailing shoe
BR-32
REAR DRUM BRAKE SHOE

8) Disconnect parking brake cable from parking lever.
Brake
6) While positioning shoes (one at a time) in groove on wheel cylinder, secure shoes.
B: INSTALLATION
S405174A11
1) Clean back plate and wheel cylinder. 2) Apply grease to portions indicated by arrows in Figure. Brake grease: Dow Corning Molykote No. 7439 (Part No. 725191460)
S4M0458A
(1) (2)
Wheel cylinder Shoe (Trailing)
G4M0407
3) Apply grease to adjusting screw and both ends of adjuster. Brake grease: Dow Corning Molykote No. 7439 (Part No. 725191460)
7) Fix shoes by connecting hold-down cup to holddown pin. 8) Connect lower shoe return spring. 9) Set the outside diameter of brake shoes less than 0.5 to 0.8 mm (0.020 to 0.031 in) in comparison with the inside diameter of brake drum. 10) Install drum.
C: INSPECTION
S405174A10
1) Measure the lining thickness. Lining thickness: Standard 4.1 mm (0.161 in) Service limit 1.5 mm (0.059 in) 2) If the deformation or wear of back plate, shoe, etc. are notable, replace them. 3) When the shoe return spring tension is excessively weakened, replace it, taking care to identify upper and lower springs.
S4M0457B
4) Connect upper shoe return spring to shoes. 5) Connect parking brake cable to parking lever.
BR-33
Brake
REAR DRUM BRAKE DRUM

S405180
9. Rear Drum Brake Drum

A: REMOVAL
S405180A18
B: INSTALLATION
S405180A11
1) Loosen wheel nuts, jack-up vehicle, support it with safety stands, and remove wheel. 2) Release parking brake. 3) Remove brake drum from brake assembly. NOTE: If it is difficult to remove brake drum, remove adjusting hole cover from drum, and then turn adjuster assembly pawls using a slot-type screwdriver until brake shoe separates from the drum.
1) Set the outside diameter of brake shoes less than 0.5 to 0.8 mm (0.020 to 0.031 in) in comparison with the inside diameter of brake drum. 2) Install drum.
C: INSPECTION
S405180A10
1) If the inside surface of brake drum is streaked, correct the surface. And, if it is unevenly worn, taperingly streaked, or the outside surface of brake drum is damaged, correct or replace it. 2) Measure the drum inner diameter. Drum inner diameter: L Standard 228.6 mm (9 in) Service limit 230.6 mm (9.08 in)
S4M0369A
(1) (2) (3) (4) (5) (6)
Back plate Wheel cylinder Adjuster ASSY pawls Adjusting lever Tightening direction Push.
G4M0403
If brake drum is difficult to remove, drive it out by installing an 8-mm bolt into bolt hole in brake drum.
B4M0243
BR-34
REAR DRUM BRAKE ASSEMBLY
Brake
10. Rear Drum Brake Assembly

S405179
10) Remove the bolts installing wheel cylinder on back plate, and remove it.
A: REMOVAL
S405179A18
1) Disconnect battery ground terminal from battery. 2) Loosen wheel nuts, jack-up vehicle, support it with safety stands, and remove wheel. 3) Release parking brake. 4) Remove brake drum from brake assembly. <Ref. to BR-34, REMOVAL, Rear Drum Brake Drum.> 5) Remove brake shoe. <Ref. to BR-32, REMOVAL, Rear Drum Brake Shoe.> 6) Unscrew the brake pipe flare nut and disconnect brake pipe.
S4M0454A
(1)
Air bleeder
S405179A11
B: INSTALLATION
1) Clean back plate and wheel cylinder. 2) Install wheel cylinder on back plate, and tighten bolts. Tightening torque: 10 Nm (1.0 kgf-m, 7.2 ft-lb)
G4M0399
7) Disconnect ABS sensor from back plate. (only vehicle equipped with ABS) 8) Remove hub. <Ref. to DS-23, Rear Axle.> 9) Remove the bolts installing back plate, and then, remove brake assembly.
S4M0454
3) Apply grease to portions indicated by arrows in Figure. Brake grease: Dow Corning Molykote No. 7439 (Part No. 725191460)
G4M0400
G4M0407
BR-35
Brake
REAR DRUM BRAKE ASSEMBLY C: DISASSEMBLY

S405179A06
4) Install brake assembly on housing, and tighten bolts to install back plate. Tightening torque: 52 Nm (5.3 kgf-m, 38.3 ft-lb)
1) Remove right and left dust boots from wheel cylinder.
B4M1126B G4M0400
5) Install hub. <Ref. to DS-23, Rear Axle.> 6) Connect brake pipe, and tighten brake pipe flange nut. Tightening torque: 15 Nm (1.5 kgf-m, 10.8 ft-lb) 7) Connect ABS sensor to back plate. (only vehicle equipped with ABS) Tightening torque: 32 Nm (3.3 kgf-m, 24 ft-lb) 8) Apply grease to adjusting screw and both ends of adjuster. Brake grease: Dow Corning Molykote No. 7439 (Part No. 725191460)
(1) (2) (3) (4) (5) (6) (7)
Bleeder cap Bleeder screw Spring Cylinder Cup Piston Boot
2) Remove piston, cup, spring and air bleeder screw and cap.
D: ASSEMBLY
S405179A02
1) Clean all parts in brake fluid. Check and replace faulty parts. Cup and boot for damage or fatigue Cylinder, piston and spring or damage or rust formation 2) Assembly is the reverse order of disassembly. (1) When installing the cup, use ST, apply brake fluid to the frictional surface for smooth installation and pay attention to cup direction. (2) STs are available in different sizes. CAUTION: When replacing the repair kit, make sure that the sizes of cylinder and cup are the same as those which were replaced. Use only the tool of the correct size.
ST: ADAPTER Applicable size 19.0 mm (3/4 in) Part No. 926460000
S4M0457B
9) Install brake shoe. <Ref. to BR-33, INSTALLATION, Rear Drum Brake Shoe.> 10) Install drum. <Ref. to BR-34, INSTALLATION, Rear Drum Brake Drum.> 11) Bleed air from brake system. <Ref. to BR-47, Air Bleeding.>
BR-36
REAR DRUM BRAKE ASSEMBLY

CAUTION: While assembling, be careful to prevent any metal chip, dust or dirt from entering the wheel cylinder.
Brake
S405179A10
E: INSPECTION
1) Check wheel cylinder for leakage. 2) Inspect the disassembled parts for wear, rust or damage. 3) Inspect lining thickness. <Ref. to BR-33, INSPECTION, Rear Drum Brake Shoe.> 4) Inspect brake drum. <Ref. to BR-34, INSPECTION, Rear Drum Brake Drum.>
S4M0455A
(1) (2)
Cup Piston
3) Apply rubber grease to the boot inside as shown in Figure. CAUTION: Never use brake grease. Grease: NIGLUBE RX-2 (Part No. 003606000)
S4M0456B
BR-37
Brake
MASTER CYLINDER
S405168
11. Master Cylinder

A: REMOVAL
S405168A18
2. DISASSEMBLING PROCEDURE
S405168A0603
1) Pull up parking brake lever, and block the tires. 2) Disconnect battery ground terminal from battery. 3) Thoroughly drain brake fluid from reservoir tank. 4) Disconnect fluid level indicator harness connector. 5) Remove brake pipes from master cylinder. 6) Remove master cylinder mounting nuts, and take out master cylinder from brake booster. CAUTION: Be extremely careful not to spill brake fluid. Brake fluid spilt on the vehicle body will harm the painted surface; wipe it off quickly if spilt.
1) Remove pin with drift pin which secures reserve tank to master cylinder. 2) Remove cylinder pin with magnetic pick-up tool while pushing in primary piston. (Only vehicle equipped with ABS)
S4M0123B
B: INSTALLATION
S405168A11
(1)
Cylinder pin
1) Install in the reverse order of removal. Tightening torque: Master cylinder mounting nut 14 Nm (1.4 kgf-m, 10.1 ft-lb) Piping flare nut 15 Nm (1.5 kgf-m, 10.8 ft-lb) CAUTION: Be sure to use recommended brake fluid. 2) Bleed air from brake system. <Ref. to BR-47, Air Bleeding.>
3) Pry up the pawl and remove the piston retainer. NOTE: Piston may jump out from master cylinder.
C: DISASSEMBLY
S405168A0602
S405168A06
1. PRECAUTIONS FOR DISASSEMBLING

1) Remove mud and dirt from the surface of brake master cylinder. 2) Prepare tools necessary for disassembly operation, and arrange them neatly on work bench. 3) Clean work bench.
S4M0124
4) Extract primary piston assembly and secondary piston assembly. CAUTION: Do not disassemble the piston assembly; otherwise, the spring set value may be changed. Use brake fluid or methanol to wash inside wall of cylinder, 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 become swelled.
BR-38
MASTER CYLINDER D: ASSEMBLY

S405168A0201 S405168A02
Brake
S405168A10
E: INSPECTION
1. PRECAUTIONS FOR ASSEMBLING

1) When assembling, be sure to use recommended brake fluid. 2) Ensure that the inside wall of cylinder, pistons, and piston cups are free from dirt when assembling. 3) Be extremely careful not to damage, scratch, or dent cylinder inside wall, pistons, and piston cups. 4) Do not drop parts. Never attempt to use any part that has been dropped accidentally.
If any damage, deformation, wear, swelling, rust, and other faults are found on the primary piston assembly, secondary piston assembly, supply valve stopper, or gasket, replace the faulty part. CAUTION: The primary and secondary pistons must be replaced as complete assemblies. The service limit of the clearance between each piston and the master cylinder inner dia. is 0.11 mm (0.0043 in). When handling parts, be extremely careful not to damage or scratch the parts, or let any foreign matter get on them.
2. ASSEMBLING PROCEDURE
S405168A0202
1) Assembling piston assembly: Apply recommended brake fluid to inside wall of cylinder, and to outer surface of piston assembly, and install piston assemblies carefully into cylinder. 2) Press the pawl (only vehicle equipped with ABS) and install the piston retainer into the master cylinder.
S4M0124
3) Install seal to reservoir tank.
B4M1450C
(1)
Seal
4) Install pin with drift pins which secures reservoir tank to master cylinder.
BR-39
Brake
BRAKE BOOSTER
S405166
12. Brake Booster

A: REMOVAL
S405166A18
Do not change the push rod length. If it has been changed, reset the projected length L to the standard length. Standard: L = 10 mm (0.39 in)
CAUTION: If external force F is applied from above when brake booster is placed in this position, the resin portion as indicated by P, may be damaged.
G4M0424
S4M0464B
1) Pull up parking brake lever, and block the tires. 2) Disconnect battery ground terminal from battery. 3) Remove or disconnect the following parts at engine compartment. (1) Disconnect connector for brake fluid level indicator. (2) Remove brake pipes from master cylinder. (3) Remove master cylinder installing nuts. (4) Disconnect vacuum hose from brake booster. 4) Remove the following parts from the pedal bracket. (1) Snap pin and clevis pin (2) Four brake booster installing nuts 5) Remove brake booster while shunning brake pipes. NOTE: Be careful not to drop brake booster. Brake booster should be discarded if it has been dropped. Use special care when handling operating rod. If excessive force is applied to operating rod, sufficient to cause a change in the angle in excess of 3, it may result in damage to the power piston cylinder. Use care when placing brake booster on the floor.
BR-40
BRAKE BOOSTER B: INSTALLATION

S405166A11
Brake
7) Adjust operating rod of brake booster. Standard: L LHD: 144.6 mm (5.69 in) RHD: 173.2 mm (6.82 in) If it is not in specified value, adjust it by adjusting brake booster operating rod.
1) Mount brake booster in position. 2) Connect operating rod to brake pedal with clevis pin and snap pin.
B4M0616A
8) Measure the clearance between threaded end of stop light switch and stopper. If it is not in specified value, adjust it by adjusting position of stop light switch. CAUTION: Be careful not to rotate stop light switch. Stop light switch clearance: A 0.3 mm (0.012 in)
B4M0117C
(1) (2) (3) (4)
Nuts Clevis pin Snap pin Operating rod
3) Connect vacuum hose to brake booster.
B4M0617H
9) Apply grease to operating rod connecting pin to prevent it from wearing. 10) Bleed air from brake system.
S4M0125
4) Mount master cylinder onto brake booster. 5) Connect brake pipes to master cylinder. 6) Connect electric connector for brake fluid level indicator.
Tightening torque (Air bleeder screw): 8 Nm (0.8 kgf-m, 5.8 ft-lb) 11) Conduct road tests to ensure brakes do not drag.
BR-41
Brake
BRAKE BOOSTER
S405166A10
C: INSPECTION
Operation check
1) With engine off, depress brake pedal several times applying the same pedal force and make sure that the pedal height does not vary with each depression of the pedal.
1. OPERATION CHECK (WITHOUT GAUGES) S405166A1001

CAUTION: When checking operation, be sure to securely apply the hand brake.
Checking without gauges

This method cannot determine the exact portion which has failed, but it can provide a rough understanding of the nature of the failure if checking is conducted in accordance with the following procedures.
Air tightness check

Start engine, and run it for 1 to 2 minutes, then turn it off. Depress brake pedal several 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. If no change occurs in the pedal height while in a depressed state, brake booster is faulty.
(1) (2) When engine is stopped When engine is started
S4M0466A
2) With brake pedal depressed, start engine. 3) As engine starts, brake pedal should move slightly toward the floor. If no change occurs in the pedal height, brake booster is faulty. NOTE: If faulty, check precisely with gauges.
Loaded air tightness check

Depress brake pedal while engine is running, and turn off engine while the pedal is still depressed. Keep the pedal depressed for 30 seconds; if no change occurs in the pedal height, brake booster is functioning normally; if the pedal height increases, it is faulty.
S4M0465A
NOTE: If faulty, check precisely with gauges.
(1) (2) (3) (4) (5)
OK NOT OK 1st 2nd 3rd
2. OPERATION CHECK (WITH GAUGES)

S405166A1002
NOTE: In the event of defective operation, inspect the condition of the check valve and vacuum hose. Replace them if faulty and conduct the test again. If no improvement is observed, check precisely with gauges.
CAUTION: When checking operation, be sure to securely apply the hand brake.
BR-42
BRAKE BOOSTER
Checking with gauges
Connect gauges as shown in Figure. After bleeding air from pressure gauges, proceed to each check.
Brake
Loaded air tightness check

1) Start engine and depress brake pedal with pedal force of 196 N (20 kg, 44 lb). Keep engine running until a vacuum of 66.7 kPa (500 mmHg, 19.69 inHg) = point B is indicated on vacuum gauge while the pedal is still depressed.
S4M0467A
(1) (2) (3) (4) (5)
Pressure gauge Vacuum gauge Adapter hose Vacuum hose Pedal force gauge
S4M0469A
Air tightness check

1) Start engine and keep it running until a vacuum of 66.7 kPa (500 mmHg, 19.69 inHg) = point A is indicated on vacuum gauge. Do not depress brake pedal.
(1) (2) (3) (4)
Pressure gauge Vacuum gauge Pedal force gauge Depress
2) Stop engine and watch vacuum gauge. If the vacuum drop range is less than 3.3 kPa (25 mmHg, 0.98 inHg) within 15 seconds after stopping engine, brake booster is functioning properly. If defective, refer to AIR TIGHTNESS CHECK. <Ref. to BR-42 INSPECTION, Brake Booster.>
Lack of boosting action check

Turn off engine, and set the vacuum gauge reading at 0. Then, check the fluid pressure when brake pedal is depressed. The pressure must be greater than the standard value listed.
Brake pedal force Fluid pressure 147 N (15 kgf, 33 lb) 588 kPa (6 kg/cm2, 85 psi) 294 N (30 kgf, 66 lb) 1,667 kPa (17 kg/cm2, 242 psi)
S4M0468A
(1) (2)
Pressure gauge Vacuum gauge
Boosting action check

Set the vacuum gauge reading at 66.7 kPa (500 mmHg, 19.69 inHg) by running engine. Then, check the fluid pressure when brake pedal is depressed. The pressure must be greater than the standard value listed.
Brake pedal force Fluid pressure 147 N (15 kgf, 33 lb) 5,394 kPa (55 kg/cm2, 782 psi) 294 N (30 kgf, 66 lb) 10,003 kPa (102 kg/cm2, 1,450 psi)
2) Stop engine and watch the gauge. If the vacuum drop range is less than 3.3 kPa (25 mmHg, 0.98 inHg) within 15 seconds after stopping engine, brake booster is functioning properly. If defective, the cause may be one of those listed below. Check valve malfunction Leak from vacuum hose Leak from the shell jointed portion or stud bolt welded portion Damaged diaphragm Leak from valve body seal and bearing portion Leak from plate and seal assembly portion Leak from poppet valve assembly portion
BR-43
Brake
PROPORTIONING VALVE
S405167
13. Proportioning Valve

A: REMOVAL
With ABS model
S405167A18
B: INSTALLATION
S405167A11
1) Install proportioning valve to bracket. 2) Connect brake pipes correctly to proportioning valve. 3) Bleed air, then check each joint of brake pipe for oil leaks. Tightening torque: Proportioning valve to brake pipe flare nut: 15 Nm (1.5 kgf-m, 10.8 ft-lb) Proportioning valve to bracket: 18 Nm (1.8 kgf-m, 13.0 ft-lb)
C: INSPECTION
B4M1177C
S405167A10
(1)
Proportioning valve
Without ABS model
1) Install the oil pressure gauges to measure the master cylinder fluid pressure (front wheel brake fluid pressure) and rear wheel cylinder fluid pressure. 2) Bleed air from the oil pressure gauges. 3) Check the master cylinder fluid pressure and rear wheel cylinder fluid pressure. The standard values are shown in Figure.
B4M1197B
(1)
Proportioning valve
B4M1198A
1) Pull up parking brake lever, and block the tires. 2) Remove brake pipe from proportioning valve at four places. 3) Remove proportioning valve from its bracket. CAUTION: Do not disassemble or adjust the proportioning valve. (The proportioning valve must be replaced as an assembly.)
4) For the oil pressure in case of split point, refer to SPECIFICATIONS. <Ref. to BR-2 SPECIFICATIONS, General Description.>
BR-44
BRAKE FLUID
Brake
14. Brake Fluid

A: INSPECTION
S405162
S405162A10
5) Install one end of a vinyl tube onto the air bleeder of and insert the other end of the tube into a container to collect the brake fluid.
1) Check that brake fluid level remains between MIN and MAX. If out of the specified range, refill or drain fluid. If fluid level becomes close to MIN, refill fluid. 2) Check fluid for discoloration. If fluid color has excessively changed, drain the fluid and refill with new fluid.
B: REPLACEMENT
S405162A20
CAUTION: To always maintain the brake fluid characteristics, replace the brake fluid according to maintenance schedule or earlier than that when used in severe condition. The FMVSS No. 116, fresh DOT3 or 4 brake fluid must be used. Cover bleeder with waste cloth, when loosening it, to prevent brake fluid from being splashed over surrounding parts. Avoid mixing different brands of brake fluid to prevent degrading the quality of the fluid. Be careful not to allow dirt or dust to get into the reservoir tank. NOTE: During bleeding operation, keep the brake reservoir tank filled with brake fluid to eliminate entry of air. Brake pedal operating must be very slow. For convenience and safety, two people should do the work. The amount of brake fluid required is approximately 500 m (16.9 US fl oz, 17.6 Imp fl oz) for total brake system. 1) Either jack-up vehicle and place a safety stand under it, or lift-up vehicle. 2) Remove both front and rear wheels. 3) Draw out the brake fluid from master cylinder with syringe. 4) Refill reservoir tank with recommended brake fluid. Recommended brake fluid: FMVSS No. 116, fresh DOT3 or 4 brake fluid
S4M0246
S4M0477A
CAUTION: Brake fluid replacement sequence; (A) Front right (B) Rear left (C) Front left (D) Rear right
S4M0475A
(1) (2) (3)
Master cylinder Hydraulic unit Proportioning valve
6) Instruct your co-worker to depress the brake pedal slowly two or three times and then hold it depressed. 7) Loosen bleeder screw approximately 1/4 turn until a small amount of brake fluid drains into container, and then quickly tighten screw. 8) Repeat steps 6) and 7) above until there are no air bubbles in drained brake fluid and new fluid flows through vinyl tube.
BR-45
Brake
BRAKE FLUID
NOTE: Add brake fluid as necessary while performing the air bleed operation, in order to prevent the tank from running short of brake fluid. 9) After completing the bleeding operation, hold brake pedal depressed and tighten screw and install bleeder cap. Tightening torque (Bleeder screw): 8 Nm (0.8 kgf-m, 5.8 ft-lb) 10) Bleed air from each wheel cylinder using the same procedures as described in steps 6) through 7) above. 11) Depress brake pedal with a force of approximately 294 N (30 kgf, 66 lb) and hold it there for approximately 20 seconds. At this time check pedal to see if it shows any unusual movement. Visually inspect bleeder screws and brake pipe joints to make sure that there is no fluid leakage. 12) Install wheels, and drive vehicle for a short distance between 2 to 3 km (1 to 2 miles) to make sure that brakes are operating properly.
BR-46
AIR BLEEDING
Brake
15. Air Bleeding

A: PROCEDURE
S405163
5) Close outlet plug with your finger, and release brake pedal.
S405163E45
CAUTION: The FMVSS No. 116, fresh DOT3 or 4 brake fluid must be used. Cover bleeder with waste cloth when loosening it to prevent brake fluid from being splashed over surrounding parts. Avoid mixing different brands of brake fluid to prevent degrading the quality of the fluid. Be careful not to allow dirt or dust to get into the reservoir tank. NOTE: Start with the brakes (wheels) connected to the secondary chamber of the master cylinder. The time interval between two brake pedal operations (from the time when the pedal is released to the time when it is depressed another time) shall be approximately 3 seconds. The air bleeder on each brake shall be released for 1 to 2 seconds.
S4M0541
6) Repeat items 3) and 4), until brake fluid come out of all outlet port. 7) Remove the plastic bag cover. 8) Install brake pipes to master cylinder. Tightening torque: 8 Nm (0.8 kgf-m, 5.8 ft-lb) 9) Cleanly wash away brake fluid spill on master cylinder etc. 10) Bleed air from brake system. <Ref. to BR-47, BRAKE LINE, PROCEDURE, Air Bleeding.>
1. MASTER CYLINDER
S405163E4501
NOTE: If master cylinder is disassembled or reservoir tank is empty, bleed master cylinder. During bleeding operation, keep the brake reservoir tank filled with brake fluid to eliminate entry of air. Brake pedal operating must be very slow. For convenience and safety, two people should do the work. 1) Loosen wheel nuts, jack-up vehicle, support it with safety stands, and remove wheel. 2) Disconnect brake line at primary and secondary sides. 3) Put plastic bag cover on the master cylinder. 4) Carefully depress and hold brake pedal.
2. BRAKE LINE
S405163E4502
NOTE: During bleeding operation, keep the brake reservoir tank filled with brake fluid to eliminate entry of air. Brake pedal operating must be very slow. For convenience and safety, two people should do the work. 1) Make sure that there is no leak from joints and connections of the brake system. 2) Fit one end of vinyl tube into the air bleeder and put the other end into a brake fluid container.
S4M0246
S4M0540
BR-47
Brake
AIR BLEEDING
6) Check the pedal stroke. While the engine is idling, depress the brake pedal with a 490 N (50 kgf, 110 lb) load and measure the distance between the brake pedal and steering wheel. With the brake pedal released, measure the distance between the pedal and steering wheel again. The difference between the two measurements must be more than specified.
CAUTION: Brake fluid replacement sequence; (A) Front right (B) Rear left (C) Front left (D) Rear right
S4M0475A
(1) (2) (3)
Master cylinder Hydraulic unit Proportioning valve (1) (2) Steering wheel Toe board
S4M0467A
3) Slowly depress the brake pedal and keep it depressed. Then, open the air bleeder to discharge air together with the fluid. Release air bleeder for 1 to 2 seconds. Next, with the bleeder closed, slowly release the brake pedal. Repeat these steps until there are no more air bubbles in the vinyl tube. Allow 3 to 4 seconds between two brake pedal operations. CAUTION: Cover bleeder with waste cloth, when loosening it, to prevent brake fluid from being splashed over surrounding parts. NOTE: Brake pedal operating must be very slow. 4) Tighten air bleeder securely when no air bubbles are visible. Air bleeder tightening torque: 8 Nm (0.8 kgf-m, 5.8 ft-lb) 5) Perform these steps for the brakes connecting to the secondary chamber of master cylinder, first, and then for the ones connecting to primary chamber. With all procedures completed, fully depress the brake pedal and keep it in that position for approximately 20 seconds to make sure that there is no leak evident in the entire system.
Specified pedal stroke: Without ABS 90 mm (3.54 in) With ABS 95 mm (3.74 in) When depressing brake pedal with a 490 N (50 kgf, 110 lb) load. 7) If the distance is more than specifications, there is a possibility that air is in the brake line. Bleed brake line until pedal stroke meets the specification. 8) Operate hydraulic control unit in the sequence control mode. (Only vehicle equipped with ABS) <Ref. to ABS-11 ABS Sequence Control.> 9) Recheck the brake stroke. 10) If the distance is more than specifications, there is a possibility air is in the inside of the hydraulic unit. Repeat above steps 2) to 9) above until pedal stroke meets the specification. 11) Add brake fluid to the required level (MAX. level) of reservoir tank. 12) As a final step, test run the vehicle at low speed and apply brakes relatively hard 2 to 3 times to ensure that brakes provide normal braking action on all four wheels without dragging and uneven braking.
BR-48
BRAKE HOSE
Brake
16. Brake Hose

A: REMOVAL
S405164
S405164A18
1) Loosen wheel nuts, jack-up vehicle, support it with safety stands, and remove wheel. 2) Separate brake pipe from brake hose. (Always use flare nut wrench and be careful not to deform flare nut.)
5) Temporarily tighten flare nut to connect brake pipe and hose. 6) Fix brake hose with clamp at wheel apron bracket. 7) While holding hexagonal part of brake hose fitting with a wrench, tighten flare nut to the specified torque. Tightening torque (Brake pipe flare nut): 15 Nm (1.5 kgf-m, 10.8 ft-lb) 8) Bleed air from the brake system. <Ref. to BR-47, Air Bleeding.>
2. REAR BRAKE HOSE
S405164A1102
S4M0470A
1) Pass brake hose through the hole of bracket, and lightly tighten flare nut to connect brake pipe. 2) Insert clamp upward to fix brake hose. 3) While holding hexagonal part of brake hose fitting with a wrench, tighten flare nut to the specified torque. Tightening torque (Brake pipe flare nut): 15 Nm (1.5 kgf-m, 10.8 ft-lb) 4) Bleed air from the brake system. <Ref. to BR-47, Air Bleeding.>
(1) (2) (3)
Clamp Brake pipe Brake hose
3) Pull out clamp to remove brake hose. 4) Remove clamp at strut and union bolt.
C: INSPECTION
S405164A10
B: INSTALLATION
S405164A11
1. FRONT BRAKE HOSE
S405164A1101
1) Route end of brake hose (on caliper side) through hole in brake hose bracket at strut location. 2) Tighten end of brake hose at caliper using a union bolt. Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft-lb)
Ensure there are no cracks, breakage, or damage on hoses. Check joints for fluid leakage. If any cracks, breakage, damage or leakage is found, repair or replace hose.
S4M0113
3) Secure middle fitting of brake hose to bracket at strut location using a clamp. 4) Position disc in straight-forward direction and route brake hose through hole in bracket on wheel apron side. CAUTION: Be sure brake hose is not twisted.
BR-49
Brake
BRAKE PIPE
S405165
17. Brake Pipe

A: REMOVAL
C: INSPECTION
S405165A10
S405165A18
NOTE: Airbag system wiring harness is routed near the center brake pipe. CAUTION: All Airbag system wiring harness and connectors are colored yellow. Do not use electrical test equipment on these circuits. Be careful not to damage Airbag system wiring harness when servicing the center brake pipe. When removing the brake pipe, make sure that it is not bent.
Ensure there are no cracks, breakage, or damage on pipes. Check joints for fluid leakage. If any cracks, breakage, damage or leakage is found, repair or replace pipe. NOTE: Use a mirror when inspecting low-visible part or back side.
B: INSTALLATION
S405165A11
NOTE: Airbag system wiring harness is routed near the center brake pipe. CAUTION: All Airbag system wiring harness and connectors are colored yellow. Do not use electrical test equipment on these circuits. Be careful not to damage Airbag system wiring harness when servicing the center brake pipe. When installing the brake pipe, make sure that it is not bent. After installing the brake pipe and hose, bleed the air. After installing the brake hose, make sure that it does not touch the tire or suspension assembly, etc. Brake pipe tightening torque: 15 Nm (1.5 kgf-m, 10.8 ft-lb)
BR-50
HILL HOLDER
Brake
18. Hill Holder

A: REMOVAL
S405661
7) Detach PHV along with support from side frame.

S405661A1801
S405661A18
1. PHV (PRESSURE HOLD VALVE)
1) Remove air cleaner case. (Non-turbo model) <Ref. to IN(SOHC)-7, REMOVAL, Air Cleaner Case.> 2) Remove intercooler. (Turbo model) <Ref. to IN(DOHC TURBO)-10, REMOVAL, Intercooler.> 3) Drain brake fluid from reservoir of master cylinder. 4) Remove adjusting nut and lock nut.
CAUTION: Exercise utmost care to prevent foreign matter from entering into PHV when removing it.
S4M0243
2. PHV CABLE
S405661A1802
S4M0241C
(1) (2) (3)
1) Remove air cleaner case. (Non-turbo model) <Ref. to IN(SOHC)-7, REMOVAL, Air Cleaner Case.> 2) Remove intercooler. (Turbo model) <Ref. to IN(DOHC TURBO)-10, REMOVAL, Intercooler.> 3) Remove adjusting nut and lock nut.
5) Remove cable clamp, and disconnect PHV cable from PHV. CAUTION: Carefully protect boots and inner cable from damage when disconnecting PHV cable.
S4M0241C
(1) (2) (3)
S4M0242C
(1) (2)
PHV cable Clamp
6) Disconnect brake pipes from PHV. CAUTION: Pay attention not to drop brake fluid onto body painting since it may dissolve paint. Pay attention not to damage hexagonal head of flare nut by using pipe wrench without fail.
BR-51
Brake
HILL HOLDER B: INSTALLATION

S405661A11
1. PHV (PRESSURE HOLD VALVE)

1) Install PHV onto side frame. Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft-lb) 2) Connect brake pipes to PHV. Tightening torque: 15 Nm (1.5 kgf-m, 10.8 ft-lb)
S405661A1101
CAUTION: Confirm that brake pipes are not deformed and/or damaged. Replace them with new ones if necessary.
S4M0242C
3) Install PHV cable to PHV. CAUTION: If cable clamp (and clips) is damaged, replace it with a new one. 4) Connect PHV cable with clips. NOTE: Avoid sharp bending of PHV cable as it may cause breakage. 5) Apply grease to the following points. Hook portion of return spring Cable end portion of lever Grease: SUNLIGHT 2 (Part No. 003602010)
(1) (2)
PHV cable Clamp
5) Remove cable clamp from clutch pedal bracket. LHD model
S4M0244B
6) Be sure to bleed air from the brake system. 7) Adjust PHV cable. <Ref. to BR-53 ADJUSTMENT, Hill Holder.> CAUTION: After replacing PHV cable with new one, operate clutch pedal about 30 times as a running-in operation prior to adjustment. 8) Install <Ref. to Case.> 9) Install IN(DOHC cooler.> air cleaner case. (Non-turbo model) IN(SOHC)-7, REMOVAL, Air Cleaner intercooler. (Turbo model) <Ref. to TURBO)-10, INSTALLATION, InterS405661A1102
(1) (2) (3)
Clamp PHV cable Clutch pedal
RHD model
2. PHV CABLE
1) Install PHV cable in the reverse order of removal.

S4M0245B
(1) (2) (3)
Clamp PHV cable Clutch pedal
6) Remove PHV cable.
CAUTION: If cable clamp is damaged, replace it with a new one. Avoid sharp bending of PHV cable as it may cause breakage. 2) Apply grease to the following points. Hook portion of return spring Cable end portion of lever
BR-52
HILL HOLDER
Grease: SUNLIGHT 2 (Part No. 003602010) 3) Adjust PHV cable. <Ref. ADJUSTMENT, Hill Holder.> to BR-53
Brake
S405661A01
D: ADJUSTMENT
CAUTION: After replacing PHV cable with new one, operate clutch pedal about 30 times as a running-in operation prior to adjustment. 4) Install air cleaner case. (Non-turbo model) <Ref. to IN (SOHC)-7, INSTALLATION, Air Cleaner Case.> 5) Install intercooler. (Turbo model) <Ref. to IN (DOHC TURBO)-10, INSTALLATION, Intercooler.>
C: INSPECTION
S405661A10
Check up removed parts as follows, and replace defective ones. 1) Check if boots of PHV cable are damaged or degraded, and if inner cable is damaged or corroded. 2) Check if return spring is worn out, damaged or corroded. 3) Confirm that rolling sound of ball is heard with PHV inclined and lever rotates smoothly. CAUTION: Never disassemble PHV. Replace entire PHV assembly if necessary.
Confirm stopping and starting performances by activating hill holder on an uphill road of 3 or higher inclination. 1) If vehicle does not stop; Tighten adjusting nut of PHV cable. 2) If vehicle does not start properly; Case A When hill holder is released later than engagement of clutch pedal (Engine tends to stall.): Loosen adjusting nut gradually until smooth starting is enabled. Case B When hill holder is released earlier than engagement of clutch pedal (Vehicle slips down slightly.): Tighten adjusting nut so that hill holder is released later than engagement of clutch pedal (status in Case A). Then make adjustment the same as in Case A. CAUTION: Whenever turning adjusting nut, prevent PHV cable from revolving.
S4M0241B
(1) (2) (3)
3) Tighten lock nut. Tightening torque: 3.4 Nm (0.35 kgf-m, 2.5 ft-lb)
BR-53
Brake
BRAKE PEDAL
S405541
19. Brake Pedal

A: REMOVAL
1. MT MODEL LHD model
S405541A18 S405541A1801
1) Pull up parking brake lever and block tires. 2) Disconnect battery ground terminal from battery. 3) Remove steering column. <Ref. to PS-30 REMOVAL, Tilt Steering Column.> 4) Disconnect connectors from stop light and clutch switches. 5) Remove snap pins which secure lever to push rod and operating rod. 6) Remove clevis pins which secure lever to push rod and operating rod.
S4M0242B
(A) (B)
PHV cable Clamp
9) Remove nut which secures clutch master cylinder.
B4M1743A
(A) (B) (C) (D)
Operating rod Push rod Snap pin Clevis pin
B4M1744
10) Remove bolts and nuts which secure brake and clutch pedals, and remove pedal assembly.
S4M0241B
(A) (B) (C)
BR-54
BRAKE PEDAL
RHD model
1) Pull up parking brake lever. 2) Disconnect battery ground terminal from battery. 3) Disconnect accelerator cable from throttle body. CAUTION: Be careful not to kink accelerator cable. 4) Remove instrument panel lower cover from instrument panel. 5) Remove clevis pin which secures brake pedal to brake booster operating rod. Also disconnect electrical connectors (for stop light switch, etc.). 6) Disconnect accelerator cable from accelerator pedal lever.
Brake
10) Remove nuts and bolts which secure pedal bracket.
B4M0157B
S4M0482A
(1) (2)
Accelerator pedal Brake pedal
(1)
7) Remove the casing cap out of the toe board by turning it clockwise.
B4M0156B
(1) (2) (3)
Accelerator cable Toe board hole Casing cap
8) Pull out the cable from the toe board hole. 9) Disconnect stop light switch connector.
BR-55
Brake
BRAKE PEDAL
S405541A1802
2. AT MODEL LHD model
B: INSTALLATION
S405541A11
1) Install in the reverse order of removal. CAUTION: Be careful not to bend clutch cable too much. Never fail to cover outer cable end with boot. Be careful not to kink accelerator cable. Make sure that holder and casing cap are securely connected. (LHD model only)
1) Pull up parking brake lever. 2) Disconnect battery ground terminal from battery. 3) Remove instrument panel lower cover from instrument panel. 4) Remove clevis pin which secures brake pedal to brake booster operating rod. Also disconnect stop light switch connector. 5) Remove two bolts and four nuts which secure brake pedal to pedal.
B4M0159B
G4M0324
RHD model
NOTE: For removal procedures, refer to MT MODEL. <Ref. to BR-54 MT MODEL, REMOVAL, Brake Pedal.>
(1) (2) (3) (4) (5)
Casing cap Accelerator cable Toe board Accelerator pedal bracket Holder
2) Adjustment of clutch pedal <Ref. to BR-58 ASSEMBLY, Brake Pedal.> 3) Inspect after pedal installation <Ref. to BR-59 INSPECTION, Brake Pedal.>
BR-56
BRAKE PEDAL C: DISASSEMBLY

1. MT MODEL LHD model
1) Remove the stop light switch. <Ref. to BR-60 REMOVAL, Stop Light Switch.> 2) Remove the clutch pedal. <Ref. to CL-38 DISASSEMBLY, Clutch Pedal.> 3) Remove the clutch master cylinder bracket.
S405541A0601 S405541A06
Brake
RHD model
1) Remove the stop light switch and kick-down switch. 2) Remove clip, bushing, accelerator spring and accelerator pedal.
S4M0542A
B4M2349
(1) (2) (3) (4)
Clip Bushing Accelerator spring Accelerator pedal
4) Remove bushing, spring and stopper.
3) Unbolt, and then remove the brake pedal.
B4M2350A
S4M0543
(1) (2) (3) (4)
Stopper Bushing Brake pedal Brake pedal spring
4) Remove spacer, bushing, brake pedal spring and brake pedal.
5) Remove the brake pedal pad.
B4M2350A
(1) (2) (3) (4)
Stopper Bushing Brake pedal Brake pedal spring
BR-57
Brake
BRAKE PEDAL
S405541A0602
2. AT MODEL
D: ASSEMBLY
S405541A02
1) Remove the brake switch. 2) Unbolt, and then remove the brake pedal.
1) Attach stop light switch, etc. to pedal bracket temporarily. 2) Clean inside of bores of clutch pedal and brake pedal, apply grease, and set bushings into bores. 3) Align bores of pedal bracket, clutch pedal and brake pedal, attach brake pedal return spring and clutch pedal effort reducing spring (vehicle with hill holder), and then install pedal bolt. NOTE: Clean up inside of bushings and apply grease before installing spacer.
B4M2347
Tightening torque: T: 29 Nm (3.0 kgf-m, 21.7 ft-lb)
3) Remove bushing, spacer and spring.
B4M1753C B4M2348A
(1) (2) (3) (4) (5) (6)
Spacer Bushing Stopper Brake pedal Brake spacer Brake pedal spring
4) Set brake pedal position by adjusting position of stop light switch. Pedal position: L LHD model 125.9 mm (4.96 in) RHD model 154.9 mm (6.10 in) Tightening torque: T: 8 Nm (0.8 kgf-m, 5.8 ft-lb)
B4M1754B
BR-58
BRAKE PEDAL E: INSPECTION

S405541A10
Brake
2) Check position of pedal pad. Pedal height: L 148 mm (5.83 in) Brake pedal free play: A 1 3 mm (0.04 0.12 in) [Depress brake pedal pad with a force of less than 10 N (1 kgf, 2 lb).]
1) Move brake and clutch pedal pads in the lateral direction with a force of approximately 10 N (1 kgf, 2 lb) to ensure pedal deflection is in specified range. CAUTION: If excessive deflection is noted, replace bushings with new ones. Deflection of brake and clutch pedal: Service limit 5.0 mm (0.197 in) or less
B4M0366B
(1) (2) (3) (4)

S4M0135B
Stop light switch Mat Toe board Brake booster operating rod
(1) (2)
Clutch pedal Brake pedal
3) If it is not in specified value, adjust it by adjusting brake booster operating rod length.
G4M0326
BR-59
Brake
STOP LIGHT SWITCH

S405542
20. Stop Light Switch

A: REMOVAL
S405542A18
C: INSPECTION
S405542A10
1) Disconnect ground terminal from battery. 2) Disconnect stop light switch connector. 3) Loosen nuts, and unscrew stop light switch to remove.
1) If stop light switch does not operate properly (or if it does not stop at the specified position), replace with a new one. Specified position: L 2+1.5/0 mm (0.079+0.059/0 in)
B4M1753D
G4M0327
(1)
Stop light switch

S405542A11
2) Measure the clearance between threaded end of stop light switch and stopper. CAUTION: Be careful not to rotate stop light switch. Stop light switch clearance: A 0.3 mm (0.012 in)
B: INSTALLATION
1) Screw the stop light switch onto a bracket and secure it temporarily with a nut. 2) Adjust stop light switch position, and then tighten the nut. <Ref. to BR-61 ADJUSTMENT, Stop Light Switch.> Tightening torque: 8 Nm (0.8 kgf-m, 5.8 ft-lb)
B4M0617E
(1) (2) (3)

B4M1753E
Stop light switch Stopper Brake pedal
3) If it is not in specified value, adjust it by adjusting position of stop light switch. CAUTION: Be careful not to rotate stop light switch.
BR-60
STOP LIGHT SWITCH D: ADJUSTMENT

S405542A01
Brake
Loosen the lock nut, and adjust stop light switch position until the clearance between threaded end of the stop light switch and the stopper becomes 0.3 mm (0.012 in). Then, tighten the lock nut.
B4M0617E
BR-61
Brake
GENERAL DIAGNOSTICS
S405278
21. General Diagnostics

A: INSPECTION
1. BRAKE SYSTEM
S405278A10 S405278A1001
Trouble and possible cause 1. Insufficient braking (1) Fluid leakage from the hydraulic mechanism (2) Entry of air into the hydraulic mechanism (3) Excessively wide shoe clearance (4) Wear, deteriorated surface material, adhering water or fluid on the lining (5) Improper operation of master cylinder, disc caliper, brake booster or check valve 2. Unstable or uneven (1) Fluid on the lining, drum or rotor braking (2) Drum or rotor eccentricity (3) Worn brake drum, or damage to the drum caused by sand (4) Improper lining contact, deteriorated surface material, improper inferior material, or wear (5) Deformed back plate (6) Improper tire inflation (7) Disordered wheel alignment (8) Loosened back plate or the support installing bolts (9) Loosened wheel bearing (10) Trouble in the hydraulic system (11) Uneven effect of the parking brake 3. Excessive pedal stroke (1) Entry of air into the hydraulic mechanism (2) Excessive play in the master cylinder push rod (3) Fluid leakage from the hydraulic mechanism
Corrective action Repair or replace (cup, piston seal, piston boot, master cylinder piston kit, pipe or hose). Bleed the air. Adjust the clearance. Replace, grind or clean. Correct or replace. Eliminate cause of fluid leakage, clean, or replace. Correct or replace the drum or rotor. Correct by grinding, or replace. Correct by grinding, or replace. Correct or replace. Inflate to correct pressure. Adjust alignment. Retighten. Retighten to normal tightening torque or replace. Replace the cylinder, brake pipe or hose. Check, adjust, or replace the rear brake and cable system. Bleed the air. Adjust. Repair or replace (cup, piston seal, piston boot, master cylinder piston kit, pipe or hose). Adjust. Correct or replace. Adjust play. Clean or replace the cylinder. Replace. Correct or adjust. Replace the spring. Adjust the clearance. Correct or replace. Adjust or replace. Replace the shoe assembly or pad. Replace the shoe assembly or pad. Retighten. Retighten to normal tightening torque. Clean the drum or rotor, or clean and replace the brake assembly.
(4) Improperly adjusted shoe clearance (5) Improper lining contact or worn lining 4. Brake dragging or (1) Insufficient pedal play improper brake return (2) Improper master cylinder return (3) Clogged hydraulic system (4) Improper return or adjustment of parking brake (5) Weakened spring tension or breakage of shoe return spring (6) Excessively narrow shoe clearance (7) Improper disc caliper operation (8) Improper adjusted wheel bearing 5. Brake noise (1) (1) Hardened or deteriorated lining (creak sound) (2) Worn lining (3) Loosened back plate or the support installing bolts (4) Loose wheel bearing (5) Dirty drum or rotor
BR-62
GENERAL DIAGNOSTICS
Trouble and possible cause (1) Worn lining (2) Improper installed shoe or pad (3) Loose or bent drum or rotor In the case of the disc brake: (1) Excessively worn pad or the support In the case of the drum brake: (1) Excessively worn shoe ridge (2) Lack of oil on the shoe ridge surface and anchor
Brake
6. Brake noise (2) (hissing sound) 7. Brake noise (3) (click sound)
Corrective action Replace the shoe assembly or pad. Correct or replace the shoe assembly or pad. Retighten or replace. Replace the pad or the support. Replace the back plate. Add more grease.
2. HILL HOLDER
S405278A1002
CAUTION: Description in parentheses is a characteristic of hill holder and does not indicate abnormality. Depressing force required for clutch pedal equipped to hill holder specifications is 20 to 29 N (2 to 3 kg, 4 to 7 lb) larger than the conventional specifications, which does not constitute abnormality.
When vehicle cannot travel (brake cannot be released) because return spring is broken, remove adjust nut, disconnect clutch and PHV, and then return PHV lever to release the brake. (Be sure to apply the parking brake before starting this operation.) The hill holder may not be activated on a slope of an extremely small inclination.
Trouble and possible cause (1) PHV cable is damaged or does not operate properly. (2) Lever of PHV is defective. (3) Clutch system is anomalous. (1) Front side of vehicle is lowered. 2. Vehicle does not stop on uphill road of (2) PHV cable is broken. 3 or higher inclina(3) Play of clutch is excessive. tion. (4) PHV cable is elongated. (5) Sealing of PHV is poor. 3. Shock is felt when (1) Poor adjustment of starting performance. starting. (2) When depressing the brake pedal strongly: 1. Counterforce of clutch pedal is too strong. (3) When starting on flat road after stopping reverse movement: 4. Vehicle slips down (1) PHV cable is elongated. when starting. (2) Clutch facing is worn out. (3) Bracket (cable) or stay (PHV) is deformed. 5. Vehicle cannot start (1) Return spring is fatigued or broken. after stoppage. (2) PHV lever wont return. (3) When intentionally depressing brake pedal strongly: 6. Abnormal sound is (1) Rotor and pad matched with each other due to inadequate depressing force to brake pedal. generated upon releasing brake pedal when stopping. 7. Abnormal sound is (1) Grease is inadequate for the hook of return generated when oper- spring and sliding portion of PHV cable end. ating clutch pedal. (2) When releasing after maintaining high fluid pressure: (3) Clutch system is anomalous.
Corrective action Repair or replace. Replace entire PHV assembly. Replace clutch system. Replace suspension. Replace. Adjust. Adjust. Replace entire PHV assembly. Adjust. (The stronger brake pedal depressing force, the later hill holder releases.) (Because hill holder is activated.) Adjust. Adjust or replace. Repair or replace. Replace. Replace entire PHV assembly. [When the brake pedal is depressed by a force of 1,177 N (120 kgf, 265 lb) or more.] (Abnormal sound is not generated when depressing brake pedal a little stronger.)
Apply grease. (Flowing sound of fluid when releasing high fluid pressure.) Replace clutch system.
BR-63
Brake
GENERAL DIAGNOSTICS
MEMO:
BR-64
PARKING BRAKE
PB
1. 2. 3. 4. 5. Page General Description.....................................................................................2 Parking Brake Lever....................................................................................6 Parking Brake Cable ...................................................................................7 Parking Brake Assembly (Rear Disc Brake) ...............................................9 General Diagnostic Table ..........................................................................12
Parking Brake
GENERAL DESCRIPTION
S404001
A: SPECIFICATIONS
Model Type Effective drum diameter Lining dimensions (length width thickness) Clearance adjustment Lever stroke
S404001E49
mm (in) mm (in)
noches/N (kgf, lb)
Rear drum brake Rear disc brake Mechanical on rear brakes, drum in disc 228.6 (9) 170 (6.69) 218.8 35.0 4.1 162.6 30.0 3.2 (8.61 1.378 0.161) (6.40 1.181 0.126) Automatic adjustment Manual adjustment 7 to 8/196 (20, 44)
PB-2

S404001A05
Parking Brake
S404001A0501
B4M1127A
(1) (2) (3) (4) (5) (6) (7)
Back plate Retainer Spring washer Lever Parking brake shoe (Primary) Parking brake show (Secondary) Strut spring
(8) (9) (10) (11) (12) (13) (14)
Strut Shoe guide plate Primary return spring Secondary return spring Adjusting spring Adjuster Shoe hold-down cup
(15) Shoe hold down spring (16) Shoe hold down pin (17) Adjusting hole cover
PB-3
Parking Brake
GENERAL DESCRIPTION
S404001A0502
2. PARKING BRAKE CABLE
B4M0070B
(1) (2) (3) (4) (5) (6)
Parking brake lever Parking brake switch Lock nut Adjusting nut Equalizer Bracket
(7) (8) (9) (10)
Clamp Parking brake cable RH Cable guide Clamp (Rear disc brake model only) (11) Parking brake cable LH
Tightening torque: Nm (kgf-m, ft-lb) T1: 5.9 (0.60, 4.3) T2: 18 (1.8, 13.0) T3: 32 (3.3, 24)
PB-4

S404001A03
Parking Brake
Wear working clothing, including a cap, protective goggles, and protective shoes during operation. Remove contamination including dirt and corrosion before removal, installation or disassembly. Keep the disassembled parts in order and protect them from dust or dirt. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly, and replacement. Be careful not to burn your hands, because each part on the vehicle is hot after running. Use SUBARU genuine grease etc. or the equivalent. Do not mix grease etc. with that of another grade or from other manufacturers. Be sure to tighten fasteners including bolts and nuts to the specified torque. Place shop jacks or safety stands at the specified points. Apply grease onto sliding or revolution surfaces before installation. Before installing O-rings or snap rings, apply sufficient amount of grease to avoid damage and deformation. Before securing a part on a vise, place cushioning material such as wood blocks, aluminum plate, or shop cloth between the part and the vise. Keep grease etc. away from parking brake shoes.
PB-5
Parking Brake
PARKING BRAKE LEVER

S404171
2. Parking Brake Lever

A: REMOVAL
S404171A18
Be sure to adjust the lever stroke. <Ref. to PB-6 ADJUSTMENT, Parking Brake Lever.>
C: INSPECTION
S404171A10
1) To immobilize vehicle, put the select lever in 1st or P position, and lock the tires. 2) Disconnect ground terminal connector from battery. 3) Remove console cover. <Ref. to EI-30, Console Box.> 4) Disconnect connector parking brake switch. 5) Loosen parking cable adjusting nut and remove inner cable end from equalizer. 6) Remove parking brake lever.
While pulling parking brake lever upward, count the notches. Lever stroke: 7 to 8 notches when pulled with a force of 196 N (20 kgf, 44 lb) Incorrect, adjust the parking brake. <Ref. to PB-11 ADJUSTMENT, Parking Brake Assembly (Rear Disc Brake).>
D: ADJUSTMENT
S404171A01
1) Remove console cover. 2) Forcibly pull parking brake lever 3 to 5 times. 3) Adjust parking brake lever by turning adjuster until parking brake lever stroke is set at 7 to 8 notches with operating force of 196 N (20 kgf, 44 lb). 4) Tighten lock nut. Lever stroke: 7 to 8 notches when pulled with a force of 196 N (20 kgf, 44 lb) Tightening torque (Lock nut): 5.9 Nm (0.60 kgf-m, 4.3 ft-lb)
S4M0126B
(1) (2)
Console bracket Parking brake lever
7) Unbend parking brake lever pawls and remove cable.
S4M0520A
S4M0471A
(1) (2) (3)
(1) (2)
Parking brake lever Cable

S404171A11
5) Install console cover.
B: INSTALLATION
Install in the reverse order of removal. Tightening torque: Parking brake lever; 18 Nm (1.8 kgf-m, 13.0 ft-lb) Adjusting nut; 5.9 Nm (0.6 kgf-m, 4.3 ft-lb) NOTE: Be sure to pass cable through guide inside the tunnel.
PB-6
PARKING BRAKE CABLE
Parking Brake
3. Parking Brake Cable

A: REMOVAL
S404170A18
S404170
11) Remove inner cable end from equalizer.
1) Set vehicle on a lift. 2) Disconnect battery ground terminal from battery. 3) Lift-up vehicle. 4) Remove rear tires and wheels. 5) Remove rear cushion. 6) Remove console box. <Ref. to EI-30, Console Box.> 7) Loosen parking cable adjusting nut and console bracket. 8) Remove parking brake lever.
S4M0473A
(1) (2)
Equalizer Inner cable end
12) Pull out parking brake cable from rear brake. Disc brake: <Ref. to PB-9 REMOVAL, Parking Brake Assembly (Rear Disc Brake).> Dram brake: <Ref. to BR-35, Rear Drum Brake Assembly.> 13) Pull out clamp from rear brake. 14) Remove bolt and bracket from trailing link bracket. 15) Remove bolt and clamp from rear floor.
S4M0126B
(1) (2)
Console bracket Parking brake lever
9) Roll up floor mat and remove clamps.
S4M0474
16) Detach grommet from rear floor. 17) Remove cable assembly from cabin by forcibly pulling it backward. 18) Detach parking brake cable from cable guide at rear trailing link.
S4M0472
10) Remove equalizer cover.
PB-7
Parking Brake
PARKING BRAKE CABLE

S404170A11
B: INSTALLATION
C: INSPECTION
S404170A10
Install (new) parking brake assembly in the reverse order of removal. NOTE: Be sure to pass cable through cable guide inside the tunnel. Be sure to adjust the lever stroke. <Ref. to PB-6 ADJUSTMENT, Parking Brake Lever.>
Check the removed cable and replace if damaged, rusty, or malfunctioning. 1) Check for smooth operation of the cable. 2) Check the inner cable for damage and rust. 3) Check the outer cable for damage, bends, and cracks. 4) Check the boot for damage, cracks, and deterioration.
PB-8
PARKING BRAKE ASSEMBLY (REAR DISC BRAKE)
Parking Brake
4. Parking Brake Assembly (Rear Disc Brake)

S404552
(2) If disc rotor seizes up within hub, drive disc rotor out by installing an 8-mm bolt in holes B on the rotor.
A: REMOVAL
S404552A18
1) Set vehicle on a lift. 2) Disconnect battery ground terminal from battery. 3) Loosen wheel nuts. 4) Lift-up vehicle, and remove wheels. 5) Remove the two mounting bolts and remove the disc brake assembly.
G4M0383
9) Remove shoe return spring from parking brake assembly. 10) Remove front shoe hold down spring and pin with pliers.
S4M0459A
6) Suspend the disc brake assembly so that the hose is not stretched. 7) Pull down and release parking brake. 8) Remove the disc rotor. NOTE: If the disc rotor is difficult to remove try the following two methods in order. (1) Turn adjusting screw using a slot-type screwdriver until brake shoe gets away enough from the disc rotor.
S4M0524
11) Remove strut and strut spring. 12) Remove adjuster assembly from parking brake assembly. 13) Remove brake shoe. 14) Remove rear shoe hold-down spring and pin with pliers. 15) Remove parking cable from parking lever.
S4M0569A
(1) (2) (3) (4)
Adjusting screw Adjusting hole cover (rubber) Slot-type screwdriver Back plate
B4M1774B
(1) (2)
Parking brake cable Parking brake lever
16) Using a standard screwdriver, raise retainer. Remove parking lever and washer from brake shoe.
PB-9
Parking Brake
PARKING BRAKE ASSEMBLY (REAR DISC BRAKE)

S404552A11
B: INSTALLATION
CAUTION: Be sure lining surface is free from oil contamination. Brake grease: Dow Corning Molykote No. 7439 (Part No. 725191460) 1) Apply brake grease to the following places. Six contact surfaces of shoe rim and back plate packing Contact surface of shoe wave and anchor pin Contact surface of lever and strut Contact surface of shoe wave and adjuster assembly Contact surface of shoe wave and strut Contact surface of lever and shoe wave 2) Install in reverse order of removal. CAUTION: Use new retainers and clinch them when installing brake shoes to levers. Ensure that parking lever moves smoothly. Do not confuse left parking lever with right one. Do not confuse left strut with right one. NOTE: Ensure that adjuster assembly is securely installed with screw in the left side, facing vehicle front.
NOTE: Ensure that shoe return spring is installed as shown in Figure.
S4M0462A
(1) (2) (3) (4) (5) (6) (7) (8) (9)
Back plate Shoe guide plate Retainer Spring washer Lever Primary shoe return spring (Blue) Secondary shoe return spring (Yellow) Parking brake shoe (Primary) Parking brake shoe (Secondary)
3) Adjust parking brakes. <Ref. to PB-11 ADJUSTMENT, Parking Brake Assembly (Rear Disc Brake).> CAUTION: After replacing parking brake lining, be sure to drive vehicle for break-in purposes. (1) Drive the vehicle about 35 km/h (22 MPH). (2) With the parking brake release button pushed in, pull the parking brake lever gently. (3) Drive the vehicle for about 200 meter (0.12 mile) in this condition. (4) Wait 5 to 10 minutes for the parking brake to cool down. Repeat this procedure once more. (5) After breaking-in, re-adjust parking brakes.
S4M0461A
(1)
LEFT
PB-10
PARKING BRAKE ASSEMBLY (REAR DISC BRAKE) C: INSPECTION

S404552A10
Parking Brake
D: ADJUSTMENT
S404552A01
1) Measure brake disc inside diameter. If the disc is scored or worn, replace the brake disc. Disc inside diameter: Standard 170 mm (6.69 in) Service limit 171 mm (6.73 in) 2) Measure the lining thickness. If it exceeds the limit, replace shoe assembly. Lining thickness: Standard 3.2 mm (0.126 in) Service limit 1.5 mm (0.059 in) CAUTION: Replace the brake shoes on the right and left brake assembly at the same time.
1. SHOE CLEARANCE
S404552A0101
1) Remove adjusting hole cover from back plate. 2) Turn adjusting screw using a slot-type screwdriver until brake shoe is in close contact with disc rotor.
S4M0463A
(1) (2) (3) (4)
Adjusting screw Adjusting hole cover (rubber) Slot-type screwdriver Back plate
3) Turn back (downward) adjusting screw 3 or 4 notches. 4) Install adjusting hole cover to back plate.
2. LEVER STROKE
S404552A0102
1) Remove console box lid. 2) Forcibly pull parking brake lever 3 to 5 times. 3) Adjust parking brake lever by turning adjuster until parking brake lever stroke is set at 6 notches with operating force of 196 N (20 kgf, 44 lb).
S4M0520A
(1) (2) (3)
4) Tighten lock nut. 5) Install console box lid. Lever stroke: 7 to 8 notches when pulled with a force of 196 N (20 kgf, 44 lb) Tightening torque (Adjuster lock nut): 5.9 Nm (0.60 kgf-m, 4.3 ft-lb)
PB-11
Parking Brake

S404257

A: INSPECTION
Symptom
S404257A10
Brake drag
Noise from brake
Possible cause Parking brake lever is maladjusted. Parking brake cable does not move. Parking brake shoe clearance is maladjusted. Return spring is faulty. Return spring is faulty. Shoe hold down spring is faulty.
Remedy Adjustment. Repair or replace. Adjustment. Replace. Replace. Replace.
PB-12
POWER ASSISTED SYSTEM (POWER STEERING)
PS
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Page General Description.....................................................................................2 Steering Wheel..........................................................................................27 Universal Joint...........................................................................................28 Tilt Steering Column..................................................................................30 Steering Gearbox [LHD Model].................................................................33 Steering Gearbox [RHD Model] ................................................................53 Pipe Assembly...........................................................................................78 Oil Pump....................................................................................................93 Reservoir Tank ........................................................................................100 Power Steering Fluid...............................................................................101 General Diagnostic Table ........................................................................103
Power Assisted System (Power Steering)
GENERAL DESCRIPTION
S601001
A: SPECIFICATIONS
Steering wheel Turning angle Steering shaft
S601001E49
Model Free play Inner tire & wheel Outer tire & wheel Clearance between steering wheel and column cover Sliding resistance Right-turn steering Rack shaft play in radial direction Left-turn steering In radial direction Input shaft play In axial direction Turning resistance Radial play Axial play Ditch deflection Pulley Resistance to rotation Regular pressure Relief pressure Radial play Pulley shaft Axial play Ditch deflection Pulley Resistance to rotation Regular pressure Relief pressure At standstill with engine idling on a concrete road At standstill with engine stalled on a concrete road Pulley shaft
LHD mm (in) 17 (0.67) 34.41.5 30.21.5 3.0 (0.118)
RHD
mm (in) N (kgf, lb) mm (in)
Steering gearbox (Power steering system)
mm (in)
304.0 (31.0, 68.4) or less Horizontal movement: 0.6 (0.024) or less 0.15 (0.0059) or less Vertical movement: 0.4 (0.016) or less Horizontal movement: 0.3 (0.012) or less 0.4 (0.016) or less Vertical movement: 0.15 (0.0059) or less 0.18 (0.0071) or less 0.1 (0.004) or less
mm (in) mm (in)
Oil pump [Non-turbo model (Power steering system)]
Within 30 mm (1.18 in) from rack center in straight N (kgf, lb) ahead position: Less than 11.18 (1.14, 2.51) Maximum allowable value: 12.7 (1.3, 2.9) mm (in) 0.4 (0.016) or less mm (in) 0.9 (0.035) or less mm (in) 1.0 (0.039) or less N (kgf, lb) kPa (kg/cm2, psi) kPa (kg/cm2, psi) mm (in) mm (in) mm (in) N (kgf, lb) kPa (kg/cm , psi) kPa (kg/cm2, psi) N (kgf, lb) N (kgf, lb)
2
9.22 (0.94, 2.07) or less 981 (10, 142) or less 7,355 (75, 1,067) 0.4 (0.016) or less 0.6 (0.024) or less 1.0 (0.039) or less 9.22 (0.94, 2.07) or less 981 (10, 142) or less 9,807 (100, 1,422) 29.4 (3.0, 6.6) or less 294.2 (30, 66.2) or less
Oil pump [Turbo model (Power steering system)]
Steering wheel effort (Power steering system)
Recommended power steering fluid
ATF DEXRON IIE or III
Manufacturer B.P. CALTEX CASTROL MOBIL SHELL TEXACO
PS-2
GENERAL DESCRIPTION
Model Minimum turning radius Steering angle (Inside-Outside) Whole system Steering wheel diameter m (ft) Non-turbo
mm (in)
Overall gear ratio (Turns, lock to lock) Type Backlash Valve (Power steering system) Type Oil tank cm3 (cu in)/ Output rev. kPa (kg/cm2, Relief pressure psi) Hydraulic fluid control (US qt, Imp Hydraulic fluid qt) Range of revolution rpm Revolving direction Name Oil tank (US qt, Imp qt) Capacity Total (US qt, Imp qt)
Gearbox
Turbo 5.4 (17.7) 34.41.5 30.21.5 With AIRBAG: 385 (15.16) Without AIRBAG: 385 (15.16) LHD: 19.0 (3.4) RHD: 16.7 (3.0) Rack and pinion, Integral 0 (Automatically adjustable) Rotary valve Vane pump Installed on pump 9.6 0.65 (0.586 0.040) 7,846 (80, 1,138)
7.2 0.6 (0.439 0.037) 7,355 (75, 1,067)
Pump (Power steering system)
Drooping in response to increased engine revolutions 1,000 rpm: 7 (7.4, 6.2) 3,000 rpm: 5 (5.3, 4.4) 500 7,500 500 8,000 Clockwise ATF DEXRON IIE or III 0.3 (0.3, 0.3) 0.7 (0.7, 0.6)
Working fluid (Power steering system)
CAUTION: This table lists various clearances that must be correctly adjusted to ensure normal vehicle driving without interfering noise, or any other faults.
Location (1) Crossmember Pipe (2) DOJ Shaft or joint (3) DOJ Valve housing (4) Pipe Pipe (5) Stabilizer Pipe (6) Exhaust pipe Pipe (7) Exhaust pipe Gearbox bolt (8) Side frame Hose A and B (9) Cruise control pump Hose A and B (10) Pipe portion of hose A Pipe portion of hose B (11) AT cooling hose Joint (LHD model) Minimum allowance 5 mm (0.20 in) 14 mm (0.55 in) 11 mm (0.43 in) 2 mm (0.08 in) 5 mm (0.20 in) 15 mm (0.59 in) 15 mm (0.59 in) 15 mm (0.59 in) 15 mm (0.59 in) 1.5 mm (0.059 in) 20 mm (0.79 in)
PS-3
GENERAL DESCRIPTION
Non-turbo model
S4M0172A
Turbo model
S4M0565A
PS-4

With Airbag Model
S601001A05
1. STEERING WHEEL AND COLUMN
S601001A0501
S4M0304B
(1) (2) (3) (4) (5)
Bushing Steering shaft Knee protector Steering roll connector Column cover
(6) Steering wheel (7) Airbag module
Tightening torque: Nm (kgf-m, ft-lb) T1: 1.2 (0.12, 0.9) T2: 3.4 (0.35, 2.5) T3: 25 (2.5, 18.1) T4: 44 (4.5, 32.5)
PS-5
GENERAL DESCRIPTION
Without Airbag Model
S4M0311A
(1) (2) (3) (4) (5)
Bushing Steering shaft Knee protector Combination switch Column cover
(6) Steering wheel (7) Pad ASSY
Tightening torque: Nm (kgf-m, ft-lb) T1: 1.2 (0.12, 0.9) T2: 3.4 (0.35, 2.5) T3: 25 (2.5, 18.1) T4: 44 (4.5, 32.5)
PS-6
GENERAL DESCRIPTION
MEMO:
PS-7
GENERAL DESCRIPTION
S601001A0504
2. POWER ASSISTED SYSTEM FOR NON-TURBO MODEL LHD Model
S4M0175E
PS-8
GENERAL DESCRIPTION
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) Eye bolt Pipe C Gasket Clip Pipe D Clamp E O-ring Cap Strainer Upper shell Buffle Seal washer Lower shell Pulley Oil pump Bracket Belt tension nut Bushing Belt cover Pipe E Pipe F Clamp plate Universal joint Dust cover Valve housing Gasket (27) (28) (29) (30) (31) (32) (33) (34) (35) (36) (37) (38) (39) (40) (41) (42) (43) (44) (45) (46) (47) (48) (49) (50) (51) (52) Oil seal Special bearing Seal ring Pinion and valve ASSY Oil seal Back-up washer Ball bearing Snap ring Lock nut Adjusting screw Spring Sleeve Adapter Clamp Cotter pin Castle nut Dust seal Clip Tie-rod end Clip Boot Band Tie-rod Lock washer Pipe B Pipe A

(53) (54) (55) (56) (57) (58) (59) Steering body Oil seal Piston ring Rack Rack bushing Rack stopper Circlip
Tightening torque: Nm (kgf-m, ft-lb) T1: 6 (0.6, 4.3) T2: 7.4 (0.75, 5.4) T3: 8 (0.8, 5.8) T4: 13 (1.3, 9.4) T5: 15 (1.5, 10.8) T6: 18 (1.8, 13.0) T7: 22 (2.2, 15.9) T8: 24 (2.4, 17.4) T9: 25 (2.5, 18.1) T10: 27.0 (2.75, 19.9) T11: 39 (4.0, 28.9) T12: 52 (5.3, 38) T13: 59 (6.0, 43) T14: 78 (8.0, 58) T15: 83 (8.5, 61.5)
PS-9
GENERAL DESCRIPTION
RHD Model
S4M0232C
PS-10
GENERAL DESCRIPTION
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) Eye bolt Pipe C Gasket Clip Pipe D Clamp E O-ring Cap Strainer Upper shell Buffle Seal washer Lower shell Pulley Oil pump Bracket Belt tension nut Bushing Belt cover Universal joint Dust cover Valve housing Oil seal Ball bearing Retaining ring Seal ring Valve sleeve Seal ring (29) (30) (31) (32) (33) (34) (35) (36) (37) (38) (39) (40) (41) (42) (43) (44) (45) (46) (47) (48) (49) (50) (51) (52) (53) (54) (55) (56) O-ring Oil seal Spacer Pinion Shim Adapter Clamp Castle nut Cotter pin Dust seal Clip Tie-rod end Clip Boot Wire Tie-rod Lock washer Holder Bushing Oil seal Oil seal O-ring Rack Oil seal Back-up washer Steering body Pipe A Pipe B

(57) (58) (59) (60) (61) Lock nut Adjusting screw Spring Sleeve Seat pad
Tightening torque: Nm (kgf-m, ft-lb) T1: 7.4 (0.75, 5.4) T2: 8 (0.8, 5.8) T3: 13 (1.3, 9.4) T4: 15 (1.5, 10.8) T5: 18 (1.8, 13.0) T6: 20 (2.0, 14.5) T7: 22 (2.2, 15.9) T8: 24 (2.4, 17.4) T9: 24.5 (2.50, 18.1) T10: 25 (2.5, 18.1) T11: 27.0 (2.75, 19.9) T12: 39 (4.0, 28.9) T13: 59 (6.0, 43) T14: 52 (5.3, 38) T15: 64 (6.5, 47) T16: 78 (8.0, 58) T17: 83 (8.5, 61.5)
PS-11
GENERAL DESCRIPTION
S601001A0505
3. POWER ASSISTED SYSTEM FOR TURBO MODEL LHD Model
S4M0566A
PS-12
GENERAL DESCRIPTION
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) Eye bolt Pipe C Gasket Clip Pipe D Clamp E O-ring Cap Reservoir tank Reservoir tank bracket Pulley Oil pump Bracket Belt tension nut Bushing Belt cover Pipe E Pipe F Clamp plate Universal joint Dust cover Valve housing Gasket Oil seal Special bearing Seal ring Pinion and valve ASSY (28) (29) (30) (31) (32) (33) (34) (35) (36) (37) (38) (39) (40) (41) (42) (43) (44) (45) (46) (47) (48) (49) (50) (51) (52) (53) (54) Oil seal Back-up washer Ball bearing Snap ring Lock nut Adjusting screw Spring Sleeve Adapter Clamp Cotter pin Castle nut Dust seal Clip Tie-rod end Clip Boot Band Tie-rod Lock washer Pipe B Pipe A Steering body Oil seal Piston ring Rack Rack bushing

(55) (56) (57) (58) Rack stopper Circlip Suction hose Tank hose
Tightening torque: Nm (kgf-m, ft-lb) T1: 6 (0.6, 4.3) T2: 7.4 (0.75, 5.4) T3: 8 (0.8, 5.8) T4: 13 (1.3, 9.4) T5: 15 (1.5, 10.8) T6: 15 (1.5, 10.8) T7: 15.7 (1.6, 11.6) T8: 22 (2.2, 15.9) T9: 24 (2.4, 17.4) T10: 25 (2.5, 18.1) T11: 25 (2.5, 18.1) T12: 27 (2.75, 19.9) T13: 37.3 (3.8, 27.5) T14: 39 (4.0, 28.9) T15: 59 (6.0, 43) T16: 78 (8.0, 58) T17: 83 (8.5, 61.5) T18: 25 (2.5, 18.1)
PS-13
GENERAL DESCRIPTION
RHD Model
S4M0567A
PS-14
GENERAL DESCRIPTION
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) Eye bolt Pipe C Gasket Clip Pipe D Clamp E Cap Reservoir tank Reservoir tank bracket Pulley Oil pump Bracket Belt tension nut Bushing Belt cover Universal joint Dust cover Valve housing Oil seal Ball bearing Retaining ring Seal ring Valve sleeve Seal ring O-ring Oil seal Spacer (28) (29) (30) (31) (32) (33) (34) (35) (36) (37) (38) (39) (40) (41) (42) (43) (44) (45) (46) (47) (48) (49) (50) (51) (52) (53) (54) Pinion Shim Adapter Clamp Castle nut Cotter pin Dust seal Clip Tie-rod end Clip Boot Wire Tie-rod Lock washer Holder Bushing Oil seal Seal ring O-ring Rack Oil seal Back-up ring Steering body Pipe A Pipe B Lock nut Adjusting screw

(55) (56) (57) (58) (59) Spring Sleeve Seat pad Suction hose Tank hose
Tightening torque: Nm (kgf-m, ft-lb) T1: 7.4 (0.75, 5.4) T2: 8 (0.8, 5.8) T3: 13 (1.3, 9.4) T4: 15 (1.5, 10.8) T5: 15.7 (1.6, 11.6) T6: 20 (2.0, 14.5) T7: 22 (2.2, 15.9) T8: 24 (2.4, 17.4) T9: 24 (2.4, 17.4) T10: 24.5 (2.50, 18.1) T11: 25 (2.5, 18.1) T12: 27.0 (2.75, 19.9) T13: 37.3 (3.8, 27.5) T14: 39 (4.0, 28.9) T15: 59 (6.0, 43) T16: 64 (6.5, 47) T17: 78 (8.0, 58) T18: 83 (8.5, 61.5)
PS-15
GENERAL DESCRIPTION
C: CAUTION
S601001A03
This section includes Airbag related repair works. For those corresponding to the repair procedures, read carefully CAUTION items in AB section before working and be sure to follow the instructions. Wear working clothing, including a cap, protective goggles, and protective shoes during operation. Remove contamination including dirt and corrosion before removal, installation or disassembly. Keep the disassembled parts in order and protect them from dust or dirt. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement. Be careful not to burn your hands, because each part on the vehicle is hot after running. Use SUBARU genuine steering fluid, grease etc. or the equivalent. Do not mix steering fluid, grease etc. with that of another grade or from other manufacturers. Be sure to tighten fasteners including bolts and nuts to the specified torque. Place shop jacks or safety stands at the specified points. Apply steering fluid onto sliding or revolution surfaces before installation. Before installing O-rings or snap rings, apply sufficient amount of steering fluid to avoid damage and deformation. Before securing a part on a vise, place cushioning material such as wood blocks, aluminum plate, or shop cloth between the part and the vise.
PS-16

1. SPECIAL TOOLS
ILLUSTRATION
S601001A1701 S601001A17
DESCRIPTION WRENCH
REMARKS Used for removing and installing tie-rod. Apply this tool to rack.
B4M2411
925711000
PRESSURE GAUGE Used for measuring oil pump pressure.
B4M2412
926200000
STAND
Used when inspecting characteristic of gearbox assembly and disassembling it.
B4M2413
34099AC010
ADAPTER HOSE A
Used with PRESSURE GAUGE (925711000).
B4M2414
PS-17

ILLUSTRATION
GENERAL DESCRIPTION
DESCRIPTION ADAPTER HOSE B REMARKS Used with PRESSURE GAUGE (925711000).
TOOL NUMBER 34099AC020
B4M2415
926230000
SPANNER
For the lock nut when adjusting backlash of gearbox. Measurement of rotating resistance of gearbox assembly.
B4M2416
34199AE040
OIL CHARGE GUIDE
Used for charging power steering oil. For TURBO model
B4M2419
927640000
INSTALLER B
Used for installing ball bearing into housing. For LHD model
B4M2420
926370000
INSTALLER A
Used for installing valve assembly into valve housing assembly. Used with STAND BASE (927630000). For LHD model
B4M2421
PS-18
GENERAL DESCRIPTION
ILLUSTRATION TOOL NUMBER 926390001 DESCRIPTION COVER & REMOVER ASSY
REMARKS Used for assembling rack assembly. For LHD model
B4M2422
926420000
PLUG
When oil leaks from pinion side of gearbox assembly, remove pipe B from valve housing, attach this tool and check oil leaking points. For LHD model
B4M2423
926400000
GUIDE
Right side of rack when installing rack bush. Used with GUIDE (927660000). For LHD model
B4M2424
927660000
GUIDE
Right side of rack when installing rack bush. Used with GUIDE (926400000). For LHD model
B4M2425
927620000
INSTALLER B
Used for installing oil seal of valve housing. Used with INSTALLER A (926360000). For LHD model
B4M2426
PS-19

ILLUSTRATION
GENERAL DESCRIPTION
DESCRIPTION STAND BASE REMARKS Used for assembling power steering gearbox. For LHD model
TOOL NUMBER 34099FA100
B4M2427
926360000
INSTALLER A
Used as a guide to install oil seal. Used with INSTALLER B (927620000). For LHD model
B4M2428
34199AE050
INSTALLER
Used for installing oil seal. For LHD model
B4M2429
34099FA120
INSTALLER
Used for installing valve housing oil seal. For LHD model
B4M2430
34199AE050
REMOVER OIL SEAL
Used for removing back-up ring and oil seal. For LHD model
B4M2432
PS-20
GENERAL DESCRIPTION
ILLUSTRATION TOOL NUMBER 34099FA130 DESCRIPTION INSTALLER SEAL
REMARKS Used for installing valve housing oil seal. Used with INSTALLER AND REMOVER SEAL (34099FA120). For LHD model
B4M2431
926250000
GUIDE
Used for installing holder ASSY into rack hous-ing. For RHD model
B4M2488
926270000
COVER
Used for installing oil seal to pinion. For RHD model
B4M2489
926280000
FORMER
Used for installing seal ring to pinion. For RHD model
B4M2490
PS-21

ILLUSTRATION
GENERAL DESCRIPTION
DESCRIPTION COVER REMARKS Used for installing oil seal to pinion. For RHD model
B4M2491
927490000
INSTALLER A, B, C
Used for installing oil seal into rack ASSY. For RHD model
B4M2492A
927580000
REMOVER
Used for removing back-up ring and oil seal. For RHD model
B4M2493
927590000
WRENCH
Used for removing wire from boot. For RHD model
B4M2494
PS-22
GENERAL DESCRIPTION
ILLUSTRATION TOOL NUMBER 927600000 DESCRIPTION FORMER
REMARKS Used for installing seal ring to rack pinion. For RHD model
B4M2495
927520000
INSTALLER D
Used for installing pinion bearing. For RHD model
B4M2496
927530000
INSTALLER E
Used for installing pinion bearing. For RHD model
B4M2497
34099FA000
INSTALLER & REMOVER
Used for removing and installing Y-packing. For RHD model
B4M2499
PS-23

ILLUSTRATION
GENERAL DESCRIPTION
DESCRIPTION GUIDE REMARKS Used for installing rack and seal into housing assembly. For RHD model
TOOL NUMBER 34099FA010
B4M2500
34099FA020
GUIDE
Used for installing valve assembly into valve housing assembly. For RHD model
B4M2501
34099FA030
INSTALLER & REMOVER
Used for removing and installing rack oil seal (outer & inner). For RHD model
B4M2502
34099FA040
INSTALLER
Used for installing rack oil seal (outer). For RHD model
B4M2503
PS-24
GENERAL DESCRIPTION
ILLUSTRATION TOOL NUMBER 34099FA050 DESCRIPTION SPACER
REMARKS Used for installing bearing into valve housing. For RHD model
B4M2504
34099FA060
PUNCH
Used for caulking. For RHD model
B4M2505
34099FA070
BASE
Used for supporting housing assembly. For RHD model
B4M2506
34099FA080
PUNCH
Used for removing caulking. For RHD model
B4M2507
PS-25

ILLUSTRATION
GENERAL DESCRIPTION
DESCRIPTION FORMER REMARKS Used for installing seal ring to rack pinion. For RHD model
B4M2508

TOOL NAME Spring scale Snap ring pliers Dial gauge
S601001A1702
REMARKS Used for measuring tightening torque. Used for removing and installing snap ring. Used for measuring steering gearbox.
PS-26
STEERING WHEEL
2. Steering Wheel
A: REMOVAL
S601274A18
S601274
NOTE: Align matching marks on steering wheel and steering column. Tightening torque: 44 Nm (4.5 kgf-m, 32.5 ft-lb) Column cover-to-steering wheel clearance: 2 4 mm (0.08 0.16 in) WARNING: Always refer to Airbag System before performing airbag module service (if so equipped). (with airbag model) <Ref. to AB-12 CAUTION, Drivers Airbag Module.> CAUTION: 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 connector and cruise control connectors from guide hole of steering wheel lower end. (with airbag model)
1) Disconnect ground terminal from battery. 2) Set tires to straight-ahead position. 3) Remove airbag module. (with airbag model) <Ref. to AB-12 REMOVAL, Drivers Airbag Module.> WARNING: Always refer to Airbag System before performing airbag module service (if so equipped). <Ref. to AB-12 CAUTION, Drivers Airbag Module.> 4) Remove lower screw and slide horn pad assembly forward, then disconnect connector. (without airbag model) 5) Remove horn pad by pulling on it. (without airbag model)
C: INSPECTION
S601274A10
1) Check steering wheel for deformation. If the deformation is excessive, replace steering wheel. 2) Check splines on steering wheel for damage. If the damage is excessive, replace steering wheel.
B4M0125B
(1) (2)
Front Screw
6) Remove steering wheel nut, and then draw out steering wheel from shaft using steering puller. NOTE: Make matching marks on steering wheel and steering column in advance.
B4M2433A
(1)
Matching mark
S601274A11
B: INSTALLATION
1) Align center of roll connector. <Ref. to AB-20 ADJUSTMENT, Roll Connector.> 2) Install in the reverse order of removal.
PS-27
UNIVERSAL JOINT B: INSTALLATION

S601273A11
3. Universal Joint
A: REMOVAL
S601273A18
S601273
1) Set the vehicle on the lift. 2) Remove the steering wheel. <Ref. to PS-27 REMOVAL, Steering Wheel.> 3) Lift-up the vehicle. 4) Remove universal joint bolts and then remove universal joint. CAUTION: Scribe alignment marks on universal joint so that it can be reassembled at the original serration.
1) Install universal joint. (1) Align bolts hole on the long yoke side of universal joint with the cutout at the serrated section of shaft end, and insert universal joint. (2) Align bolt hole on the short yoke side of universal joint with the cutout at the serrated section of gearbox assembly. Lower universal joint completely. (3) Temporarily tighten bolt on the short yoke side. Raise universal joint to make sure the bolt is properly passing through the cutout at the serrated section. (4) Tighten bolt on the long yoke, then that on the short yoke side. Tightening torque: 24 Nm (2.4 kgf-m, 17.4 ft-lb) CAUTION: Make sure that universal joint bolt is tightened through notch in shaft serration. Excessively large tightening torque of universal joint bolts may lead to heavy steering wheel operation.
B4M1653
Standard clearance between gearbox to DOJ: Over 15 mm (0.59 in) 2) Lower the vehicle. 3) Align center of roll connector. (with airbag model) <Ref. to AB-20 ADJUSTMENT, Roll Connector.> CAUTION: Ensure that front wheel are set straight forward direction. 4) Install steering wheel and airbag module. (with airbag model) <Ref. to PS-27 INSPECTION, Steering Wheel.> WARNING: Always refer to Airbag System before performing airbag module service (if so equipped). <Ref. to AB-12 CAUTION, Driver s Airbag Module.> and <Ref. to AB-13 INSTALLATION, Driver s Airbag Module.> 5) Install horn pad to steering wheel. (without airbag model)
PS-28
UNIVERSAL JOINT C: INSPECTION

S601273A10
Clean the disassembled parts with a cloth, and check for wear, damage, or any other faults. If necessary, repair or replace faulty parts.
Inspection Free play Swinging torque Yawing torque Looseness Corrective action
Replace if faulty.
G4M0089
Standard value of universal joint free play: 0 mm (0 in) Max. value of universal joint swinging torque: 0.3 Nm (0.03 kgf-m, 0.2 ft-lb)
Measurement of folding torque of universal joint is as shown in the figures. Service limit: Maximum load; 5.49 N (0.56 kgf, 1.23 lb) or less
Service limit: Maximum load; 8.43 N (0.86 kgf, 1.90 lb) or less
S4M0445A
(1)
S4M0443A
Short yoke
(1)
Long yoke
S4M0446A
(1)
S4M0444A
Short yoke
(1)
Long yoke
PS-29
TILT STEERING COLUMN

S601544
4. Tilt Steering Column

A: REMOVAL
S601544A18
S4M0136B
(1) Tilt steering column (2) Universal joint
PS-30

1) Set the vehicle on the lift. 2) Disconnect battery minus terminal. 3) Remove airbag module. <Ref. to AB-12 REMOVAL, Driver s Airbag Module.> WARNING: Always refer to Airbag System before performing airbag module service (if so equipped). <Ref. to AB-12 CAUTION, Driver s Airbag Module.> 4) Remove steering wheel. <Ref. to PS-27 REMOVAL, Steering Wheel.> 5) Lift-up the vehicle. 6) Remove universal joint. <Ref. to PS-28 REMOVAL, Universal Joint.> 7) Lower the vehicle. 8) Remove trim panel under instrument panel. 9) Remove knee bolster.

S601544A11
B: INSTALLATION
1) Insert end of steering shaft into toe board grommet. 2) Tighten steering shaft mounting bolts under instrument panel. Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft-lb) 3) Connect all connectors under instrument panel. 4) Connect airbag system connector at harness spool. NOTE: Make sure to apply double lock. 5) Install lower column cover with tilt lever held in the lowered position. 6) Install universal joint. <Ref. to PS-28 INSTALLATION, Universal Joint.> 7) Install knee bolster.
S4M0138B
(1)
Knee bolster (1) Knee bolster
S4M0138B
10) Disconnect connectors for ignition switch and combination switch wiring harness under instrument panel. 11) Remove the two bolts under instrument panel securing steering column.
8) Align center of roll connector. <Ref. to AB-20 ADJUSTMENT, Roll Connector.> CAUTION: Ensure that front wheels are set in straight forward direction. 9) Install steering wheel. <Ref. to PS-27 INSTALLATION, Steering Wheel> Set steering wheel to neutral and install it onto steering shaft. CAUTION: 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 connector and cruise control connectors from guide hole of steering wheel lower end. 10) Install airbag module to steering wheel. (with airbag model) <Ref. to AB-13, INSTALLATION, Driver s Airbag Module.> WARNING: Always refer to Airbag System before performing the service operation. <Ref. to AB-12 CAUTION, Driver s Airbag Module.>
S4M0139B
(1)
Steering column
12) Pull out steering shaft assembly from hole on toe board. CAUTION: Be sure to remove universal joint before removing steering shaft assembly installing bolts when removing steering shaft assembly or when lowering it for servicing of other parts.
PS-31
11) Install horn pad to steering wheel. (without airbag model)
C: DISASSEMBLY
S601544A06
Remove the two screws securing upper steering column covers, and the two screws securing combination switch, then remove related parts.
D: ASSEMBLY
S601544A02
1) Insert combination switch to upper column shaft, and install upper column cover. Then route ignition key harness and combination switch harness between column cover mounting bosses. Tightening torque: 1.2 Nm (0.12 kgf-m, 0.9 ft-lb) CAUTION: Dont overtorque screw.
E: INSPECTION
S601544A10
1. BASIC INSPECTION
S601544A1001
Clean the disassembled parts with a cloth, and check for wear, damage, or any other faults. If necessary, repair or replace faulty parts.
Inspection Overall length of steering column Measure overall length of steering column. Standard overall length of steering column: Corrective action
Replace steering column assembly.
S4M0141B
2. AIRBAG MODEL INSPECTION
S601544A1002
WARNING: For airbag model inspection procedures, refer to Airbag System. <Ref. to AB-12 CAUTION, Airbag Module.> and <Ref. to AB-13 INSPECTION, Driver s Airbag Module.>
PS-32
STEERING GEARBOX [LHD MODEL]
5. Steering Gearbox [LHD Model]

S601272
A: REMOVAL
S601272A18
7) Remove one pipe joint at the center of gearbox, and connect vinyl hose to pipe and joint. Discharge fluid by turning steering wheel fully clockwise and counterclockwise. Discharge fluid similarly from the other pipe.
1) Disconnect battery ground terminal. 2) Loosen front wheel nut. 3) Lift vehicle and remove front wheels. 4) Remove front exhaust pipe assembly. (Nonturbo model) With OBD: <Ref. to EX(SOHC)-5, REMOVAL, Front Exhaust Pipe.> Without OBD: <Ref. to EX(SOHCw/oOBD)-6, REMOVAL, Front Exhaust Pipe.> WARNING: Be careful, exhaust pipe is hot. 5) Using a puller, remove tie-rod end from knuckle arm after pulling off cotter pin and removing castle nut.
(1) (2) Pipe A Pipe B
S4M0381A
8) Remove universal joint. <Ref. to PS-28, REMOVAL, Universal Joint.> 9) Disconnect pipes C and D from pipe of gearbox. CAUTION: Be careful not to damage these pipes. NOTE: Disconnect upper pipe D first, and lower pipe C second.
S4M0379A
(1) (2) (3)
Castle nut Tie-rod end Knuckle arm
6) Remove jack-up plate and front stabilizer.

S4M0382A
(1) (2)
Pipe C Pipe D
10) Remove clamp bolts securing gearbox to crossmember, and remove gearbox.
S4M0380A
(1)
Jack-up plate
PS-33

4) Connect tie-rod end and knuckle arm, and tighten with castle nut. Fit cotter pin into the nut and bend the pin to lock. Castle nut tightening torque: Tighten to 27.0 Nm (2.75 kgf-m, 19.9 ft-lb), and tighten further within 60 until cotter pin hole is aligned with a slot in the nut.
S4M0383A
(1)
Clamp
S601272A11
CAUTION: When connecting, do not hit cap at the bottom of tie-rod end with hammer.
B: INSTALLATION
1) Insert gearbox into crossmember, being careful not to damage gearbox boot. 2) Tighten gearbox to crossmember bracket via clamp with bolt to the specified torque. Tightening torque: 59 Nm (6.0 kgf-m, 43 ft-lb)
S4M0379A
(1) (2) (3)
S4M0383A
(1)
Clamp
3) Install universal joint. <Ref. INSTALLATION, Universal Joint.>
to
PS-28,
5) Install front stabilizer to vehicle. <Ref. to FS-22, INSTALLATION, Front Stabilizer.> 6) Install front exhaust pipe assembly. (Non-turbo model) With OBD: <Ref. to EX(SOHC)-6, INSTALLATION, Front Exhaust Pipe.> Without OBD: <Ref. to EX(SOHCw/oOBD)-7, INSTALLATION, Front Exhaust Pipe.> 7) Install tires. 8) Tighten wheel nuts to the specified torque. Tightening torque: 88 Nm (9.0 kgf-m, 65 ft-lb) 9) Connect ground terminal to battery. 10) Pour fluid into oil tank, and bleed air. <Ref. to PS-101, Power Steering Fluid.> 11) Check for fluid leaks. <Ref. to PS-51, OIL LEAKING, INSPECTION, Steering Gearbox [LHD Model].> 12) Install jack-up plate. WARNING: Be careful, exhaust manifold is hot. 13) Lower vehicle. 14) Check fluid level in oil tank.
PS-34

15) After adjusting toe-in and steering angle, tighten lock nut on tie-rod end. Tightening torque: 83 Nm (8.5 kgf-m, 61.5 ft-lb) CAUTION: When adjusting toe-in, hold boot as shown to prevent it from being rotated or twisted. If twisted, straighten it.
4) Remove small clip from boot using pliers, and move boot to tie-rod end side.
S4M0144B
(1)
Clip
5) Using standard screwdriver, remove band from boot.

G4M0132
C: DISASSEMBLY
S601272A06
1. RACK HOUSING ASSEMBLY
S601272A0601
1) Disconnect four pipes from gearbox. 2) Secure gearbox removed from vehicle in vise using ST. ST 926200000 STAND CAUTION: Secure the gearbox in a vise using the ST as shown. Do not attempt to secure it without this ST.
(1) (2) Band Standard screwdriver
S4M0145B
6) Extend rack approximately 40 mm (1.57 in) out. Unlock lock wire at lock washer on each side of tie-rod end using a standard screwdriver. CAUTION: Be careful not to scratch rack surface as oil leaks may result.
S4M0143A
3) Remove tie-rod end and lock nut from gearbox.
S4M0146B
(1) (2)
Standard screwdriver Lock washer
PS-35

11) Remove two bolts securing valve assembly.
7) Using ST, loosen lock nut. ST 926230000 SPANNER
S4M0154 S4M0147B
(1)
Lock nut
12) Carefully draw out input shaft and remove valve assembly.
8) Tighten adjusting screw until it no longer tightens.
S4M0155B
(1)
S4M0148B
Valve ASSY
(1)
Adjusting screw
9) Using a wrench [32 mm (1.26 in) width across flats] or adjustable wrench, remove tie-rod. CAUTION: Check ball joint for free play, and tie-rod for bends. Replace if necessary. Check dust seals used with tie-rod end ball joint for damage or deterioration. Replace if necessary.
13) Using a sharp pointed pliers, rotate the rack stopper in the direction of the arrow until the end of the circlip comes out of the stopper. Rotate the circlip in the opposite direction and pull it out.
S4M0158B
(1)
Rack stopper
S4M0149B
(1)
Tie-rod
10) Loosen adjusting screw and remove spring and sleeve. CAUTION: Replace spring and/or sleeve if damaged.
PS-36

14) Pull rack assembly from cylinder side, and draw out rack bushing and rack stopper together with rack assembly. CAUTION: Be careful not to contact rack to inner wall of cylinder when drawing out. Any scratch on cylinder inner wall will cause oil leakage.
NOTE: Discard removed oil seal.
2. CONTROL VALVE ASSEMBLY
S601272A0602
NOTE: Parts requiring replacement are described in the smallest unit of spare parts including damaged parts and spare parts damaged. In actual disassembly work, accidental damage as well as inevitable damage to some related parts must be taken into account, and spare parts for them must also be prepared. However, it is essential to pinpoint the cause of trouble, and limit the number of replacement parts as much as possible. 1) Using ST, loosen lock nut. ST 926230000 SPANNER
S4M0402A
(1) (2) (3)
Rack bushing Rack ASSY Rack stopper
15) Remove rack bushing and rack stopper from rack assembly. CAUTION: Do not reuse removed rack bushing and circlip. 16) Insert ST from pinion housing side and remove oil seal using a press. ST 34199AE050 OIL SEAL REMOVER
(1) Lock nut
S4M0147B
S4M0148B
(1)
Adjusting screw
S4M0163B
(1) (2)
Press Oil seal
PS-37

6) Using a press remove pinion and valve assembly from valve housing.
3) Remove two bolts securing valve assembly.
S4M0154
4) Carefully draw out input shaft and remove valve assembly.
S4M0157B
(1) (2) (3)
Valve ASSY Valve housing Cloth
7) Using ST and press, remove dust seal, oil seal and special bearing from valve housing. ST 34099FA120 SEAL INSTALLER & REMOVER CAUTION: Do not apply a force to end surface of valve housing. Do not reuse oil seal after removal.
S4M0155B
(1)
Valve ASSY
5) Slide dust cover out.
S4M0159B
(1) (2)
S4M0156B
Oil seal Special bearing
(1)
Dust cover
PS-38

8) Remove snap ring using snap ring pliers. CAUTION: Do not reuse removed snap ring. Be careful not to scratch pinion and valve assembly.

S601272A02
D: ASSEMBLY
S601272A0201
CAUTION: Use only SUBARU genuine grease for gearbox. Grease: VALIANT GREASE M2 [Part No. 003608001, net 0.5 kg (1.1 lb)] 1) Clean all parts and tools before reassembling. 2) Apply grease to teeth of rack so that grease applied is about as high as teeth, and also apply a thin film of grease to sliding portion of rack shaft. CAUTION: When moving rack to stroke end without tierod attached, prevent shocks from being applied at the end. Do not apply grease to threaded portion at end of rack shaft. Move rack shaft to stroke end two (2) or three (3) times to squeeze grease which accumulates on both ends. Remove grease to prevent it from choking air passage hole. 3) Apply grease to sleeve insertion hole. 4) Apply grease to dust seal insertion hole. CAUTION: Apply clean grease with clean hands. If material having a sharp edge is used for applying grease, oil seal at the inside might be damaged. 5) Apply grease to sliding surface of sleeve and spring seat, then insert sleeve into pinion housing. Fit spring into sleeve screw, pack grease inside of screw, then install the screw.
G4M0147
9) Press out bearing together with backing washer using pipe of I.D. 38.5 to 39.5 mm (1.516 to 1.555 in) and press. CAUTION: Do not reuse removed bearing.
B4M1129B S4M0403A
(1) (2) (3) (4)
Bearing Backing washer Oil seal Pipe
(1) (2) (3)
Adjusting screw Spring Sleeve
6) Force-fit oil seal using ST. ST 34099FA110 INSTALLER CAUTION: Be careful not to damage or scratch cylinder inner wall. NOTE: Apply specified power steering fluid to oil seal.
10) Remove oil seal. CAUTION: Do not reuse removed oil seal.
PS-39

8) Fit ST over toothed portion of rack assembly, and check for binding or unsmooth insertion. If any deformation is noted on flats at the end of rack, shape by using file, and wash with cleaning fluid. ST 926390001 COVER & REMOVER
Pay special attention not to install oil seal in wrong direction. Push oil seal until the stepped portion of A contacts end face of B.
S4M0406A
(1)
Rack ASSY
9) Apply genuine grease to teeth of thoroughly washed rack assembly, and fit ST over the toothed portion. CAUTION: Be careful not to block air passage with grease. Remove excessive grease. After fitting cover, check air passage hole for clogging. If clogged, open by removing grease from the hole. Check rack shaft for damage. Apply specified power steering fluid to this ST and surface of piston ring to prevent seal from being damaged. 10) Insert rack assembly into rack housing from cylinder side, and remove ST after it has passed completely through oil seal. NOTE: Before inserting rack assembly, apply a coat of specified power steering fluid to surfaces of ST and rack piston. ST 926390001 COVER & REMOVER
S4M0164B
(1) (2)
Press Oil seal
7) Fixing rack housing Fix rack housing in vise using ST. ST 926200000 STAND CAUTION: When fixing rack housing in vise, be sure to use this special tool. Do not fix rack housing in vise using pad such as aluminum plates, etc. When using old rack housing, be sure to clean and remove rust before assembling. Check pinion housing bushing carefully.
PS-40

11) Fit ST1 and ST2 over the end of rack, and install rack bushing. ST1 926400000 GUIDE ST2 927660000 GUIDE CAUTION: If burrs, or nicks are found on this guide and rack shaft portion, remove by filing. Dip rack bushing in specified power steering fluid before installing, and pay attention not to damage O-ring and oil seal.
15) Apply genuine grease to pinion gear and bearing of valve assembly.
G4M0158
16) Install gasket on valve assembly. Insert valve assembly into place while facing rack teeth toward pinion. CAUTION: Be sure to use a new gasket.
S4M0407A
(1)
Rack bushing ASSY
NOTE: Do not allow packing to be caught when installing valve assembly.
12) Insert rack stopper into cylinder tube until internal groove (on cylinder side) is aligned with external groove (on rack stopper). Turn rack stopper with ST so that rack stopper hole is seen through cylinder slits. 13) Insert rack stopper into rack housing, and wrap circlip using a sharp pointed pliers to secure rack stopper in position. CAUTION: Be careful not to scratch rack while winding circlip. NOTE: Rotate wrench another 90 to 180 after the end of circlip has been wrapped in.
S4M0155B
(1)
Valve ASSY
17) Tighten bolts alternately to secure valve assembly. Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft-lb) CAUTION: Be sure to alternately tighten bolts. 18) Install lock washers and tighten left and right tie-rods into rack ends. On condition L: Approximately 40 mm (1.57 in)
S4M0167
14) Fit mounting rubber onto rack housing.
PS-41

(4) Tighten adjusting screw by two threads.
G4M0121 S4M0150B
(1)
Tie-rod
(5) Apply liquid packing to at least 1/3 of entire perimeter of adjusting screw thread. Liquid packing: THREE BOND 1141
19) Bend lock washer using a chisel. CAUTION: Be careful not to scratch rack when bending lock washer.
S4M0385A
(1)
S4M0384A
Apply liquid packing to at least 1/3 of entire perimeter.
(1)
Lock washer
20) Rack and pinion backlash adjustment (1) Loosen adjusting screw. (2) Rotate input shaft so that rack is in the straight ahead direction. (3) Apply grease to sleeve.
(6) Tighten adjusting screw to 7.4 Nm (0.75 kgf-m, 5.4 ft-lb) and back off 25. (7) Install lock nut. While holding adjusting screw with a wrench, tighten lock nut using ST. ST 926230000 SPANNER Tightening torque (Lock nut): 39 Nm (4.0 kgf-m, 29 ft-lb) NOTE: Hold adjusting screw with a wrench to prevent it from turning while tightening lock nut. Make adjustment so that steering wheel can be rotated fully from lock to lock without binding. 21) Inspect for service limit as per article of Service limit. <Ref. to PS-49, SERVICE LIMIT, INSPECTION, Steering Gearbox [LHD Model].> Make replacement and adjustment if necessary.
B4M1130B
(1) (2) (3) (4)
Adjusting screw Lock nut Spring Sleeve
PS-42

22) Install boot to housing. NOTE: Before installing boot, be sure to apply grease to the groove of tie-rod. Install fitting portions of boots to the following portions in both sides of assembled steering gearbox. The groove on gearbox The groove on the rod Make sure that boot is installed without unusual inflation or deflation.
24) Fix boot end with clip (small). CAUTION: After installing, check boot end is positioned into groove on tie-rod.
S4M0144B
(1)
Clip
25) 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 figure.
S4M0151A
23) Using a screwdriver, tighten the screw until the ends A and B of the band come into contact with each other. NOTE: Always tighten the band from the underside of the gearbox.
Installed tie-rod length: L 15 mm (0.59 in) NOTE: Pay attention to difference between right and left tie-rod ends.
G4M0126
S4M0152A
PS-43

ST1 SEAL INSTALLER & REMOVER ST2 34099FA130 SEAL INSTALLER (1) Face oil seal in the direction shown in figure when installing. (2) To avoid scratching oil seal, apply a coat of grease to contact surface of installer and oil seal. (3) To facilitate installation, attach oil seal to installer and position in valve housing before pressing into place. 34099FA120
26) Inspect gearbox as follows: A Holding tie-rod end, repeat lock to lock two or three times as quickly as possible. B Holding tie-rod end, turn it slowly at a radius one or two times as large as possible. After all, make sure that boot is installed in the specified position without deflation.
G4M0127
27) Remove gearbox from ST. ST 926200000 STAND 28) Install four pipes on gearbox. (1) Connect pipes A and B to four pipe joints of gearbox. Connect upper pipe B first, and lower pipe A. Tightening torque: 13 Nm (1.3 kgf-m, 9.4 ft-lb) (2) Connect pipes C and D to gearbox. Connect lower pipe C first, and upper pipe D second. Tightening torque: 15 Nm (1.5 kgf-m, 10.8 ft-lb)
S4M0160A
S601272A0202

Specified steering grease: VALIANT GREASE M2 (Part No. 003608001)
4) Using ST and press, install special bearing in valve housing. ST 34099FA120 SEAL INSTALLER & REMOVER NOTE: To facilitate installation, attach ball bearing to remover and position in valve housing before pressing it into place.
1) Clean all parts and tools before reassembling. 2) Apply a coat of specified power steering fluid to inner wall of valve housing.
S4M0162B
(1)
Fluid (1) (2) Special bearing Oil seal
S4M0161B
3) Attach ST2 to ST1, and press oil seal into place using a press.
PS-44

5) Put vinyl tape around pinion shaft splines to protect oil seal from damage. 6) Fit pinion and valve assembly into valve housing. NOTE: Apply specified power steering fluid to outer diameter surface of input shaft and outer surface of valve body seal ring, and pay special attention not to damage seal when inserting pinion and valve assembly. 7) Secure valve assembly to ST1 and ST2. 8) Put ST3 over pinion, and insert oil seal, then force-fit oil seal into housing using ST4. ST1 926370000 INSTALLER A ST2 34099FA100 STAND BASE ST3 926360000 INSTALLER A ST4 927620000 INSTALLER B
10) Force-fit ball bearing using ST3. ST1 926370000 INSTALLER A ST2 34099FA100 STAND BASE ST3 927640000 INSTALLER B
S4M0405A
(1) (2)
Ball bearing Backing washer
NOTE: Be careful not to tilt ball bearing during installation. 11) Install snap ring using snap ring pliers. NOTE: Rotate snap ring to check for proper installation. 12) Apply specified grease to dust cover.
S4M0166B
(1)
S4M0404A
Dust cover
(1)
Oil seal
13) Install dust cover on valve assembly. 14) Apply genuine grease to pinion gear and bearing of valve assembly.
NOTE: Apply specified power steering fluid to oil seal and ST3, being careful not to damage oil seal lip. Push oil seal until ST3 contacts housing end face. 9) Remove ST3, and fit backing washer.
G4M0158
PS-45

20) Rack and pinion backlash adjustment (1) Loosen adjusting screw. (2) Rotate input shaft so that rack is in the straight ahead direction. (3) Apply grease to sleeve.
15) Install gasket on valve assembly. Insert valve assembly into place while facing rack teeth toward pinion. CAUTION: Be sure to use a new gasket. NOTE: Do not allow packing to be caught when installing valve assembly.
B4M1130B
S4M0155B
(1) (2) (3) (4)
Adjusting screw Lock nut Spring Sleeve
(1)
Valve ASSY
(4) Tighten adjusting screw by two threads.
16) Tighten bolts alternately to secure valve assembly. Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft-lb) CAUTION: Be sure to alternately tighten bolts. 17) Apply grease to sleeve insertion hole. 18) Apply grease to dust seal insertion hole. CAUTION: Apply clean grease with clean hands. If material having a sharp edge is used for applying grease, oil seal at the inside might be damaged. 19) Apply grease to sliding surface of sleeve and spring seat, then insert sleeve into pinion housing. Fit spring into sleeve screw, pack grease inside of screw, then install the screw.
G4M0121
(5) Apply liquid packing to at least 1/3 of entire perimeter of adjusting screw thread. Liquid packing: THREE BOND 1141
S4M0385A B4M1129B
(1)
Apply liquid packing to at least 1/3 of entire perimeter.
(1) (2) (3)
Adjusting screw Spring Sleeve
(6) Tighten adjusting screw to 7.4 Nm (0.75 kgf-m, 5.4 ft-lb) and back off 25.
PS-46

(7) Install lock nut. While holding adjusting screw with a wrench, tighten lock nut using ST. ST 926230000 SPANNER Tightening torque (Lock nut): 39 Nm (4.0 kgf-m, 29 ft-lb) NOTE: Hold adjusting screw with a wrench to prevent it from turning while tightening lock nut. Make adjustment so that steering wheel can be rotated fully from lock to lock without binding. 21) Check for service limit as per article of Service limit. <Ref. to PS-49, SERVICE LIMIT, INSPECTION, Steering Gearbox [LHD Model].> Make replacement and adjustment if necessary.
PS-47
E: INSPECTION
S601272A10
1. BASIC INSPECTION
S601272A1001
1) Clean all disassembled parts, and check for wear, damage, or any other faults, then repair or replace as necessary. 2) When disassembling, check inside of gearbox for water. If any water is found, carefully check boot for damage, input shaft dust seal, adjusting screw and boot clips for poor sealing. If faulty, replace with new parts.
No. 1 2 Parts Input shaft Dust seal (1) (2) (1) (2) Inspection Bend of input shaft Damage on serration Crack or damage Wear Corrective action If bend or damage is excessive, replace entire gearbox. If outer wall slips, lip is worn out or damage is found, replace it with new one. (1) Adjust backlash properly. By measuring turning torque of gearbox and sliding resistance of rack, check if rack and pinion engage uniformly and smoothly with each other. (Refer to Service limit.) (2) Keeping rack pulled out all the way so that all teeth emerge, check teeth for damage. Even if abnormality is found in either (1) or (2), replace entire gearbox. Replace gearbox with new one. If free play of rack shaft in radial direction is out of the specified range, replace gearbox with new one. (Refer to Service limit.) If free plays of input shaft in radial and axial directions are out of the specified ranges, replace gearbox with new one. (Refer to Service limit.) Replace. Replace. Replace. Replace. Replace. Replace. Replace.
Rack and pinion
Poor mating of rack with pinion
(1) Bend of rack shaft (2) Bend of cylinder portion (3) Crack or damage on cast iron portion 4 Gearbox unit (4) Wear or damage on rack bush
(5) Wear on input shaft bearing 5 6 7 8 9 10 11 Boot Tie-rod Tie-rod end Adjusting screw spring Boot clip Sleeve Pipes Crack, damage or deterioration (1) Looseness of ball joint (2) Bend of tie-rod Damage or deterioration on dust seal Deterioration Deterioration Damage (1) Damage to flared surface (2) Damage to flare nut (3) Damage to pipe
PS-48

2. SERVICE LIMIT
S601272A1002
Make a measurement as follows. If it exceeds the specified service limit, adjust or replace. NOTE: When making a measurement, vise gearbox by using ST. Never vise gearbox by inserting aluminum plates, etc. between vise and gearbox. ST 926200000 STAND Sliding resistance of rack shaft: Service limit 304 N (31 kgf, 68 lb) or less
3. RACK SHAFT PLAY IN RADIAL DIRECTION S601272A1003

Right-turn steering: Service limit 0.19 mm (0.0075 in) or less On condition L: 5 mm (0.20 in) P: 122.6 N (12.5 kgf, 27.6 lb)
G4M0111
Left-turn steering:
G4M0109
Service limit Direction 0.3 mm (0.012 in) or less Direction 0.15 mm (0.0059 in) or less
G4M0110
G4M0112
PS-49

S601272A1004
4. INPUT SHAFT PLAY

In radial direction:
5. TURNING RESISTANCE OF GEARBOX

S601272A1005
Service limit 0.18 mm (0.0071 in) or less On condition P: 98 N (10 kgf, 22 lb)
Using ST, measure gearbox turning resistance. ST 926230000 SPANNER Service limit: Straight-ahead position within 30 mm (1.18 in) from rack center Less than 11.18 N (1.14 kgf, 2.51 lb) Maximum allowable resistance 12.7 N (1.3 kgf, 2.9 lb)
G4M0113
In axial direction: Service limit 0.5 mm (0.020 in) or less On condition P: 20 49 N (2 5 kgf, 4 11 lb)
G4M0115
G4M0114
PS-50

6. OIL LEAKING
S601272A1006
S4M0153A
(1) Power cylinder (2) Cylinder
(3) Rack piston (4) Rack axle
(5) Input shaft (6) Valve housing
NOTE: If gearbox is dismounted without confirming where the leak is, it must be mounted again to locate the leak point. 1) Even if the location of the leak can be easily found by observing the leaking condition, it is necessary to thoroughly remove the oil from the suspected portion and turn the steering wheel from lock to lock about 30 to 40 times with engine running, then make comparison of the suspected portion between immediately after and several hours after this operation. 2) Inspect leakage from a. The oil seal is damaged. Replace valve assembly with a new one. 3) Inspect leakage from b. The torsion bar O-ring is damaged. Replace valve assembly with a new one. 4) Inspect leakage from c. The oil seal is damaged. Replace valve assembly or oil seal with a new one. 5) Inspect leakage from d. The pipe is damaged. Replace the faulty pipe or O-ring. 6) If leak is other than a, b, c, or d, and if oil is leaking from the gearbox, move the right and left boots toward tie-rod end side, respectively, with the gearbox mounted to the vehicle, and remove oil from the surrounding portions. Then, turn the steering wheel from lock to lock 30 to 40 times with the engine running, then make comparison of the leaked portion immediately after and several hours after this operation.
(1) Inspect leakage from e. The cylinder seal is damaged. Replace rack bushing with a new one. (2) Inspect leakage from f. There are two possible causes. Take following step first. Remove the pipe assembly B from the valve housing, and close the circuit with ST. ST 926420000 PLUG CAUTION: If leakage from f is noted again: The oil seal of pinion and valve assembly is damaged. Replace pinion and valve assembly with a new one. Or replace the oil seal and the parts that are damaged during disassembly with new ones. If oil stops leaking from f: The oil seal of rack housing is damaged. Replace the oil seal and the parts that are damaged during disassembly with new ones.
PS-51
F: ADJUSTMENT
1) Adjust front toe.
S601272A01
Standard of front toe: IN 3 OUT 3 mm (IN 0.12 OUT 0.12 in)
G4M0133
2) Adjust steering angle of wheels. Standard of steering angle: Inner wheel: 37.41.5 Outer wheel: 32.51.5
PS-52
STEERING GEARBOX [RHD MODEL]
6. Steering Gearbox [RHD Model]

S601276
A: REMOVAL
S601276A18
7) Disconnect one pipe joint A from center of gearbox assembly, and connect a vinyl hose to it. While turning steering wheel to the left and right, drain fluid through the hose. Similarly, drain fluid from the other pipe joint B.
1) Disconnect battery minus terminal. 2) Lift vehicle with a jack and remove front wheel. 3) Disconnect front exhaust pipe assembly. (Nonturbo model) With OBD: <Ref. to EX(SOHC)-5, REMOVAL, Front Exhaust Pipe.> Without OBD: <Ref. to EX(SOHCw/oOBD)-6, REMOVAL, Front Exhaust Pipe.> 4) Remove universal joint. <Ref. to PS-28, REMOVAL, Universal Joint.> 5) Remove cotter pin and castle nut. Using a puller, remove tie-rod end from knuckle arm.
S4M0387A
(1) (2)
Pipe A Pipe B
8) Remove lower and upper bolts from universal joint, and remove universal joint in the upward direction. NOTE: Scribe alignment marks on universal joint so that it can be reassembled at the original serration. 9) Using ST, remove flare nuts from control valve of gearbox assembly, and disconnect upper and lower hoses. ST 34099AC050 GEARBOX SPANNER CAUTION: Always disconnect hoses B and A in that order. Be careful not to damage the hoses during removal.
S4M0379A
(1) (2) (3)
6) Remove jack-up plate and stabilizer.
S4M0235B S4M0380A
(1) (1) Jack-up plate
Steering gearbox
10) Remove bolts securing gearbox crossmember, and detach gearbox.
to
PS-53

11) Check for fluid leaks. <Ref. to PS-76, OIL LEAKING, INSPECTION, Steering Gearbox [RHD Model].> 12) Install jack-up plate. WARNING: Be careful, exhaust manifold is hot. 13) Lower vehicle. 14) Check fluid level in oil tank. 15) After adjusting toe-in and steering angle, tighten lock nut on tie-rod end. Tightening torque: 83 Nm (8.5 kgf-m, 61.5 ft-lb) CAUTION: When adjusting toe-in, hold boot as shown to prevent it from being rotated or twisted. If twisted, straighten it.
B: INSTALLATION
S601276A11
1) Insert gearbox into crossmember, being careful not to damage gearbox boot. 2) Tighten gearbox to crossmember bracket via clamp with bolt to the specified torque. Tightening torque: 59 Nm (6.0 kgf-m, 43 ft-lb) 3) Install the universal joint. <Ref. to PS-28, INSTALLATION, Universal Joint.> 4) Connect tie-rod end and knuckle arm, and tighten with castle nut. Fit cotter pin into the nut and bend the pin to lock. Castle nut tightening torque: Tighten to 27.0 Nm (2.75 kgf-m, 19.9 ft-lb), and tighten further within 60 until cotter pin hole is aligned with a slot in the nut. CAUTION: When connecting, do not hit cap at the bottom of tie-rod end with hammer.
G4M0132
C: DISASSEMBLY
S4M0379A
S601276A06

(1) (2) (3) Castle nut Tie-rod end Knuckle arm
S601276A0601
5) Install front stabilizer to vehicle. <Ref. to FS-22, INSTALLATION, Front Stabilizer.> 6) Install front exhaust pipe assembly. (Non-turbo model) With OBD: <Ref. to EX(SOHC)-6, INSTALLATION, Front Exhaust Pipe.> Without OBD: <Ref. to EX(SOHCw/oOBD)-7, INSTALLATION, Front Exhaust Pipe.> 7) Install tires. 8) Tighten wheel nuts to the specified torque. Tightening torque: 88 Nm (9.0 kgf-m, 65 ft-lb) 9) Connect ground terminal to battery. 10) Pour fluid into oil tank, and bleed air. <Ref. to PS-101, Power Steering Fluid.>
NOTE: Parts requiring replacement are described in the smallest unit of spare parts including damaged parts and spare parts damaged. In actual disassembly work, accidental damage as well as inevitable damage to some related parts must be taken into account, and spare parts for them must also be prepared. However, it is essential to pinpoint the cause of trouble, and limit the number of replacement parts as much as possible. 1) Disconnect four pipes from gearbox.
PS-54

2) Secure gearbox removed from vehicle in vise using ST. ST 926200000 STAND CAUTION: Secure the gearbox assembly in a vise using the ST as shown. Do not attempt to secure it without this ST.
5) Extend rack approximately 40 mm (1.57 in) out. Unlock lock wire at lock washer on each side of tie-rod end using a standard screwdriver. CAUTION: Be careful not to scratch rack surface as oil leaks may result.
G4M0791 S4M0388A
(1)
Clamp
3) Pry off clip from outer end of boot, and slide boot toward tie-rod end.
NOTE: Parts requiring replacement are described in the smallest unit of spare parts including damaged parts and spare parts damaged. In actual disassembly work, accidental damage as well as inevitable damage to some related parts must be taken into account, and spare parts for them must also be prepared. However, it is essential to pinpoint the cause of trouble, and limit the number of replacement parts as much as possible. 6) Using ST, loosen lock nut. ST 926230000 SPANNER
S4M0389A
(1)
Clip
4) Using ST, remove lock wire from inner end of boot, and remove boot. ST 927590000 WRENCH
S4M0391A
(1)
Lock nut
S4M0390A
(1)
Wire
PS-55

10) Disconnect pipes A and B from steering body and control valve housing. CAUTION: Replace pipes and/or flare nuts if damaged.
S4M0392A
(1)
Adjusting screw
S4M0394A
8) Using a wrench (32 mm width across flats) or adjustable wrench, remove tie-rod. CAUTION: Check ball joint for free play, and tie-rod for bends. Replace if necessary. Check dust seals used with tie-rod end ball joint for damage or deterioration. Replace if necessary.
(1) (2)
Pipe A Pipe B
11) Slide dust cover out. CAUTION: Be careful not to scratch housing or input shaft during dust cover removal. Also do not allow foreign matter to enter housing interior. Replace dust cover with a new one if its inside bore or lips are worn or damaged.
S4M0393A
(1)
Tie-rod
S4M0409A
9) Loosen adjusting screw and remove spring and sleeve. CAUTION: Replace spring and/or sleeve if damaged.
(1)
Dust cover
12) Remove the two bolts securing valve housing.
S4M0410A
(1)
Socket bolt
PS-56

13) Remove valve housing, pinion and valve as a unit.
15) Install ST on valve side of rack and press outer side oil seal out. ST 34099FA030 INSTALLER & REMOVER CAUTION: Block pipe connection of steering body to prevent fluid from flowing out. Do not allow rack to come in contact with inner wall of cylinder. Otherwise, cylinder wall may be scratched, resulting in oil leaks. Remove holder and rack as a unit. Check rack and steering body for bends or cracks; replace as required. Discard oil seal after removal and replace with new ones.
G4M0819
14) Remove holder using a 32 mm wrench or adjustable wrench. CAUTION: Discard old holder and replace with new one.
G4M0820
S4M0411A
(1) (2)
Rack piston Outer side oil seal
PS-57

17) Using ST1 and ST2, repair cylinder s clinched sections. ST1 34099FA080 PUNCH ST2 34099FA070 BASE
16) Insert ST from valve side and press back-up ring and oil seal out. CAUTION: Discard back-up ring and oil seal after removal and replace with new ones. ST 927580000 REMOVER
S4M0412A
(1)
G4M0822
Cylinder
18) If cylinder edge is deformed in a convex shape, repair using an oil stone.
G4M0889
19) Using a sharp-edged, long rod, remove seal ring and O-ring from rack piston. CAUTION: 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.
PS-58
4) Using ST, remove lock wire from inner end of boot, and remove boot. ST 927590000 WRENCH
S4M0423A
(1) (2) (3)
Sharp-edged, long rod Seal ring O-ring

S601276A0602
S4M0390A
(1)
Wire
1) Disconnect four pipes from gearbox. 2) Secure gearbox removed from vehicle in vice using ST. ST 926200000 STAND CAUTION: Secure the gearbox assembly in a vice using the ST as shown. Do not attempt to secure it without this ST.
5) Using ST, loosen lock nut. ST 926230000 SPANNER
S4M0391A
(1)
Lock nut

S4M0388A
(1)
Clamp
3) Pry off clip from outer end of boot, and slide boot toward tie-rod end.
S4M0392A
(1)
Adjusting screw
7) Loosen adjusting screw and remove spring and sleeve.

S4M0389A
CAUTION: Replace spring and/or sleeve if damaged.
(1)
Clip
PS-59

11) After removing dust cover, extract pinion and valve from valve housing. CAUTION: If pinion and valve is difficult to remove, use a press. Discard oil seal after removal and replace with a new one. Check rotor for bends and serrations for damage and replace as required.
8) Slide dust cover out. CAUTION: Be careful not to scratch housing or input shaft during dust cover removal. Also do not allow foreign matter to enter housing interior. Replace dust cover with a new one if its inside bore or lips are worn or damaged.
S4M0409A
(1)
Dust cover
G4M0824
9) Remove the two bolts securing valve housing.
12) Using ST and press, remove dust seal, back-up washer, oil seal and ball bearing from valve housing. CAUTION: Use the A end of remover. Do not apply a force to end surface of valve housing. Do not reuse oil seal after removal. ST 34099FA000 INSTALLER & REMOVER
S4M0410A
(1)
Socket bolt
10) Remove valve housing, pinion and valve as a unit.
H4M1250B
(1) (2) (3) (4)

G4M0819
Oil seal Ball bearing A side B side
PS-60

13) Remove snap ring securing valve sleeve to pinion and valve, and remove valve sleeve. CAUTION: Be careful not to scratch pinion and valve when removing snap ring.

S601276A02
D: ASSEMBLY
CAUTION: Use only SUBARU genuine grease for gearbox. Specified grease for gearbox: VALIANT GREASE M2 (Part No. 003608001)
S601276A0201
1) Clean all parts and tools before reassembling. 2) Move rack shaft fully to the left and right two or three times to lubricate shaft ends with grease. Remove excess grease, being careful not to block air vent hole.
S4M0417A
(1) (2)
Valve sleeve Retaining ring
14) Remove oil seal and spacer. 15) Using a long rod, remove seal ring and O-ring from pinion. CAUTION: Be careful not to scratch outer surface and seal ring groove of input shaft. If scratched, sealing effect will be lost, resulting in a malfunctioning valve.
CAUTION: When rack is fully moved to its stroke ends with tie-rod removed, be careful not to bump rack ends. Ensure that screw located at end of rack shaft is free from grease. 3) Apply grease to bore wall which accommodates sleeve. CAUTION: Ensure that hands are clean when applying grease. 4) Install O-ring and seal ring in groove on rack piston. CAUTION: Do not expand O-ring and seal ring more than necessary. To facilitate installation of seal ring, first position one half of entire seal ring in groove. Then slowly position the second half using a spatula, as shown.
S4M0418A
(1) (2) (3) (4) (5)
Ball bearing Spacer Oil seal Seal ring O-ring
S4M0424A
(1) (2) (3)
O-ring Seal ring Spatula
PS-61

7) Using STB and STC, attach oil seal to STA. Insert STA into rack from gear side. Remove oil seal from STA when it approaches piston and remove STs from rack. ST 927490000 INSTALLER; ABC NOTE: Face oil seal in the direction shown in figure.
5) Apply a coat of grease to inner surface of ST and insert rack piston into it. Leave ST at least 10 minutes until seal ring settles down in place. CAUTION: Be careful not to scratch rack, piston and seal ring during installation. ST 927600000 FORMER
S4M0425A
S4M0427A
(1) (2)
Seal ring O-ring
(1) (2)
Oil-seal Rack
6) Attach steering body to ST as shown. Apply a coat of grease to needle bearing. ST 926200000 STAND CAUTION: Use a ST to support steering body. Ensure that needle bearing is free from defects. If it is faulty, replace steering body with a new one. NOTE: If steering body is removed from vehicle, be sure to remove rust and clean.
8) Install back-up ring from gear side of rack.
S4M0428A
(1) (2) (3)
Oil seal Back-up ring Rack
S4M0426A
(1)
Steering body
PS-62

9) Install ST on rack and equally apply a thin coat of grease to rack and ST, then install oil seal. ST 926250000 GUIDE CAUTION: Be careful not to scratch oil seal lips with pistons knurl section.
11) Slowly press inner side oil seal until distance between ST and end of rack is 65 mm (2.56 in). ST 34099FA010 GUIDE (Oil seal) CAUTION: Ensure STs inner wall is free of scratches. Otherwise, it may damage oil seal during installation.
S4M0429A
(1) (2) (3)
Rack piston inner ring Outer side oil seal Rack
S4M0431A
10) Apply a coat of grease to grooves in rack, sliding surface of sleeve and sealing surface of piston. Install ST on the end of steering body cylinder. Then insert rack into steering body from cylinder side. ST 34099FA010 GUIDE (Oil seal) CAUTION: Be sure to apply grease so that it covers the entire surface of rack gear teeth. Do not allow grease to block air vent hole on rack.
(1) (2) (3)
Rack piston Inner side oil seal Back-up ring
12) Pass ST2 and pipe through rack and press outer side oil seal until ST1 is in contact with ST2. ST1 34099FA010 GUIDE (Oil seal) ST2 34099FA040 INSTALLER (Oil seal)
S4M0432A
(1) (2)
Pipe Outer side oil seal
S4M0430A
(1) (2) (3) (4)
Cylinder side of steering body Air vent hole Oil seal Rack
PS-63

15) Using ST, clinch steering body cylinder at a point less than 3 mm (0.12 in) from holder. CAUTION: Be careful not to deform holder. ST 34099FA060 PUNCH
13) Install holder from cylinder side of steering body. Tightening torque: 64 Nm (6.5 kgf-m, 47.0 ft-lb)
G4M0820
14) Attach ST to rack cylinder. Using a press, install back-up ring and oil seal. NOTE: Press ST until its groove is aligned with end of holder. ST 34099FA030 INSTALLER & REMOVER
S4M0434A
(1)
Holder
16) Remove traces of sealer, oil, rust, etc., from mating surfaces of valve housing and steering body. 17) Position a shim in graded portion of steering body pinion housing, and apply an even coat of sealer (Fuji Bond C: 004403004) to end of pinion housing.
S4M0433A
(1) (2) (3) (4) (5)
Installer guide Holder Rack piston Oil seal Back-up ring
S4M0435A
(1) (2)
Shim Fuji Bond C (004403004)
18) Use the same number of shims as that used when steering body was removed. 19) If steering body, valve housing or pinion and valve is replaced with a new one, add two or three shims, install valve on pinion housing and tighten
PS-64

with two bolts to 25 Nm (2.5 kgf-m, 18.1 ft-lb). Then, measure clearance between steering body and valve housing using a thickness gauge. Remove shims so that the clearance is zero. 20) Extend rack 72.4 mm (2.850 in) beyond pinion side of steering body.
23) Apply a coat of grease to sliding surface of seat pad, sleeve and seating surface of spring, and insert sleeve into steering body. Charge adjusting screw with grease, insert spring into adjusting screw and install on steering body.
S4M0274A S4M0436A
(1)
Rack
21) Apply grease to pinion gear teeth and ball bearing. Insert valve into place.
(1) (2) (3) (4) (5)
Seat pad Sleeve Spring Adjusting screw Lock nut
24) Installation of tie-rod (1) Tighten adjusting screw until it will no longer tighten. (2) Install lock washers and tighten left and right tie-rods into rack ends. On condition L: Approximately 40 mm (1.57 in) Tightening torque: 78 Nm (8.0 kgf-m, 58 ft-lb)
G4M0853
22) Alternately and slowly tighten socket bolts. NOTE: Replace faulty parts before installing valve. Otherwise, valve may not be installed properly. Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
G4M0804
PS-65

(5) Tighten adjusting plug to 5 Nm (0.5 kgf-m, 3.6 ft-lb) and loosen, then tighten to 5 Nm (0.5 kgf-m, 3.6 ft-lb) and loosen, and finally tighten to 5 Nm (0.5 kgf-m, 3.6 ft-lb) and loosen 30. (6) While holding adjusting plug using a closed wrench, tighten lock nut using ST. ST 926300000 SPANNER Tightening torque: 39 Nm (4 kgf-m, 29 ft-lb) CAUTION: Do not allow liquid packing to come in contact with sleeve. While rotating input shaft to fully move rack shaft to the left and right, ensure that rack moves smoothly without binding, and that rotating torque is constant.
25) Using a chisel and hammer, bend lock washers (at two places). CAUTION: Be careful not to scratch rack.
S4M0399A
(1)
Lock washer
26) Rack and pinion backlash adjustment (1) Loosen adjusting plug. (2) Rotate input shaft so that rack is in the straight ahead direction. [Ensure that distance between rack end and stopper is 70.8 mm (2.787 in).] (3) Tighten adjusting plug by two threads.
G4M0808
27) Installation of boot (1) Apply a coat of grease to inner wall of boot small end. (2) Position boot large end in rubber mount groove and gearbox, and small end in groove of tie-rod.
G4M0807
(4) Turn adjusting screw so that the entire thread area is coated with liquid packing. Liquid packing: THREE BOND 1102 or equivalent NOTE: Apply liquid packing of approximately 1.5 g (0.053 oz) to adjusting screw thread area. Also turn plug to ensure that its entire contact area is coated with liquid packing.
CAUTION: Ensure that both ends of boot are properly situated in grooves. Ensure that boot is free from abnormal swelling or dents.
PS-66

28) Attach lock wire to boot large end, and twist it while pulling it upward (with a force of approximately 39 N (4 kgf, 9 lb). ST 927590000 WRENCH CAUTION: Ensure that lock wire is not loose.
31) Install pipes A and B. Tightening torque: Valve housing side 20 Nm (2.0 kgf-m, 14.5 ft-lb) Steering body side 24 Nm (2.4 kgf-m, 17.4 ft-lb)
S601276A0202
1) Clean all parts and tools before reassembling. 2) Attach ST to pinion, and apply grease to outer perimeter of the cover and mating surface of oil seal. ST 926270000 COVER
S4M0390A
(1)
Wire
29) Then bend wire end along boot as shown.
G4M0828
3) Apply a coat of grease to spacer and sealing lips of oil seal, and install spacer and oil seal. CAUTION: Face chamfered side of spacer toward oil seal. Face oil seal in correct direction.
S4M0400A
(1)
Twist wire up to this point.
30) Install clip using pliers. CAUTION: After installing clip, ensure that boots small end is properly positioned in groove on tie-rod.
S4M0419A
(1) (2)
Spacer Oil seal
S4M0401A
(1)
Clip
PS-67

9) Apply a coat of grease to the inner wall of the ST. Secure the four seal rings (installed in the former procedure) using the ST as shown in the figure. Leave the seal rings for approximately 10 minutes until they have properly set. ST 926050000 FORMER
4) Install ST to input shaft, and apply a coat of grease to the cover surface. Install O-ring and seal ring. CAUTION: Do not expand O-ring and seal ring more than necessary. ST 926450000 COVER
S4M0271B S4M0420A
(1) (2)
Seal ring Valve sleeve
(1) (2)
O-ring Seal ring
5) Apply a coat of grease to inner wall of ST, and secure seal ring assembled in the former procedure as shown. Leave seal ring unattended for approximately 10 minutes until it settles down. ST 926280000 FORMER
10) While aligning valve sleeve pin with groove on pinion, secure with snap ring. CAUTION: Be careful not to damage inner wall of valve sleeve and contact surface of pinion. Before assembling valve sleeve and pinion, clean in kerosene and dry with compressed air.
S4M0421A S4M0422A
(1) (2)
Seal ring O-ring
(1) (2)
Pin Groove on pinion
6) Remove the four seal rings from the valve sleeve using a sharp-pointed tool. CAUTION: Be careful not to scratch seal ring grooves on the valve sleeve. A scratch may reduce the sealing effect, resulting in faulty valve operation. 7) Clean the valve sleeve. 8) Attach the four seal rings to the valve sleeve grooves. CAUTION: Do not expand the seal rings more than necessary.
PS-68

11) Apply a coat of grease to inner wall of valve housing, oil seal and outer perimeter of dust seal.
13) Attach ST2 to ST1, and press ball bearing into place using a press. NOTE: To facilitate installation, attach ball bearing to remover and position in valve housing before pressing it into place. Use the B end of remover. ST1 ST2 34099FA000 34099FA050 INSTALLER & REMOVER SPACER
S4M0413A
(1)
Valve housing
12) Using ST and press, install oil seal in valve housing. (1) Face oil seal in the direction shown in figure when installing. (2) To avoid scratching oil seal, apply a coat of grease to contact surface of installer and oil seal. (3) To facilitate installation, attach oil seal to installer and position in valve housing before pressing into place. ST 34099FA000 INSTALLER & REMOVER
S4M0414A
(1)
B side
14) Charge oil seal with specified steering grease.
G4M0840
H4M1251B
(1)
Oil seal
15) Apply a coat of specified steering grease to ST surface, and install ST onto end of input shaft. Insert pinion and valve until A of oil seal contacts B of valve housing. The ST is used to prevent scratching oil seal. ST 34099FA020 GUIDE
G4M0841
PS-69

20) Position a shim in graded portion of steering body pinion housing, and apply an even coat of sealer (Fuji Bond C: 004403004) to end of pinion housing.
16) While supporting pinion and valve, push end of pinion until bearing contacts brazed end of valve housing. CAUTION: Do not allow spacer to extend beyond brazed end. Otherwise, pinion cannot be inserted properly.
S4M0435A
(1) (2)
S4M0415A
Shim Fuji Bond C (004403004)
(1)
Spacer
17) Apply a coat of grease to sealing lips of dust cover, and insert dust cover until it contacts staged portion of input shaft.
21) Use the same number of shims as that used when steering body was removed. 22) If steering body, valve housing or pinion and valve is replaced with a new one, add two or three shims, install valve on pinion housing and tighten with two bolts to 25 Nm (2.5 kgf-m, 18.1 ft-lb). Then, measure clearance between steering body and valve housing using a thickness gauge. Remove shims so that the clearance is zero. 23) Extend rack 72.4 mm (2.850 in) beyond pinion side of steering body.
S4M0416A
(1)
Dust cover
18) Adjust sealing lip-to-housing end clearance to 0 to 0.5 mm (0 to 0.020 in). If sealing lip is too close to housing end, steering wheel will not return smoothly; if it is too far from housing end, dust or dirt will enter the clearance. NOTE: Ensure that pinion and valve is properly positioned in valve housing before adjustment. 19) Remove traces of sealer, oil, rust, etc., from mating surfaces of valve housing and steering body.
S4M0436A
(1)
Rack
24) Apply grease to pinion gear teeth and ball bearing. Insert valve into place.
G4M0853
PS-70

25) Alternately and slowly tighten socket bolts. NOTE: Replace faulty parts before installing valve. Otherwise, valve may not be installed properly. Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft-lb) 26) Apply a coat of grease to sliding surface of seat pad, sleeve and seating surface of spring, and insert sleeve into steering body. Charge adjusting screw with grease, insert spring into adjusting screw and install on steering body.
Also turn plug to ensure that its entire contact area is coated with liquid packing. (5) Tighten adjusting plug to 5 Nm (0.5 kgf-m, 3.6 ft-lb) and loosen, then tighten to 5 Nm (0.5 kgf-m, 3.6 ft-lb) and loosen, and finally tighten to 5 Nm (0.5 kgf-m, 3.6 ft-lb) and loosen 30. (6) While holding adjusting plug using a closed wrench, tighten lock nut using ST. ST 926300000 SPANNER Tightening torque: 39 Nm (4 kgf-m, 29 ft-lb) CAUTION: Do not allow liquid packing to come in contact with sleeve. While rotating input shaft to fully move rack shaft to the left and right, ensure that rack moves smoothly without binding, and that rotating torque is constant.
S4M0274A
(1) (2) (3) (4) (5)
Seat pad Sleeve Spring Adjusting screw Lock nut

G4M0808
27) Rack and pinion backlash adjustment (1) Loosen adjusting plug. (2) Rotate input shaft so that rack is in the straight ahead direction. [Ensure that distance between rack end and stopper is 70.8 mm (2.787 in).] (3) Tighten adjusting plug by two threads.
28) Installation of boot (1) Apply a coat of grease to inner wall of boot small end. (2) Position boot large end in rubber mount groove and gearbox, and small end in groove of tie-rod. CAUTION: Ensure that both ends of boot are properly situated in grooves. Ensure that boot is free from abnormal swelling or dents.
G4M0807
(4) Turn adjusting screw so that the entire thread area is coated with liquid packing. Liquid packing: THREE BOND 1102 or equivalent NOTE: Apply liquid packing of approximately 1.5 grams (0.053 oz) to adjusting screw thread area.
PS-71
29) Attach lock wire to boot large end, and twist it while pulling it upward (with a force of approximately 39 N (4 kgf, 9 lb). ST 927590000 WRENCH CAUTION: Ensure that lock wire is not loose.
S4M0390A
(1)
Wire
30) Then bend wire end along boot as shown.
S4M0400A
(1)
Twist wire up to this point.
31) Install clip using pliers. CAUTION: After installing clip, ensure that boots small end is properly positioned in groove on tie-rod.
S4M0401A
(1)
Clip
PS-72
STEERING GEARBOX [RHD MODEL] E: INSPECTION

S601276A10
1. BASIC INSPECTION
S601276A1001
1) Clean all disassembled parts, and check for wear, damage, or any other faults, then repair or replace as necessary. 2) When disassembling, check inside of gearbox for water. If any water is found, carefully check boot for damage, input shaft dust seal, adjusting screw and boot clips for poor sealing. If faulty, replace with new parts.
No. 1 2 Input shaft Dust seal Parts (1) (2) (1) (2) Inspection Bend of input shaft Damage on serration Crack or damage Wear Corrective action If bend or damage is excessive, replace entire gearbox. If outer wall slips, lip is worn out or damage is found, replace it with new one. (1) Adjust backlash properly. By measuring turning torque of gearbox and sliding resistance of rack, check if rack and pinion engage uniformly and smoothly with each other. (Refer to Service limit.) (2) Keeping rack pulled out all the way so that all teeth emerge, check teeth for damage. Even if abnormality is found in either (1) or (2), replace entire gearbox. Replace gearbox with new one. If free play of rack shaft in radial direction is out of the specified range, replace gearbox with new one. (Refer to Service limit.) If free plays of input shaft in radial and axial directions are out of the specified ranges, replace gearbox with new one. (Refer to Service limit.) Replace. Replace. Replace. Replace. Replace. Replace. Replace.
Rack and pinion
Poor mating of rack with pinion
(1) Bend of rack shaft (2) Bend of cylinder portion (3) Crack or damage on cast iron portion 4 Gearbox unit (4) Wear or damage on rack bush
(5) Wear on input shaft bearing 5 6 7 8 9 10 11 Boot Tie-rod Tie-rod end Adjusting screw spring Boot clip Sleeve Pipes Crack, damage or deterioration (1) Looseness of ball joint (2) Bend of tie-rod Damage or deterioration on dust seal Deterioration Deterioration Damage (1) Damage to flared surface (2) Damage to flare nut (3) Damage to pipe
PS-73

3. RACK SHAFT PLAY IN RADIAL DIRECTION S601276A1003
Right-turn steering: Service limit Less than 0.4 mm (0.016 in) ) (direction Less than 0.6 mm (0.024 in) ) (direction On condition L: 5 mm (0.20 in) P: 98 N (10 kgf, 22 lb)
2. SERVICE LIMIT
S601276A1002
Make a measurement as follows. If it exceeds the specified service limit, adjust or replace. NOTE: When making a measurement, vise gearbox by using ST. Never vise gearbox by inserting aluminum plates, etc. between vise and gearbox. ST 926200000 STAND Sliding resistance of rack shaft: Service limit 304 N (31 kgf, 68 lb) or less Difference between left and right sliding resistance Less than 20%
G4M0798
Left-turn steering:
G4M0796
Service limit Less than 0.4 mm (0.016 in) and ) (direction On condition L: 5 mm (0.20 in) P: 98 N (10 kgf, 22 lb)
G4M0797
G4M0799
PS-74

4. INPUT SHAFT PLAY
In radial direction: Service limit 0.18 mm (0.0071 in) or less On condition P: 98 N (10 kgf, 22 lb)
S601276A1004
5. TURNING RESISTANCE OF GEARBOX

S601276A1005
Using ST, measure gearbox turning resistance. ST 926230000 SPANNER Service limit: Straight-ahead position within 30 mm (1.18 in) from rack center Less than 11.18 N (1.14 kgf, 2.51 lb) Maximum allowable resistance 15.79 N (1.61 kgf, 3.55 lb) or less Difference between left and right sliding resistance: Less than 20%
G4M0800
In axial direction: Service limit 0.27 mm (0.0106 in) or less On condition P: 20 49 N (2 5 kgf, 4 11 lb)
G4M0802
G4M0801
PS-75
6. OIL LEAKING
S601276A1006
S4M0408A
(1) Power cylinder (2) Cylinder (3) Rack piston
(4) Rack shaft (5) Gearbox (6) Pinion shaft
(7) From pump (8) To tank
NOTE: If gearbox is dismounted without confirming where the leak is, it must be mounted again to locate the leak point. 1) Even if the location of the leak can be easily found by observing the leaking condition, it is necessary to thoroughly remove the oil from the suspected portion and turn the steering wheel from lock to lock about 30 to 40 times with engine running, then make comparison of the suspected portion between immediately after and several hours after this operation. 2) Inspect leakage from a. The oil seal is damaged. Replace valve assembly with a new one. 3) Inspect leakage from b. The torsion bar O-ring is damaged. Replace valve assembly with a new one. 4) Inspect leakage from c. The oil seal is damaged. Replace valve assembly with a new one. 5) Inspect leakage from d. The pipe is damaged. Replace the faulty pipe or O-ring.
6) If leak is other than a, b, c, or d, and if oil is leaking from the gearbox, move the right and left boots toward tie-rod end side, respectively, with the gearbox mounted to the vehicle, and remove oil from the surrounding portions. Then, turn the steering wheel from lock to lock 30 to 40 times with the engine running, then make comparison of the leaked portion immediately after and several hours after this operation. (1) Inspect leakage from e. The cylinder seal is damaged. Replace rack bushing with a new one. (2) Inspect leakage from f. There are two possible causes. Take following step first. Remove the pipe assembly B from the valve housing, and close the circuit with ST. ST 926420000 PLUG
PS-76

CAUTION: If leakage from f is noted again: The oil seal of pinion and valve assembly is damaged. Replace pinion and valve assembly with a new one. Or replace the oil seal and the parts that are damaged during disassembly with new ones. If oil stops leaking from f: The oil seal of rack housing is damaged. Replace the oil seal and the parts that are damaged during disassembly with new ones.
4) If steering wheel spokes are not horizontal with vehicle set in the straight ahead position after this adjustment, correct it by turning the right and left tie-rods in the same direction by the same amount.
F: ADJUSTMENT
1) Adjust front toe.
S601276A01
Standard of front toe: IN 3 OUT 3 mm (IN 0.12 OUT 0.12 in)
G4M0135
G4M0133
2) Adjust steering angle of wheels. Standard of steering angle: Inner wheel: 37.41.5 Outer wheel: 32.51.5 3) If steering wheel spokes are not horizontal when wheels are set in the straight ahead position, and error is more than 5 on the periphery of steering wheel, correctly re-install the steering wheel.
S4M0188A
PS-77
PIPE ASSEMBLY
RHD model
7. Pipe Assembly
A: REMOVAL
S601277A18
S601277
1. NON-TURBO MODEL
S601277A1803
1) Set the vehicle on the lift. 2) Disconnect battery minus terminal. 3) Lift vehicle and remove jack-up plate.
B4M0671F
(1) (2)
Pipe A Pipe B
5) Remove clamp E from pipes. LHD model

S4M0380A
(1)
Jack-up plate
4) Remove one pipe joint at the center of gearbox, and connect vinyl hose to pipe and joint. Discharge fluid by turning steering wheel fully clockwise and counterclockwise. Discharge fluid similarly from the other pipe. CAUTION: Improper removal and installation of parts often causes fluid leak trouble. To prevent this, clean the surrounding portions before disassembly and reassembly, and pay special attention to keep dirt and other foreign matter from mating surfaces. LHD model
S4M0437A
(1) (2) (3) (4) (5)

S4M0381A
Return hose Pressure hose Clamp E Pipe C Pipe D
(1) (2)
Pipe A Pipe B
PS-78
PIPE ASSEMBLY
RHD model
S4M0235B
(1)
Steering gearbox
7) Lower the vehicle. 8) Remove intake duct and cleaner case. <Ref. IN(SOHC)-8, INSTALLATION, Air Intake Duct.> and <Ref. IN(SOHC)-7, Air Cleaner Case.> 9) Remove bolt A. 10) Disconnect pipe C from oil pump. Disconnect pipe D from return hose. CAUTION: Do not allow fluid from the hose end to come into contact with pulley belt. To prevent foreign matter from entering the hose and pipe, cover the open ends of them with a clean cloth.
B4M2509A
6) Disconnect pipe CD. (1) LHD model Disconnect pipe CD from pipe (on the gearbox side). CAUTION: When disconnecting pipe CD, use two wrenches to prevent deformities. Be careful to keep pipe connections free from foreign matter.
S4M0310B
(1) (2) (3)
Bolt A Pipe C Pipe D

S601277A1804
2. TURBO MODEL
S4M0382A
(1) (2)
Pipe C Pipe D
1) Set the vehicle on the lift. 2) Disconnect battery minus terminal.
(2) RHD model Using ST, remove flare nuts from control valve of gearbox assembly, and then disconnect pipe. ST 34099AC050 GEARBOX SPANNER CAUTION: When disconnecting pipes, use two wrenches to prevent deformities. Be careful to keep pipe connections free from foreign matter.
PS-79
PIPE ASSEMBLY
RHD model
3) Lift vehicle and remove jack-up plate.
S4M0380A
B4M0671F
(1)
Jack-up plate
(1) (2)
Pipe A Pipe B
4) Remove one pipe joint at the center of gearbox, and connect vinyl hose to pipe and joint. Discharge fluid by turning steering wheel fully clockwise and counterclockwise. Discharge fluid similarly from the other pipe. CAUTION: Improper removal and installation of parts often causes fluid leak trouble. To prevent this, clean the surrounding portions before disassembly and reassembly, and pay special attention to keep dirt and other foreign matter from mating surfaces. LHD model
5) Remove clamp E from pipes. LHD model
S4M0381A
S4M0437A
(1) (2)
Pipe A Pipe B
(1) (2) (3) (4) (5)
Return hose Pressure hose Clamp E Pipe C Pipe D
PS-80
PIPE ASSEMBLY
RHD model
(2) RHD model Using ST, remove flare nuts from control valve of gearbox assembly, and then disconnect pipe. ST 34099AC050 GEARBOX SPANNER CAUTION: When disconnecting pipes, use two wrenches to prevent deformities. Be careful to keep pipe connections free from foreign matter.
S4M0235B
(1)
B4M2509A
Steering gearbox
6) Disconnect pipe CD. (1) LHD model Disconnect pipe CD from pipe (on the gearbox side). CAUTION: When disconnecting pipe CD, use two wrenches to prevent deformities. Be careful to keep pipe connections free from foreign matter.
7) Lower the vehicle. 8) Remove intake duct. 9) Remove bolt A. (1) Remove air intake duct, air cleaner upper cover and air intake boot. <Ref. to IN(DOHC TURBO)-8, REMOVAL, Air Intake Duct.> and <Ref. to IN(DOHC TURBO)-9, REMOVAL, Intake Duct.> (2) Remove two bolts fixing pipe C and D. (3) Remove coolant filler tank.
B4M1696B
(1) (2)
Pipe C Pipe D
EN0126
PS-81
PIPE ASSEMBLY B: INSTALLATION

1) Tighten bolt A. CAUTION: Visually check that hose between tank and pipe D is free from bending or twisting. (1) Connect pipe D to oil tank. (2) Connect pipe C or pressure hose to oil pump. CAUTION: Use a new gasket. Tightening torque: 39 Nm (4.0 kgf-m, 28.9 ft-lb) (3) Tighten bolt A.
ST0012
S601277A11
(4) Disconnect pipe C from oil pump. Disconnect pipe D from return hose. CAUTION: Do not allow fluid from the hose end to come into contact with pulley belt. To prevent foreign matter from entering the hose and pipe, cover the open ends of them with a clean cloth.
1. NON-TURBO MODEL
S601277A1103
(1) (2)
Pipe C Pipe D
S4M0310B
(1) (2) (3)
PS-82
PIPE ASSEMBLY
2) Temporarily connect pipes C and D. (LHD model)
4) Temporarily install clamp E on pipes C and D, and tighten clamp E firmly. CAUTION: Ensure that the letter 8 on each clamp are diagonally opposite each other as shown in figure. Tightening torque: 7.4 Nm (0.75 kgf-m, 5.4 ft-lb)
B4M0667C
(1) (2)
S4M0438A
Clamp E Pipe C
5) Tighten joint nut. Tightening torque: 15 Nm (1.5 kgf-m, 10.8 ft-lb) 6) Connect pipe A and B. (1) LHD model Connect pipes A and B to four pipe joints of gearbox. Connect upper pipe B first, and lower pipe A second. Tightening torque: 13 Nm (1.3 kgf-m, 9.4 ft-lb)
(1) (2) (3) (4) (5) (6) (7)
Return hose Pressure hose Approx. 30 mm (1.18 in) Clamp E Pipe C Pipe Pipe (on gearbox side)
3) Using ST, remove flare nuts from control valve of gearbox assembly, and disconnect upper and lower hoses. ST 34099AC050 GEARBOX SPANNER CAUTION: Always disconnect hoses B and A in that order. Be careful not to damage the hoses during removal.
S4M0381A
(1) (2)
Pipe A Pipe B
S4M0235B
(1)
Steering gearbox
PS-83
PIPE ASSEMBLY
7) Install jack-up plate. 8) Connect battery ground terminal. 9) Feed the specified fluid. NOTE: Never start the engine before feeding the fluid; otherwise vane pump might be seized up.
(2) RHD model Connect pipes A and B to four pipe joints of gearbox. Connect upper pipe A first, and lower pipe B second. Tightening torque: T1: 20 Nm (2.0 kgf-m, 14.5 ft-lb) T2: 24 Nm (2.4 kgf-m, 17.4 ft-lb)
B4M0671G
(1) (2)
Pipe A Pipe B
LHD model
S4M0272B
(1) (2) (3)
High-pressure hose No interference is allowed between hoses. Clearance between crossmember and pipe: 3 8 mm (0.12 0.31 in)
PS-84
PIPE ASSEMBLY
RHD model
B4M1205B
(1) (2) (3) (4) (5)
Clearance between blow-by hose and pipe: 3 5 mm (0.12 0.20 in) No interference is allowed between hoses Clearance between side frame and hose: 15 mm (0.59 in) or more Clearance between crossmember and pipe: 5 13 mm (0.20 0.51 in) Steering gearbox
10) Finally check clearance between pipes and/or hoses, as shown above. If clearance between cruise control pump and power steering hose is less than 10 mm (0.39 in), proceed as follows: (1) Move clamped section (A) (refer to figure above.) down to a point where pipe is close to crossmember. Pipe-to-crossmember clearance: 10 mm (0.39 in), min. (2) Check that clearance between cruise control pump and power steering hose is at least 10 mm (0.39 in). If it is not, bend section (B) down until a clearance of at least 10 mm (0.39 in) is obtained.
PS-85
PIPE ASSEMBLY
2) Install coolant filler tank. (Turbo model) Tightening torque: T1: 19 Nm (1.9 kgf-m, 13.7 ft-lb) T2: 21 Nm (2.1 kgf-m, 15.2 ft-lb)
2. TURBO MODEL
1) Tighten bolt A.
S601277A1104
CAUTION: Visually check that hose between tank and pipe D is free from bending or twisting. (1) Connect pipe D to oil tank. (2) Connect pipe C or pressure hose to oil pump. CAUTION: Use a new gasket. Tightening torque: 39 Nm (4.0 kgf-m, 28.9 ft-lb) (3) Tighten bolt A. Tightening torque: 13 Nm (1.3 kgf-m, 9.4 ft-lb)
EN0127
B4M1658B
(1) (2) (3)
PS-86
PIPE ASSEMBLY
3) Temporarily connect pipes C and D. (LHD model)
5) Temporarily install clamp E on pipes C and D, and tighten clamp E firmly. CAUTION: Ensure that the letter 8 on each clamp are diagonally opposite each other as shown in figure. Tightening torque: 7.4 Nm (0.75 kgf-m, 5.4 ft-lb)
B4M0667C
(1) (2)
S4M0438A
Clamp E Pipe C
6) Tighten joint nut. Tightening torque: 15 Nm (1.5 kgf-m, 10.8 ft-lb) 7) Connect pipe A and B. (1) LHD model Connect pipes A and B to four pipe joints of gearbox. Connect upper pipe B first, and lower pipe A second. Tightening torque: 13 Nm (1.3 kgf-m, 9.4 ft-lb)
(1) (2) (3) (4) (5) (6) (7)
Return hose Pressure hose Approx. 30 mm (1.18 in) Clamp E Pipe C Pipe Pipe (on gearbox side)
4) Using ST, temporarily connect pipes to control valve of gearbox. (RHD model) ST 34099AC050 GEARBOX SPANNER
S4M0381A S4M0235B
(1)
Steering gearbox
(1) (2)
Pipe A Pipe B
PS-87
PIPE ASSEMBLY
8) Install jack-up plate. 9) Connect battery ground terminal. 10) Feed the specified fluid. NOTE: Never start the engine before feeding the fluid; otherwise vane pump might be seized up.
(2) RHD model Connect pipes A and B to four pipe joints of gearbox. Connect upper pipe A first, and lower pipe B second. Tightening torque: T1: 20 Nm (2.0 kgf-m, 14.5 ft-lb) T2: 24 Nm (2.4 kgf-m, 17.4 ft-lb)
B4M0671G
(1) (2)
Pipe A Pipe B
LHD model
S4M0272B
(1) (2) (3)
High-pressure hose No interference is allowed between hoses. Clearance between crossmember and pipe: 3 8 mm (0.12 0.31 in)
PS-88
PIPE ASSEMBLY
RHD model
B4M1205B
(1) (2) (3) (4) (5)
Clearance between blow-by hose and pipe: 3 5 mm (0.12 0.20 in) No interference is allowed between hoses Clearance between side frame and hose: 15 mm (0.59 in) or more Clearance between crossmember and pipe: 5 13 mm (0.20 0.51 in) Steering gearbox
11) Finally check clearance between pipes and/or hoses, as shown above. If clearance between cruise control pump and power steering hose is less than 10 mm (0.39 in), proceed as follows: (1) Move clamped section (A) (refer to figure above.) down to a point where pipe is close to crossmember. Pipe-to-crossmember clearance: 10 mm (0.39 in), min. (2) Check that clearance between cruise control pump and power steering hose is at least 10 mm (0.39 in). If it is not, bend section (B) down until a clearance of at least 10 mm (0.39 in) is obtained.
PS-89
PIPE ASSEMBLY
C: INSPECTION
S601277A10
Check all disassembled parts for wear, damage or other abnormalities. Repair or replace faulty parts as required.
Part name Pipe Clamp B Clamp C Clamp E Inspection O-ring fitting surface for damage Nut for damage Pipe for damage Clamps for weak clamping force Remedy Replace with new one.
Replace with new one.
Hose
Flared surface for damage Flare nut for damage Outer surface for cracks Replace with Outer surface for wear new one. Clip for damage End coupling or adapter for degradation
CAUTION: Although surface layer materials of rubber hoses have excellent weathering resistance, heat resistance and resistance for low temperature brittleness, they are likely to be damaged chemically by brake fluid, battery electrolyte, engine oil and automatic transmission fluid and their service lives are to be very shortened. It is very important to keep the hoses free from before mentioned fluids and to wipe out immediately when the hoses are adhered with the fluids. Since resistances for heat or low temperature brittleness are gradually declining according to time accumulation of hot or cold conditions for the hoses and their service lives are shortening accordingly, it is necessary to perform careful inspection frequently when the vehicle is used in hot weather areas, cold weather area and/or a driving condition in which many steering operations are required in short time. Particularly continuous work of relief valve over 5 seconds causes to reduce service lives of the hoses, the oil pump, the fluid, etc. due to over heat. So, avoid to keep this kind of condition when servicing as well as driving.
Trouble Pressure hose burst Possible cause Excessive holding time of relief status Malfunction of relief valve Poor cold characteristic of fluid Poor connection Poor holding of clip Poor cold characteristic of fluid Wrong layout, tensioned Excessive play of engine due to deterioration of engine mounting rubber Improper stop position of pitching stopper Excessive holding time of relief status Crack on hose Excessive tightening torque for return hose clip Power steering fluid, brake fluid, engine oil, electrolyte adhere on the hose surface Too many times use in extremely cold weather Corrective action Instruct customers. Replace oil pump. Replace fluid. Correct. Retighten. Replace fluid. Replace hose. Replace defective parts. Replace defective parts. Replace. Instruct customer. Replace. Replace. Pay attention on service work. Replace. Instruct customers.
Forced out return hose
Fluid bleeding out of hose slightly
PS-90
PIPE ASSEMBLY
CAUTION: It is likely that although one judges fluid leakage, there is actually no leakage. This is because the fluid spilt during the last maintenance was not completely wiped off. Be sure to wipe off spilt fluid thoroughly after maintenance. Non-turbo model
S4M0171A
Fluid leaking area
Leakage from connecting portions of pipes and hoses, numbered with (1) through (9) in figure
Possible cause Insufficient tightening of flare nut, catching dirt or the like, damage to flare or flare nut or eye bolt Poor insertion of hose, poor clamping Damaged O-ring or gasket
Corrective action Loosen and retighten, if ineffective, replace. Retighten or replace clamp. Replace O-ring or gasket pipe or hose with new one, if ineffective, replace gearbox also. Replace with a new one. Replace with a new one. Replace oil pump. Replace oil pump. Replace oil tank. Replace O-ring. Replace cap. Replace oil tank. Adjust fluid level. Replace oil seal. Replace problem parts. Replace control valve.
Leakage from hose (10) and (11) in figure
Crack or damage in hose Crack or damage in hose hardware
Leakage from surrounding of cast Damaged O-ring iron portion of oil pump (12) and (13) Damaged gasket in figure Crack in oil tank, (14) Leakage from oil tank (14) and (15) in figure Damaged O-ring, (15) Damaged cap packing Leakage from filler neck (16) Crack in root of filler neck High fluid level *1 Leakage from surrounding of power Damaged oil seal cylinder of gearbox (17) in figure Leakage from control valve of gear- Damaged packing or oil seal box (18) and (19) in figure Damage in control valve
PS-91
PIPE ASSEMBLY
Turbo model
S4M0565B
Fluid leaking area
Leakage from connecting portions of pipes and hoses, numbered with (1) through (11) in figure
Possible cause Insufficient tightening of flare nut, catching dirt or the like, damage to flare or flare nut or eye bolt Poor insertion of hose, poor clamping Damaged O-ring or gasket
Corrective action Loosen and retighten, if ineffective, replace. Retighten or replace clamp. Replace O-ring or gasket pipe or hose with new one, if ineffective, replace gearbox also. Replace with a new one. Replace with a new one. Replace oil pump. Replace oil pump. Replace oil tank. Replace cap. Replace oil tank. Adjust fluid level. Replace oil seal. Replace problem parts. Replace control valve.
Leakage from hose (12), (13) and (14) in figure
Crack or damage in hose Crack or damage in hose hardware
Leakage from surrounding of cast Damaged O-ring iron portion of oil pump (15) and (16) Damaged gasket in figure Leakage from oil tank (17) and (18) Crack in oil tank in figure Damaged cap packing Leakage from filler neck (19) Crack in root of filler neck High fluid level *1 Leakage from surrounding of power Damaged oil seal cylinder of gearbox (20) in figure Leakage from control valve of gear- Damaged packing or oil seal box (21) and (22) in figure Damage in control valve
NOTE: Fluid level is specified at optimum position (range) for ordinary use. Accordingly, if the vehicle is used often under hard conditions such as on very rough roads or in mountainous areas, fluid may bleed out from cap air vent hole. This is not a problem. If a customer complains strongly and is not likely to be satisfied with the leakage, lower the fluid level to the extent that fluid will not bleed out under the conditions described, and have the customer check the fluid level and its quality more frequency than usual.
PS-92
OIL PUMP
8. Oil Pump
A: REMOVAL
S601070
8) Remove three bolts from the front side of oil pump and detach the pump.
S601070A1804
S601070A18
1. NON-TURBO MODEL
1) Remove ground cable from battery. 2) Drain the working fluid about 0.3 (0.3 US qt, 0.3 Imp qt) from oil tank. 3) Remove pulley belt cover bracket. 4) Loosen oil pump pulley nut, then remove bolts which secure alternator.
H4M1077B
(1)
Oil pump
9) Remove three bolts from the lower side of bracket and detach the bracket. CAUTION: The bracket does not need to be removed unless it is damaged.
H4M1076B
(1)
Oil pump pulley nut
10) Place oil pump in a vise, and remove upper shell and baffle from lower shell. CAUTION: Do not clamp oil pump too hard; otherwise oil pump may be dented.
5) Loosen pulley belt(s). 6) Remove the nut and detach oil pump pulley. 7) Disconnect pipe C from oil pump. Disconnect pipe D from oil tank. CAUTION: Do not allow fluid from the hose end to come into contact with pulley belt. To prevent foreign matter from entering the hose and pipe, cover the open ends of them with a clean cloth. Except when only oil tank needs to be inspected, detach oil tank and oil pump as a unit. Then separate one from the other on a work bench to prevent oil from spilling on any part of the engine.
H4M1078B
(1) (2)
Upper shell Lower shell
11) Remove lower shell from oil pump.
S4M0310B
(1) (2) (3)
H4M1075B
(1)
Lower shell
PS-93
OIL PUMP
2. TURBO MODEL
S601070A1805
1) Remove ground terminal from battery. 2) Remove intake duct. <Ref. to IN(DOHC TURBO)-8, REMOVAL, Air Intake Duct.> 3) Remove pulley belt cover. 4) Loosen lock bolt and slider bolt and remove power steering pump drive V-belt.
B2M3151
9) Place oil pump bracket in a vise, remove two bolts from the front side of oil pump. CAUTION: Do not place oil pump bracket directly in the vise; use soft pads and hold oil pump lightly to protect the pump.
G2M0286
5) Disconnect connector from power steering pressure switch. 6) Remove intake boot and air cleaner upper. <Ref. to IN(DOHC TURBO)-7, REMOVAL, Air Cleaner.> 7) Disconnect pipe C and suction hose from oil pump. CAUTION: Do not allow fluid from the hose end to come into contact with pulley belt. To prevent foreign matter from entering the hose and pipe, cover the open ends of them with a clean cloth.
B4M1660
10) Remove bolt from the rear side of oil pump. 11) Disassemble oil pump and bracket by inserting a screwdriver as shown in the figure.
B4M1661 ST0017
(1) (2)
Suction hose Pipe C
8) Remove bolts which install power steering pump bracket.
PS-94
OIL PUMP B: INSTALLATION

S601070A11
1. NON-TURBO MODEL
1) Install bracket on engine.
S601070A1104
Tightening torque: 22 Nm (2.2 kgf-m, 15.9 ft-lb) 2) Install oil pump on oil tank as follows outside the vehicle: NOTE: Prior to installation, make sure that all oil is removed from oil pump, oil tank and pipe. 3) Place oil pump in a vise and install stay to oil pump. CAUTION: Do not place oil pump directly in vise; use soft pads and hold oil pump lightly to protect it. Tightening torque: 15.7 Nm (1.60 kgf-m, 11.6 ft-lb) 4) Install lower shell to oil pump. Tightening torque: 18 Nm (1.8 kgf-m, 13.0 ft-lb) CAUTION: Be sure to use a new seal washer.
H4M1077B H4M1078B
(1) (2)
Upper shell Lower shell
6) Install oil pump, previously assembled to oil tank, on bracket. Tightening torque: 18 Nm (1.8kgf-m, 13.0 ft-lb)
(1)
Oil pump
7) Install in the reverse order of removal. 8) Inspect pulley belt tension. <Ref. to ME(SOHC)-43, INSPECTION, V-belt.> 9) Feed the specified power steering fluid. <Ref. to PS-101, Power Steering Fluid.>
H4M1075B
2. TURBO MODEL
S601070A1105
(1)
Lower shell
5) Install upper shell and baffle to lower shell. Tightening torque: 13 Nm (1.3 kgf-m, 9.4 ft-lb)
1) Install oil pump to bracket. (1) Place oil pump bracket in a vise. Tighten bushing using a 12.7 mm (1/2) type 14- and 21-mm box wrench until it is in contact with oil pump mounting surface. CAUTION: Do not place oil pump bracket directly in the vise; use soft pads and hold oil pump lightly to protect the pump.
PS-95
OIL PUMP
2) Tighten bolt which install power steering pump bracket. Tightening torque: 22 Nm (2.2 kgf-m, 15.9 ft-lb)
B4M1670B
(1) (2) (3) (4) (5)
Bush Nut 21 mm 14 mm Bolt
B2M3151
3) Interconnect pipes C and suction hose. Tightening torque: Joint nut 39.2 Nm (4 kgf-m, 28.9 ft-lb) CAUTION: If a hose is twisted at this step, the hose may come into contact with some other parts.
(2) Tighten bolt which installs oil pump to bracket. Tightening torque: 37.3 Nm (3.8 kgf-m, 27.5 ft-lb)
B4M2532
ST0017
(1) (2)
Suction hose Pipe C
4) Connect connector to power steering oil pressure switch. 5) Install pulley belt to oil pump. 6) Check pulley belt tension. <Ref. to ME(DOHC TURBO)-45, INSPECTION, V-belt.> 7) Tighten bolt belt tension. Tightening torque: 8 Nm (0.8 kgf-m, 5.8 ft-lb)
B4M1660
8) Install pulley belt cover. 9) Install air intake boot. 10) Connect ground terminal of battery. 11) Feed the specified power steering fluid. <Ref. to PS-101, Power Steering Fluid.> CAUTION: Never start the engine before feeding the fluid; otherwise vane pump might be seized up.
PS-96
OIL PUMP C: INSPECTION

S601070A10
1. BASIC INSPECTION
S601070A1002
In accordance with the following table, check all removed parts for wear and damage, and make repair or replacement if necessary.
No. 1 Parts Oil pump (Exterior) Inspection (1) Crack, damage or oil leakage (2) Play of pulley shaft (1) Damage 2 3 4 Pulley Cap Strainer (2) Bend Crack or damage (1) Clogging with dirt (2) Breakage (1) Defect or burning of vane pump 5 Oil pump (Interior) (2) Bend in the shaft or damage to bearing 6 7 8 O-ring Oil tank Bracket Crack or deterioration Crack, damage or oil leakage Crack Corrective action Replace oil pump with a new one. Measure radial play and axial play. If any of these exceeds the service limit, replace oil pump with a new one. Replace it with a new one. Measure V ditch deflection. If it exceeds the service limit, replace pulley with a new one. Replace it with a new one. Wash it. Replace it with a new one. Check resistance to rotation of pulley. If it is past the service limit, replace oil pump with a new one. Oil pump emits a noise that is markedly different in tone and loudness from a sound of a new oil pump when turning with a string put around its pulley, replace oil pump with a new one. Replace it with a new one. Replace it with a new one. Replace it with a new one.
PS-97
OIL PUMP
NOTE: Read the value for one surface of V ditch, and then the value for another off the dial.
2. SERVICE LIMIT
S601070A1001
Make a measurement as follows. If it exceeds the specified service limit, replace the parts with new ones. CAUTION: Fix oil pump on a vise to make a measurement. At this time, hold oil pump with the least possible force between two wood pieces. Do not set outside of flow control valve or pulley on a vise; otherwise outside or pulley might be deformed. Select properly sized wood pieces. 1) Play of pulley shaft On condition: P: 9.8 N (1.0 kgf, 2.2 lb) Service limit: ) Radial play (Direction 0.4 mm (0.016 in) or less
S4M0441A
(1)
Dial indicator
3) Resistance to rotation of pulley Service limit: Maximum load; 9.22 N (0.94 kgf, 2.07 lb) or less NOTE: A rather higher value may be indicated when pulley starts turning. Measure the load during rotation and make a judgment.
S4M0439A
(1)
Dial indicator
Axial play (Direction ) Non-turbo model: 0.9 mm (0.035 in) or less Turbo model: 0.6 mm (0.024 in) or less
S4M0442A
(1)
Spring balance
S601070A1003
3. HYDRAULIC PRESSURE
S4M0440A
(1)
Dial indicator
2) Ditch deflection of pulley Service limit: 1.0 mm (0.039 in) or less
CAUTION: Be sure to complete all items aforementioned in INSPECTION, prior to measuring hydraulic pressure. Otherwise, pressure can not be measured correctly. <Ref. to PS-103 INSPECTION, General Diagnostic Table.> Do not leave the valve of pressure gauge closed or hold the steering wheel at stop end for 5 seconds or more in any case, as the oil pump may be damaged due to long keep of these conditions. Put cotton cloth waste at a place where fluid drops before pressure gauge is installed. Wipe off split fluid thoroughly after the measurement.
PS-98
OIL PUMP
NOTE: Keep engine idling during the measurement. 1) MEASURE REGULAR PRESSURE. (1) Remove two bolts securing power steering pipes to engine. (2) Install ST1, 2 and 3 between power steering pump and pipes using gasket (Part No. 34621AC021) and bolt (Part No. 34620AC010). (3) Replenish power steering fluid up to specified level. (4) Open valve, and start the engine. (5) Measure regular pressure. ST1 925711000 PRESSURE GAUGE ST2 34099AC020 ADAPTER HOSE B ST3 34099AC010 ADAPTER HOSE A
Service limit: Non-turbo model: 7,159 7,748 kPa (73 79 kg/cm2, 1,038 1,123 psi) Turbo model: 9,611 10,199 kPa (98 104 kg/cm2, 1,394 1,479 psi) (4) If it is not within the specified value, replace the oil pump. 3) Measure working pressure. (1) Using STs, measure working pressure. (2) Open valve. (3) Measure working pressure of control valve by turning wheel from stop to stop. ST1 925711000 PRESSURE GAUGE ST2 34099AC020 ADAPTER HOSE B ST3 34099AC010 ADAPTER HOSE A
B4M1675A B4M1675A
Service limit: 981 kPa (10 kg/cm2, 142 psi) or less (6) If it is not within the specified value, replace the troubled part caused by the following symptoms; pipe or hose clogged, leaks from fluid line, and mix of foreign objects in fluid line. 2) Measure relief pressure. (1) Using STs, measure relief pressure. (2) Close valve. (3) Measure relief pressure. ST1 925711000 PRESSURE GAUGE ST2 34099AC020 ADAPTER HOSE B ST3 34099AC010 ADAPTER HOSE A
Service limit: Non-turbo model: 7,159 7,748 kPa (73 79 kg/cm2, 1,038 1,123 psi) Turbo model: 9,611 10,199 kPa (98 104 kg/cm2, 1,394 1,479 psi) (4) If it is within the specified value, measure steering effort. <Ref. to PS-106 MEASUREMENT OF STEERING EFFORT, INSPECTION, General Diagnostic Table.> If it is not within specified value, replace control valve itself or control valve and pinion as a single unit with new ones.
B4M1676A
PS-99
RESERVOIR TANK
2. TURBO MODEL
S601075A1105
9. Reservoir Tank
A: REMOVAL
S601075A18
S601075
1. NON-TURBO MODEL
S601075A1804
1) Install reservoir tank to bracket. 2) Connect return hose and suction hose to reservoir tank.
Refer to Oil Pump section for details of reservoir tank removal order. <Ref. to PS-93, NON-TURBO MODEL, REMOVAL, Oil Pump.>
2. TURBO MODEL
S601075A1805
1) Remove air intake duct. <Ref. to IN(DOHC TURBO)-8, REMOVAL, Air Intake Duct.> 2) Drain fluid from the reservoir tank. 3) Disconnect return hose and suction hose from reservoir tank. CAUTION: Do not allow fluid from the hose end to come into contact with pulley belt. To prevent foreign matter from entering the hose, cover the open ends of them with a clean cloth.
(1) (2) (3) Suction hose Pipe D Return hose
ST0022
3) Feed the specified power steering fluid. <Ref. to PS-101, Power Steering Fluid.>
C: INSPECTION
S601075A10
Check reservoir tank for cracks, breakage, or damage. If any cracks, breakage, or damage is found, replace reservoir tank.
ST0022
(1) (2) (3)
Suction hose Pipe D Return hose
4) Remove reservoir tank from bracket by pulling it upwards.
B: INSTALLATION
S601075A11
1. NON-TURBO MODEL
S601075A1104
Refer to Oil Pump section for details of reservoir tank installation order. <Ref. to PS-95, NONTURBO MODEL, INSTALLATION, Oil Pump.>
PS-100
POWER STEERING FLUID

S601275A18
10. Power Steering Fluid

A: SPECIFICATION
S601275A22
S601275
C: REMOVAL
1) 2) 3) 4) 5) 6) 7)
Recommended power steering fluid
DEXRON IIE or III
Manufacturer B.P. CALTEX CASTROL MOBIL SHELL TEXACO
Set the vehicle on the lift. Disconnect battery minus terminal. Remove air intake duct. Drain fluid from the reservoir tank. Lift-up the vehicle. Remove under cover. Remove jack-up plate.
B: INSPECTION
S601275A10
S4M0380A
(1)
Jack-up plate
8) Disconnect one pipe joint A from center of gearbox assembly, and connect a vinyl hose to it. While turning steering wheel to the left and right, drain fluid through the hose. Similarly, drain fluid from the other pipe joint B. LHD model
S4M0381A
(1) (2)
H4M1007
Pipe A Pipe B
Turbo model
B4M1674A
PS-101
POWER STEERING FLUID

8) Stop the engine, and take out safety stands after jacking up vehicle again. Then lower the vehicle, and idle the engine. 9) Continue to turn steering wheel from lock to lock until bubbles stop appearing and change of the fluid level is within 3 mm (0.12 in). 10) In case the following happens, leave it about half an hour and then do step 8) again. (1) The fluid level changes over 3 mm (0.12 in). (2) Bubbles remain on the upper surface of the fluid. (3) Grinding noise is generated from oil pump. 11) Check the fluid leakage at flare nuts after turning steering wheel from lock to lock with engine running. CAUTION: Before checking, wipe off any fluid on flare nuts and piping. In case the fluid leaks from flare nut, it is caused by dust (or the like) and/or damage between flare and tapered seat in piping. So remove the flare nut, tighten again it to the specified torque after cleaning flare and tapered seat. If flare or tapered seat is damaged, replace it with a new one.
RHD model
B4M0671F
(1) (2)
Pipe A Pipe B
9) Connect pipe joint A and B. 10) When pouring power steering fluid, refer to Installation under Power Steering Fluid. <Ref. to PS-102 INSTALLATION, Power Steering Fluid.> 11) Install in the reverse order of removal.
D: INSTALLATION
S601275A11
1) Feed the specified fluid with its level being about 4 cm (1.6 in) lower than the mouth of tank. 2) Set ST on top of reservoir tank and fill it about half way with the specified fluid. (Turbo model) ST 34199AE040 OIL CHARGE
B4M1673A
3) Continue to turn steering wheel slowly from lock to lock until bubbles stop appearing in the tank while keeping the fluid at that level. 4) In case air is absorbed to deliver bubbles into piping because the fluid level is lower, leave it about half an hour and then do the step 2) all over again. 5) Start, and idle the engine. 6) Continue to turn steering wheel slowly from lock to lock again until bubbles stop appearing in the tank while keeping the fluid at that level. It is normal that bubbles stop appearing after three times turning of steering wheel. 7) In case bubbles do not stop appearing in the tank, leave it about half an hour and then do the step 5) all over again.
PS-102

S601257
A: INSPECTION
Trouble
S601257A10
Possible cause 1. Pulley belt Unequal length of pulley belts Adhesion of oil and grease Loose or damage of pulley belt Poor uniformity of pulley belt cross section Pulley belt touches to pulley bottom Poor revolution of pulleys except oil pump pulley Poor revolution of oil pump pulley 2. Tire and rim Improper tires out of specification Improper rims out of specification Heavy steering effort in all Tires not properly inflated*1 ranges 3. Fluid Heavy steering effort at Low fluid level stand still Steering wheel surges when Aeration Dust mix turning. Deterioration of fluid Poor warming-up of fluid *2 4. Idling speed Lower idling speed Excessive drop of idling speed at start or at turning steering wheel *3 5. Measure hydraulic pressure. <Ref. to PS-97 INSPECTION, Oil Pump.> 6. Measure steering effort. <Ref. PS-103 INSPECTION, General Diagnostic Table.> 1. Fluid line Folded hose Flattened pipe 2. Tire and rim Flat tire Mix use of different tires Mix use of different rims Vehicle leads to one side or Abnormal wear of tire Unbalance of remained grooves the other. Unbalance of tire pressure Poor return of steering 3. Front alignment wheel to center Steering wheel surges when Improper or unbalance caster Improper or unbalance toe-in turning. Loose connection of suspension 4. Others Damaged joint assembly Unbalanced height One-sided weight 5. Measure steering effort. <Ref. to PS-103 INSPECTION, General Diagnostic Table.>
Corrective action
Adjust or replace.
Replace or reinflate.
Refill, bleed air, replace or instruct customer.
Adjust or instruct customer.
Replace problem parts. Adjust or replace. Reform or replace.
Fix or replace.
Adjust or retighten.
Replace, adjust or instruct customer. Adjust or replace.
*1 If tires and/or rims are wider, the load to power steering system is the more. Accordingly, in a condition, for example before fluid warms-up, relief valve may work before maximum turning angle. In this case, steering effort may be heavy. When measured hydraulic pressure is normal, there is no abnormal thing. *2 In cold weather, steering effort may be heavy due to increased flow resistance of cold fluid. After warming-up engine, turn steering wheel from stop to stop several times to warm-up fluid. Then if steering effort reduces normally, there is no abnormal thing. *3 In cold weather or with insufficient warm-up of engine, steering effort may be heavy due to excessive drop of idling when turning steering wheel. In this case, it is recommended to start the vehicle with increasing engine speed than usual. Then if steering effort reduces normally, there is no abnormal thing.
PS-103

S601257A1001
1. NOISE AND VIBRATION
CAUTION: Dont keep the relief valve operated over 5 seconds at any time or inner parts of the oil pump may be damaged due to rapid increase of fluid temperature. NOTE: Grinding noise may be heard immediately after the engine start in extremely cold condition. In this case, if the noise goes off during warm-up there is no abnormal function in the system. This is due to the fluid characteristic in extremely cold condition. 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 stand still there is no abnormal function in the system provided that the noise eliminates when the vehicle is running. When stopping with service brake and/or parking brake applied, power steering can be operated easily due to its light steering effort. If doing so, the disk rotates slightly and makes creaking noise. The noise is generated by creaking between the disk and pads. If the noise goes off when the brake is released, there is no abnormal function in the system. There may be a little vibration around the steering devices when turning steering wheel at standstill, even though the component parts are properly adjusted and have no defects. Hydraulic systems are likely to generate this kind of vibration as well as working noise and fluid noise because of combined conditions, i.e., road surface and tire surface, engine speed and turning speed of steering wheel, fluid temperature and braking condition. This phenomena does not indicate there is some abnormal function in the system. The vibration can be known when steering wheel is turned repeatedly at various speeds from slow to rapid step by step with parking brake applied on concrete road and in D range for automatic transmission vehicle.
PS-104

Trouble Hiss noise (continuous) While engine is running.

Corrective action Normal Defective Replace oil pump. Check clearance. Correct if necessary. <Ref. to PS-90 INSPECTION, Pipe Assembly.>
Possible cause Relief valve emits operating sound when steering wheel is completely turned in either direction. (Dont keep this condition over 5 seconds.) Relief valve emits operating sound when steering wheel is not turned. This means that the relief valve is faulty. Interference with adjacent parts
Rattling noise (intermittent) While engine is running.
Loosened installation of oil pump, oil tank, pump bracket, Retighten. gearbox or crossmember Loosened installation of oil pump pulley or other pulley(s) Retighten. Loosened linkage or play of steering or suspension LoosRetighten or replace. ened tightening of joint or steering column Replace bad parts of the gearSound generates from the inside of gearbox or oil pump. box or oil pump. Adjust and retighten. Retighten or replace. Inspect and retighten fluid line connection. Refill fluid and vent air. Replace oil pump. Replace oil pump. Replace.
Knocking Excessive backlash When turning steering wheel in Loosened lock nut for adjusting backlash both direction with small angle repeatedly at engine ON or OFF. Loosened tightening or play of tie-rod, tie-rod end Vane pump aeration Grinding noise (continuous) While engine is running.
Squeal, squeak (intermittent or continuous) While engine is running.
Sizzling noise (continuous) While engine is running.
Whistle (continuous) While engine is running. Whine or growl (continuous or intermittent) While engine is running with/ without steering turned.
Creaking noise (intermittent) While engine is running with steering turned.
Vibration While engine is running with/ without steering turned.
Vane pump seizing Pulley bearing seizing of oil pump Folded hose, flat pipe Maladjustment of pulley belt Adjust or replace. Damaged or charged pulley belt (Replace two belts as a set.) Unequal length of pulley belts Run out or soilage of V-groove surface of oil pump pulley Clean or replace. Fix wrong part causing aeration. Fluid aeration Replace fluid and vent air. Damaged pipe of gearbox Replace pipe. Abnormal inside of hose or pipe Rectify or replace. Flat hose or pipe Abnormal inside of oil tank Replace. Removed oil tank cap Install cap. Replace bad parts of gearbox or Abnormal pipe of gearbox or abnormal inside of hose hose. Loosened installation of oil pump, oil pump bracket Retighten. Replace oil pump, hose, if the Abnormal inside of oil pump, hose noise can be heard when running as well as stand still. Torque converter growl, air conditioner compression Remove power steering pulley growl belt and confirm. Abnormal inside of gearbox Replace bad parts of gearbox. Abnormal bearing for steering shaft Apply grease or replace. Generates when turning steering wheel with brake (serIf the noise goes off when brake vice or parking) applied. is released, it is normal. Too low engine speed at start Adjust and instruct customers. Fix wrong part. Vane pump aeration Vent air. Replace oil pump, bad parts of Damaged valve in oil pump, gearbox gearbox. Looseness of play of steering, suspension parts Retighten.
PS-105

S601257A1002
2. MEASUREMENT OF STEERING EFFORT

No. 1 Step CHECK STEERING EFFORT. 1) Stop the vehicle on a concrete road. 2) Start the engine. 3) Idle the engine. 4) Install spring scale on the steering wheel. 5) Pull spring scale at an right angle to the steering wheel, and measure both right and left steering wheel effort. NOTE: When turning steering more quickly than necessary from a direction to the other direction at an engine speed over 2,000 rpm, steering effort may be heavy. This is caused by flow characteristic of oil pump and is not a problem. CHECK STEERING EFFORT. 1) Stop the engine. 2) Pull spring scale at an right angle to the steering wheel, and measure both right and left steering wheel effort. CHECK STEERING WHEEL EFFORT. 1) Remove universal joint. 2) Measure steering wheel effort. CHECK STEERING WHEEL EFFORT. Measure steering wheel effort. CHECK UNIVERSAL JOINT. Measure folding torque of the joint (short yoke). <Ref. to PS-29 INSPECTION, Universal Joint.> CHECK UNIVERSAL JOINT. Measure folding torque of the joint (long yoke). <Ref. to PS-29 INSPECTION, Universal Joint.> CHECK FRONT WHEEL.
Check Yes Is the steering effort 29.4 N Go to step 2. (3.0 kgf, 6.6 lb) or less?
No Adjustment backlash.
Is the steering effort 29.4 N Go to step 3. (3.0 kgf, 6.6 lb) or less?
Adjustment.
Is the maximum force Go to step 4. steering wheel effort 2.26 N (0.23 kgf, 0.51 lb) or less? Is the fluctuation width 1.08 Go to step 5. N (0.11 kgf, 0.24 lb) or less? Is the folding torque 8.43 N Go to step 6. (0.86 kgf, 1.90 lb) or less?
Check, adjust and replace if necessary. Check, adjust and replace if necessary. Replace with new one.
Is the folding torque 5.49 N Go to step 7. (0.56 kgf, 1.23 lb) or less?
Replace with new one.
CHECK TIE-ROD ENDS. Remove the tie-rod ends. CHECK BALL JOINT.
10
CHECK GEARBOX. Measure rotating of gearbox. <Ref. to PS-50 TURNING RESISTANCE OF GEAR BOX, INSPECTION, Steering Gearbox.>
11
CHECK GEARBOX. Measure sliding of gearbox. <Ref. to PS-49 SERVICE LIMIT, INSPECTION, Steering Gearbox.>
Are front wheels for unsteady revolution or rattling and brake for dragging? Are tie-rod ends of suspension for unsteady revolution or ratting? Are ball joints of suspension for unsteady revolution or ratting? Is rotating resistance is 11.18 N (1.14 kgf, 2.51 lb) or less around center position and 15.79 N (1.61 kgf, 3.55 lb) or less in all positions within 20% difference between clockwise and counterclockwise? Is rotating resistance is 304 N (31 kgf, 68 lb) or less with 20% difference between left and right direction?
Inspect, readjust and replace if necessary. Inspect and replace if necessary. Inspect and replace if necessary. Go to step 11.
Go to step 8.
Go to step 9.
Go to step 10.
Readjust backlash, and if ineffective, replace bad parts.
Steering effort is normal.
Readjust backlash, and if ineffective, replace bad parts.
PS-106
ABS (DIAGNOSTICS)
ABS
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Page Basic Diagnostic Procedure ........................................................................2 Check List for Interview...............................................................................6 General Description.....................................................................................9 Electrical Components Location................................................................12 Control Module I/O Signal.........................................................................14 Subaru Select Monitor...............................................................................18 Read Diagnostic Trouble Code .................................................................20 Inspection Mode ........................................................................................21 Clear Memory Mode..................................................................................22 ABS Warning Light Illumination Pattern....................................................23 List of Diagnostics Trouble Code ..............................................................24 Diagnostics Chart with Diagnosis Connector............................................28 Diagnostics Chart with Subaru Select Monitor .........................................90 General Diagnostics Table ......................................................................174
ABS (DIAGNOSTICS)

S006501

A: PROCEDURE
S006501E45
S006501E4501
CAUTION: Remove foreign matter (dust, water, etc.) from the ABSCM&H/U connector during removal and installation. NOTE: To check harness for broken wires or short circuits, shake it while holding it or the connector. When ABS warning light illuminates, read and record trouble code indicated by ABS warning light.
No. 1 Step Check Is unit that might influence CHECK PRE-INSPECTION. the ABS problem normal? 1) Ask the customer when and how the trouble occurred using interview checklist. <Ref. to ABS-6, Check List for Interview.> 2) Before performing diagnosis, inspect unit which might influence the ABS problem. <Ref. to ABS-9, INSPECTION, General Description.> CHECK INDICATION OF TROUBLE CODE. Is trouble code readable? Calling up trouble code. <Ref. to ABS-20, Read Diagnostic Trouble Code.> Yes Go to step 2. No Repair or replace each unit.
Go to step 3.
CHECK TROUBLE CODE. NOTE: Record all trouble codes. PERFORM THE GENERAL DIAGNOSTICS. 1) Inspect using General Diagnostics Table. <Ref. to ABS-174, General Diagnostics Table.> 2) Perform the clear memory mode. <Ref. to ABS-22, WITHOUT SUBARU SELECT MONITOR, OPERATION, Clear Memory Mode.> 3) Perform the inspection mode. <Ref. to ABS-21, Inspection Mode.> Calling up the trouble code. <Ref. to ABS-20, Read Diagnostic Trouble Code.>
Is only the start code issued? Is only the start code issued?
Go to step 4.
Inspect using diagnostic chart for ABS warning light failure.<Ref. to ABS-28, Diagnostics Chart with Diagnosis Connector.> NOTE: Call up trouble code again after inspecting ABS warning light. <Ref. to ABS-20, Read Diagnostic Trouble Code.> Go to step 5.
Complete the diagnosis.
Go to step 5.
ABS-2

No. 5 Step Check Is only the start code PERFORM THE DIAGNOSIS. 1) Inspect using Diagnostics Chart with Diag- issued? nostic Connector.<Ref. to ABS-28, Diagnostics Chart with Diagnosis Connector.> NOTE: For trouble code list, refer to List of Diagnostics Trouble Code.<Ref. to ABS-24, WITHOUT SUBARU SELECT MONITOR, LIST, List of Diagnostics Trouble Code.> 2) Repair trouble cause. 3) Perform the clear memory mode. <Ref. to ABS-22, WITHOUT SUBARU SELECT MONITOR, OPERATION, Clear Memory Mode.> 4) Perform the inspection mode. <Ref. to ABS-21, Inspection Mode.> 5) Calling up the trouble code. <Ref. to ABS20, Read Diagnostic Trouble Code.> Yes Complete the diagnosis.
ABS (DIAGNOSTICS)
No Inspect using Diagnostics Chart with Diagnostic Connector. <Ref. to ABS-28, Diagnostics Chart with Diagnosis Connector.>
ABS-3
ABS (DIAGNOSTICS)

S006501E4502
CAUTION: Remove foreign matter (dust, water, etc.) from the ABSCM&H/U connector during removal and installation. NOTE: To check harness for broken wires or short circuits, shake it while holding it or the connector. Check list for interview. <Ref. to ABS-26, WITH SUBARU SELECT MONITOR, LIST, List of Diagnostics Trouble Code.>
No. 1 Step CHECK PRE-INSPECTION. 1) Ask the customer when and how the trouble occurred using interview checklist. <Ref. to ABS-6, Check List for Interview.> 2) Before performing diagnosis, inspect unit which might influence the ABS problem. <Ref. to ABS-9, INSPECTION, General Description.> CHECK INDICATION OF TROUBLE CODE DISPLAY. 1) Turn ignition switch to OFF. 2) Connect the SUBARU SELECT MONITOR to data link connector. 3) Turn ignition switch to ON and SUBARU SELECT MONITOR to ON. NOTE: If the communication function of the select monitor cannot be executed normally, check the communication circuit. <Ref. to ABS-90, COMMUNICATION FOR INITIALIZING IMPOSSIBLE , Diagnostics Chart with Subaru Select Monitor.> 4) Read diagnostic trouble code. <Ref. to ABS-18, OPERATION, Subaru Select Monitor.> 5) Record all trouble codes and frame data. PERFORM THE GENERAL DIAGNOSTICS. 1) Inspect using General Diagnostics Table. <Ref. to ABS-174, General Diagnostics Table.> 2) Perform the clear memory mode. <Ref. to ABS-19, CLEAR MEMORY MODE, OPERATION, Subaru Select Monitor.> 3) Perform the inspection mode. <Ref. to ABS-21, Inspection Mode.> 4) Calling up the trouble code. <Ref. to ABS18, READ DIAGNOSTIC TROUBLE CODE, OPERATION, Subaru Select Monitor.> Check Is unit that might influence the ABS problem normal? Yes Go to step 2. No Repair or replace each unit.
Is the corresponding trouble encoding?
Go to step 3.
Go to step 4.
Is no trouble code designated and ABS warning light goes out after turning on?
Complete the diagnosis.
Go to step 4.
ABS-4

No. 4 Step PERFORM THE DIAGNOSIS. 1) Inspect using Diagnostics Chart with Subaru Select Monitor.<Ref. to ABS-90, Diagnostics Chart with Subaru Select Monitor.> NOTE: For trouble code list, refer to List of Diagnostics Trouble Code.<Ref. to ABS-24, WITHOUT SUBARU SELECT MONITOR, LIST, List of Diagnostics Trouble Code.> 2) Repair trouble cause. 3) Perform the clear memory mode. <Ref. to ABS-19, CLEAR MEMORY MODE, OPERATION, Subaru Select Monitor.> 4) Perform the inspection mode. <Ref. to ABS-21, Inspection Mode.> 5) Calling up the trouble code. <Ref. to ABS18, READ DIAGNOSTIC TROUBLE CODE, OPERATION, Subaru Select Monitor.> Check Yes Complete the Is no trouble code designated and does ABS warn- diagnosis. ing light go out after turning on?
ABS (DIAGNOSTICS)
No Inspect using Diagnostics Chart with Subaru Select Monitor. <Ref. to ABS-90, Diagnostics Chart with Subaru Select Monitor.>
ABS-5
ABS (DIAGNOSTICS)

S006502

A: CHECK
S006502A04
Check the following items about the vehicles state.
1. STATE OF ABS WARNING LIGHT

ABS warning light comes on.
S006502A0401
Ignition key position
Timing
Always Sometimes Only once Does not come on When / how long does it come on?: LOCK ACC ON (before starting engine) START On after starting (Engine is running) On after starting (Engine is stop) Immediately after ignition is ON. Immediately after ignition starts. When advancing While traveling at a constant speed When decelerating When turning to right When turning to left When moving other electrical parts Parts name : Operating condition : Steering Steering Steering Steering angle : time : angle : time : km/h
km/h to MPH to km/h to MPH to
km/h MPH MPH km/h MPH deg sec deg sec
ABS-6

2. SYMPTOMS
ABS operating condition
S006502A0402
ABS (DIAGNOSTICS)
Performs no work. Operates only when abruptly applying brakes. How to step on brake pedal : a) Operating time : b) Operating noise : Produce / Does not produce What kind of noise?
Vehicle speed :
km/h MPH sec
Knock Gong gong Bong Buzz Gong gong buzz Others :
c) Reaction force of brake pedal Stick Press down once with a clunk Press and released Others : a) Directional stability cannot be obtained or steering arm refuses to work when applying brakes : Yes / No When : Vehicle turns to right Vehicle turns to left Spins Others : b) Directional stability cannot be obtained or steering arm refuses to work when accelerating : Yes / No When : Vehicle turns to right Vehicle turns to left Spins Others : c) Brakes are out of order : Yes / No What : Braking distance is long Brakes lock or drag Pedal stroke is long Pedal sticks Others : d) Poor acceleration : Yes / No What : Fails to accelerate Engine stalls Others : e) Occurrence of vibration : Yes / No Where What kind : f) Occurrence of abnormal noise : Yes / No Where What kind : g) Occurrence of other phenomena : Yes / No What kind :
Behavior of vehicle
ABS-7
ABS (DIAGNOSTICS)

S006502A0403
3. CONDITIONS UNDER WHICH TROUBLE OCCURS

Environment a) Weather
Fine Cloudy Rainy Snowy Various/Others : F (C)
b) Ambient temperature c) Road
d) Road surface
Condition
a) Brakes b) Accelerator c) Vehicle speed
d) Tire inflation pressure
e) Degree of wear
Urban area Suburbs Highway General road Ascending slope Descending slope Paved road Gravel road Muddy road Sandy place Others : Dry Wet New-fallen snow Compressed snow Frozen slope Others : Deceleration : Continuous / Intermittent Acceleration : Continuous / Intermittent km/h Advancing Accelerating Reducing speed Low speed Turning Others : Front RH tire : Front LH tire : Rear RH tire : Rear LH tire : Front RH tire : Front LH tire : Rear RH tire : Rear LH tire :
g g MPH
kPa kPa kPa kPa
f) Genuine parts are used. : Yes / No g) Chain is passed around tires. : Yes / No h) T tire is used. : Yes / No i) Condition of suspension alignment : j) Loading state : k) Repair parts are used. : Yes / No What : l) Others :
ABS-8
GENERAL DESCRIPTION
ABS (DIAGNOSTICS)
S006001A10
A: CAUTION
S006001A03
S006001
B: INSPECTION
1. SUPPLEMENTAL RESTRAINT SYSTEM AIRBAG S006001A0301

Airbag system wiring harness is routed near the ABS sensor, ABS control module and hydraulic control unit. CAUTION: All Airbag system wiring harness and connectors are colored yellow. Do not use electrical test equipment on these circuit. Be careful not to damage Airbag system wiring harness when servicing the ABS sensor, ABS control module and hydraulic control unit.
Before performing diagnostics, check the following items which might affect ABS problems:
1. BATTERY
S006001A1001
Measure battery voltage and specific gravity of electrolyte. Standard voltage: 12 V, or more Specific gravity: Above 1.260
2. BRAKE FLUID
S006001A1002
1) Check brake fluid level. 2) Check brake fluid leakage.
3. HYDRAULIC UNIT
S006001A1006
Check the hydraulic unit. With brake tester <Ref. to ABS-9, CHECKING THE HYDRAULIC UNIT ABS OPERATION WITH BRAKE TESTER, INSPECTION, ABS Control Module and Hydraulic Control Unit (ABSCM&H/ U).> Without brake tester <Ref. to ABS-8, CHECKING THE HYDRAULIC UNIT ABS OPERATION BY PRESSURE GAUGE, INSPECTION, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).>
4. BRAKE DRAG
Check brake drag.
S006001A1003
5. BRAKE PAD AND ROTOR
S006001A1004
Check brake pad and rotor. Front <Ref. to BR-21, INSPECTION, Front Brake Pad.> and <Ref. to BR-22, INSPECTION, Front Disc Rotor.> Rear <Ref. to BR-26, INSPECTION, Rear Brake Pad.> and <Ref. to BR-28, INSPECTION, Rear Disc Rotor.> or <Ref. to BR-33, INSPECTION, Rear Drum Brake Shoe.> and <Ref. to BR-34, INSPECTION, Rear Drum Brake Drum.>
6. TIRE
S006001A1005
Check tire specifications, tire wear and air pressure. <Ref. to WT-2, SPECIFICATIONS, General Description.>
ABS-9
ABS (DIAGNOSTICS)
GENERAL DESCRIPTION
S006001A17
C: PREPARATION TOOL
1. SPECIAL TOOLS
ILLUSTRATION
S006001A1701
B2M3876
22771AA030
SELECT MONITOR KIT
B2M3877

TOOL NAME Circuit tester Oscilloscope
S006001A1702
REMARKS Used for measuring resistance, voltage and ampere. Used for measuring sensor.
ABS-10
GENERAL DESCRIPTION
MEMO:
ABS (DIAGNOSTICS)
ABS-11
ABS (DIAGNOSTICS)

S006507

A: LOCATION
S006507A13
S4M0478A
(1) ABS control module and hydraulic control unit (ABSCM&H/U) (2) Proportioning valve (3) Diagnosis connector (4) ABS warning light (5) Data link connector (for SUBARU select monitor)
(6) Automatic transmission control module (7) Front tone wheel (8) Front ABS sensor (9) Rear tone wheel (10) Rear ABS sensor (11) Wheel cylinder
(12) G sensor (13) Stop light switch (14) Master cylinder
ABS-12
ABS (DIAGNOSTICS)
B4M1226B
S2M2018B
B4M2285A H4M1328B
B4M0646H
B4M0231E
S4M0056A
ABS-13
ABS (DIAGNOSTICS)
CONTROL MODULE I/O SIGNAL

S006524
5. Control Module I/O Signal

S006524A08
B4M1228A
NOTE: The terminal numbers in the ABS control module and hydraulic control unit connector are as shown in the figure. When the connector is removed from the ABSCM&H/U, the connector switch closes the circuit between terminal No. 21 and No. 23. The ABS warning light illuminates.
ABS-14

Contents Front left wheel Front right wheel ABS sensor*2 (Wheel speed sensor) Rear left wheel Rear right wheel Valve relay power supply Motor relay power supply Power supply G sensor*2 Ground Output Stop light switch*1 ABS warning light*2 AT ABS signal*2 (AT model only) ABS operation signal monitor*2 Data is received. Data is sent. ABS diagnosis connec- Terminal No. 3 tor*2 Terminal No. 6 Power supply*1 Grounding line Grounding line Select monitor*2 Terminal No. (+)() 910 1112 78 1315 2423 2523 3028 28 628 223 2123 3123 323 2023 523 2923 423 123 23 26
ABS (DIAGNOSTICS)
Input/Output signal Measured value and measuring conditions 0.12 1 V (When it is 20 Hz.) 10 15 V 10 15 V 4.75 5.25 V 2.30.2 V when vehicle is in horizontal position. Less than 1.5 V when the stop light is OFF and, 10 15 V when the stop light is ON. Less than 1.5 V during 1.5 seconds when ignition switch is ON, and 10 15 V after 1.5 seconds. Less than 1.5 V when the ABS control still operates and more than 5.5 V when ABS does not operate. Less than 1.5 V when the ABS control still operates and more than 5.5 V when ABS does not operate. Less than 1.5 V when no data is received. 4.75 5.25 V when no data is sent. 10 15 V when ignition switch is ON. 10 15 V when ignition switch is ON. 10 15 V when ignition switch is ON.
*1: Measure the I/O signal voltage after removing the connector from the ABSCM&H/U terminal. *2: Measure the I/O signal voltage at connector (B62) and (R48) of LHD model or (B100) of RHD model.
ABS-15
ABS (DIAGNOSTICS)

S006524A21
B: SCHEMATIC
B4M2226
(1) ABS control module and hydraulic control unit (ABSCM&H/U) (2) ABS control module area (3) Valve relay (4) Motor relay (5) Motor (6) Front left inlet solenoid valve (7) Front left outlet solenoid valve (8) Front right inlet solenoid valve
(9) (10) (11) (12) (13) (14)
Front right outlet solenoid valve Rear left inlet solenoid valve Rear left outlet solenoid valve Rear right inlet solenoid valve Rear right outlet solenoid valve Transmission control module (only AT model) (15) Diagnosis connector (16) Data link connector
(17) (18) (19) (20) (21) (22) (23) (24)
ABS warning light Stop light switch Stop light G sensor Front left ABS sensor Front right ABS sensor Rear left ABS sensor Rear right ABS sensor
ABS-16
CONTROL MODULE I/O SIGNAL C: WAVEFORM

S006524G79
ABS (DIAGNOSTICS)
B4M2526A
ABS-17
ABS (DIAGNOSTICS)

S006503

A: OPERATION
S006503A1601 S006503A16
5) Turn ignition switch to ON (engine OFF) and Subaru Select Monitor switch to ON.
1. READ DIAGNOSTIC TROUBLE CODE

S2M0288D
(1)
Power switch
S2M0285
2) Connect diagnosis cable to Subaru Select Monitor. 3) Insert cartridge into Subaru Select Monitor. <Ref. to ABS-10, SPECIAL TOOLS, PREPARATION TOOL, General Description.>
6) On the Main Menu display screen, select the {Each System Check} and press the [YES] key. 7) On the System Selection Menu display screen, select the {Brake Control System} and press the [YES] key. 8) Press the [YES] key after displayed the information of engine type. 9) On the ABS Diagnosis display screen, select the {Diagnostic Code(s) Display} and press the [YES] key. 10) On the Diagnostic Code(s) Display display screen, select the {Current Diagnostic Code(s)} or {History Diagnostic Code(s)} and press the [YES] key. NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. For detailed concerning diagnostic trouble codes, refer to the LIST OF DIAGNOSTICS TROUBLE CODE. <Ref. to ABS-24, List of Diagnostics Trouble Code.>
S2M0286
S2M2157
ABS-18

2. READ CURRENT DATA
S006503A1602
ABS (DIAGNOSTICS)
1) On the Main Menu display screen, select the {Each System Check} and press the YES key. 2) On the System Selection Menu display screen, select the {Brake Control System} and press the YES key. 3) Press the YES key after displayed the information of ABS type. 4) On the Brake Control Diagnosis display screen, select the {Current Data Display & Save} and press the YES key. 5) On the Data Display Menu display screen, select the {Data Display} and press the YES key. 6) Using the scroll key, move the display screen up or down until the desired data is shown. A list of the support data is shown in the following table.
Display screen FR Wheel Speed FL Wheel Speed RR Wheel Speed RL Wheel Speed Stop Light Switch Stop Light Switch G sensor output Signal Valve Relay Signal Motor Relay Signal ABS Signal to TCM ABS Warning Lamp Motor Relay Monitor Valve Relay Monitor CCM Signal Contents to be monitored Wheel speed detected by the Front Right ABS sensor is displayed Wheel speed detected by the Front Left ABS sensor is displayed Wheel speed detected by the Rear Right ABS sensor is displayed Wheel speed detected by the Rear Left ABS sensor is displayed Stop light switch signal Stop light switch monitor voltage is displayed. Refers to vehicle acceleration detecting by the analog G sensor. It appears on the select monitor display in volts. Valve Relay Signal Motor Relay Signal ABS operation signal from ABS control module to TCM ON operation of the ABS warning light is displayed. Operating condition of the motor relay is displayed. Operating condition of the valve relay is displayed. ABS operation signal from ABS control module to TCM Unit of measure km/h or MPH km/h or MPH km/h or MPH km/h or MPH ON or OFF V V ON or OFF ON or OFF ON or OFF ON or OFF High or Low ON or OFF ON or OFF
3. CLEAR MEMORY MODE
S006503A1603
1) On the Main Menu display screen, select the {2. Each System Check} and press the YES key. 2) On the System Select Menu display screen, select {Brake System} and press the YES key. 3) Press the YES key after displayed the information of engine type. 4) On the Brake Control Diagnosis display screen, select the {Clear Memory} and press the YES key. 5) When the Done and turn ignition switch OFF are shown on the display screen, turn the Subaru Select Monitor and ignition switch to OFF. NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.
ABS-19
ABS (DIAGNOSTICS)

S006508

A: OPERATION
S006508A1602 S006508A16

1) Take out diagnosis connector from side of driver s seat heater unit.
2) Turn ignition switch OFF. 3) Connect diagnosis connector terminal 6 to diagnosis terminal. 4) Turn ignition switch ON. 5) ABS warning light is set in the diagnostic mode and blinks to identify trouble code.
B4M0231E
6) After the start code (11) is shown, the trouble codes will be shown in order of the last information first. These repeat for a maximum of 3 minutes. NOTE: When there are no trouble codes in memory, only the start code (11) is shown. When on-board diagnosis of the ABS control module detects a problem, the information (up to a maximum of three) will be stored in the EEPROM as a trouble code. When there are more than three, the most recent three will be stored. (Stored codes will stay in memory until they are cleared.)
B4M0232A
S006508A1601
Refer to SUBARU SELECT MONITOR for information about how to obtain and understand trouble codes. <Ref. to ABS-18, Subaru Select Monitor.>
ABS-20
INSPECTION MODE
ABS (DIAGNOSTICS)
8. Inspection Mode
A: OPERATION
S006510A16
S006510
Reproduce the condition under which the problem has occurred as much as possible. Drive the vehicle at a speed more than 40 km/h (25 MPH) for at least one minute.
ABS-21
ABS (DIAGNOSTICS)
CLEAR MEMORY MODE

S006513

A: OPERATION
S006513A1602 S006513A16

1) After calling up a trouble code, disconnect diagnosis connector terminal 6 from diagnosis terminal.
B4M0231E
2) Repeat 3 times within approx. 12 seconds; connecting and disconnecting terminal 6 and diagnosis terminal for at least 0.2 seconds each time.
B4M0233G
NOTE: After diagnostics is completed, make sure to clear memory. Make sure only start code (11) is shown after memory is cleared.
S006513A1601
Refer to SUBARU SELECT MONITOR for information about how to clear trouble codes. <Ref. to ABS-18, Subaru Select Monitor.>
ABS-22
ABS WARNING LIGHT ILLUMINATION PATTERN
ABS (DIAGNOSTICS)
10. ABS Warning Light Illumination Pattern

A: INSPECTION
S006581A10
S006581
B4M0781A
1) When the ABS warning light does not illuminate in accordance with this illumination pattern, there must be an electrical malfunction. 2) When the ABS warning light remains constantly OFF, repair the ABS warning light circuit or diagnosis circuit. <Ref. to ABS-28, Diagnostics Chart with Diagnosis Connector.> NOTE: Even though the ABS warning light does not go out 1.5 seconds after it illuminates, the ABS system operates normally when the warning light goes out while driving at approximately 12 km/h (7 MPH). However, the Anti-lock brakes do not work while the ABS warning light is illuminated.
ABS-23
ABS (DIAGNOSTICS)
LIST OF DIAGNOSTICS TROUBLE CODE

S006511
11. List of Diagnostics Trouble Code

A: LIST
Trouble code 11
S006511A12

Contents of diagnosis Start code Trouble code is shown after start code. Only start code is shown in normal condition.
S006511A1201
Index No.
21
23
25
27
22
24
26
28
29
<Ref. to ABS-42, TROUBLE CODE 21 ABNORMAL ABS SENFront right ABS sensor SOR (OPEN CIRCUIT OR INPUT VOLTAGE TOO HIGH) (FRONT RH) , Diagnostics Chart with Diagnosis Connector.> <Ref. to ABS-42, TROUBLE CODE 23 ABNORMAL ABS SENFront left ABS sensor SOR (OPEN CIRCUIT OR INPUT VOLTAGE TOO HIGH) (FRONT Abnormal ABS sensor LH) , Diagnostics Chart with Diagnosis Connector.> (Open circuit or input <Ref. to ABS-42, TROUBLE CODE 25 ABNORMAL ABS SENvoltage too high) Rear right ABS sensor SOR (OPEN CIRCUIT OR INPUT VOLTAGE TOO HIGH) (REAR RH) , Diagnostics Chart with Diagnosis Connector.> <Ref. to ABS-42, TROUBLE CODE 27 ABNORMAL ABS SENRear left ABS sensor SOR (OPEN CIRCUIT OR INPUT VOLTAGE TOO HIGH) (REAR LH) , Diagnostics Chart with Diagnosis Connector.> <Ref. to ABS-48, TROUBLE CODE 22 ABNORMAL ABS SENFront right ABS sensor SOR (FRONT RH) , Diagnostics Chart with Diagnosis Connector.> <Ref. to ABS-48, TROUBLE CODE 24 ABNORMAL ABS SENFront left ABS sensor SOR (FRONT LH) , Diagnostics Chart with Diagnosis Connector.> Abnormal ABS sensor <Ref. to ABS-48, TROUBLE CODE 26 ABNORMAL ABS SEN(Abnormal ABS sensor Rear right ABS sensor SOR (REAR RH) , Diagnostics Chart with Diagnosis Connecsignal) tor.> <Ref. to ABS-48, TROUBLE CODE 28 ABNORMAL ABS SENRear left ABS sensor SOR (REAR LH) , Diagnostics Chart with Diagnosis Connector.> <Ref. to ABS-56, TROUBLE CODE 29 ABNORMAL ABS SENAny one of four SOR SIGNAL (ANY ONE OF FOUR) , Diagnostics Chart with Diagnosis Connector.>
ABS-24

Trouble code 31 Contents of diagnosis Front right inlet valve Index No.
ABS (DIAGNOSTICS)
32
Front right outlet valve
33
Front left inlet valve
34
35
Abnormal solenoid valve circuit(s) in ABS control module and hydraulic unit
Front left outlet valve
Rear right inlet valve
36
Rear right outlet valve
37
Rear left inlet valve
38 41 42 44 51 52 54 56
Rear left outlet valve Abnormal ABS control module Source voltage is abnormal. A combination of AT control abnormal Abnormal valve relay Abnormal motor and/or motor relay Abnormal stop light switch Abnormal G sensor output voltage
<Ref. to ABS-62, TROUBLE CODE 31 ABNORMAL INLET SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (FRONT RH) , Diagnostics Chart with Diagnosis Connector.> <Ref. to ABS-66, TROUBLE CODE 32 ABNORMAL OUTLET SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (FRONT RH) , Diagnostics Chart with Diagnosis Connector.> <Ref. to ABS-62, TROUBLE CODE 33 ABNORMAL INLET SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (FRONT LH) , Diagnostics Chart with Diagnosis Connector.> <Ref. to ABS-66, TROUBLE CODE 34 ABNORMAL OUTLET SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (FRONT LH) , Diagnostics Chart with Diagnosis Connector.> <Ref. to ABS-62, TROUBLE CODE 35 ABNORMAL INLET SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (REAR RH) , Diagnostics Chart with Diagnosis Connector.> <Ref. to ABS-66, TROUBLE CODE 36 ABNORMAL OUTLET SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (REAR RH) , Diagnostics Chart with Diagnosis Connector.> <Ref. to ABS-62, TROUBLE CODE 37 ABNORMAL INLET SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (REAR LH) , Diagnostics Chart with Diagnosis Connector.> <Ref. to ABS-66, TROUBLE CODE 38 ABNORMAL OUTLET SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (REAR LH) , Diagnostics Chart with Diagnosis Connector.> <Ref. to ABS-70, TROUBLE CODE 41 ABNORMAL ABS CONTROL MODULE , Diagnostics Chart with Diagnosis Connector.> <Ref. to ABS-72, TROUBLE CODE 42 SOURCE VOLTAGE IS ABNORMAL. , Diagnostics Chart with Diagnosis Connector.> <Ref. to ABS-74, TROUBLE CODE 44 A COMBINATION OF AT CONTROL ABNORMAL , Diagnostics Chart with Diagnosis Connector.> <Ref. to ABS-76, TROUBLE CODE 51 ABNORMAL VALVE RELAY , Diagnostics Chart with Diagnosis Connector.> <Ref. to ABS-78, TROUBLE CODE 52 ABNORMAL MOTOR AND/OR MOTOR RELAY , Diagnostics Chart with Diagnosis Connector.> <Ref. to ABS-82, TROUBLE CODE 54 ABNORMAL STOP LIGHT SWITCH , Diagnostics Chart with Diagnosis Connector.> <Ref. to ABS-84, TROUBLE CODE 56 ABNORMAL G SENSOR OUTPUT VOLTAGE , Diagnostics Chart with Diagnosis Connector.>
ABS-25
ABS (DIAGNOSTICS)

S006511A1202

Code Display screen Communication for initializing impossible
21
Contents of diagnosis Select monitor communication failure Although no trouble code appears on the No trouble code select monitor display, the ABS warning light remains on. Open or short circuit in Open or short circuit in front right ABS sensor front right ABS sensor circuit circuit Front right ABS sensor Front right ABS sensor abnormal signal abnormal signal Open or short circuit in Open or short circuit in front left ABS sensor front left ABS sensor circuit circuit Front left ABS sensor abnormal signal Front left ABS sensor abnormal signal
Index No. <Ref. to ABS-90, COMMUNICATION FOR INITIALIZING IMPOSSIBLE , Diagnostics Chart with Subaru Select Monitor.> <Ref. to ABS-94, NO TROUBLE CODE, Diagnostics Chart with Subaru Select Monitor.> <Ref. to ABS-98, TROUBLE CODE 21 OPEN OR SHORT CIRCUIT IN FRONT RIGHT ABS SENSOR CIRCUIT , Diagnostics Chart with Subaru Select Monitor.> <Ref. to ABS-106, TROUBLE CODE 22 FRONT RIGHT ABNORMAL ABS SENSOR SIGNAL , Diagnostics Chart with Subaru Select Monitor.> <Ref. to ABS-98, TROUBLE CODE 23 OPEN OR SHORT CIRCUIT IN FRONT LEFT ABS SENSOR CIRCUIT , Diagnostics Chart with Subaru Select Monitor.> <Ref. to ABS-106, TROUBLE CODE 24 FRONT LEFT ABNORMAL ABS SENSOR SIGNAL , Diagnostics Chart with Subaru Select Monitor.> <Ref. to ABS-98, TROUBLE CODE 25 OPEN OR SHORT CIRCUIT IN REAR RIGHT ABS SENSOR CIRCUIT , Diagnostics Chart with Subaru Select Monitor.> <Ref. to ABS-106, TROUBLE CODE 26 REAR RIGHT ABNORMAL ABS SENSOR SIGNAL , Diagnostics Chart with Subaru Select Monitor.> <Ref. to ABS-98, TROUBLE CODE 27 OPEN OR SHORT CIRCUIT IN REAR LEFT ABS SENSOR CIRCUIT , Diagnostics Chart with Subaru Select Monitor.> <Ref. to ABS-106, TROUBLE CODE 28 REAR LEFT ABNORMAL ABS SENSOR SIGNAL , Diagnostics Chart with Subaru Select Monitor.> <Ref. to ABS-114, TROUBLE CODE 29 ABNORMAL ABS SENSOR SIGNAL ON ANY ONE OF FOUR SENSOR , Diagnostics Chart with Subaru Select Monitor.> <Ref. to ABS-120, TROUBLE CODE 31 FRONT RIGHT INLET VALVE MALFUNCTION , Diagnostics Chart with Subaru Select Monitor.> <Ref. to ABS-124, TROUBLE CODE 32 FRONT RIGHT OUTLET VALVE MALFUNCTION , Diagnostics Chart with Subaru Select Monitor.> <Ref. to ABS-120, TROUBLE CODE 33 FRONT LEFT INLET VALVE MALFUNCTION , Diagnostics Chart with Subaru Select Monitor.> <Ref. to ABS-124, TROUBLE CODE 34 FRONT LEFT OUTLET VALVE MALFUNCTION , Diagnostics Chart with Subaru Select Monitor.> <Ref. to ABS-120, TROUBLE CODE 35 REAR RIGHT INLET VALVE MALFUNCTION , Diagnostics Chart with Subaru Select Monitor.> <Ref. to ABS-124, TROUBLE CODE 36 REAR RIGHT OUTLET VALVE MALFUNCTION , Diagnostics Chart with Subaru Select Monitor.> <Ref. to ABS-120, TROUBLE CODE 37 REAR LEFT INLET VALVE MALFUNCTION , Diagnostics Chart with Subaru Select Monitor.>
22
23
24
25
Open or short circuit in Open or short circuit in rear right ABS sensor rear right ABS sensor circuit circuit Rear right ABS sensor abnormal signal Rear right ABS sensor abnormal signal
26
27
Open or short circuit in Open or short circuit in rear left ABS sensor rear left ABS sensor circuit circuit Rear left ABS sensor abnormal signal Abnormal ABS sensor signal on any one of four sensor Front right inlet valve malfunction Front right outlet valve malfunction Front left inlet valve malfunction Front left outlet valve malfunction Rear right inlet valve malfunction Rear right outlet valve malfunction Rear left inlet valve malfunction Rear left ABS sensor abnormal signal Abnormal ABS sensor signal on any one of four Front right inlet valve malfunction Front right outlet valve malfunction Front left inlet valve malfunction Front left outlet valve malfunction Rear right inlet valve malfunction Rear right outlet valve malfunction Rear left inlet valve malfunction
28
29
31
32
33
34
35
36
37
ABS-26

Code 38 Display screen Rear left outlet valve malfunction ABS control module malfunction Power supply voltage too low Power supply voltage too high ABS-AT control (Non Controlled) ABS-AT control (Controlled) Contents of diagnosis Rear left outlet valve malfunction ABS control module and hydraulic control unit malfunction Power supply voltage too low Power supply voltage too high ABS-AT control (Non Controlled) ABS-AT control (Controlled)
ABS (DIAGNOSTICS)
41
42
42
44
44 51 51 52 52 52 54
Valve relay malfunction Valve relay malfunction Valve relay ON failure Open circuit in motor relay circuit Motor relay ON failure Motor malfunction Valve relay ON failure Open circuit in motor relay circuit Motor relay ON failure Motor malfunction
Stop light switch signal Stop light switch signal circuit malfunction circuit malfunction Open or short circuit in Open or short circuit in G sensor circuit G sensor circuit Battery short in G sen- Battery short in G sensor circuit sor circuit Abnormal G sensor high output Detection of G sensor stick Abnormal G sensor high output Detection of G sensor stick
56
56
56
56
Index No. <Ref. to ABS-124, TROUBLE CODE 38 REAR LEFT OUTLET VALVE MALFUNCTION , Diagnostics Chart with Subaru Select Monitor.> <Ref. to ABS-128, TROUBLE CODE 41 ABS CONTROL MODULE MALFUNCTION , Diagnostics Chart with Subaru Select Monitor.> <Ref. to ABS-130, TROUBLE CODE 42 POWER SUPPLY VOLTAGE TOO LOW , Diagnostics Chart with Subaru Select Monitor.> <Ref. to ABS-132, TROUBLE CODE 42 POWER SUPPLY VOLTAGE TOO HIGH , Diagnostics Chart with Subaru Select Monitor.> <Ref. to ABS-134, TROUBLE CODE 44 ABS-AT CONTROL (NON CONTROLLED) , Diagnostics Chart with Subaru Select Monitor.> <Ref. to ABS-136, TROUBLE CODE 44 ABS-AT CONTROL (CONTROLLED) , Diagnostics Chart with Subaru Select Monitor.> <Ref. to ABS-138, TROUBLE CODE 51 VALVE RELAY MALFUNCTION , Diagnostics Chart with Subaru Select Monitor.> <Ref. to ABS-140, TROUBLE CODE 51 VALVE RELAY ON FAILURE , Diagnostics Chart with Subaru Select Monitor.> <Ref. to ABS-142, TROUBLE CODE 52 OPEN CIRCUIT IN MOTOR RELAY CIRCUIT , Diagnostics Chart with Subaru Select Monitor.> <Ref. to ABS-146, TROUBLE CODE 52 MOTOR RELAY ON FAILURE , Diagnostics Chart with Subaru Select Monitor.> <Ref. to ABS-150, TROUBLE CODE 52 MOTOR MALFUNCTION , Diagnostics Chart with Subaru Select Monitor.> <Ref. to ABS-154, TROUBLE CODE 54 STOP LIGHT SWITCH SIGNAL CIRCUIT MALFUNCTION , Diagnostics Chart with Subaru Select Monitor.> <Ref. to ABS-156, TROUBLE CODE 56 OPEN OR SHORT CIRCUIT IN G SENSOR CIRCUIT , Diagnostics Chart with Subaru Select Monitor.> <Ref. to ABS-160, TROUBLE CODE 56 BATTERY SHORT IN G SENSOR CIRCUIT , Diagnostics Chart with Subaru Select Monitor.> <Ref. to ABS-166, TROUBLE CODE 56 ABNORMAL G SENSOR HIGH OUTPUT , Diagnostics Chart with Subaru Select Monitor.> <Ref. to ABS-170, TROUBLE CODE 56 DETECTION OF G SENSOR STICK , Diagnostics Chart with Subaru Select Monitor.>
NOTE: High means high friction coefficient against road surface.
ABS-27
ABS (DIAGNOSTICS)
DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR

S006522
12. Diagnostics Chart with Diagnosis Connector

A: ABS WARNING LIGHT DOES NOT COME ON.
S006522E24
DIAGNOSIS: ABS warning light circuit is open or shorted. TROUBLE SYMPTOM: When ignition switch is turned ON (engine OFF), ABS warning light does not come on.
ABS-28

ABS (DIAGNOSTICS)
S4M0553
ABS-29
ABS (DIAGNOSTICS)
WIRING DIAGRAM: RHD MODEL
S4M0554
ABS-30

No. 1 Step CHECK IF OTHER WARNING LIGHTS TURN ON. Turn ignition switch to ON (engine OFF). Check Yes Do other warning lights turn Go to step 2. on?
ABS (DIAGNOSTICS)
No Repair combination meter. <Ref. to IDI-15, Combination Meter Assembly.> Replace ABS warning light bulb. <Ref. to IDI-15, Combination Meter Assembly.> Repair warning light harness.
CHECK ABS WARNING LIGHT BULB. 1) Turn ignition switch to OFF. 2) Remove combination meter. 3) Remove ABS warning light bulb from combination meter. CHECK BATTERY SHORT OF ABS WARNING LIGHT HARNESS. 1) Disconnect connector (B62) or (B100) from connector (F45) or (F2). 2) Measure voltage between connector (B200) and chassis ground. Connector & terminal LHD turbo: (B62) No. 10 (+) Chassis ground (): LHD non-turbo: (B62) No. 8 (+) Chassis ground (): RHD: (B100) No. 14 (+) Chassis ground (): CHECK BATTERY SHORT OF ABS WARNING LIGHT HARNESS. 1) Turn ignition switch to ON. 2) Measure voltage between connector (B62) or (B100) and chassis ground. Connector & terminal LHD turbo: (B62) No. 10 (+) Chassis ground (): LHD non-turbo: (B62) No. 8 (+) Chassis ground (): RHD: (B100) No. 14 (+) Chassis ground (): CHECK WIRING HARNESS. 1) Turn ignition switch to OFF. 2) Install ABS warning light bulb to combination meter. 3) Install combination meter. 4) Turn ignition switch to ON. 5) Measure voltage between connector (B62) or (B100) and chassis ground. Connector & terminal LHD turbo: (B62) No. 10 (+) Chassis ground (): LHD non-turbo: (B62) No. 8 (+) Chassis ground (): RHD: (B100) No. 14 (+) Chassis ground ():
Is ABS warning light bulb OK?
Go to step 3.
Go to step 4.
Go to step 5.
Repair warning light harness.
Is the voltage between 10 and 15 V?
Go to step 6.
Repair wiring harness.
ABS-31
ABS (DIAGNOSTICS)
No. 6

Check Is the voltage less than 3 V? Yes Go to step 7. No Repair wiring harness.
10
Step CHECK BATTERY SHORT OF ABS WARNING LIGHT HARNESS. 1) Turn ignition switch to OFF. 2) Measure voltage between connector (F45) or (F2) and chassis ground. Connector & terminal LHD turbo: (F45) No. 10 (+) Chassis ground (): LHD non-turbo: (F45) No. 8 (+) Chassis ground (): RHD: (F2) No. 14 (+) Chassis ground (): CHECK BATTERY SHORT OF ABS WARNING LIGHT HARNESS. 1) Turn ignition switch to ON. 2) Measure voltage between connector (F45) or (F2) and chassis ground. Connector & terminal LHD turbo: (F45) No. 10 (+) Chassis ground (): LHD non-turbo: (F45) No. 8 (+) Chassis ground (): RHD: (F2) No. 14 (+) Chassis ground (): CHECK GROUND CIRCUIT OF ABSCM&H/U. Measure resistance between ABSCM&H/U and chassis ground. Connector & terminal (F49) No. 23 GND: CHECK WIRING HARNESS. Measure resistance between connector (F45) or (F2) and chassis ground. Connector & terminal LHD turbo: (F45) No. 10 (+) Chassis ground (): LHD non-turbo: (F45) No. 8 (+) Chassis ground (): RHD: (F2) No. 14 (+) Chassis ground (): CHECK POOR CONTACT IN CONNECTORS. Turn ignition switch to OFF.
Go to step 8.
Go to step 9.
Repair ABSCM&H/U ground harness.
Go to step 10.
Repair harness/ connector.
Repair connector. Is there poor contact in connectors between combination meter and ABSCM&H/U?
Replace ABSCM&H/U. <Ref. to ABS-7, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).>
ABS-32

MEMO:
ABS (DIAGNOSTICS)
ABS-33
ABS (DIAGNOSTICS)

S006522E25
B: ABS WARNING LIGHT DOES NOT GO OFF.
DIAGNOSIS: ABS warning light circuit is open or shorted. TROUBLE SYMPTOM: When starting the engine and while ABS warning light is kept ON. WIRING DIAGRAM: LHD MODEL
S4M0553
ABS-34

ABS (DIAGNOSTICS)
S4M0554
ABS-35
ABS (DIAGNOSTICS)
No. 1

Check Is ABSCM&H/U connector inserted into ABSCM until the clamp locks onto it? Yes Go to step 2. No Insert ABSCM&H/U connector into ABSCM&H/U until the clamp locks onto it. Repair diagnosis terminal harness.
Step CHECK INSTALLATION OF ABSCM&H/U CONNECTOR. Turn ignition switch to OFF.
5 6
CHECK DIAGNOSIS TERMINAL. Measure resistance between diagnosis terminals (B81) and chassis ground. Terminals Diagnosis terminal (A) Chassis ground: Diagnosis terminal (B) Chassis ground: CHECK DIAGNOSIS LINE. 1) Turn ignition switch to OFF. 2) Connect diagnosis terminal (B81) to diagnosis connector (B82) No. 6. 3) Disconnect connector from ABSCM&H/U. 4) Measure resistance between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 4 Chassis ground: CHECK GENERATOR. 1) Start the engine. 2) Idle the engine. 3) Measure voltage between generator and chassis ground. Terminal Generator B terminal (+) Chassis ground (): CHECK BATTERY TERMINAL. Turn ignition switch to OFF. CHECK POWER SUPPLY OF ABSCM. 1) Disconnect connector from ABSCM&H/U. 2) Start engine. 3) Idle the engine. 4) Measure voltage between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 1 (+) Chassis ground (): CHECK WIRING HARNESS. 1) Disconnect connector (F45) or (F2) from connector (B62) or (B100). 2) Turn ignition switch to ON. CHECK PROJECTION AT ABSCM&H/U. 1) Turn ignition switch to OFF. 2) Check for broken projection at the ABSCM&H/U terminal.
Go to step 3.
Go to step 4.
Repair harness connector between ABSCM&H/U and diagnosis connector.
Go to step 5.
Is there poor contact at battery terminal? Is the voltage between 10 and 15 V?
Repair battery terminal. Go to step 7.
Go to step 6. Repair ABSCM&H/U power supply circuit.
Does the ABS warning light Go to step 8. remain off?
Repair front wiring harness.
Are the projection broken?
Go to step 9.
CHECK ABSCM&H/U. Measure resistance between ABSCM&H/U terminals. Terminal No. 21 No. 23:
Replace ABSCM&H/U. <Ref. to ABS-7, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).> Replace ABSCM&H/U. <Ref. to ABS-7, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).>
ABS-36

No. 10 Step CHECK WIRING HARNESS. Measure resistance between connector (F45) or (F2) and chassis ground. Connector & terminal LHD turbo: (F45) No. 10 Chassis ground: LHD non-turbo: (F45) No. 8 Chassis ground: RHD: (F2) No. 14 Chassis ground: CHECK WIRING HARNESS. 1) Connect connector to ABSCM&H/U. 2) Measure resistance between connector (F45) or (F2) and chassis ground. Connector & terminal LHD turbo: (F45) No. 10 Chassis ground: LHD non-turbo: (F45) No. 8 Chassis ground: RHD: (F2) No. 14 Chassis ground: CHECK POOR CONTACT IN ABSCM&H/U CONNECTOR. Check Is the resistance less than 0.5 ? Yes Go to step 11.
ABS (DIAGNOSTICS)
No Repair harness.
11
Repair harness.
12
Is there poor contact in ABSCM&H/U connector?
Repair connector.
ABS-37
ABS (DIAGNOSTICS)

S006522E50
C: TROUBLE CODE DOES NOT APPEAR.

DIAGNOSIS: Diagnosis circuit is open.
TROUBLE SYMPTOM: The ABS warning light turns on or off normally but the start code cannot be read out in the diagnostic mode.
ABS-38

ABS (DIAGNOSTICS)
S4M0553
ABS-39
ABS (DIAGNOSTICS)
S4M0554
ABS-40

No. 1 Step CHECK DIAGNOSIS TERMINAL. 1) Turn ignition switch to OFF. 2) Measure resistance between diagnosis terminals (B81) and chassis ground. Terminals Diagnosis terminal (A) Chassis ground: Diagnosis terminal (B) Chassis ground: CHECK DIAGNOSIS LINE. 1) Turn ignition switch to OFF. 2) Connect diagnosis terminal (B81) to diagnosis connector (B82) No. 6. 3) Disconnect connector from ABSCM&H/U. 4) Measure resistance between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 4 Chassis ground: CHECK POOR CONTACT IN ABSCM&H/U CONNECTOR. Check Is the resistance less than 0.5 ? Yes Go to step 2.
ABS (DIAGNOSTICS)
No Repair diagnosis terminal harness.
Go to step 3.
Repair harness connector between ABSCM&H/U and diagnosis connector.
Repair connector.
ABS-41
ABS (DIAGNOSTICS)
D: TROUBLE CODE 21 ABNORMAL ABS SENSOR (OPEN CIRCUIT OR INPUT VOLTAGE TOO HIGH) (FRONT RH)
S006522E60
NOTE: For the diagnostic procedure, refer to TROUBLE CODE 27. <Ref. to ABS-42, TROUBLE CODE 27 ABNORMAL ABS SENSOR (OPEN CIRCUIT OR INPUT VOLTAGE TOO HIGH) (REAR LH) , Diagnostics Chart with Diagnosis Connector.>
E: TROUBLE CODE 23 ABNORMAL ABS SENSOR (OPEN CIRCUIT OR INPUT VOLTAGE TOO HIGH) (FRONT LH)
S006522E61
F: TROUBLE CODE 25 ABNORMAL ABS SENSOR (OPEN CIRCUIT OR INPUT VOLTAGE TOO HIGH) (REAR RH)
S006522E62
G: TROUBLE CODE 27 ABNORMAL ABS SENSOR (OPEN CIRCUIT OR INPUT VOLTAGE TOO HIGH) (REAR LH)
S006522E63
DIAGNOSIS: Faulty ABS sensor (Broken wire, input voltage too high) Faulty harness connector TROUBLE SYMPTOM: ABS does not operate.
ABS-42

ABS (DIAGNOSTICS)
S4M0555
ABS-43
ABS (DIAGNOSTICS)
S4M0556
ABS-44

No. 1 Step CHECK ABS SENSOR. 1) Turn ignition switch to OFF. 2) Disconnect connector from ABS sensor. 3) Measure resistance of ABS sensor connector terminals. Terminal Front RH No. 1 No. 2: Front LH No. 1 No. 2: Rear RH No. 1 No. 2: Rear LH No. 1 No. 2: CHECK BATTERY SHORT OF ABS SENSOR. 1) Disconnect connector from ABSCM&H/U. 2) Measure voltage between ABS sensor and chassis ground. Terminal Front RH No. 1 (+) Chassis ground (): Front LH No. 1 (+) Chassis ground (): Rear RH No. 1 (+) Chassis ground (): Rear LH No. 1 (+) Chassis ground (): CHECK BATTERY SHORT OF ABS SENSOR. 1) Turn ignition switch to ON. 2) Measure voltage between ABS sensor and chassis ground. Terminal Front RH No. 1 (+) Chassis ground (): Front LH No. 1 (+) Chassis ground (): Rear RH No. 1 (+) Chassis ground (): Rear LH No. 1 (+) Chassis ground (): CHECK HARNESS/CONNECTOR BETWEEN ABSCM&H/U AND ABS SENSOR. 1) Turn ignition switch to OFF. 2) Connect connector to ABS sensor. 3) Measure resistance between ABSCM&H/U connector terminals. Connector & terminal Trouble code 21 / (F49) No. 11 No. 12: Trouble code 23 / (F49) No. 9 No. 10: Trouble code 25 / (F49) No. 13 No. 15: Trouble code 27 / (F49) No. 7 No. 8: Check Yes Is the resistance between 1 Go to step 2. and 1.5 k?
ABS (DIAGNOSTICS)
No Replace ABS sensor. Front: <Ref. to ABS-14, Front ABS Sensor.> Rear: <Ref. to ABS-18, Rear ABS Sensor.>
Go to step 3.
Replace ABS sensor. Front: <Ref. to ABS-14, Front ABS Sensor.> Rear: <Ref. to ABS-18, Rear ABS Sensor.>
Go to step 4.
Is the resistance between 1 Go to step 5. and 1.5 k?
Repair harness/ connector between ABSCM&H/U and ABS sensor.
ABS-45
ABS (DIAGNOSTICS)
No. 5

Check Is the voltage less than 1 V? Yes Go to step 6. No Repair harness between ABSCM&H/U and ABS sensor.
Step CHECK BATTERY SHORT OF HARNESS. Measure voltage between ABSCM&H/U connector and chassis ground. Connector & terminal Trouble code 21 / (F49) No. 11 (+) Chassis ground (): Trouble code 23 / (F49) No. 9 (+) Chassis ground (): Trouble code 25 / (F49) No. 13 (+) Chassis ground (): Trouble code 27 / (F49) No. 7 (+) Chassis ground (): CHECK BATTERY SHORT OF HARNESS. 1) Turn ignition switch to ON. 2) Measure voltage between ABSCM&H/U connector and chassis ground. Connector & terminal Trouble code 21 / (F49) No. 11 (+) Chassis ground (): Trouble code 23 / (F49) No. 9 (+) Chassis ground (): Trouble code 25 / (F49) No. 13 (+) Chassis ground (): Trouble code 27 / (F49) No. 7 (+) Chassis ground (): CHECK INSTALLATION OF ABS SENSOR. Turn ignition switch to OFF. Tightening torque: 3210 Nm (3.31.0 kgf-m, 247 ft-lb) CHECK ABS SENSOR GAP. Measure tone wheel to ABS sensor piece gap over entire perimeter of the wheel. Front wheel 0.3 0.8 mm (0.012 0.031 in) Rear wheel 0.7 1.2 mm (0.028 0.047 in)
Go to step 7.
Repair harness between ABSCM&H/U and ABS sensor.
Are the ABS sensor installation bolts tightened securely? Is the gap within the specifications?
Go to step 8.
Tighten ABS sensor installation bolts securely. Adjust the gap. NOTE: Adjust the gap using spacers (Part No. 26755AA000). If spacers cannot correct the gap, replace worn sensor or worn tone wheel. Replace tone wheel. Front: <Ref. to ABS-21, Front Tone Wheel.> Rear: <Ref. to ABS-22, Rear Tone Wheel.>
Go to step 9.
CHECK TONE WHEEL RUNOUT. Measure tone wheel runout.
Is the runout less than 0.05 Go to step 10. mm (0.0020 in)?
ABS-46

No. 10 Step CHECK GROUND SHORT OF ABS SENSOR. 1) Turn ignition switch to ON. 2) Measure resistance between ABS sensor and chassis ground. Terminal Front RH No. 1 Chassis ground: Front LH No. 1 Chassis ground: Rear RH No. 1 Chassis ground: Rear LH No. 1 Chassis ground: Check Yes Is the resistance more than Go to step 11. 1 M?
ABS (DIAGNOSTICS)
No Replace ABS sensor and ABSCM&H/U. Front: <Ref. to ABS-14, Front ABS Sensor.> Rear: <Ref. to ABS-18, Rear ABS Sensor.> and <Ref. to ABS-7, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).> Repair harness between ABSCM&H/U and ABS sensor. Replace ABSCM&H/U. <Ref. to ABS-7, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).>
11
12
CHECK GROUND SHORT OF HARNESS. 1) Turn ignition switch to OFF. 2) Connect connector to ABS sensor. 3) Measure resistance between ABSCM&H/U connector terminal and chassis ground. Connector & terminal Trouble code 21 / (F49) No. 11 Chassis ground: Trouble code 23 / (F49) No. 9 Chassis ground: Trouble code 25 / (F49) No. 13 Chassis ground: Trouble code 27 / (F49) No. 7 Chassis ground: CHECK POOR CONTACT IN CONNECTORS.
13
CHECK ABSCM&H/U. 1) Connect all connectors. 2) Erase the memory. 3) Perform inspection mode. 4) Read out the trouble code.
Is there poor contact in connectors between ABSCM&H/U and ABS sensor? Is the same trouble code as in the current diagnosis still being output?
Repair connector.
Go to step 13.
14
CHECK ANY OTHER TROUBLE CODES APPEARANCE.
Replace ABSCM&H/U. <Ref. to ABS-7, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).> Proceed with the diagnosis corresponding to the trouble code.
Go to step 14.
A temporary poor contact. NOTE: Check harness and connectors between ABSCM&H/U and ABS sensor.
ABS-47
ABS (DIAGNOSTICS)
H: TROUBLE CODE 22 ABNORMAL ABS SENSOR (FRONT RH)
S006522E64
NOTE: For the diagnostic procedure, refer to TROUBLE CODE 28. <Ref. to ABS-48, TROUBLE CODE 28 ABNORMAL ABS SENSOR (REAR LH) , Diagnostics Chart with Diagnosis Connector.>
I: TROUBLE CODE 24 ABNORMAL ABS SENSOR (FRONT LH)
S006522E65
J: TROUBLE CODE 26 ABNORMAL ABS SENSOR (REAR RH)
S006522E66
K: TROUBLE CODE 28 ABNORMAL ABS SENSOR (REAR LH)

DIAGNOSIS: Faulty ABS sensor signal (noise, irregular signal, etc.) Faulty harness/connector TROUBLE SYMPTOM: ABS does not operate.
S006522E67
ABS-48

ABS (DIAGNOSTICS)
S4M0555
ABS-49
ABS (DIAGNOSTICS)
S4M0556
ABS-50

No. 1 Step CHECK INSTALLATION OF ABS SENSOR. Turn ignition switch to OFF. Tightening torque: 3210 Nm (3.31.0 kgf-m, 247 ft-lb) CHECK ABS SENSOR GAP. Measure tone wheel to ABS sensor piece gap over entire perimeter of the wheel. Front wheel 0.3 0.8 mm (0.012 0.031 in) Rear wheel 0.7 1.2 mm (0.028 0.047 in) Check Are the ABS sensor installation bolts tightened securely? Is the gap within the specifications? Yes Go to step 2.
ABS (DIAGNOSTICS)
No Tighten ABS sensor installation bolts securely. Adjust the gap. NOTE: Adjust the gap using spacer (Part No. 26755AA000). If spacers cannot correct the gap, replace worn sensor or worn tone wheel. Go to step 5. Go to step 7.
Go to step 3.
3 4
PREPARE OSCILLOSCOPE. CHECK ABS SENSOR SIGNAL. 1) Raise all four wheels of ground. 2) Turn ignition switch OFF. 3) Connect the oscilloscope to the connector. 4) Turn ignition switch ON. 5) Rotate wheels and measure voltage at specified frequency. <Ref. to ABS-17, WAVEFORM, Control Module I/O Signal.> NOTE: When this inspection is completed, the ABS control module sometimes stores the trouble code 29. Connector & terminal Trouble code 22 / LHD turbo: (B62) No. 7 (+) No. 18 (): LHD non-turbo: (B62) No. 5 (+) No. 14 (): RHD: (B100) No. 8 (+) No. 20 (): Trouble code 24 / LHD turbo: (B62) No. 9 (+) No. 20 (): LHD non-turbo: (B62) No. 7 (+) No. 16 (): RHD: (B100) No. 10 (+) No. 22 (): Trouble code 26 / LHD: (F55) No. 12 (+) No. 11 (): RHD: (B98) No. 15 (+) No. 16 (): Trouble code 28 / LHD: (F55) No. 5 (+) No. 4 (): RHD: (B98) No. 5 (+) No. 6 (): CHECK CONTAMINATION OF ABS SENSOR OR TONE WHEEL. Remove disc rotor or drum from hub in accordance with trouble code.
Is an oscilloscope available? Is oscilloscope pattern smooth, as shown in figure?
Is the ABS sensor piece or the tone wheel contaminated by dirt or other foreign matter?
Go to step 6. Thoroughly remove dirt or other foreign matter.
ABS-51
ABS (DIAGNOSTICS)
No. 6

Yes No Replace ABS sen- Go to step 7. sor or tone wheel. Front: <Ref. to ABS-14, Front ABS Sensor.> Rear: <Ref. to ABS-18, Rear ABS Sensor.> and Front: <Ref. to ABS-21, Front Tone Wheel.> Rear: <Ref. to ABS-22, Rear Tone Wheel.> Is the runout less than 0.05 Go to step 8. Replace tone mm (0.0020 in)? wheel. Front: <Ref. to ABS-21, Front Tone Wheel.> Rear: <Ref. to ABS-22, Rear Tone Wheel.> Is the resistance between 1 Go to step 9. Replace ABS senand 1.5 k? sor. Front: <Ref. to ABS-14, Front ABS Sensor.> Rear: <Ref. to ABS-18, Rear ABS Sensor.> Check Are there broken or damaged in the ABS sensor piece or the tone wheel?
Step CHECK DAMAGE OF ABS SENSOR OR TONE WHEEL.
10
CHECK RESISTANCE OF ABS SENSOR. 1) Turn ignition switch OFF. 2) Disconnect connector from ABS sensor. 3) Measure resistance between ABS sensor connector terminals. Terminal Front RH No. 1 No. 2: Front LH No. 1 No. 2: Rear RH No. 1 No. 2: Rear LH No. 1 No. 2: CHECK GROUND SHORT OF ABS SENSOR. Measure resistance between ABS sensor and chassis ground. Terminal Front RH No. 1 Chassis ground: Front LH No. 1 Chassis ground: Rear RH No. 1 Chassis ground: Rear LH No. 1 Chassis ground: CHECK HARNESS/CONNECTOR BETWEEN ABSCM&H/U AND ABS SENSOR. 1) Connect connector to ABS sensor. 2) Disconnect connector from ABSCM&H/U. 3) Measure resistance at ABSCM&H/U connector terminals. Connector & terminal Trouble code 22 / (F49) No. 11 No. 12: Trouble code 24 / (F49) No. 9 No. 10: Trouble code 26 / (F49) No. 13 No. 15: Trouble code 28 / (F49) No. 7 No. 8:
ABS-52

No. 11 Step CHECK GROUND SHORT OF HARNESS. Measure resistance between ABSCM&H/U connector and chassis ground. Connector & terminal Trouble code 22 / (F49) No. 11 Chassis ground: Trouble code 24 / (F49) No. 9 Chassis ground: Trouble code 26 / (F49) No. 13 Chassis ground: Trouble code 28 / (F49) No. 7 Chassis ground: CHECK GROUND CIRCUIT OF ABSCM&H/U. Measure resistance between ABSCM&H/U and chassis ground. Connector & terminal (F49) No. 23 GND: CHECK POOR CONTACT IN CONNECTORS. Check Yes Is the resistance more than Go to step 12. 1 M?
ABS (DIAGNOSTICS)
No Repair harness/ connector between ABSCM&H/U and ABS sensor.
12
Go to step 13.
13
14
CHECK SOURCES OF SIGNAL NOISE.
Is there poor contact in connectors between ABSCM&H/U and ABS sensor? Is the car telephone or the wireless transmitter properly installed?
Repair connector.
Go to step 14.
Go to step 15.
15
16
17
CHECK SHIELD CIRCUIT. 1) Connect all connectors. 2) Measure resistance between shield connector and chassis ground. Connector & terminal Trouble code 22 / LHD turbo: (B62) No. 19 Chassis ground: LHD non-turbo: (B62) No. 15 Chassis ground: RHD: (B100) No. 21 Chassis ground: Trouble code 24 / LHD turbo: (B62) No. 8 Chassis ground: LHD non-turbo: (B62) No. 6 Chassis ground: RHD: (B100) No. 9 Chassis ground: Trouble code 26 / LHD: (F55) No. 10 Chassis ground: RHD: (B100) No. 12 Chassis ground: Trouble code 28 / LHD: (F55) No. 3 Chassis ground: RHD: (B100) No. 2 Chassis ground: Is the same trouble code CHECK ABSCM&H/U. as in the current diagnosis 1) Connect all connectors. still being output? 2) Erase the memory. 3) Perform inspection mode. 4) Read out the trouble code.
Are noise sources (such as Install the noise an antenna) installed near sources apart the sensor harness? from the sensor harness. Is the resistance less than Go to step 17. 0.5 ?
Properly install the car telephone or the wireless transmitter. Go to step 16.
Repair shield harness.
Go to step 18. Replace ABSCM&H/U. <Ref. to ABS-7, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).>
ABS-53
ABS (DIAGNOSTICS)
No. 18

Check Are other trouble codes being output? Yes Proceed with the diagnosis corresponding to the trouble code. No A temporary noise interference.
Step CHECK ANY OTHER TROUBLE CODES APPEARANCE.
ABS-54

MEMO:
ABS (DIAGNOSTICS)
ABS-55
ABS (DIAGNOSTICS)
L: TROUBLE CODE 29 ABNORMAL ABS SENSOR SIGNAL (ANY ONE OF FOUR)

DIAGNOSIS: Faulty ABS sensor signal (noise, irregular signal, etc.) Faulty tone wheel Wheels turning freely for a long time TROUBLE SYMPTOM: ABS does not operate.
S006522E68
ABS-56

ABS (DIAGNOSTICS)
S4M0555
ABS-57
ABS (DIAGNOSTICS)
S4M0556
ABS-58

No. 1 Step CHECK IF THE WHEELS HAVE TURNED FREELY FOR A LONG TIME. Check Check if the wheels have been turned freely for more than one minute, such as when the vehicle is jackedup, under full-lock cornering or when tire is not in contact with road surface.
ABS (DIAGNOSTICS)
2 3 4 5
CHECK TIRE SPECIFICATIONS. Turn ignition switch to OFF. CHECK WEAR OF TIRE. CHECK TIRE PRESSURE. CHECK INSTALLATION OF ABS SENSOR. Tightening torque: 3210 Nm (3.31.0 kgf-m, 247 ft-lb) CHECK ABS SENSOR GAP. Measure tone wheel to ABS sensor piece gap over entire perimeter of the wheel. Specifications Front wheel 0.3 0.8 mm (0.012 0.031 in) Rear wheel 0.7 1.2 mm (0.028 0.047 in)
Are the tire specifications correct? Is the tire worn excesReplace tire. sively? Is the tire pressure correct? Go to step 5. Are the ABS sensor installation bolts tightened securely? Is the gap within the specifications?
Yes No Go to step 2. The ABS is normal. Erase the trouble code. NOTE: When the wheels turn freely for a long time, such as when the vehicle is towed or jacked-up, or when steering wheel is continuously turned all the way, this trouble code may sometimes occur. Go to step 3. Replace tire. Go to step 4. Adjust tire pressure. Tighten ABS sensor installation bolts securely. Adjust the gap. NOTE: Adjust the gap using spacer (Part No. 26755AA000). If spacers cannot correct the gap, replace worn sensor or worn tone wheel. Go to step 9.
Go to step 6.
Go to step 7.
PREPARE OSCILLOSCOPE.
Is an oscilloscope available?
Go to step 8.
ABS-59
ABS (DIAGNOSTICS)
No. 8

Check Is oscilloscope pattern smooth, as shown in figure? Yes Go to step 12. No Go to step 9.
Step CHECK ABS SENSOR SIGNAL. 1) Raise all four wheels of ground. 2) Turn ignition switch OFF. 3) Connect the oscilloscope to the connector. 4) Turn ignition switch ON. 5) Rotate wheels and measure voltage at specified frequency. <Ref. to ABS-17, WAVEFORM, Control Module I/O Signal.> NOTE: When this inspection is completed, the ABSCM&H/U sometimes stores the trouble code 29. Connector & terminal Front RH LHD turbo: (B62) No. 7 (+) No. 18 (): LHD non-turbo: (B62) No. 5 (+) No. 14 (): RHD: (B100) No. 8 (+) No. 20 (): Front LH LHD turbo: (B62) No. 9 (+) No. 20 (): LHD non-turbo: (B62) No. 7 (+) No. 16 (): RHD: (B100) No. 10 (+) No. 22 (): Rear RH LHD: (F55) No. 12 (+) No. 11 (): RHD: (B98) No. 15 (+) No. 16 (): Rear LH LHD: (F55) No. 5 (+) No. 4 (): RHD: (B98) No. 5 (+) No. 6 (): CHECK CONTAMINATION OF ABS SENSOR OR TONE WHEEL. Remove disc rotor from hub. CHECK DAMAGE OF ABS SENSOR OR TONE WHEEL.
10
11
Go to step 10. Thoroughly remove dirt or other foreign matter. Replace ABS sen- Go to step 11. sor or tone wheel. Front: <Ref. to ABS-14, Front ABS Sensor.> Rear: <Ref. to ABS-18, Rear ABS Sensor.> and Front: <Ref. to ABS-21, Front Tone Wheel.> Rear: <Ref. to ABS-22, Rear Tone Wheel.> Is the runout less than 0.05 Go to step 12. Replace tone mm (0.0020 in)? wheel. Front: <Ref. to ABS-21, Front Tone Wheel.> Rear: <Ref. to ABS-22, Rear Tone Wheel.> Is the ABS sensor piece or the tone wheel contaminated by dirt or other foreign matter? Are there broken or damaged teeth in the ABS sensor piece or the tone wheel?
ABS-60

No. 12 Step CHECK ABSCM&H/U. 1) Turn ignition switch to OFF. 2) Connect all connectors. 3) Erase the memory. 4) Perform inspection mode. 5) Read out the trouble code. CHECK ANY OTHER TROUBLE CODES APPEARANCE. Check Is the same trouble code as in the current diagnosis still being output?
ABS (DIAGNOSTICS)
13
Yes No Go to step 13. Replace ABSCM&H/U. <Ref. to ABS-7, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).> Proceed with the A temporary poor contact. diagnosis corresponding to the trouble code.
ABS-61
ABS (DIAGNOSTICS)
M: TROUBLE CODE 31 ABNORMAL INLET SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (FRONT RH)
S006522E69
NOTE: For the diagnostic procedure, refer to TROUBLE CODE 37. <Ref. to ABS-62, TROUBLE CODE 37 ABNORMAL INLET SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (REAR LH) , Diagnostics Chart with Diagnosis Connector.>
N: TROUBLE CODE 33 ABNORMAL INLET SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (FRONT LH)
S006522E70
O: TROUBLE CODE 35 ABNORMAL INLET SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (REAR RH)
S006522E71
P: TROUBLE CODE 37 ABNORMAL INLET SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (REAR LH)
S006522E72
DIAGNOSIS: Faulty harness/connector Faulty inlet solenoid valve in ABSCM&H/U TROUBLE SYMPTOM: ABS does not operate.
ABS-62

WIRING DIAGRAM:
ABS (DIAGNOSTICS)
S4M0557
ABS-63
ABS (DIAGNOSTICS)
No. 1 2

Step Check Is the fuse blown out? Is the voltage between 10 and 15 V? Yes Replace fuse. Go to step 3. No Go to step 2. Repair harness connector between fuse and ABSCM&H/U.
CHECK FUSE. CHECK INPUT VOLTAGE OF ABSCM&H/U. 1) Disconnect connector from ABSCM&H/U. 2) Run the engine at idle. 3) Measure voltage between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 1 (+) Chassis ground (): CHECK GROUND CIRCUIT OF ABSCM&H/U. 1) Turn ignition switch to OFF. 2) Measure resistance between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 23 Chassis ground: CHECK POOR CONTACT IN CONNECTORS.
Go to step 4.
Is there poor contact in connectors between generator, battery and ABSCM&H/U? Is the same trouble code as in the current diagnosis still being output?
Repair connector.
Go to step 5.
Go to step 6. Replace ABSCM&H/U. <Ref. to ABS-7, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).> Proceed with the A temporary poor contact. diagnosis corresponding to the trouble code.
ABS-64

MEMO:
ABS (DIAGNOSTICS)
ABS-65
ABS (DIAGNOSTICS)
Q: TROUBLE CODE 32 ABNORMAL OUTLET SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (FRONT RH)
S006522E73
NOTE: For the diagnostic procedure, refer to TROUBLE CODE 38. <Ref. to ABS-66, TROUBLE CODE 38 ABNORMAL OUTLET SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (REAR LH) , Diagnostics Chart with Diagnosis Connector.>
R: TROUBLE CODE 34 ABNORMAL OUTLET SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (FRONT LH)
S006522E74
S: TROUBLE CODE 36 ABNORMAL OUTLET SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (REAR RH)
S006522E75
T: TROUBLE CODE 38 ABNORMAL OUTLET SOLENOID VALVE CIRCUIT(S) IN ABSCM&H/U (REAR LH)
S006522E76
DIAGNOSIS: Faulty harness/connector Faulty outlet solenoid valve in ABSCM&H/U TROUBLE SYMPTOM: ABS does not operate.
ABS-66

WIRING DIAGRAM:
ABS (DIAGNOSTICS)
S4M0557
ABS-67
ABS (DIAGNOSTICS)
No. 1 2

CHECK FUSE. CHECK INPUT VOLTAGE OF ABSCM&H/U. 1) Disconnect connector from ABSCM&H/U. 2) Run the engine at idle. 3) Measure voltage between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 1 (+) Chassis ground (): CHECK GROUND CIRCUIT OF ABSCM&H/U. 1) Turn ignition switch to OFF. 2) Measure resistance between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 23 Chassis ground: CHECK POOR CONTACT IN CONNECTORS.
Go to step 4.
Repair connector.
Go to step 5.
ABS-68

MEMO:
ABS (DIAGNOSTICS)
ABS-69
ABS (DIAGNOSTICS)
U: TROUBLE CODE 41 ABNORMAL ABS CONTROL MODULE

DIAGNOSIS: Faulty ABSCM&H/U. TROUBLE SYMPTOM: ABS does not operate. WIRING DIAGRAM:
S006522D29
B4M1457
ABS-70

No. 1 Step CHECK GROUND CIRCUIT OF ABSCM&H/U. 1) Turn ignition switch to OFF. 2) Disconnect connector from ABSCM&H/U. 3) Measure resistance between ABSCM&H/U and chassis ground. Connector & terminal (F49) No. 23 Chassis ground: CHECK POOR CONTACT IN CONNECTORS. Check Is the resistance less than 0.5 ? Yes Go to step 2.
ABS (DIAGNOSTICS)
No Repair ABSCM&H/U ground harness.
Is there poor contact in connectors between battery, ignition switch and ABSCM&H/U? Is the car telephone or the wireless transmitter properly installed?
Repair connector.
Go to step 3.
Go to step 4.
Are noise sources (such as Install the noise an antenna) installed near sources apart the sensor harness? from the sensor harness. Go to step 6. Replace Is the same trouble code as in the current diagnosis ABSCM&H/U. <Ref. to ABS-7, still being output? ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).> Are other trouble codes Proceed with the A temporary poor contact. being output? diagnosis corresponding to the trouble code.
ABS-71
ABS (DIAGNOSTICS)
V: TROUBLE CODE 42 SOURCE VOLTAGE IS ABNORMAL.
S006522D37
DIAGNOSIS: Power source voltage of the ABSCM&H/U is low or high. TROUBLE SYMPTOM: ABS does not operate. WIRING DIAGRAM:
S4M0557
ABS-72

No. 1 Step CHECK GENERATOR. 1) Start engine. 2) Idling after warm-up. 3) Measure voltage between generator B terminal and chassis ground. Terminal Generator B terminal Chassis ground: CHECK BATTERY TERMINAL. Turn ignition switch to OFF. CHECK FUSE. CHECK INPUT VOLTAGE OF ABSCM&H/U. 1) Disconnect connector from ABSCM&H/U. 2) Run the engine at idle. 3) Measure voltage between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 1 (+) Chassis ground (): CHECK GROUND CIRCUIT OF ABSCM&H/U. 1) Turn ignition switch to OFF. 2) Measure resistance between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 23 Chassis ground: CHECK POOR CONTACT IN CONNECTORS. Check Is the voltage between 10 and 17 V? Yes Go to step 2.
ABS (DIAGNOSTICS)
3 4
Are the positive and nega- Go to step 3. tive battery terminals tightly clamped? Is the fuse blown out? Replace fuse. Is the voltage between 10 and 17 V? Go to step 5.
Tighten the clamp of terminal. Go to step 4. Repair harness connector between fuse and ABSCM&H/U.
Go to step 6.
Repair connector.
Go to step 7.
ABS-73
ABS (DIAGNOSTICS)
W: TROUBLE CODE 44 A COMBINATION OF AT CONTROL ABNORMAL

DIAGNOSIS: Combination of AT control faults TROUBLE SYMPTOM: ABS does not operate. WIRING DIAGRAM:
S006522D42
S4M0558
ABS-74

No. 1 Step CHECK SPECIFICATIONS OF THE ABSCM&H/U. Check specifications of the mark to the ABSCM&H/U. C7: AT C8: MT CHECK GROUND SHORT OF HARNESS. 1) Turn ignition switch to OFF. 2) Disconnect two connectors from TCM. 3) Disconnect connector from ABSCM&H/U. 4) Measure resistance between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 3 Chassis ground: CHECK BATTERY SHORT OF HARNESS. Measure voltage between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 3 (+) Chassis ground (): CHECK BATTERY SHORT OF HARNESS. 1) Turn ignition switch to ON. 2) Measure voltage between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 3 (+) Chassis ground (): CHECK TCM. 1) Turn ignition switch to OFF. 2) Connect all connectors to TCM. 3) Turn ignition switch to ON. 4) Measure voltage between TCM connector terminal and chassis ground. Connector & terminal (B55) No. 21 (+) Chassis ground (): CHECK AT. CHECK OPEN CIRCUIT OF HARNESS. Measure voltage between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 3 (+) Chassis ground (): (F49) No. 31 (+) Chassis ground (): CHECK POOR CONTACT IN CONNECTORS. CHECK ABSCM&H/U. 1) Turn ignition switch to OFF. 2) Connect all connectors. 3) Erase the memory. 4) Perform inspection mode. 5) Read out the trouble code. CHECK ANY OTHER TROUBLE CODES APPEARANCE. Check Is an ABSCM&H/U for AT model installed on a MT model?
ABS (DIAGNOSTICS)
Yes No Go to step 2. Replace ABSCM&H/U. <Ref. to ABS-7, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).> Is the resistance more than Go to step 3. Repair harness 1 M? between TCM and ABSCM&H/U.
Go to step 4.
Repair harness between TCM and ABSCM&H/U.
Go to step 5.
Go to step 7.
Go to step 6.
6 7
Is the AT functioning normally? Is the voltage between 10 and 15 V?
Replace TCM. Go to step 8.
Repair AT. Repair harness/ connector between TCM and ABSCM&H/U.
Is there poor contact in connectors between TCM and ABSCM&H/U? Is the same trouble code as in the current diagnosis still being output?
Repair connector.
Go to step 9.
10
ABS-75
ABS (DIAGNOSTICS)
X: TROUBLE CODE 51 ABNORMAL VALVE RELAY

DIAGNOSIS: Faulty valve relay TROUBLE SYMPTOM: ABS does not operate. WIRING DIAGRAM:
S006522D61
S4M0559
ABS-76

No. 1 2 CHECK FUSE. CHECK INPUT VOLTAGE OF ABSCM&H/U. 1) Turn ignition switch to OFF. 2) Disconnect connector from ABSCM&H/U. 3) Run the engine at idle. 4) Measure voltage between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 1 (+) Chassis ground (): (F49) No. 24 (+) Chassis ground (): CHECK GROUND CIRCUIT OF ABSCM&H/U. 1) Turn ignition switch to OFF. 2) Measure resistance between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 23 Chassis ground: CHECK VALVE RELAY IN ABSCM&H/U. Measure resistance between ABSCM&H/U and terminals. Terminals No. 23 (+) No. 24 (): Step Check Is the fuse blown out? Is the voltage between 10 and 15 V? Yes Replace fuse. Go to step 3.
ABS (DIAGNOSTICS)
No Go to step 2. Repair harness connector between fuse and ABSCM&H/U.
Go to step 4.
CHECK POOR CONTACT IN CONNECTORS.
Repair connector.
Replace ABSCM&H/U. <Ref. to ABS-7, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).> Go to step 6.
ABS-77
ABS (DIAGNOSTICS)
Y: TROUBLE CODE 52 ABNORMAL MOTOR AND/OR MOTOR RELAY

DIAGNOSIS: Faulty motor Faulty motor relay Faulty harness connector TROUBLE SYMPTOM: ABS does not operate.
S006522D65
ABS-78

WIRING DIAGRAM:
ABS (DIAGNOSTICS)
S4M0560
ABS-79
ABS (DIAGNOSTICS)
No. 1

Check Is the voltage between 10 and 15 V? Yes Go to step 2. No Repair harness/ connector between battery and ABSCM&H/U and check fuse SBF-holder.
3 4
Step CHECK INPUT VOLTAGE OF ABSCM&H/U. 1) Turn ignition switch to OFF. 2) Disconnect connector from ABSCM&H/U. 3) Turn ignition switch to ON. 4) Measure voltage between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 25 (+) Chassis ground (): CHECK GROUND CIRCUIT OF MOTOR. 1) Turn ignition switch to OFF. 2) Measure resistance between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 26 Chassis ground: CHECK FUSE. CHECK INPUT VOLTAGE OF ABSCM&H/U. 1) Run the engine at idle. 2) Measure voltage between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 1 (+) Chassis ground (): CHECK GROUND CIRCUIT OF ABSCM&H/U. 1) Turn ignition switch to OFF. 2) Measure resistance between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 23 Chassis ground: CHECK MOTOR OPERATION. Operate the sequence control. <Ref. to ABS11, ABS Sequence Control.> NOTE: Use the diagnosis connector to operate the sequence control. CHECK POOR CONTACT IN CONNECTORS. Turn ignition switch to OFF. CHECK ABSCM&H/U. 1) Connect all connectors. 2) Erase the memory. 3) Perform inspection mode. 4) Read out the trouble code.
Go to step 3.
Is the fuse blown out? Is the voltage between 10 and 15 V?
Replace fuse. Go to step 5.
Go to step 4. Repair harness connector between fuse and ABSCM&H/U.
Go to step 6.
Can motor revolution noise (buzz) be heard when carrying out the sequence control?
Go to step 7.
Is there poor contact in connector between generator, battery and ABSCM&H/U? Is the same trouble code as in the current diagnosis still being output?
Repair connector.
ABS-80

MEMO:
ABS (DIAGNOSTICS)
ABS-81
ABS (DIAGNOSTICS)
Z: TROUBLE CODE 54 ABNORMAL STOP LIGHT SWITCH

DIAGNOSIS: Faulty stop light switch TROUBLE SYMPTOM: ABS does not operate. WIRING DIAGRAM:
S006522D72
S4M0561
ABS-82

No. 1 2 Step CHECK STOP LIGHTS COME ON. Depress the brake pedal. CHECK OPEN CIRCUIT IN HARNESS. 1) Turn ignition switch to OFF. 2) Disconnect connector from ABSCM&H/U. 3) Depress brake pedal. 4) Measure voltage between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 2 (+) Chassis ground (): CHECK POOR CONTACT IN CONNECTORS. Check Do stop lights come on? Is the voltage between 10 and 15 V? Yes Go to step 2. Go to step 3.
ABS (DIAGNOSTICS)
No Repair stop lights circuit. Repair harness between stop light switch and ABSCM&H/U.
Is there poor contact in connector between stop light switch and ABSCM&H/U? Is the same trouble code as in the current diagnosis still being output?
Repair connector.
Go to step 4.
ABS-83
ABS (DIAGNOSTICS)
AA: TROUBLE CODE 56 ABNORMAL G SENSOR OUTPUT VOLTAGE

DIAGNOSIS: Faulty G sensor output voltage TROUBLE SYMPTOM: ABS does not operate. WIRING DIAGRAM: LHD MODEL
S006522E77
S4M0562
ABS-84

ABS (DIAGNOSTICS)
S4M0563
ABS-85
ABS (DIAGNOSTICS)
No. 1

Yes The ABS is normal. Erase the trouble code. No Go to step 2.
Step CHECK ALL FOUR WHEELS FOR FREE TURNING.
Check Have the wheels been turned freely such as when the vehicle is lifted up, or operated on a rolling road? CHECK SPECIFICATIONS OF ABSCM&H/U. Does the vehicle specification and the ABSCM&H/U Check specifications of the mark to the specification match? ABSCM&H/U. C7: AT C8: MT
Go to step 3. Replace ABSCM&H/U. <Ref. to ABS-7, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).> CAUTION: Be sure to turn ignition switch to OFF when removing ABSCM&H/U. Repair harness/ connector between G sensor and ABSCM&H/U.
CHECK INPUT VOLTAGE OF G SENSOR. 1) Turn ignition switch to OFF. 2) Remove console box. 3) Disconnect G sensor from body. (Do not disconnect connector.) 4) Turn ignition switch to ON. 5) Measure voltage between G sensor connector terminals. Connector & terminal (R70) No. 1 (+) No. 3 (): CHECK OPEN CIRCUIT IN G SENSOR OUTPUT HARNESS AND GROUND HARNESS. 1) Turn ignition switch to OFF. 2) Disconnect connector from ABSCM&H/U. 3) Measure resistance between ABSCM&H/U connector terminals. Connector & terminal (F49) No. 6 No. 28: CHECK GROUND SHORT IN G SENSOR OUTPUT HARNESS. 1) Disconnect connector from G sensor. 2) Measure resistance between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 6 Chassis ground: CHECK BATTERY SHORT OF HARNESS. Measure voltage between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 6 (+) Chassis ground (): CHECK BATTERY SHORT OF HARNESS. 1) Turn ignition switch to ON. 2) Measure voltage between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 6 (+) Chassis ground ():
Is the voltage between 4.75 Go to step 4. and 5.25 V?
Go to step 5.
Repair harness/ connector between G sensor and ABSCM&H/U.
Repair harness between G sensor and ABSCM&H/U.
Go to step 7.
Go to step 8.
ABS-86

No. 8 Step CHECK GROUND SHORT OF HARNESS. Measure resistance between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 28 Chassis ground: Check Yes Is the resistance more than Go to step 9. 1 M?
ABS (DIAGNOSTICS)
No Repair harness between G sensor and ABSCM&H/U. Replace ABSCM&H/U. <Ref. to ABS-7, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).> Replace G sensor. <Ref. to ABS23, G Sensor.>
10
11
12
CHECK G SENSOR. 1) Turn ignition switch to OFF. 2) Remove G sensor from vehicle. 3) Connect connector to G sensor. 4) Connect connector to ABSCM&H/U. 5) Turn ignition switch to ON. 6) Measure voltage between G sensor connector terminals. Connector & terminal (R70) No. 2 (+) No. 3 (): CHECK G SENSOR. Measure voltage between G sensor connector terminals. Connector & terminal (R70) No. 2 (+) No. 3 (): CHECK G SENSOR. Measure voltage between G sensor connector terminals. Connector & terminal (R70) No. 2 (+) No. 3 (): CHECK POOR CONTACT IN CONNECTORS.
Is the voltage between 2.1 and 2.4 V when G sensor is horizontal?
Go to step 10.
Is the voltage between 3.7 Go to step 11. and 4.1 V when G sensor is inclined forwards to 90?
Replace G sensor. <Ref. to ABS23, G Sensor.>
Is the voltage between 0.5 and 0.9 V when G sensor is inclined backwards to 90? Is there poor contact in connector between ABSCM&H/U and G sensor? Is the same trouble code as in the current diagnosis still being output?
Go to step 12.
Repair connector.
Go to step 13.
13
14
ABS-87
ABS (DIAGNOSTICS)

S006522E48
AB: SELECT MONITOR
Applicable cartridge of select monitor: <Ref. to ABS-10, Special Tools, PREPARATION TOOL, General Description.> NOTE: For basic handling of the select monitor, refer to its Operation Manual.
AE: ANALOG DATA ARE DISPLAYED.

S006522E29
AC: TROUBLE CODES ARE DISPLAYED.

S006522E51
A maximum of 3 trouble codes are displayed in order of occurrence. If a particular trouble code is not properly stored in memory (due to a drop in ABSCM&H/U power supply, etc.) when a problem occurs, the trouble code, followed by a question mark ?, appears on the select monitor display. This shows it may be an unreliable reading.
Contents to be monitored Wheel speed detected by the Front FR wheel speed Right ABS sensor is displayed in km/h or mile/h. Wheel speed detected by the Front Left FL wheel speed ABS sensor is displayed in km/h or mile/h. Wheel speed detected by the Rear RR wheel speed Right ABS sensor is displayed in km/h or mile/h. Wheel speed detected by the Rear Left RL wheel speed ABS sensor is displayed in km/h or mile/h. Stop light switch monitor voltage is disStop light switch played. G sensor output voltage Refers to vehicle acceleration detecting by the analog G sensor. It appears on the select monitor display in volts.
Display screen
AF: ON/OFF DATA ARE DISPLAYED.

S006522E43
Display screen Stop light switch Valve relay signal Motor relay signal
S4M0076A
*a* refers to the troubles in order of occurrence (Latest, Old, Older and Reference).
Display screen Latest Old Older Contents to be monitored The most recent trouble code appears on the select monitor display. The second most recent trouble code appears on the select monitor display. The third most recent trouble code appears on the select monitor display. A specified period of time proceeding trouble code appears on the select monitor display.
S006522E33
ABS signal to TCM ABS warning light Valve relay monitor Motor relay monitor CCM signal
Contents to be monitored Stop light switch signal Valve relay signal Motor relay signal ABS operation signal from ABS control module to TCM ABS warning light Valve relay operation monitor signal Motor relay operation monitor signal ABS operation signal from ABS control module to TCM
AG: ABS SEQUENCE CONTROL

S006522E23
Reference
Display screen ABS sequence control
Contents to be monitored Perform ABS sequence control by operating valve and pump motor sequentially.
Index No. <Ref. to ABS-11, ABS Sequence Control.>
AD: CLEAR MEMORY

Display screen Clear memory?
Contents to be monitored Function of clearing trouble code and freeze frame data.
ABS-88
DIAGNOSTICS CHART WITH DIAGNOSIS CONNECTOR AH: FREEZE FRAME DATA

S006522E39
ABS (DIAGNOSTICS)
NOTE: Data stored at the time of trouble occurrence is shown on display. Each time trouble occurs, the latest information is stored in the freeze frame data in memory. If freeze frame data is not properly stored in memory (due to a drop in ABSCM power supply, etc.), a trouble code, preceded by a question mark ?, appears on the select monitor display. This shows it may be an unreliable reading.
Contents to be monitored Wheel speed detected by the Front FR wheel speed Right ABS sensor is displayed in km/h or mile/h. Wheel speed detected by the Front Left FL wheel speed ABS sensor is displayed in km/h or mile/h. Wheel speed detected by the Rear RR wheel speed Right ABS sensor is displayed in km/h or mile/h. Wheel speed detected by the Rear Left RL wheel speed ABS sensor is displayed in km/h or mile/h. Power (in volts) supplied to ABSCM power ABSCM&H/U appears on the select voltage monitor display. Refers to vehicle acceleration detected G sensor output by the analog G sensor. It appears on voltage the select monitor display in volts. Motor relay Motor relay operation monitor signal monitor Stop light switch Stop light switch signal ABS signal to ABS operation signal from ABS control TCM module to TCM ABS operation signal from ABS control ABS-AT control module to TCM ABS operation signal ABS operation signal Display screen
ABS-89
ABS (DIAGNOSTICS)
DIAGNOSTICS CHART WITH SUBARU SELECT MONITOR

S006583
13. Diagnostics Chart with Subaru Select Monitor

A: COMMUNICATION FOR INITIALIZING IMPOSSIBLE
DIAGNOSIS: Faulty harness connector TROUBLE SYMPTOM: ABS warning light remains on.
S006583E34
ABS-90

WIRING DIAGRAM:
ABS (DIAGNOSTICS)
S4M0564
ABS-91
ABS (DIAGNOSTICS)
No. 1

Check Is ignition switch ON? Yes Go to step 2. No Turn ignition switch to ON, and select ABS mode using the select monitor. Charge or replace battery. Go to step 4. Go to step 5.
Step CHECK IGNITION SWITCH.
3 4
CHECK BATTERY. 1) Turn ignition switch to OFF. 2) Measure battery voltage. CHECK BATTERY TERMINAL. CHECK COMMUNICATION OF SELECT MONITOR. 1) Turn ignition switch to OFF. 2) Using the select monitor, check whether communication to other system (such as engine, TCM, etc.) can be executed normally. CHECK COMMUNICATION OF SELECT MONITOR. 1) Turn ignition switch to OFF. 2) Disconnect ABSCM&H/U connector. 3) Check whether communication to other systems (such as TCM, engine etc.) can be executed normally. CHECK COMMUNICATION OF SELECT MONITOR. 1) Turn ignition switch to OFF. 2) Connect ABSCM&H/U connector. 3) Disconnect ECM connector. 4) Check whether communication to other systems (such as TCM, engine etc.) can be executed normally. CHECK COMMUNICATION OF SELECT MONITOR. 1) Turn ignition switch to OFF. 2) Connect ECM connector. 3) Disconnect TCM connector. 4) Check whether communication to other systems (such as engine etc.) can be executed normally. CHECK COMMUNICATION OF SELECT MONITOR. 1) Turn ignition switch to OFF. 2) Connect TCM connector. 3) Disconnect cruise control module connector. 4) Check whether communication to other systems (such as engine, TCM etc.) can be executed normally. NOTE: If the vehicle is not equipped with cruise control: Go to step 9.
Is voltage more than 11 V?
Go to step 3.
Is there poor contact at battery terminal? Are the name and year of the system displayed on the select monitor?
Repair or tighten battery terminal. Go to step 10.
Go to step 10.
Go to step 6.
Inspect ECM.
Go to step 7.
Inspect TCM.
Go to step 8.
Inspect cruise control module.
Go to step 9.
ABS-92

No. 9 Step CHECK HARNESS CONNECTOR BETWEEN EACH CONTROL MODULE AND DATA LINK CONNECTOR. 1) Turn ignition switch to OFF. 2) Disconnect TCM, ECM, ABSCM&H/U, and, cruise control module connectors. 3) Measure resistance between ABSCM&H/U connector and chassis ground. Connector & terminal (B40) No. 5 Chassis ground: (B40) No. 4 Chassis ground: CHECK OUTPUT SIGNAL FOR ABSCM&H/U. 1) Turn ignition switch to ON. 2) Measure voltage between ABSCM&H/U and chassis ground. Connector & terminal (B40) No. 5 (+) Chassis ground (): (B40) No. 4 (+) Chassis ground (): CHECK HARNESS/CONNECTOR BETWEEN ABSCM&H/U AND DATA LINK CONNECTOR. Measure resistance between ABSCM&H/U connector and data link connector. Connector & terminal (F49) No. 20 (B40) No. 5: (F49) No. 5 (B40) No. 4: CHECK INSTALLATION OF ABSCM&H/U CONNECTOR. Turn ignition switch to OFF. CHECK FUSE. CHECK POWER SUPPLY CIRCUIT. 1) Turn ignition switch to ON (engine OFF). 2) Measure ignition power supply voltage between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 1 (+) Chassis ground (): CHECK HARNESS CONNECTOR BETWEEN ABSCM&H/U AND CHASSIS GROUND. 1) Turn ignition switch to OFF. 2) Disconnect connector from ABSCM&H/U and transmission. 3) Measure resistance of harness between ABSCM&H/U and chassis ground. Connector & terminal (F49) No. 23 Chassis ground: CHECK POOR CONTACT IN CONNECTORS. Check Is the resistance less than 1 ? Yes Go to step 10.
ABS (DIAGNOSTICS)
No Repair harness and connector between each control module and data link connector.
10
Go to step 11. Repair harness and connector between each control module and data link connector.
11
Repair harness and connector between ABSCM&H/U and data link connector.
Go to step 12.
12
13 14
Is ABSCM&H/U connector inserted into ABSCM&H/U until the clamp locks onto it? Is the fuse blown out?
Go to step 13.
Replace fuse.
Insert ABSCM&H/U connector into ABSCM&H/U. Go to step 14. Repair open circuit in harness between ABSCM&H/U and fuse.
15
Go to step 16.
Repair open circuit in harness between ABSCM&H/U and inhibitor side connector, and poor contact in coupling connector. Replace ABSCM&H/U. <Ref. to ABS-7, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).>
16
Is there poor contact in control module power supply, ground line and data link connector?
Repair connector.
ABS-93
ABS (DIAGNOSTICS)

S006583E41
B: NO TROUBLE CODE
DIAGNOSIS: ABS warning light circuit is shorted. TROUBLE SYMPTOM: ABS warning light remains on. NO TROUBLE CODE displayed on the select monitor. NOTE: When the ABS warning light is OFF and NO TROUBLE CODE is displayed on the select monitor, the system is in normal condition.
ABS-94

ABS (DIAGNOSTICS)
S4M0553
ABS-95
ABS (DIAGNOSTICS)
S4M0554
ABS-96

No. 1 Step CHECK WIRING HARNESS. 1) Turn ignition switch to OFF. 2) Disconnect connector (F45) or (F2) from connector (B62) or (B100). 3) Turn ignition switch to ON. CHECK PROJECTION AT ABSCM&H/U. 1) Turn ignition switch to OFF. 2) Disconnect connector from ABSCM&H/U. 3) Check for broken projection at the ABSCM&H/U terminal. Check Yes Does the ABS warning light Go to step 2. remain off?
ABS (DIAGNOSTICS)
No Repair front wiring harness.
Are the projection broken?
Go to step 3.
CHECK ABSCM&H/U. Measure resistance between ABSCM&H/U terminals. Terminals No. 21 No. 23:
CHECK WIRING HARNESS. Measure resistance between connector (F45) or (F2) and chassis ground. Connector & terminal LHD turbo: (F45) No. 10 Chassis ground: LHD non-turbo: (F45) No. 8 Chassis ground: RHD: (F2) No. 14 Chassis ground: CHECK WIRING HARNESS. 1) Connect connector to ABSCM&H/U. 2) Measure resistance between connector (F45) or (F2) and chassis ground. Connector & terminal LHD turbo: (F45) No. 10 Chassis ground: LHD non-turbo: (F45) No. 8 Chassis ground: RHD: (F2) No. 14 Chassis ground: CHECK POOR CONTACT IN ABSCM&H/U CONNECTOR.
Go to step 5.
Replace ABSCM&H/U. <Ref. to ABS-7, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).> Replace ABSCM&H/U. <Ref. to ABS-7, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).> Repair harness.
Repair harness.
Repair connector.
ABS-97
ABS (DIAGNOSTICS)
C: TROUBLE CODE 21 OPEN OR SHORT CIRCUIT IN FRONT RIGHT ABS SENSOR CIRCUIT
S006583C50
NOTE: For the diagnostic procedure, refer to TROUBLE CODE 27. <Ref. to ABS-98, TROUBLE CODE 27 OPEN OR SHORT CIRCUIT IN REAR LEFT ABS SENSOR CIRCUIT , Diagnostics Chart with Subaru Select Monitor.>
D: TROUBLE CODE 23 OPEN OR SHORT CIRCUIT IN FRONT LEFT ABS SENSOR CIRCUIT
S006583C60
E: TROUBLE CODE 25 OPEN OR SHORT CIRCUIT IN REAR RIGHT ABS SENSOR CIRCUIT
S006583C69
F: TROUBLE CODE 27 OPEN OR SHORT CIRCUIT IN REAR LEFT ABS SENSOR CIRCUIT
DIAGNOSIS: Faulty ABS sensor (Broken wire, input voltage too high) Faulty harness connector TROUBLE SYMPTOM: ABS does not operate.
S006583C78
ABS-98

ABS (DIAGNOSTICS)
S4M0555
ABS-99
ABS (DIAGNOSTICS)
S4M0556
ABS-100

No. 1 Step CHECK OUTPUT OF ABS SENSOR USING SELECT MONITOR. 1) Select Current data display & Save on the select monitor. 2) Read the ABS sensor output corresponding to the faulty system in the select monitor data display mode. Check Does the speed indicated on the display change in response to the speedometer reading during acceleration/deceleration when the steering wheel is in the straight-ahead position? CHECK INSTALLATION OF ABS SENSOR. Are the ABS sensor instalTightening torque: lation bolts tightened 3210 Nm (3.31.0 kgf-m, 247 ft-lb) securely? Is the gap within the speciCHECK ABS SENSOR GAP. Measure tone wheel to ABS sensor piece gap fications? over entire perimeter of the wheel. Front wheel 0.3 0.8 mm (0.012 0.031 in) Rear wheel 0.7 1.2 mm (0.028 0.047 in) Yes Go to step 2.
ABS (DIAGNOSTICS)
No Go to step 8.
Go to step 3.
Go to step 4.
CHECK POOR CONTACT IN CONNECTORS. Turn ignition switch to OFF. CHECK ABSCM&H/U. 1) Connect all connectors. 2) Erase the memory. 3) Perform inspection mode. 4) Read out the trouble code.
Repair connector.
Tighten ABS sensor installation bolts securely. Adjust the gap. NOTE: Adjust the gap using spacers (Part No. 26755AA000). If spacers cannot correct the gap, replace worn sensor or worn tone wheel. Replace tone wheel. Front: <Ref. to ABS-21, Front Tone Wheel.> Rear: <Ref. to ABS-22, Rear Tone Wheel.> Go to step 6.
Replace ABSCM&H/U. <Ref. to ABS-7, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).> Proceed with the diagnosis corresponding to the trouble code.
Go to step 7.
Is the resistance between 1 Go to step 9. CHECK ABS SENSOR. and 1.5 k? 1) Turn ignition switch to OFF. 2) Disconnect connector from ABS sensor. 3) Measure resistance of ABS sensor connector terminals. Terminal Front RH No. 1 No. 2: Front LH No. 1 No. 2: Rear RH No. 1 No. 2: Rear LH No. 1 No. 2:
A temporary poor contact. NOTE: Check harness and connectors between ABSCM&H/U and ABS sensor. Replace ABS sensor. Front: <Ref. to ABS-14, Front ABS Sensor.> Rear: <Ref. to ABS-18, Rear ABS Sensor.>
ABS-101
ABS (DIAGNOSTICS)
No. 9

Check Is the voltage less than 1 V? Yes Go to step 10. No Replace ABS sensor. Front: <Ref. to ABS-14, Front ABS Sensor.> Rear: <Ref. to ABS-18, Rear ABS Sensor.>
10
11
12
Step CHECK BATTERY SHORT OF ABS SENSOR. 1) Disconnect connector from ABSCM&H/U. 2) Measure voltage between ABS sensor and chassis ground. Terminal Front RH No. 1 (+) Chassis ground (): Front LH No. 1 (+) Chassis ground (): Rear RH No. 1 (+) Chassis ground (): Rear LH No. 1 (+) Chassis ground (): CHECK BATTERY SHORT OF ABS SENSOR. 1) Turn ignition switch to ON. 2) Measure voltage between ABS sensor and chassis ground. Terminal Front RH No. 1 (+) Chassis ground (): Front LH No. 1 (+) Chassis ground (): Rear RH No. 1 (+) Chassis ground (): Rear LH No. 1 (+) Chassis ground (): CHECK HARNESS/CONNECTOR BETWEEN ABSCM&H/U AND ABS SENSOR. 1) Turn ignition switch to OFF. 2) Connect connector to ABS sensor. 3) Measure resistance between ABSCM&H/U connector terminals. Connector & terminal Trouble code 21 / (F49) No. 11 No. 12: Trouble code 23 / (F49) No. 9 No. 10: Trouble code 25 / (F49) No. 13 No. 15: Trouble code 27 / (F49) No. 7 No. 8: CHECK BATTERY SHORT OF HARNESS. Measure voltage between ABSCM&H/U connector and chassis ground. Connector & terminal Trouble code 21 / (F49) No. 11 (+) Chassis ground (): Trouble code 23 / (F49) No. 9 (+) Chassis ground (): Trouble code 25 / (F49) No. 13 (+) Chassis ground (): Trouble code 27 / (F49) No. 7 (+) Chassis ground ():
Go to step 11.
Go to step 13.
Repair harness between ABSCM&H/U and ABS sensor.
ABS-102

No. 13 Step CHECK BATTERY SHORT OF HARNESS. 1) Turn ignition switch to ON. 2) Measure voltage between ABSCM&H/U connector and chassis ground. Connector & terminal Trouble code 21 / (F49) No. 11 (+) Chassis ground (): Trouble code 23 / (F49) No. 9 (+) Chassis ground (): Trouble code 25 / (F49) No. 13 (+) Chassis ground (): Trouble code 27 / (F49) No. 7 (+) Chassis ground (): CHECK INSTALLATION OF ABS SENSOR. Tightening torque: 3210 Nm (3.31.0 kgf-m, 247 ft-lb) CHECK ABS SENSOR GAP. Measure tone wheel to ABS sensor piece gap over entire perimeter of the wheel. Front wheel 0.3 0.8 mm (0.012 0.031 in) Rear wheel 0.7 1.2 mm (0.028 0.047 in) Check Is the voltage less than 1 V? Yes Go to step 14.
ABS (DIAGNOSTICS)
No Repair harness between ABSCM&H/U and ABS sensor.
14
15
Are the ABS sensor installation bolts tightened securely? Is the gap within the specifications?
Go to step 15.
Go to step 16.
16
17
CHECK GROUND SHORT OF ABS SENSOR. 1) Turn ignition switch to ON. 2) Measure resistance between ABS sensor and chassis ground. Terminal Front RH No. 1 Chassis ground: Front LH No. 1 Chassis ground: Rear RH No. 1 Chassis ground: Rear LH No. 1 Chassis ground:
Tighten ABS sensor installation bolts securely. Adjust the gap. NOTE: Adjust the gap using spacers (Part No. 26755AA000). If spacers cannot correct the gap, replace worn sensor or worn tone wheel. Replace tone wheel. Front: <Ref. to ABS-21, Front Tone Wheel.> Rear: <Ref. to ABS-22, Rear Tone Wheel.> Replace ABS sensor and ABSCM&H/U. Front: <Ref. to ABS-14, Front ABS Sensor.> Rear: <Ref. to ABS-18, Rear ABS Sensor.> and <Ref. to ABS-7, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).>
ABS-103
ABS (DIAGNOSTICS)
No. 18

Check Yes Is the resistance more than Go to step 19. 1 M? No Repair harness between ABSCM&H/U and ABS sensor. And replace ABSCM&H/U. <Ref. to ABS-7, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).>
19
Step CHECK GROUND SHORT OF HARNESS. 1) Turn ignition switch to OFF. 2) Connect connector to ABS sensor. 3) Measure resistance between ABSCM&H/U connector terminal and chassis ground. Connector & terminal Trouble code 21 / (F49) No. 11 Chassis ground: Trouble code 23 / (F49) No. 9 Chassis ground: Trouble code 25 / (F49) No. 13 Chassis ground: Trouble code 27 / (F49) No. 7 Chassis ground: CHECK POOR CONTACT IN CONNECTORS.
20
21
CHECK ABSCM&H/U. 1) Connect all connectors. 2) Erase the memory. 3) Perform inspection mode. 4) Read out the trouble code. CHECK ANY OTHER TROUBLE CODES APPEARANCE.
Repair connector.
Go to step 20.
Replace ABSCM&H/U.
Go to step 21.
A temporary poor contact. NOTE: Check harness and connectors between ABSCM&H/U and ABS sensor.
ABS-104

MEMO:
ABS (DIAGNOSTICS)
ABS-105
ABS (DIAGNOSTICS)
G: TROUBLE CODE 22 FRONT RIGHT ABNORMAL ABS SENSOR SIGNAL
S006583C54
NOTE: For the diagnostic procedure, refer to TROUBLE CODE 28. <Ref. to ABS-106, TROUBLE CODE 28 REAR LEFT ABNORMAL ABS SENSOR SIGNAL , Diagnostics Chart with Subaru Select Monitor.>
H: TROUBLE CODE 24 FRONT LEFT ABNORMAL ABS SENSOR SIGNAL
S006583C64
I: TROUBLE CODE 26 REAR RIGHT ABNORMAL ABS SENSOR SIGNAL
S006583C73
J: TROUBLE CODE 28 REAR LEFT ABNORMAL ABS SENSOR SIGNAL

DIAGNOSIS: Faulty ABS sensor signal (noise, irregular signal, etc.) Faulty harness/connector TROUBLE SYMPTOM: ABS does not operate.
S006583C82
ABS-106

ABS (DIAGNOSTICS)
S4M0555
ABS-107
ABS (DIAGNOSTICS)
S4M0556
ABS-108

No. 1 Step CHECK OUTPUT OF ABS SENSOR USING SELECT MONITOR. 1) Select Current data display & Save on the select monitor. 2) Read the ABS sensor output corresponding to the faulty system in the select monitor data display mode. CHECK POOR CONTACT IN CONNECTORS. Turn ignition switch to OFF. CHECK SOURCES OF SIGNAL NOISE. Check Does the speed indicated on the display change in response to the speedometer reading during acceleration/deceleration when the steering wheel is in the straight-ahead position? Is there poor contact in connectors between ABSCM&H/U and ABS sensor? Is the car telephone or the wireless transmitter properly installed? Yes Go to step 2.
ABS (DIAGNOSTICS)
No Go to step 8.
Repair connector.
Go to step 3.
Go to step 4.
CHECK SHIELD CIRCUIT. 1) Turn ignition switch to OFF. 2) Connect all connectors. 3) Measure resistance between shield connector and chassis ground. Connector & terminal Trouble code 22 / LHD turbo: (B62) No. 19 Chassis ground: LHD non-turbo: (B62) No. 15 Chassis ground: RHD: (B100) No. 21 Chassis ground: Trouble code 24 / LHD turbo: (B62) No. 8 Chassis ground: LHD non-turbo: (B62) No. 6 Chassis ground: RHD: (B100) No. 9 Chassis ground: Trouble code 26 / LHD: (F55) No. 10 Chassis ground: RHD: (B100) No. 12 Chassis ground: Trouble code 28 / LHD: (F55) No. 3 Chassis ground: RHD: (B100) No. 2 Chassis ground: Is the same trouble code CHECK ABSCM&H/U. as in the current diagnosis 1) Connect all connectors. still being output? 2) Erase the memory. 3) Perform inspection mode. 4) Read out the trouble code.
CHECK INSTALLATION OF ABS SENSOR. Tightening torque: 3210 Nm (3.31.0 kgf-m, 247 ft-lb)
Are the ABS sensor installation bolts tightened securely?
Replace ABSCM&H/U. <Ref. to ABS-7, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).> Proceed with the diagnosis corresponding to the trouble code. Go to step 9.
Go to step 7.
A temporary noise interference.
Tighten ABS sensor installation bolts securely.
ABS-109
ABS (DIAGNOSTICS)
No. 9

Yes Go to step 10. No Adjust the gap. NOTE: Adjust the gap using spacer (Part No. 26755AA000). If spacers cannot correct the gap, replace worn sensor or worn tone wheel. Go to step 12. Go to step 12.
Step Check Is the gap within the speciCHECK ABS SENSOR GAP. Measure tone wheel to ABS sensor piece gap fications? over entire perimeter of the wheel. Front wheel 0.3 0.8 mm (0.012 0.031 in) Rear wheel 0.7 1.2 mm (0.028 0.047 in)
10 11
PREPARE OSCILLOSCOPE. CHECK ABS SENSOR SIGNAL. 1) Raise all four wheels of ground. 2) Turn ignition switch OFF. 3) Connect the oscilloscope to the connector. 4) Turn ignition switch ON. 5) Rotate wheels and measure voltage at specified frequency. <Ref. to ABS-17, WAVEFORM, Control Module I/O Signal.> NOTE: When this inspection is completed, the ABSCM&H/U sometimes stores the trouble code 29. Connector & terminal Trouble code 22 / LHD turbo: (B62) No. 7 (+) No. 18 (): LHD non-turbo: (B62) No. 5 (+) No. 14 (): RHD: (B100) No. 8 (+) No. 20 (): Trouble code 24 / LHD turbo: (B62) No. 9 (+) No. 20 (): LHD non-turbo: (B62) No. 7 (+) No. 16 (): RHD turbo: (B100) No. 10 (+) No. 22 (): Trouble code 26 / LHD: (F55) No. 12 (+) No. 11 (): RHD: (B98) No. 15 (+) No. 16 (): Trouble code 28 / LHD: (F55) No. 5 (+) No. 4 (): RHD: (B98) No. 5 (+) No. 6 (): CHECK CONTAMINATION OF ABS SENSOR OR TONE WHEEL. Remove disc rotor or drum from hub in accordance with trouble code.
Is an oscilloscope available? Is oscilloscope pattern smooth, as shown in figure?
12
Is the ABS sensor piece or the tone wheel contaminated by dirt or other foreign matter?
Go to step 13. Thoroughly remove dirt or other foreign matter.
ABS-110

No. 13 Step CHECK DAMAGE OF ABS SENSOR OR TONE WHEEL. Check Are there broken or damaged in the ABS sensor piece or the tone wheel?
ABS (DIAGNOSTICS)
14
15
16
17
CHECK RESISTANCE OF ABS SENSOR. 1) Turn ignition switch OFF. 2) Disconnect connector from ABS sensor. 3) Measure resistance between ABS sensor connector terminals. Terminal Front RH No. 1 No. 2: Front LH No. 1 No. 2: Rear RH No. 1 No. 2: Rear LH No. 1 No. 2: CHECK GROUND SHORT OF ABS SENSOR. Measure resistance between ABS sensor and chassis ground. Terminal Front RH No. 1 Chassis ground: Front LH No. 1 Chassis ground: Rear RH No. 1 Chassis ground: Rear LH No. 1 Chassis ground: CHECK HARNESS/CONNECTOR BETWEEN ABSCM&H/U AND ABS SENSOR. 1) Connect connector to ABS sensor. 2) Disconnect connector from ABSCM&H/U. 3) Measure resistance at ABSCM&H/U connector terminals. Connector & terminal Trouble code 22 / (F49) No. 11 No. 12: Trouble code 24 / (F49) No. 9 No. 10: Trouble code 26 / (F49) No. 13 No. 15: Trouble code 28 / (F49) No. 7 No. 8:
Yes No Replace ABS sen- Go to step 14. sor or tone wheel. Front: <Ref. to ABS-14, Front ABS Sensor.> Rear: <Ref. to ABS-18, Rear ABS Sensor.> and Front: <Ref. to ABS-21, Front Tone Wheel.> Rear: <Ref. to ABS-22, Rear Tone Wheel.> Is the runout less than 0.05 Go to step 15. Replace tone mm (0.0020 in)? wheel. Front: <Ref. to ABS-21, Front Tone Wheel.> Rear: <Ref. to ABS-22, Rear Tone Wheel.> Is the resistance between 1 Go to step 16. Replace ABS senand 1.5 k? sor. Front: <Ref. to ABS-14, Front ABS Sensor.> Rear: <Ref. to ABS-18, Rear ABS Sensor.>
ABS-111
ABS (DIAGNOSTICS)
No. 18

Check Yes Is the resistance more than Go to step 19. 1 M? No Repair harness/ connector between ABSCM&H/U and ABS sensor.
19
20
Step CHECK GROUND SHORT OF HARNESS. Measure resistance between ABSCM&H/U connector and chassis ground. Connector & terminal Trouble code 22 / (F49) No. 11 Chassis ground: Trouble code 24 / (F49) No. 9 Chassis ground: Trouble code 26 / (F49) No. 13 Chassis ground: Trouble code 28 / (F49) No. 7 Chassis ground: CHECK GROUND CIRCUIT OF ABSCM&H/U. Measure resistance between ABSCM&H/U and chassis ground. Connector & terminal (F49) No. 23 GND: CHECK POOR CONTACT IN CONNECTORS.
Go to step 20.
21
Is there poor contact in connectors between ABSCM&H/U and ABS sensor? Is the car telephone or the wireless transmitter properly installed?
Repair connector.
Go to step 21.
Go to step 22.
22
23
24
CHECK SHIELD CIRCUIT. 1) Connect all connectors. 2) Measure resistance between shield connector and chassis ground. Connector & terminal Trouble code 22 / LHD turbo: (B62) No. 19 Chassis ground: LHD non-turbo: (B62) No. 15 Chassis ground: RHD: (B100) No. 21 Chassis ground: Trouble code 24 / LHD turbo: (B62) No. 8 Chassis ground: LHD non-turbo: (B62) No. 6 Chassis ground: RHD: (B100) No. 9 Chassis ground: Trouble code 26 / LHD: (F55) No. 10 Chassis ground: RHD: (B100) No. 12 Chassis ground: Trouble code 28 / LHD: (F55) No. 3 Chassis ground: RHD: (B100) No. 2 Chassis ground: Is the same trouble code CHECK ABSCM&H/U. as in the current diagnosis 1) Connect all connectors. still being output? 2) Erase the memory. 3) Perform inspection mode. 4) Read out the trouble code.
Go to step 25. Replace ABSCM&H/U. <Ref. to ABS-7, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).>
ABS-112

No. 25 Step CHECK ANY OTHER TROUBLE CODES APPEARANCE. Check Are other trouble codes being output? Yes Proceed with the diagnosis corresponding to the trouble code.
ABS (DIAGNOSTICS)
No A temporary noise interference.
ABS-113
ABS (DIAGNOSTICS)
K: TROUBLE CODE 29 ABNORMAL ABS SENSOR SIGNAL ON ANY ONE OF FOUR SENSOR
DIAGNOSIS: Faulty ABS sensor signal (noise, irregular signal, etc.) Faulty tone wheel Wheels turning freely for a long time TROUBLE SYMPTOM: ABS does not operate.
S006583E78
ABS-114

ABS (DIAGNOSTICS)
S4M0555
ABS-115
ABS (DIAGNOSTICS)
S4M0556
ABS-116

No. 1 Step CHECK IF THE WHEELS HAVE TURNED FREELY FOR A LONG TIME. Check Check if the wheels have been turned freely for more than one minute, such as when the vehicle is jackedup, under full-lock cornering or when tire is not in contact with road surface.
ABS (DIAGNOSTICS)
2 3 4 5
CHECK TIRE SPECIFICATIONS. Turn ignition switch to OFF. CHECK WEAR OF TIRE. CHECK TIRE PRESSURE. CHECK INSTALLATION OF ABS SENSOR. Tightening torque: 3210 Nm (3.31.0 kgf-m, 247 ft-lb) CHECK ABS SENSOR GAP. Measure tone wheel to ABS sensor piece gap over entire perimeter of the wheel. Front wheel 0.3 0.8 mm (0.012 0.031 in) Rear wheel 0.7 1.2 mm (0.028 0.047 in)
Are the tire specifications correct? Is the tire worn excesReplace tire. sively? Is the tire pressure correct? Go to step 5. Are the ABS sensor installation bolts tightened securely? Is the gap within the specifications?
Yes No Go to step 2. The ABS is normal. Erase the trouble code. NOTE: When the wheels turn freely for a long time, such as when the vehicle is towed or jacked-up, or when steering wheel is continuously turned all the way, this trouble code may sometimes occur. Go to step 3. Replace tire. Go to step 4. Adjust tire pressure. Tighten ABS sensor installation bolts securely. Adjust the gap. NOTE: Adjust the gap using spacer (Part No. 26755AA000). If spacers cannot correct the gap, replace worn sensor or worn tone wheel. Go to step 9.
Go to step 6.
Go to step 7.
PREPARE OSCILLOSCOPE.
Is an oscilloscope available?
Go to step 8.
ABS-117
ABS (DIAGNOSTICS)
No. 8

Check Is oscilloscope pattern smooth, as shown in figure? Yes Go to step 12. No Go to step 9.
Step CHECK ABS SENSOR SIGNAL. 1) Raise all four wheels of ground. 2) Turn ignition switch OFF. 3) Connect the oscilloscope to the connector (B99), (F95) or (F94) in accordance with trouble code. 4) Turn ignition switch ON. 5) Rotate wheels and measure voltage at specified frequency. <Ref. to ABS-17, WAVEFORM, Control Module I/O Signal.> NOTE: When this inspection is completed, the ABSCM&H/U sometimes stores the trouble code 29. Connector & terminal Front RH LHD turbo: (B62) No. 7 (+) No. 18 (): LHD non-turbo: (B62) No. 5 (+) No. 14 (): RHD: (B100) No. 8 (+) No. 20 (): Front LH LHD turbo: (B62) No. 9 (+) No. 20 (): LHD non-turbo: (B62) No. 7 (+) No. 16 (): RHD: (B100) No. 10 (+) No. 22 (): Rear RH LHD: (F55) No. 12 (+) No. 11 (): RHD: (B98) No. 15 (+) No. 16 (): Rear LH LHD: (F55) No. 5 (+) No. 4 (): RHD: (B98) No. 5 (+) No. 6 (): CHECK CONTAMINATION OF ABS SENSOR OR TONE WHEEL. Remove disc rotor from hub. CHECK DAMAGE OF ABS SENSOR OR TONE WHEEL.
10
11
Go to step 10. Thoroughly remove dirt or other foreign matter. Replace ABS sen- Go to step 11. sor or tone wheel. Front: <Ref. to ABS-14, Front ABS Sensor.> Rear: <Ref. to ABS-18, Rear ABS Sensor.> and Front: <Ref. to ABS-21, Front Tone Wheel.> Rear: <Ref. to ABS-22, Rear Tone Wheel.> Is the runout less than 0.05 Go to step 12. Replace tone mm (0.0020 in)? wheel. Front: <Ref. to ABS-21, Front Tone Wheel.> Rear: <Ref. to ABS-22, Rear Tone Wheel.> Is the ABS sensor piece or the tone wheel contaminated by dirt or other foreign matter? Are there broken or damaged teeth in the ABS sensor piece or the tone wheel?
ABS-118

ABS (DIAGNOSTICS)
13
ABS-119
ABS (DIAGNOSTICS)
L: TROUBLE CODE 31 FRONT RIGHT INLET VALVE MALFUNCTION
S006583C93
NOTE: For the diagnostic procedure, refer to TROUBLE CODE 37. <Ref. to ABS-120, TROUBLE CODE 37 REAR LEFT INLET VALVE MALFUNCTION , Diagnostics Chart with Subaru Select Monitor.>
M: TROUBLE CODE 33 FRONT LEFT INLET VALVE MALFUNCTION
S006583D03
N: TROUBLE CODE 35 REAR RIGHT INLET VALVE MALFUNCTION
S006583D11
O: TROUBLE CODE 37 REAR LEFT INLET VALVE MALFUNCTION

DIAGNOSIS: Faulty harness/connector Faulty inlet solenoid valve TROUBLE SYMPTOM: ABS does not operate.
S006583D20
ABS-120

WIRING DIAGRAM:
ABS (DIAGNOSTICS)
S4M0557
ABS-121
ABS (DIAGNOSTICS)
No. 1 2

CHECK FUSE. CHECK INPUT VOLTAGE OF ABSCM&H/U. 1) Turn ignition switch to OFF. 2) Disconnect connector from ABSCM&H/U. 3) Run the engine at idle. 4) Measure voltage between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 1 (+) Chassis ground (): CHECK GROUND CIRCUIT OF ABSCM&H/U. 1) Turn ignition switch to OFF. 2) Measure resistance between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 23 Chassis ground: CHECK POOR CONTACT IN CONNECTORS.
Go to step 4.
Repair connector.
Go to step 5.
ABS-122

MEMO:
ABS (DIAGNOSTICS)
ABS-123
ABS (DIAGNOSTICS)
P: TROUBLE CODE 32 FRONT RIGHT OUTLET VALVE MALFUNCTION
S006583C99
NOTE: For the diagnostic procedure, refer to TROUBLE CODE 38. <Ref. to ABS-124, TROUBLE CODE 38 REAR LEFT OUTLET VALVE MALFUNCTION , Diagnostics Chart with Subaru Select Monitor.>
Q: TROUBLE CODE 34 FRONT LEFT OUTLET VALVE MALFUNCTION
S006583D08
R: TROUBLE CODE 36 REAR RIGHT OUTLET VALVE MALFUNCTION
S006583D15
S: TROUBLE CODE 38 REAR LEFT OUTLET VALVE MALFUNCTION

DIAGNOSIS: Faulty harness/connector Faulty outlet solenoid valve TROUBLE SYMPTOM: ABS does not operate.
S006583D24
ABS-124

WIRING DIAGRAM:
ABS (DIAGNOSTICS)
S4M0557
ABS-125
ABS (DIAGNOSTICS)
No. 1 2

CHECK FUSE. CHECK INPUT VOLTAGE OF ABSCM&H/U. 1) Turn ignition switch to OFF. 2) Disconnect connector from ABSCM&H/U. 3) Run the engine at idle. 4) Measure voltage between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 1 (+) Chassis ground (): CHECK GROUND CIRCUIT OF ABSCM&H/U. 1) Turn ignition switch to OFF. 2) Measure resistance between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 23 Chassis ground: CHECK POOR CONTACT IN CONNECTORS.
Go to step 4.
Repair connector.
Go to step 5.
ABS-126

MEMO:
ABS (DIAGNOSTICS)
ABS-127
ABS (DIAGNOSTICS)
T: TROUBLE CODE 41 ABS CONTROL MODULE MALFUNCTION

DIAGNOSIS: Faulty ABSCM&H/U TROUBLE SYMPTOM: ABS does not operate. WIRING DIAGRAM:
S006583D31
B4M1457
ABS-128

No. 1 Step CHECK GROUND CIRCUIT OF ABSCM&H/U. 1) Turn ignition switch to OFF. 2) Disconnect connector from ABSCM&H/U. 3) Measure resistance between ABSCM&H/U and chassis ground. Connector & terminal (F49) No. 23 Chassis ground: CHECK POOR CONTACT IN CONNECTORS. Check Is the resistance less than 0.5 ? Yes Go to step 2.
ABS (DIAGNOSTICS)
No Repair ABSCM&H/U ground harness.
Is there poor contact in connectors between battery, ignition switch and ABSCM&H/U? Is the car telephone or the wireless transmitter properly installed?
Repair connector.
Go to step 3.
Go to step 4.
CHECK ABSCM&H/U. 1) Turn ignition switch to OFF. 2) Connect all connectors. 3) Erase the memory. 4) Perform inspection mode. 5) Read out the trouble code. CHECK ANY OTHER TROUBLE CODES APPEARANCE.
Are noise sources (such as Install the noise an antenna) installed near sources apart the sensor harness? from the sensor harness. Go to step 6. Replace Is the same trouble code as in the current diagnosis ABSCM&H/U. <Ref. to ABS-7, still being output? ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).> Are other trouble codes Proceed with the A temporary poor contact. being output? diagnosis corresponding to the trouble code.
ABS-129
ABS (DIAGNOSTICS)
U: TROUBLE CODE 42 POWER SUPPLY VOLTAGE TOO LOW

DIAGNOSIS: Power source voltage of the ABSCM&H/U is low. TROUBLE SYMPTOM: ABS does not operate. WIRING DIAGRAM:
S006583D36
S4M0557
ABS-130

No. 1 Step CHECK GENERATOR. 1) Start engine. 2) Idling after warm-up. 3) Measure voltage between generator B terminal and chassis ground. Terminal Generator B terminal Chassis ground: CHECK BATTERY TERMINAL. Turn ignition switch to OFF. CHECK INPUT VOLTAGE OF ABSCM&H/U. 1) Disconnect connector from ABSCM&H/U. 2) Run the engine at idle. 3) Measure voltage between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 1 (+) Chassis ground (): CHECK GROUND CIRCUIT OF ABSCM&H/U. 1) Turn ignition switch to OFF. 2) Measure resistance between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 23 Chassis ground: CHECK POOR CONTACT IN CONNECTORS. Check Is the voltage between 10 and 15 V? Yes Go to step 2.
ABS (DIAGNOSTICS)
Are the positive and nega- Go to step 3. tive battery terminals tightly clamped? Is the voltage between 10 Go to step 4. and 15 V?
Tighten the clamp of terminal. Repair harness connector between battery, ignition switch and ABSCM&H/U.
Go to step 5.
Repair connector.
Go to step 6.
ABS-131
ABS (DIAGNOSTICS)
V: TROUBLE CODE 42 POWER SUPPLY VOLTAGE TOO HIGH

DIAGNOSIS: Power source voltage of the ABSCM&H/U is high. TROUBLE SYMPTOM: ABS does not operate. WIRING DIAGRAM:
S006583D35
S4M0557
ABS-132

No. 1 Step CHECK GENERATOR. 1) Start engine. 2) Idling after warm-up. 3) Measure voltage between generator B terminal and chassis ground. Terminal Generator B terminal Chassis ground: CHECK BATTERY TERMINAL. Turn ignition switch to OFF. CHECK FUSE. CHECK INPUT VOLTAGE OF ABSCM&H/U. 1) Disconnect connector from ABSCM&H/U. 2) Run the engine at idle. 3) Measure voltage between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 1 (+) Chassis ground (): CHECK GROUND CIRCUIT OF ABSCM&H/U. 1) Turn ignition switch to OFF. 2) Measure resistance between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 23 Chassis ground: CHECK POOR CONTACT IN CONNECTORS. Check Is the voltage between 10 and 17 V? Yes Go to step 2.
ABS (DIAGNOSTICS)
3 4
Are the positive and nega- Go to step 3. tive battery terminals tightly clamped? Is the fuse blown out? Replace fuse. Is the voltage between 10 and 17 V? Go to step 5.
Tighten the clamp of terminal. Go to step 4. Repair harness connector between fuse and ABSCM&H/U.
Go to step 6.
Repair connector.
Go to step 7.
ABS-133
ABS (DIAGNOSTICS)
W: TROUBLE CODE 44 ABS-AT CONTROL (NON CONTROLLED)

S006583E79
S4M0558
ABS-134

No. 1 Step CHECK SPECIFICATIONS OF THE ABSCM&H/U. Check specifications of the mark to the ABSCM&H/U. C7: AT C8: MT Check Is an ABSCM&H/U for AT model installed on a MT model?
ABS (DIAGNOSTICS)
4 5
CHECK GROUND SHORT OF HARNESS. 1) Turn ignition switch to OFF. 2) Disconnect two connectors from TCM. 3) Disconnect connector from ABSCM&H/U. 4) Measure resistance between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 3 Chassis ground: Is the voltage between 10 CHECK TCM. and 15 V? 1) Connect all connectors to TCM. 2) Turn ignition switch to ON. 3) Measure voltage between TCM connector terminal and chassis ground. Connector & terminal (B55) No. 21 (+) Chassis ground (): CHECK AT. Is the AT functioning normally? Is the voltage more than 10 CHECK OPEN CIRCUIT OF HARNESS. Measure voltage between ABSCM&H/U con- V? nector and chassis ground. Connector & terminal (F49) No. 3 (+) Chassis ground (): (F49) No. 31 (+) Chassis ground (): CHECK POOR CONTACT IN CONNECIs there poor contact in TORS. connectors between TCM and ABSCM&H/U? Is the same trouble code CHECK ABSCM&H/U. as in the current diagnosis 1) Connect all connectors. still being output? 2) Erase the memory. 3) Perform inspection mode. 4) Read out the trouble code.
Yes No Go to step 2. Replace ABSCM&H/U. <Ref. to ABS-7, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).> Is the resistance more than Go to step 3. Repair harness 1 M? between TCM and ABSCM&H/U.
Go to step 5.
Go to step 4.
Replace TCM. Go to step 6.
Repair AT. Repair harness/ connector between TCM and ABSCM&H/U.
Repair connector.
Go to step 7.
ABS-135
ABS (DIAGNOSTICS)
X: TROUBLE CODE 44 ABS-AT CONTROL (CONTROLLED)

S006583E80
S4M0558
ABS-136

No. 1 Step CHECK BATTERY SHORT OF HARNESS. 1) Turn ignition switch to OFF. 2) Disconnect two connectors from TCM. 3) Disconnect connector from ABSCM&H/U. 4) Measure voltage between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 3 (+) Chassis ground (): CHECK BATTERY SHORT OF HARNESS. 1) Turn ignition switch to ON. 2) Measure voltage between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 3 (+) Chassis ground (): CHECK OPEN CIRCUIT OF HARNESS. 1) Turn ignition switch to OFF. 2) Connect all connectors to TCM. 3) Turn ignition switch to ON. 4) Measure voltage between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 3 (+) Chassis ground (): (F49) No. 31 (+) Chassis ground (): CHECK POOR CONTACT IN CONNECTORS. Turn ignition switch to OFF. CHECK ABSCM&H/U. 1) Connect all connectors. 2) Erase the memory. 3) Perform inspection mode. 4) Read out the trouble code. Check Is the voltage less than 1 V? Yes Go to step 2.
ABS (DIAGNOSTICS)
No Repair harness between TCM and ABSCM&H/U.
Go to step 3.
Go to step 4.
Repair harness/ connector between TCM and ABSCM&H/U.
Is there poor contact in connectors between TCM and ABSCM&H/U? Is the same trouble code as in the current diagnosis still being output?
Repair connector.
Go to step 5.
ABS-137
ABS (DIAGNOSTICS)
Y: TROUBLE CODE 51 VALVE RELAY MALFUNCTION

S006583E81
S4M0559
ABS-138

No. 1 2 CHECK FUSE. CHECK INPUT VOLTAGE OF ABSCM&H/U. 1) Turn ignition switch to OFF. 2) Disconnect connector from ABSCM&H/U. 3) Run the engine at idle. 4) Measure voltage between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 1 (+) Chassis ground (): (F49) No. 24 (+) Chassis ground (): CHECK GROUND CIRCUIT OF ABSCM&H/U. 1) Turn ignition switch to OFF. 2) Measure resistance between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 23 Chassis ground: CHECK POOR CONTACT IN CONNECTORS. Step Check Is the fuse blown out? Is the voltage between 10 and 15 V? Yes Replace fuse. Go to step 3.
ABS (DIAGNOSTICS)
No Go to step 2. Repair harness connector between fuse and ABSCM&H/U.
Go to step 4.
Repair connector.
Go to step 5.
ABS-139
ABS (DIAGNOSTICS)
Z: TROUBLE CODE 51 VALVE RELAY ON FAILURE

S006583D63
S4M0559
ABS-140

No. 1 Step CHECK VALVE RELAY IN ABSCM&H/U. Measure resistance between ABSCM&H/U terminals. Terminals No. 23 (+) No. 24 (): Check Yes Is the resistance more than Go to step 2. 1 M?
ABS (DIAGNOSTICS)
No Replace ABSCM&H/U. <Ref. to ABS-7, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).> Go to step 3.
CHECK POOR CONTACT IN CONNECTORS.
Repair connector.
ABS-141
ABS (DIAGNOSTICS)
AA: TROUBLE CODE 52 OPEN CIRCUIT IN MOTOR RELAY CIRCUIT

S006583E82
ABS-142

WIRING DIAGRAM:
ABS (DIAGNOSTICS)
S4M0560
ABS-143
ABS (DIAGNOSTICS)
No. 1

Check Is the voltage between 10 and 13 V? Yes Go to step 2. No Repair harness/ connector between battery and ABSCM&H/U and check fuse SBF6.
Step CHECK INPUT VOLTAGE OF ABSCM&H/U. 1) Turn ignition switch to OFF. 2) Disconnect connector from ABSCM&H/U. 3) Turn ignition switch to ON. 4) Measure voltage between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 25 (+) Chassis ground (): CHECK GROUND CIRCUIT OF MOTOR. 1) Turn ignition switch to OFF. 2) Measure resistance between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 26 Chassis ground: CHECK MOTOR OPERATION. Operate the sequence control. <Ref. to ABS11, ABS Sequence Control.> NOTE: Use the diagnosis connector to operate the sequence control. CHECK POOR CONTACT IN CONNECTORS. Turn ignition switch to OFF. CHECK ABSCM&H/U. 1) Connect all connectors. 2) Erase the memory. 3) Perform inspection mode. 4) Read out the trouble code.
Go to step 3.
Can motor revolution noise (buzz) be heard when carrying out the check sequence?
Go to step 4.
Is there poor contact in connector between hydraulic unit, relay box and ABSCM&H/U? Is the same trouble code as in the current diagnosis still being output?
Repair connector.
ABS-144

MEMO:
ABS (DIAGNOSTICS)
ABS-145
ABS (DIAGNOSTICS)
AB: TROUBLE CODE 52 MOTOR RELAY ON FAILURE

S006583E83
ABS-146

WIRING DIAGRAM:
ABS (DIAGNOSTICS)
S4M0560
ABS-147
ABS (DIAGNOSTICS)
No. 1

Check Yes Is the resistance more than Go to step 2. 1 M? No Replace ABSCM&H/U. <Ref. to ABS-7, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).> Replace ABSCM&H/U. <Ref. to ABS-7, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).> Go to step 4.
Step CHECK MOTOR RELAY IN ABSCM&H/U. Measure resistance between ABSCM&H/U terminals. Terminals No. 25 No. 26:
CHECK MOTOR OPERATION. Operate the sequence control. <Ref. to ABS11, ABS Sequence Control.> NOTE: Use the diagnosis connector to operate the sequence control. CHECK POOR CONTACT IN CONNECTORS. Turn ignition switch to OFF. CHECK ABSCM&H/U. 1) Connect all connectors. 2) Erase the memory. 3) Perform inspection mode. 4) Read out the trouble code.
Go to step 3.
Is there poor contact in connector between hydraulic unit, relay box and ABSCM&H/U? Is the same trouble code as in the current diagnosis still being output?
Repair connector.
ABS-148

MEMO:
ABS (DIAGNOSTICS)
ABS-149
ABS (DIAGNOSTICS)
AC: TROUBLE CODE 52 MOTOR MALFUNCTION

S006583D68
ABS-150

WIRING DIAGRAM:
ABS (DIAGNOSTICS)
S4M0560
ABS-151
ABS (DIAGNOSTICS)
No. 1

Check Is the voltage between 10 and 13 V? Yes Go to step 2. No Repair harness/ connector between battery and ABSCM&H/U and check fuse SBF6.
Step CHECK INPUT VOLTAGE OF ABSCM&H/U. 1) Turn ignition switch to OFF. 2) Disconnect connector from ABSCM&H/U. 3) Turn ignition switch to ON. 4) Measure voltage between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 25 (+) Chassis ground (): CHECK GROUND CIRCUIT OF MOTOR. 1) Turn ignition switch to OFF. 2) Measure resistance between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 26 Chassis ground: CHECK INPUT VOLTAGE OF ABSCM&H/U. 1) Run the engine at idle. 2) Measure voltage between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 1 (+) Chassis ground (): CHECK GROUND CIRCUIT OF ABSCM&H/U. 1) Turn ignition switch to OFF. 2) Measure resistance between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 23 Chassis ground: CHECK MOTOR OPERATION. Operate the sequence control. <Ref. to ABS11, ABS Sequence Control.> NOTE: Use the diagnosis connector to operate the sequence control. CHECK POOR CONTACT IN CONNECTORS. Turn ignition switch to OFF. CHECK ABSCM&H/U. 1) Connect all connectors. 2) Erase the memory. 3) Perform inspection mode. 4) Read out the trouble code.
Go to step 3.
Go to step 4.
Repair harness connector between battery, ignition switch and ABSCM&H/U. Repair ABSCM&H/U ground harness.
Go to step 5.
Go to step 6.
Is there poor contact in connector between generator, battery and ABSCM&H/U? Is the same trouble code as in the current diagnosis still being output?
Repair connector.
ABS-152

MEMO:
ABS (DIAGNOSTICS)
ABS-153
ABS (DIAGNOSTICS)
AD: TROUBLE CODE 54 STOP LIGHT SWITCH SIGNAL CIRCUIT MALFUNCTION

DIAGNOSIS: Faulty stop light switch TROUBLE SYMPTOM: ABS does not operate. WIRING DIAGRAM:
S006583E84
S4M0561
ABS-154

No. 1 Step CHECK OUTPUT OF STOP LIGHT SWITCH USING SELECT MONITOR. 1) Select Current data display & Save on the select monitor. 2) Release the brake pedal. 3) Read the stop light switch output in the select monitor data display. CHECK OUTPUT OF STOP LIGHT SWITCH USING SELECT MONITOR. 1) Depress the brake pedal. 2) Read the stop light switch output in the select monitor data display. CHECK IF STOP LIGHTS COME ON. Depress the brake pedal. CHECK OPEN CIRCUIT IN HARNESS. 1) Turn ignition switch to OFF. 2) Disconnect connector from ABSCM&H/U. 3) Depress brake pedal. 4) Measure voltage between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 2 Chassis ground: CHECK POOR CONTACT IN CONNECTORS. Check Is the reading indicated on monitor display less than 1.5 V? Yes Go to step 2.
ABS (DIAGNOSTICS)
No Go to step 3.
Is the reading indicated on Go to step 5. monitor display between 10 and 15 V?
Go to step 3.
3 4
Do stop lights turn on? Is the voltage between 10 and 15 V?
Repair stop lights circuit. Repair harness between stop light switch and ABSCM&H/U connector.
Is there poor contact in connector between stop light switch and ABSCM&H/U? Is the same trouble code as in the current diagnosis still being output?
Repair connector.
Go to step 6.
ABS-155
ABS (DIAGNOSTICS)
AE: TROUBLE CODE 56 OPEN OR SHORT CIRCUIT IN G SENSOR CIRCUIT

S006583E85
S4M0562
ABS-156

ABS (DIAGNOSTICS)
S4M0563
ABS-157
ABS (DIAGNOSTICS)
No. 1

Check Is the G sensor output on the monitor display between 2.1 and 2.5 V when the G sensor is in horizontal position? Is there poor contact in connector between ABSCM&H/U and G sensor? Is the same trouble code as in the current diagnosis still being output? Yes Go to step 2. No Go to step 5.
Step CHECK OUTPUT OF G SENSOR USING SELECT MONITOR. 1) Select Current data display & Save on the select monitor. 2) Read the G sensor output in select monitor data display. CHECK POOR CONTACT IN CONNECTORS.
Repair connector.
Go to step 3.
CHECK INPUT VOLTAGE OF G SENSOR. 1) Turn ignition switch to OFF. 2) Remove console box. 3) Disconnect G sensor from body. (Do not disconnect connector.) 4) Turn ignition switch to ON. 5) Measure voltage between G sensor connector terminals. Connector & terminal (R70) No. 1 (+) No. 3 (): CHECK OPEN CIRCUIT IN G SENSOR OUTPUT HARNESS AND GROUND HARNESS. 1) Turn ignition switch to OFF. 2) Disconnect connector from ABSCM&H/U. 3) Measure resistance between ABSCM&H/U connector terminals. Connector & terminal (F49) No. 6 No. 28: CHECK GROUND SHORT IN G SENSOR OUTPUT HARNESS. 1) Disconnect connector from G sensor. 2) Measure resistance between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 6 Chassis ground: CHECK G SENSOR. 1) Connect connector to G sensor. 2) Connect connector to ABSCM&H/U. 3) Turn ignition switch to ON. 4) Measure voltage between G sensor connector terminals. Connector & terminal (R70) No. 2 (+) No. 3 (): CHECK G SENSOR. Measure voltage between G sensor connector terminals. Connector & terminal (R70) No. 2 (+) No. 3 ():
Replace ABSCM&H/U. <Ref. to ABS-7, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).> Are other trouble codes Proceed with the being output? diagnosis corresponding to the trouble code. Is the voltage between 4.75 Go to step 6. and 5.25 V?
Go to step 4.
Go to step 7.
Go to step 9.
ABS-158

No. 10 Step CHECK G SENSOR. Measure voltage between G sensor connector terminals. Connector & terminal (R70) No. 2 (+) No. 3 (): CHECK POOR CONTACT IN CONNECTORS. Turn ignition switch to OFF. CHECK ABSCM&H/U. 1) Connect all connectors. 2) Erase the memory. 3) Perform inspection mode. 4) Read out the trouble code. Check Is the voltage between 0.5 and 0.9 V when G sensor is inclined backwards to 90? Is there poor contact in connector between ABSCM&H/U and G sensor? Is the same trouble code as in the current diagnosis still being output? Yes Go to step 11.
ABS (DIAGNOSTICS)
No Replace G sensor. <Ref. to ABS23, G Sensor.>
11
Repair connector.
Go to step 12.
12
13
ABS-159
ABS (DIAGNOSTICS)
AF: TROUBLE CODE 56 BATTERY SHORT IN G SENSOR CIRCUIT

S006583E86
S4M0562
ABS-160

ABS (DIAGNOSTICS)
S4M0563
ABS-161
ABS (DIAGNOSTICS)
No. 1

Check Is the G sensor output on the monitor display between 2.1 and 2.5 V when the G sensor is in horizontal position? Is there poor contact in connector between ABSCM&H/U and G sensor? Is the same trouble code as in the current diagnosis still being output? Yes Go to step 2. No Go to step 5.
Step CHECK OUTPUT OF G SENSOR USING SELECT MONITOR. 1) Select Current data display & Save on the select monitor. 2) Read the G sensor output in select monitor data display. CHECK POOR CONTACT IN CONNECTORS.
Repair connector.
Go to step 3.
10
11
CHECK FREEZE FRAME DATA. 1) Select Freeze frame data on the select monitor. 2) Read front right wheel speed on the select monitor display. CHECK FREEZE FRAME DATA. Read front left wheel speed on the select monitor display. CHECK FREEZE FRAME DATA. Read rear right wheel speed on the select monitor display. CHECK FREEZE FRAME DATA. Read rear left wheel speed on the select monitor display. CHECK FREEZE FRAME DATA. Read G sensor output on the select monitor display. CHECK OPEN CIRCUIT IN G SENSOR OUTPUT HARNESS AND GROUND HARNESS. 1) Turn ignition switch to OFF. 2) Disconnect connector from ABSCM&H/U. 3) Measure resistance between ABSCM&H/U connector terminals. Connector & terminal (F49) No. 6 No. 28: CHECK BATTERY SHORT OF HARNESS. 1) Turn ignition switch to OFF. 2) Remove console box. 3) Disconnect connector from G sensor. 4) Disconnect connector from ABSCM&H/U. 5) Measure voltage between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 6 (+) Chassis ground ():
Is the front right wheel speed on monitor display 0 km?
Go to step 4.
Go to step 16.
Is the front left wheel Go to step 7. speed on monitor display 0 km? Is the rear right wheel Go to step 8. speed on monitor display 0 km? Is the rear left wheel speed Go to step 9. on monitor display 0 km? Is the G sensor output on monitor display more than 3.65 V? Is the resistance between 4.3 and 4.9 k? Go to step 10.
Go to step 16.
Go to step 16.
Go to step 16.
Go to step 16.
Go to step 11.
Go to step 12.
ABS-162

No. 12 Step CHECK BATTERY SHORT OF HARNESS. 1) Turn ignition switch to ON. 2) Measure voltage between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 6 (+) Chassis ground (): CHECK POOR CONTACT IN CONNECTORS. Check Is the voltage less than 1 V? Yes Go to step 13.
ABS (DIAGNOSTICS)
No Repair harness between G sensor and ABSCM&H/U.
13
14
15
16
17
18
19
20
CHECK INPUT VOLTAGE OF G SENSOR. 1) Turn ignition switch to OFF. 2) Remove console box. 3) Disconnect G sensor from body. (Do not disconnect connector.) 4) Turn ignition switch to ON. 5) Measure voltage between G sensor connector terminals. Connector & terminal (R70) No. 1 (+) No. 3 (): CHECK OPEN CIRCUIT IN G SENSOR OUTPUT HARNESS AND GROUND HARNESS. 1) Turn ignition switch to OFF. 2) Disconnect connector from ABSCM&H/U. 3) Measure resistance between ABSCM&H/U connector terminals. Connector & terminal (F49) No. 6 No. 28: CHECK G SENSOR. 1) Connect connector to G sensor. 2) Connect connector to ABSCM&H/U. 3) Turn ignition switch to ON. 4) Measure voltage between G sensor connector terminals. Connector & terminal (R70) No. 2 (+) No. 3 (): CHECK G SENSOR. Measure voltage between G sensor connector terminals. Connector & terminal (R70) No. 2 (+) No. 3 (): CHECK G SENSOR. Measure voltage between G sensor connector terminals. Connector & terminal (R70) No. 2 (+) No. 3 ():
Replace ABSCM&H/U. <Ref. to ABS-7, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).> Are other trouble codes Proceed with the being output? diagnosis corresponding to the trouble code. Is the voltage between 4.75 Go to step 17. and 5.25 V?
Is there poor contact in connector between ABSCM&H/U and G sensor? Is the same trouble code as in the current diagnosis still being output?
Repair connector.
Go to step 14.
Go to step 15.
Go to step 18.
Go to step 19.
Is the voltage between 0.5 and 0.9 V when G sensor is inclined backwards to 90?
Go to step 21.
ABS-163
ABS (DIAGNOSTICS)
No. 21

Check Is there poor contact in connector between ABSCM&H/U and G sensor? Is the same trouble code as in the current diagnosis still being output? Yes Repair connector. No Go to step 22.
Step CHECK POOR CONTACT IN CONNECTORS. Turn ignition switch to OFF. CHECK ABSCM&H/U. 1) Connect all connectors. 2) Erase the memory. 3) Perform inspection mode. 4) Read out the trouble code.
22
23
ABS-164

MEMO:
ABS (DIAGNOSTICS)
ABS-165
ABS (DIAGNOSTICS)
AG: TROUBLE CODE 56 ABNORMAL G SENSOR HIGH OUTPUT

S006583E87
S4M0562
ABS-166

ABS (DIAGNOSTICS)
S4M0563
ABS-167
ABS (DIAGNOSTICS)
No. 1

Check Yes Go to step 2. Is the G sensor output on monitor display between 2.1 and 2.5 V when the G sensor is in horizontal position? Is there poor contact in connector between ABSCM&H/U and G sensor? Is the same trouble code as in the current diagnosis still being output? Repair connector. No Go to step 6.
Step CHECK OUTPUT OF G SENSOR USING SELECT MONITOR. 1) Select Current data display & Save on the select monitor. 2) Read G sensor output on the select monitor display. CHECK POOR CONTACT IN CONNECTORS. Turn ignition switch to OFF. CHECK ABSCM&H/U. 1) Connect all connectors. 2) Erase the memory. 3) Perform inspection mode. 4) Read out the trouble code.
Go to step 3.
CHECK OPEN CIRCUIT IN G SENSOR OUTPUT HARNESS AND GROUND HARNESS. 1) Turn ignition switch to OFF. 2) Disconnect connector from ABSCM&H/U. 3) Measure resistance between ABSCM&H/U connector terminals. Connector & terminal (F49) No. 6 No. 28: CHECK GROUND SHORT OF HARNESS. Measure resistance between ABSCM&H/U connector and chassis ground. Connector & terminal (F49) No. 28 Chassis ground:
Go to step 4.
CHECK G SENSOR. 1) Remove console box. 2) Remove G sensor from vehicle. 3) Connect connector to G sensor. 4) Connect connector to ABSCM&H/U. 5) Turn ignition switch to ON. 6) Measure voltage between G sensor connector terminals. Connector & terminal (R70) No. 2 (+) No. 3 (): CHECK G SENSOR. Measure voltage between G sensor connector terminals. Connector & terminal (R70) No. 2 (+) No. 3 (): CHECK G SENSOR. Measure voltage between G sensor connector terminals. Connector & terminal (R70) No. 2 (+) No. 3 ():
Go to step 8.
Repair harness between G sensor and ABSCM&H/U. Replace ABSCM&H/U. <Ref. to ABS-7, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).> Replace G sensor. <Ref. to ABS23, G Sensor.>
Is the voltage between 0.5 and 0.9 V when G sensor is inclined backwards to 90?
Go to step 10.
ABS-168

ABS (DIAGNOSTICS)
11
ABS-169
ABS (DIAGNOSTICS)
AH: TROUBLE CODE 56 DETECTION OF G SENSOR STICK

S006583E88
S4M0562
ABS-170

ABS (DIAGNOSTICS)
S4M0563
ABS-171
ABS (DIAGNOSTICS)
No. 1

Check Have the wheels been turned freely such as when the vehicle is lifted up, or operated on a rolling road? Is the G sensor output on the monitor display between 2.1 and 2.5 V when the vehicle is in horizontal position? Is the G sensor output on the monitor display between 3.7 and 4.1 V when G sensor is inclined forwards to 90? Yes The ABS is normal. Erase the trouble code. Go to step 3. No Go to step 2.
Step CHECK ALL FOUR WHEELS FOR FREE TURNING.
CHECK OUTPUT OF G SENSOR USING SELECT MONITOR. 1) Select Current data display & Save on the select monitor. 2) Read the select monitor display. CHECK OUTPUT OF G SENSOR USING SELECT MONITOR. 1) Turn ignition switch to OFF. 2) Remove console box. 3) Remove G sensor from vehicle. (Do not disconnect connector.) 4) Turn ignition switch to ON. 5) Select Current data display & Save on the select monitor. 6) Read the select monitor display. CHECK OUTPUT OF G SENSOR USING SELECT MONITOR. Read the select monitor display.
Go to step 8.
Go to step 4.
CHECK POOR CONTACT IN CONNECTORS. Turn ignition switch to OFF. CHECK ABSCM&H/U. 1) Connect all connectors. 2) Erase the memory. 3) Perform inspection mode. 4) Read out the trouble code.
Is the G sensor output on the monitor display between 0.5 and 0.9 V when G sensor is inclined backwards to 90? Is there poor contact in connector between ABSCM&H/U and G sensor? Is the same trouble code as in the current diagnosis still being output?
Go to step 5.
Repair connector.
Go to step 6.
CHECK OPEN CIRCUIT IN G SENSOR OUTPUT HARNESS AND GROUND HARNESS. 1) Turn ignition switch to OFF. 2) Disconnect connector from ABSCM&H/U. 3) Measure resistance between ABSCM&H/U connector terminals. Connector & terminal (F49) No. 6 No. 28: CHECK G SENSOR. 1) Remove console box. 2) Remove G sensor from vehicle. 3) Connect connector to G sensor. 4) Connect connector to ABSCM&H/U. 5) Turn ignition switch to ON. 6) Measure voltage between G sensor connector terminals. Connector & terminal (R70) No. 2 (+) No. 3 ():
Go to step 7.
Go to step 10.
ABS-172

No. 10 Step Check Is the voltage between 3.7 CHECK G SENSOR. Measure voltage between G sensor connector and 4.1 V when G sensor is inclined forwards to 90? terminals. Connector & terminal (R70) No. 2 (+) No. 3 (): Is the voltage between 0.5 CHECK G SENSOR. Measure voltage between G sensor connector and 0.9 V when G sensor is inclined backwards to terminals. 90? Connector & terminal (R70) No. 2 (+) No. 3 (): Is the same trouble code CHECK ABSCM&H/U. as in the current diagnosis 1) Turn ignition switch to OFF. still being output? 2) Connect all connectors. 3) Erase the memory. 4) Perform inspection mode. 5) Read out the trouble code. CHECK ANY OTHER TROUBLE CODES APPEARANCE. Are other trouble codes being output? Yes Go to step 11.
ABS (DIAGNOSTICS)
No Replace G sensor. <Ref. to ABS23, G Sensor.>
11
Go to step 12.
12
13
ABS-173
ABS (DIAGNOSTICS)
GENERAL DIAGNOSTICS TABLE

S006121
14. General Diagnostics Table

A: INSPECTION
S006121A10
Symptom
Vehicle pulls to either side. Vehicle instability during braking
Vehicle spins.
Long braking/stopping distance
Wheel locks.
Brake dragging Poor braking
Long brake pedal stroke Vehicle pitching
Unstable or uneven braking
Excessive pedal vibration Noise from ABSCM&H/U
Vibration and/or noise (while driving on slippery roads)
Noise from front of vehicle
Noise from rear of vehicle
Probable faulty units/parts ABSCM&H/U (solenoid valve) ABS sensor Brake (caliper & piston, pads) Wheel alignment Tire specifications, tire wear and air pressures Incorrect wiring or piping connections Road surface (uneven, camber) ABSCM&H/U (solenoid valve) ABS sensor Brake (pads) Tire specifications, tire wear and air pressures Incorrect wiring or piping connections ABSCM&H/U (solenoid valve) Brake (pads) Air in brake line Tire specifications, tire wear and air pressures Incorrect wiring or piping connections ABSCM&H/U (solenoid valve, motor) ABS sensor Incorrect wiring or piping connections ABSCM&H/U (solenoid valve) ABS sensor Master cylinder Brake (caliper & piston) Parking brake Axle & wheels Brake pedal play Air in brake line Brake pedal play Suspension play or fatigue (reduced damping) Incorrect wiring or piping connections Road surface (uneven) ABSCM&H/U (solenoid valve) ABS sensor Brake (caliper & piston, pads) Tire specifications, tire wear and air pressures Incorrect wiring or piping connections Road surface (uneven) Incorrect wiring or piping connections Road surface (uneven) ABSCM&H/U (mount bushing) ABS sensor Brake piping ABSCM&H/U (mount bushing) ABS sensor Master cylinder Brake (caliper & piston, pads, rotor) Brake piping Brake booster & check valve Suspension play or fatigue ABS sensor Brake (caliper & piston, pads, rotor) Parking brake Brake piping Suspension play or fatigue
ABS-174
G8050GE6
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
AC
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. Page General Description.....................................................................................2 Refrigerant Pressure with Manifold Gauge Set ........................................18 Refrigerant Recovery Procedure...............................................................19 Refrigerant Charging Procedure ...............................................................20 Refrigerant Leak Check ............................................................................23 Compressor Oil .........................................................................................25 Heater Unit ................................................................................................26 Blower Motor Assembly.............................................................................27 Power Transistor (Heater Blower Resistor) ..............................................28 Heater Core...............................................................................................29 Control Unit ...............................................................................................30 Compressor ...............................................................................................32 Condenser .................................................................................................34 Receiver Drier ...........................................................................................35 Intake Unit .................................................................................................36 Flexible Hose.............................................................................................38 Relay and Fuse .........................................................................................39 Pressure Switch (Dual Switch)..................................................................40 Air Vent Grille ............................................................................................41 Heater Duct ...............................................................................................42 Heater Vent Duct.......................................................................................43 General Diagnostics ..................................................................................44
HVAC System (Heater, Ventilator and A/C)
GENERAL DESCRIPTION
S701001
A: SPECIFICATIONS
1. HEATER SYSTEM
Item LHD model Heating capacity RHD model Air flow rate Max air flow rate RHD model Heater core size (height length width) Type Blower motor Fan type and size (diameter width) LHD model RHD model LHD model RHD model LHD model RHD model LHD model RHD model LHD model
S701001E49 S701001E4901
Condition Mode selector switch: HEAT 5.1 kW (4,386 kcal/h, 17,404 BTU/h) Temperature control switch: FULL HOT or more Temperature difference between hot water and inlet air: 65C (149F) 4.93 kW (4,240 kcal/h, 16,824 BTU/h) Hot water flow rate: 360 (95.1 US gal, or more 79.2 Imp gal)/h 280 m3 (9,887 cu ft)/h Heat mode (FRESH), FULL HOT at 12.5 V 300 m3 (10,593 cu ft)/h Temperature control switch: FULL COLD 480 m3 (16,949 cu ft)/h Blower fan speed: 4th position 460 m3 (16,243 cu ft)/h Mode selector lever: RECIRC 193.5 152 35.0 mm (7.62 5.98 1.378 in) 161.4 176.4 32 mm (6.35 6.94 1.26 in) Magnet motor 260 W or less at 12 V Magnet motor 250 W or less Sirocco fan type 150 75 mm (5.91 2.95 in) Sirocco fan type 150 75 mm (5.91 2.95 in)
Specifications
AC-2
GENERAL DESCRIPTION
2. A/C SYSTEM LHD Model:
Item Type of air conditioner Cooling capacity Refrigerant Type Discharge Max. permissible speed Type Power consumption Type of belt Pulley dia. (effective dia.) Pulley ratio Type Core face area Dimensions (W H T) Radiation area Effective inner capacity Type Type Dimensions (W H T) Fan type Outer diameter width Power consumption Motor type Power consumption Fan outer diameter Motor type Power consumption Fan outer diameter ON OFF OFF ON ON OFF DIFF
S701001E4902
Compressor
Magnet clutch
Condenser
Receiver drier Expansion valve Evaporator
Blower fan
Condenser fan (Sub fan)
Radiator fan (Main fan)
Low-pressure switch operating pressure Dual switch (Pressure switch) High-pressure switch operating pressure Compressor relief valve blow-out pressure
Specifications Reheat air-mix type 5.117 kW (4,400 kcal/h, 17,459 BTU/h) HFC-134a (CH2FCF3) [0.650.05 kg (1.430.11 lb)] 5-vane rotary, fix volume (KC50G) 140 cm3 (8.54 cu in)/rev 7,000 rpm Dry, single-disc type 38 W V-Ribbed 4 PK 125 mm (4.92 in) 1.064 Corrugated fin (Multi-flow) 0.255 m2 (2.74 sq ft) 22 374 683 mm (0.87 14.72 26.89 in) 6.52 m2 (70 sq ft) 250 cm3 (15.26 cu in) Internal equalizing Single tank 60 224 235 mm (2.36 8.82 9.25 in) Sirocco fan 150 75 mm (5.91 2.95 in) 260 W at 12 V Magnet 70 W at 12 V 320 mm (12.60 in) Magnet 70 W at 12 V 320 mm (12.60 in) 17725 kPa (1.800.25 kg/cm2, 25.63.6 psi) Less than 216 kPa (2.2 kg/cm2, 31 psi) 2,940200 kPa (29.982.04 kg/cm2, 426.329.0 psi) 590200 kPa (6.022.04 kg/cm2, 85.629.0 psi) 3,600300 kPa (36.713.06 kg/cm2, 522.043.5 psi)
Thermo control amplifier working temperature (Evaporator outlet air)

S4M0511A
AC-3
GENERAL DESCRIPTION
RHD Model:
Item Type of air conditioner Cooling capacity Refrigerant Type Discharge Max. permissible speed Type Power consumption Type of belt Pulley dia. (effective dia.) Pulley ratio Type Core face area Dimensions (W H T) Radiation area Effective inner capacity Type Type Dimensions (W H T) Fan type Outer diameter width Power consumption Motor type Power consumption Fan outer diameter Motor type Power consumption Fan outer diameter ON OFF OFF ON ON OFF OFF ON Specifications Reheat air-mix type 5.059 kW (4,350 kcal/h, 17,261 BTU/h) HFC-134a (CH2FCF3) [0.650.05 kg (1.430.11 lb)] 5-vane rotary, fix volume (KC50G) 140 cm3 (8.54 cu in)/rev 7,000 rpm Dry, single-disc type 38 W V-Ribbed 4 PK 125 mm (4.92 in) 1.064 Corrugated fin (Multi-flow) 0.231 m2 (2.48 sq ft) 20 331 698 mm (0.79 13.03 27.48 in) 7.2 m2 (77 sq ft) 250 cm3 (15.26 cu in) Internal equalizing Single tank 60 224 235 mm (2.36 8.82 9.25 in) Sirocco fan 150 75 mm (5.91 2.95 in) 250 W at 12 V Magnet 70 W at 12 V 320 mm (12.60 in) Magnet 70 W at 12 V 320 mm (12.60 in) 17725 kPa (1.80.25 kg/cm2, 263.6 psi) Less than 216 kPa (2.2 kg/cm2, 31 psi) 2,650200 kPa (27.022.04 kg/cm2, 38429 psi) 1,471200 kPa (152.04 kg/cm2, 21329 psi) 3,600300 kPa (36.713.06 kg/cm2, 522.043.5 psi)
Compressor
Magnet clutch
Condenser
Receiver drier Expansion valve Evaporator
Blower fan
Condenser fan (Sub fan)
Radiator fan (Main fan)
Low-pressure switch operating pressure Dual switch (Pressure switch) High-pressure switch operating pressure Compressor relief valve blow-out pressure
Thermo control amplifier working temperature (Evaporator outlet air)

S4M0275A
AC-4

1. HEATER UNIT LHD Model:
S701001A05
S701001A0501
H4M1045B
(1) (2) (3) (4) (5) (6)
Vent door DEF door DEF lever Heater core Heater case FRONT Mix door
(7) (8) (9) (10) (11) (12)
Mix lever Foot door Foot duct Heater case REAR Foot lever lower Foot lever upper
(13) Vent lever (14) Side link

AC-5
GENERAL DESCRIPTION
RHD Model:
S4M0309A
(1) (2) (3) (4) (5) (6) (7)
Heater case upper A Heater case upper B Vent door DEF door Sealing sponge DEF door lever DEF door link
(8) (9) (10) (11) (12) (13) (14)
Vent door lever Side link Foot door Mix door Heater core Heater case lower Foot door lever
(15) Mix door lever (16) Foot duct

Tightening torque: Nm (kg-m, ft-lb) T: 7.35 (0.750, 5.421)
AC-6
GENERAL DESCRIPTION
2. INTAKE UNIT WITH EVAPORATOR LHD Model:
S701001A0505
S4M0501A
(1) Evaporator (With A/C model) (2) Boot (3) Block expansion valve (With A/C model) (4) Link (5) Lever (A) (6) Lever (B) (7) Door (A)
(8) (9) (10) (11) (12) (13) (14) (15)
Door (B) Intake unit case inlet Thermistor (With A/C model) Intake unit case upper Intake unit case lower Drain hose Resistor Blower motor ASSY
(16) (17) (18) (19)
Aspirator pipe Cover Separator Rod
AC-7
GENERAL DESCRIPTION
RHD Model:
S4M0545A
(1) (2) (3) (4) (5) (6) (7) (8)
Door (A) Sealing sponge Door (B) lever Intake unit case upper Separator Cover Intake unit case lower Blower motor ASSY
(9) (10) (11) (12) (13)
Door (B) Link Door (A) lever Evaporator (With A/C model) Thermo control amplifier (With A/C model) (14) Clamp (15) Pipe (With A/C model)
(16) Expansion valve (With A/C model) (17) Drain hose

AC-8
GENERAL DESCRIPTION
3. CONTROL UNIT
S701001A0503
S4M0083A
(1) (2) (3) (4) (5)
Temperature control cable Recirc control cable Clip Blower switch ASSY Harness ASSY
(6) (7) (8) (9) (10)
Bulb A/C switch ASSY Mode control cable Control dial knob A/C switch knob
(11) Control lever knob (12) Plate (13) Base unit
AC-9
GENERAL DESCRIPTION
4. AIR CONDITIONING UNIT LHD Model:
S701001A0504
S4M0486A
(1) Condenser (2) Pipe (From condenser to receiver drier) (3) Receiver drier (4) Pipe (From receiver drier to intake unit)
(5) Hose (Low-pressure) (6) Compressor (7) Hose (High-pressure)
AC-10
GENERAL DESCRIPTION
RHD Model:
S4M0487A
(1) (2) (3) (4)
Compressor Hose (Low-pressure) Condenser Pipe (From receiver drier to intake unit)
(5) Receiver drier (6) Pipe (From condenser to receiver drier) (7) Hose (High-pressure)
AC-11
GENERAL DESCRIPTION
5. COMPRESSOR
S701001A0506
S4M0488A
(1) (2) (3) (4) (5) (6)
Idler pulley adjuster Idler pulley bracket Idler pulley Compressor bracket upper Compressor Compressor bracket lower
(7) V-belt (8) Compressor belt cover
Tightening torque: Nm (kgf-m, ft-lb) T1: 7.4 (0.75, 5.4) T2: 23 (2.3, 17) T3: 23.0 (2.35, 17.0) T4: 28.9 (2.95, 21.3) T5: 35 (3.6, 26)
AC-12

S701001A03

S701001A0304
4. HANDLING OF REFRIGERANT
S701001A0301
1. HFC-134a A/C SYSTEM
Unlike the old conventional HFC-12 system components, the cooling system components for the HFC-134a system such as the refrigerant and compressor oil are incompatible. Vehicles with the HFC-134a system can be identified by the label A attached to the vehicle. Before maintenance, check which A/C system is installed in the vehicle.
S4M0547A
2. COMPRESSOR OIL
S701001A0302
HFC-134a compressor oil has no compatibility with that for R12 system. Use only the manufacturer-authorized compressor oil for the HFC-134a system; only use ZXL200PG. Do not mix multiple compressor oils. If HFC-12 compressor oil is used in a HFC-134a A/C system, the compressor may become stuck due to poor lubrication, or the refrigerant may leak due to swelling of rubber parts. On the other hand, if HFC-134a compressor oil is used in a HFC-12 A/C system, the durability of the A/C system will be lowered. HFC-134a compressor oil is very hygroscopic. When replacing or installing/removing A/C parts, immediately isolate the oil from the atmosphere using a plug or tape. In order to avoid moisture, store the oil in a container with its cap tightly closed.
The refrigerant boils at approx. 30C (22F). When handling it, be sure to wear safety goggles and protective gloves. Direct contact of the refrigerant with skin may cause frostbite. If the refrigerant gets into your eye, avoid rubbing your eyes with your hands. Wash your eye with plenty of water, and receive medical treatment from an eye doctor. Do not heat a service can. If a service can is directly heated, or put into boiling water, the inside pressure will become extremely high. This may cause the can to explode. If a service can must be warmed up, use hot water in 40C (104F) max. Do not drop or impact a service can. (Observe the precautions and operation procedure described on the refrigerant can.) When the engine is running, do not open the high-pressure valve of the manifold gauge. The high-pressure gas will back-flow resulting in an explosion of the can. The refrigerant is non-toxic and harmless under normal operating circumstance, but it may change to phosgene (a noxious fume) under open flames or high temperatures (caused by a cigarette or heater). Provide good ventilation and do not work in a closed area. Never perform a gas leak test using a halide torch-type leak tester. In order to avoid destroying the ozone layer, prevent HFC-134a from being released into the atmosphere. Using a refrigerant recovery system, discharge and reuse it.
3. REFRIGERANT
S701001A0303
The HFC-12 refrigerant cannot be used in the HFC-134a A/C system. The HFC-134a refrigerant, also, cannot be used in the HFC-12 A/C system. If an incorrect or no refrigerant is used, poor lubrication will result and the compressor itself may be damaged.
G4M0979
AC-13
GENERAL DESCRIPTION
Use the oil specified in the service manual to lubricate the O-rings. Apply the oil to the top and sides of the O-rings before installation. Apply the oil to the area including the O-rings and tube beads.
5. O-RING CONNECTIONS
S701001A0305
Use new O-rings. In order to keep the O-rings free of lint which will cause a refrigerant gas leak, perform operations without gloves and shop towels. Apply the compressor oil to the O-rings to avoid sticking, then install them. Use a torque wrench to tighten the O-ring fittings: Over-tightening will damage the O-ring and tube end distortion. If the operation is interrupted before completing a pipe connection, recap the tubes, components, and fittings with a plug or tape to prevent contamination from entering.
G4M0581
Visually check the surfaces and mating surfaces of O-rings, threads, and connecting points. If a failure is found, replace the applicable parts. Install the O-rings at right angle to the tube beards.
G4M0583
G4M0582
When connecting hoses or pipes, use 2 wrenches (a torque wrench for tightening). While securing one side with a wrench, tighten the other side to the specified torque with a torque wrench. If only one wrench is used to tighten, the tightening torque will be excessive or insufficient. This may cause a pipe distortion or gas leak, resulting in damage to hoses and pipes. After tightening, using a clean shop towel to remove excess oil from the connections and any oil which may have run on the vehicle body or other parts. If any leakage is suspected after tightening, do not retighten the connections, Disconnect the connections, remove the O-rings, and check the O-rings, threads, and connections.
G4M0584
AC-14

S701001A17
CAUTION: When working on vehicles with the HFC-134a system, only use HFC-134a specified tools and parts. Do not mix with CFC-12 tools and parts. If HFC-134a and CFC-12 refrigerant or compressor oil is mixed, poor lubrication will result and the compressor itself may be destroyed. In order to help prevent mixing HFC-134a and CFC-12 parts and liquid, the tool and screw type and the type of service valves used are different. The gas leak detectors for the HFC134a and CFC-12 systems must also not be interchanged.
Tool & screw type Valve type HFC-134a Millimeter size Quick joint type CFC-12 Inch size Screw-in type Description
Tools and Equipment Wrench
Various WRENCHES will be required to service any A/C system. A 7 to 40 Nm (0.7 to 4.1 kg-m, 5 to 30 ft-lb) torque wrench with various crowfoot wrenches will be needed. Open end or flare nut wrenches will be needed for back-up on the tube and hose fittings.
G4M0571
Applicator bottle
A small APPLICATOR BOTTLE is recommended to apply refrigerant oil to the various parts. They can be obtained at a hardware or drug store.
G4M0572
Manifold gauge set
A MANIFOLD GAUGE SET (with hoses) can be obtained from either a commercial refrigeration supply house or from an auto shop equipment supplier.
G4M0573
AC-15

Tools and Equipment Refrigerant recovery system
GENERAL DESCRIPTION
Description
A REFRIGERANT RECOVERY SYSTEM is used for the recovery and reuse of A/C system refrigerant after contaminants and moisture have been removed from the refrigerant.
G4M0574
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.
G4M0575
Vacuum pump
A VACUUM PUMP (in good working condition) is necessary, and may be obtained from either a commercial refrigeration supply house or an automotive equipment supplier.
G4M0576
Can tap
A CAN TAP for the 397 g (14 oz) can is available from an auto supply store.
G4M0577
AC-16
GENERAL DESCRIPTION
Tools and Equipment Thermometer

Description
Pocket THERMOMETERS are available from either industrial hardware store or commercial refrigeration supply houses.
G4M0578
Electronic leak detector
An ELECTRONIC LEAK DETECTOR can be obtained from either a specialty tool supply or an A/C equipment supplier.
G4M0579
Weight scale
A WEIGHT SCALE such as an electronic charging scale or a bathroom scale with digital display will be needed if a 13.6 kg (30 lb) refrigerant container is used.
G4M0580
AC-17
REFRIGERANT PRESSURE WITH MANIFOLD GAUGE SET

S701631
2. Refrigerant Pressure with Manifold Gauge Set

A: OPERATION
S701631A16
1) Place the vehicle in the shade and draftless condition. 2) Connect the manifold gauge set. 3) Open the front windows and close all doors. 4) Open the hood. 5) Increase engine rpm to 1,500. 6) Turn ON the A/C switch. 7) Turn the temperature control switch to MAX COOL. 8) Put in RECIRC position. 9) Turn the blower control switch to HI. 10) Read the gauge. Standard: Low pressure: 127 - 196 kPa (1.3 - 2.0 kg/cm2, 18 - 28 psi) High pressure: 1,471 - 1,667 kPa (15 - 17 kg/cm2, 213 - 242 psi) Ambient temperature: 30 - 35 C (86 - 95 F)
B: INSPECTION
Symptom
S701631A10
High-pressure side is unusually high.
High-pressure side is unusually low.
Low-pressure side is unusually high.
Low-pressure side is unusually low.
Probable cause Defective condenser fan motor Clogged condenser fan Too much refrigerant Air inside the system Defective receiver dryer Defective compressor Not enough refrigerant Clogged expansion valve Expansion valve frozen temporarily by moisture Defective compressor Defective expansion valve Too much refrigerant Not enough refrigerant Clogged expansion valve Expansion valve frozen temporarily by moisture Saturated receiver dryer
Repair order Replace the fan motor. Clean the condenser fin. Discharge refrigerant. Replace the receiver dryer.
Replace the compressor. Check for leaks. Replace the expansion valve.
Replace the compressor. Replace the expansion valve. Discharge refigerant. Check for leaks. Replace the expansion valve Replace the receiver dryer.
AC-18
REFRIGERANT RECOVERY PROCEDURE
3. Refrigerant Recovery Procedure

S701291
6) Follow the operation manual to activate the refrigerant recovery system.
A: OPERATION
S701291A16
CAUTION: During operation, be sure to wear safety goggles and protective gloves. Connect the refrigerant recovery system with the manifold gauge set to discharge the refrigerant from the A/C system and reuse it. When reusing the discharged refrigerant, keep service cans on hand. Because the discharge rate with the recovery system is approx. 90%, service cans are necessary to charge the refrigerant. Follow the detailed operation procedure described in the operation manual attached to the refrigerant recovery system. 1) Turn the A/C switch ON. Leave the engine running for approx. 5 minutes to activate the compressor. Perform the refrigerating cycle with the refrigerant to discharge the compressor oil remaining on the functional parts into the compressor as much as possible. 2) Stop the engine. 3) Close the valves on the low-/high-pressure sides of the manifold gauge set.
G4M0585
4) Install the low-/high-pressure hoses to the service ports on the low-/high-pressure sides of the vehicle respectively.
G4M0586
5) Connect the center hose to the refrigerant recovery system.
AC-19
REFRIGERANT CHARGING PROCEDURE

4) Carefully open the valves on the low-/highpressure sides to activate the vacuum pump.
4. Refrigerant Charging Procedure

S701292
A: OPERATION
S701292A16
CAUTION: During operation, be sure to wear safety goggles and protective gloves. Before charging the refrigerant, evacuate the system to remove small amounts of moisture remaining in the system. The moisture in the system can be completely evacuated only under the minimum vacuum level. The minimum vacuum level affects the temperature in the system. The list below shows the vacuum values necessary to boil water in various temperature. In addition, the vacuum levels indicated on the gauge are approx. 3.3 kPa (25 mmHg, 0.98 inHg) lower than those measured at 304.8 m (1,000 ft) above sea level.
Vacuum level required to boil water (at sea level) Temperature Vacuum 1.7C (35F) 100.9 kPa (757 mmHg, 29.8 inHg) 7.2C (45F) 100.5 kPa (754 mmHg, 29.7 inHg) 12.8C (55F) 99.8 kPa (749 mmHg, 29.5 inHg) 18.3C (65F) 99.2 kPa (744 mmHg, 29.3 inHg) 23.9C (75F) 98.5 kPa (739 mmHg, 29.1 inHg) 29.4C (85F) 97.2 kPa (729 mmHg, 28.7 inHg) 35C (95F) 95.8 kPa (719 mmHg, 28.3 inHg)
G4M0597
5) After the low-pressure gauge reaches 100.0 kPa (750 mmHg, 29.5 inHg) or higher, evacuate the system for approx. 15 minutes.
G4M0598
1) Close the valves on low-/high-pressure sides of the manifold gauge.
6) After 15 minutes of evacuation, if the reading shows 100.0 kPa (750 mmHg, 29.5 inHg) or higher, close the valves on the both sides to stop the vacuum pump.
G4M0599 G4M0596
7) Note the low-pressure gauge reading.
2) Install the low-/high-pressure hoses to the corresponding service ports on the vehicle respectively. 3) Connect the center hose of the manifold gauge set with the vacuum pump.
G4M0600
AC-20

8) Leave it at least 5 minutes, and then check the low-pressure gauge reading for any changes. When a gauge indicator shows near to zero point, this is a sign of leakage. Check pipe connector points, repair them, make sure there is no leakage by air bleeding. 9) Following the can tap operation manual instructions, install it to the refrigerant can.
15) Carefully open the high-pressure valve with the engine stopping. CAUTION: Do not open the low-pressure valve.
G4M0604
G4M0980
10) Disconnect the center manifold hose from the vacuum pump, and connect the hose to the tap valve. 11) When a 13.6 kg (30 lb) refrigerant container is used, measure the refrigerant amount in use using a weighting scale.
CAUTION: Never run the engine during charging from the high-pressure side. 16) Close the high-pressure valve when the lowpressure gauge reaches 98 kPa (1 kg/cm2, 14 psi). Using a leak tester, check the system for leaks. If any leakage is found after the refrigerant recovery is completed, repair the applicable area. 17) After confirming that there are no leaks with the leak test, charge the required amount of refrigerant. CAUTION: Never run the engine during charging from the high-pressure side. 18) Close the high-pressure valve when; the readings of low- and high-pressure gauges become almost equal, after the charging speed is reduced, the HFC-134a source becomes empty, or the system is filled with the gas.
G4M0981
12) Confirm that all the 3 hoses are tightly connected to the manifold gauge set.
G4M0605 G4M0603
13) Open the valve on the HFC-134a source. 14) Loosen the center hose connection on the manifold gauge set (if applicable, press a purge valve on the manifold gauge set) only for a couple of seconds to allow the air in the center hose to escape by the refrigerant.
AC-21

26) Close the valve on the refrigerant source.
Refrigerant HFC-134a Refrigerant amount Minimum 0.6 kg (1.3 lb) Maximum 0.7 kg (1.5 lb)
19) If the HFC-134a source is empty, close the high-pressure valve, close the valve on the can tap, and replace the HFC-134a source with a new one to restart the operation.
27) Disconnect the hose from the service port, and install the service port cap.
G4M0606
20) Confirm that both the low- and high-pressure valves can be closed. Start the engine with the A/C switch OFF. 21) Quickly repeat ON-OFF cycles a few times to prevent initial compressor damage. 22) Set up the vehicle to the following status: A/C switch ON Engine running at 1,500 rpm Blower speed setting to HI Temperature setting to MAX COOL Air inlet setting to RECIRC Windows open 23) While reading the low-pressure gauge, carefully open the low-pressure valve with the refrigerant source connected and the service hose purged. CAUTION: Never open the high-pressure valve with the engine running.
G4M0608
24) Adjust the refrigerant flow to maintain the pressure on the low-pressure side at 276 kPa (2.81 kg/cm2, 40 psi) max. 25) After the system is fully charged, close the low-pressure valve.
AC-22
REFRIGERANT LEAK CHECK
5. Refrigerant Leak Check

A: INSPECTION
S701293A10
S701293
1) Operate the A/C system for approx. 10 minutes, and confirm that the high-side pressure shows at least 690 kPa (7.03 kg/cm2, 100 psi). Then stop the engine to start the leak test. 2) Starting from the connection between the highpressure tube and evaporator, check the system for leaks along the high-pressure side through the compressor. The following items must be checked thoroughly. Connection between the tube and tube fitting
5) Check the joint between the compressor and hoses. 6) Check the machined area of compressor and other joints on the compressor. 7) Check the thermal limiter (if equipped) on the compressor housing. 8) Check the compressor shaft seal at the area near the center of compressor clutch pulley. Some shaft seals show a slight amount of leakage about 28 g (1.0 oz) per year. This is not a problem. 9) Starting from the connection between the lowpressure tube and evaporator, check the system for leakage along the high-pressure side through the compressor. The following items must be checked thoroughly. Connection between the tube and tube fitting Connection between 2 parts Connection between the tube and nut
G4M0612
Connection between 2 parts
S4M0038
10) Visually check the rubber area of the flexible hose for cracks. Check the entire length of the flexible hose, especially the connection with the metal hose end. CAUTION: Carefully check the external surface of hoses and tubes at approx. 25 mm (0.98 in) per second.
G4M0613
Connection between the tube and nut
G4M0614
G4M0617
3) Check the joint and seam between the pressure switch (dual switch) and receiver dryer. 4) Check the connections between the condenser and tubes, and welded joints on the condenser. The leak tester may detect the oil on the condenser fins as a leak.
11) Disconnect the drain hose from the evaporator case, and check the hose end for at least 10 seconds. After the test is finished, reconnect the drain hose.
AC-23
REFRIGERANT LEAK CHECK
12) Turn the ignition key to ON position, and run the blower at high speed for 1 minute. Stop the blower to check the ventilation grill on the instrument panel. While moving the tester closer to the grill, run the blower for 1 or 2 seconds, then stop it. Check the grill at that point for at least 10 seconds.
G4M0618
13) Check the valve in the service port. 14) Visually check the rubber seal in the service port cap.
G4M0619
AC-24
COMPRESSOR OIL

S701294A20
6. Compressor Oil
A: OPERATION
S701294A16
S701294
B: REPLACEMENT
NOTE: Before making repairs, conduct the oil return operation to return the compressor oil in circulation with the refrigerant to the compressor. 1) Increase engine rpm to 1,500. 2) Turn ON the A/C switch. 3) Turn the temperature control switch to MAX COOL. 4) Put in RECIRC position. 5) Turn the blower control switch to HI. 6) Leave in this condition for 10 minutes.
NOTE: If a component is replaced, add an appropriate amount of compressor oil. When replacing the compressor, the new compressor will already have the specified amount of oil in it. Install the new compressor after removing the same amount of oil that is remaining in the compressor removed.
Replacement parts Evaporator Receiver drier Condenser Hose Amount of oil replenishment 70 m (2.4 US fl oz, 2.5 Imp fl oz) 5 m (0.2 US fl oz, 0.2 Imp fl oz) 50 m (1.7 US fl oz, 1.8 Imp fl oz) 50 m (1.7 US fl oz, 1.8 Imp fl oz)
AC-25
HEATER UNIT
7. Heater Unit
A: REMOVAL
S701290
S701290A18
1) Disconnect ground cable from battery. 2) Drain engine coolant. <Ref. to CO-14, DRAINING OF ENGINE, REPLACEMENT, Engine Coolant.> 3) Remove air cleaner case. (Non-turbo model) <Ref. to IN(SOHC)-7, REMOVAL, Air Cleaner.> 4) Remove intercooler. (Turbo model) <Ref. to IN(DOHC TURBO)-10, REMOVAL, Intercooler.> 5) Release heater hose clamps in engine compartment to remove the hoses.
B4M2299
6) Remove instrument panel. <Ref. to EI-31 REMOVAL, Instrument Panel Assembly.> 7) Loosen nuts and bolts of support beam to remove support beam. 8) Remove A/C unit. <Ref. to AC-36 REMOVAL, Intake Unit.> 9) Loosen nuts and bolts of heater unit to remove heater unit.
G4M0554
B: INSTALLATION
S701290A11
1) Install in the reverse order of removal. 2) Refill engine coolant. <Ref. to CO-14, FILLING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>
AC-26
BLOWER MOTOR ASSEMBLY

S701295A11
8. Blower Motor Assembly

A: REMOVAL
S701295A18
S701295

S701295A10
1) Disconnect ground cable from battery. 2) Remove glove box.
Connect motor connector terminal 1 from the battery to the positive (+) lead and terminal 2 to the negative () lead. Make sure the motor runs smoothly.
S5M0047A
3) Disconnect motor connector.

B4M2404
B4M2304
4) Remove 3 screws. 5) Disconnect aspirator pipe (A) and remove blower motor.
S4M0033A
AC-27
POWER TRANSISTOR (HEATER BLOWER RESISTOR)
9. Power Transistor (Heater Blower Resistor)

S701553
A: REMOVAL
S701553A18
1) Remove glove box. <Ref. to EI-28 REMOVAL, Glove Box.> 2) Disconnect power transistor connector. 3) Loosen 2 screws to remove power transistor.
B4M2305
S701553A11

S701553A10
B4M2463A
Check continuity between connector terminals.

Tester connection 43 32 21 Condition Constant Constant Constant Specified condition Approx. 0.4 Approx. 0.7 Approx. 1.5
If NG, replace the blower resistor.
AC-28
HEATER CORE
10. Heater Core

A: REMOVAL
S701554A18
S701554
1) Remove heater unit. <Ref. to AC-26 REMOVAL, Heater Unit.> 2) Remove screws to separate heater unit case. 3) Remove heater core.
B4M2306
B: INSTALLATION
S701554A11
AC-29
CONTROL UNIT
7) Remove control unit assembly from center console.
11. Control Unit

A: REMOVAL
S701285A18
S701285
1) Disconnect GND cable from battery. 2) Set temperature control switch to FULL HOT and mode selector switch to DEF position and recirc switch to FRESH position. 3) Disconnect temperature control cable and mode door control cable from heater unit then disconnect recirc control cable from intake unit. NOTE: Do not attempt to move links during installation.
S4M0034
B: INSTALLATION
S701285A11
Install in the reverse order of removal. NOTE: Before installing control unit, set temperature control switch to FULL HOT and mode selector switch to DEF position and recirc switch to FRESH position.
C: INSPECTION
1. FAN SWITCH
S701285A10
S701285A1003
Check continuity between terminals at each switch position.
S5M0049A
4) Remove console box. <Ref. to EI-30 REMOVAL, Console Box.> 5) Remove center panel and then disconnect connector. 6) Remove audio.
H5M1280A
H4M1051 S5M0048A
AC-30
CONTROL UNIT
2. A/C SWITCH
S701285A1004
Check A/C switch continuity between each terminal.
H5M1281A
H4M1052
D: ADJUSTMENT
S701285A01
1) Operate temperature control switch to FULL COLD and mode selector switch to VENT position and recirc switch to RECIRC position. 2) Install control cable to lever. While pushing outer cable, secure control cable with clip.
H4M1053A
AC-31
COMPRESSOR
5) Disconnect low-pressure hose (A) and highpressure hose (B). CAUTION: Be careful not to lose O-rings on hose. Immediately seal hose with a plug or vinyl tape to prevent the entry of contamination.
12. Compressor
A: INSPECTION
S701281A1001
S701281
S701281A10
1. MAGNETIC CLUTCH CLEARANCE

1) Check the clearance of the entire circumference around the drive plate and pulley. Standard: 0.450.15 mm (0.01770.0059 in)
H4M1159C
B4M0091
2. MAGNETIC CLUTCH OPERATION

S701281A1002
1) Disconnect the compressor connector. 2) Connect the No. 3 terminal of the compressor connector from the battery to the positive (+) lead. Ground the negative () lead to the body.
6) Remove V-belt. (SOHC) <Ref. to ME(SOHC)42, REMOVAL, V-belt.> or (DOHC TURBO) <Ref. to ME(DOHC TURBO)-44, REMOVAL, V-belt.> 7) Remove generator. <Ref. to SC-12 REMOVAL, Generator.> 8) Disconnect compressor harness from body harness. 9) Remove bolts from compressor bracket.
B4M2311
B4M2407
10) Loosen bolts to remove compressor from bracket.
3) Make sure the magnet clutch engages. If NG, replace the compressor.
B: REMOVAL
S701281A18
1) Perform oil return operation. <Ref. to AC-25 OPERATION, Compressor Oil.> 2) Turn A/C switch OFF and stop the engine. 3) Using refrigerant recovery system, discharge refrigerant. <Ref. to AC-19 OPERATION, Refrigerant Recovery Procedure.> 4) Disconnect ground cable from battery.
B4M2312
AC-32
COMPRESSOR C: INSTALLATION
S701281A11
1) Install in the reverse order of removal. 2) Replace O-rings on low-/high-pressure hoses with new ones, then apply compressor oil. 3) When replacing compressor, adjust amount of compressor oil. <Ref. to AC-25 Compressor Oil.> 4) Charge refrigerant. <Ref. to AC-20 OPERATION, Refrigerant Charging Procedure.>
AC-33
CONDENSER
5) Remove 2 bolts. While lifting condenser, pull it out through the space between the radiator and the radiator panel.
13. Condenser
A: REMOVAL
S701282
S701282A18
1) Using refrigerant recovery system, discharge refrigerant. <Ref. to AC-19 OPERATION, Refrigerant Recovery Procedure.> 2) Disconnect ground cable from battery. 3) Disconnect high-pressure hose (A) and highpressure pipe (B) from condenser.
B4M1821
S4M0489A
CAUTION: Be careful not to damage condenser fins. If a damaged fin is found, repair it using a thin screwdriver. If condenser is replaced, add appropriate amount of compressor oil to the compressor. <Ref. to AC-25 REPLACEMENT, Compressor Oil.>
B: INSTALLATION
S701282A11
1) Install in the reverse order of removal. CAUTION: Replace O-rings on hoses or pipes with new ones, and then apply compressor oil. Confirm that lower guide of condenser has been fitted into holes on radiator panel.
H4M1161B
4) Remove radiator bracket (A).
S4M0490A
2) Charge refrigerant. <Ref. to AC-20 OPERATION, Refrigerant Charging Procedure.>

B4M1820A
C: INSPECTION
S701282A10
1) Confirm that no dust or insects are found on the condenser fins. Air-blow or flush fins with water as needed. 2) Confirm that no oil leaks from condenser. If a failure is found, replace condenser with a new one.
AC-34
RECEIVER DRIER
14. Receiver Drier

A: REMOVAL
S701283A18
S701283
1) Disconnect ground cable from battery. 2) Using refrigerant recovery system, discharge refrigerant. <Ref. to AC-19 OPERATION, Refrigerant Recovery Procedure.> 3) Disconnect pressure switch harness (A). 4) Disconnect pipe (B). 5) Loosen mounting bolts (C) to remove receiver dryer.
H4M1263A
CAUTION: The receiver drier contains a desiccant. After disconnecting receiver drier, plug it to avoid moisture. If receiver drier is replaced, add appropriate amount of compressor oil to the compressor. <Ref. to AC-25 REPLACEMENT, Compressor Oil.>
B: INSTALLATION
S701283A11
1) Install in the reverse order of removal. CAUTION: Replace O-rings with new ones, and apply compressor oil. 2) Charge refrigerant. <Ref. to AC-20 OPERATION, Refrigerant Charging Procedure.>
AC-35
INTAKE UNIT
7) Remove intake unit mounting bolt and nut.
15. Intake Unit

A: REMOVAL
S701632
S701632A18
1) Using refrigerant recovery system, discharge refrigerant. <Ref. to AC-19 OPERATION, Refrigerant Recovery Procedure.> 2) Disconnect ground cable from battery. 3) LHD: Remove bolt then disconnect discharge pipe and suction pipe. RHD: Disconnect discharge pipe, suction pipe and grommets.
S4M0502A
S4M0211A S4M0213A
B: INSTALLATION
S701632A11
1) Install in the reverse order of removal. CAUTION: Replace O-rings with new ones, and apply compressor oil. 2) Charge refrigerant. <Ref. to AC-20 OPERATION, Refrigerant Charging Procedure.>
S4M0212A
4) Remove glove box.
S5M0047A
5) Disconnect the harness connector from intake unit. 6) Disconnect drain hose.
AC-36
INTAKE UNIT C: DISASSEMBLY

1. LHD MODEL
S701632A0601 S701632A06

S701632A0602
2. RHD MODEL
1) Remove thermistor (A) from intake unit case. 2) Remove some screws then separate intake unit case. 3) Remove thermistor from clip with the evaporator.
1) Remove some screws, then separate intake unit case.
S4M0214
2) Remove thermostat (A) from lower case and then detach evaporator (B).
S4M0215A
S4M0503A
4) Remove the block expansion valve (A) from pipes.
3) Disconnect the connection between the expansion valve and pipe from receiver drier. 4) Remove the expansion valve (A) from pipes.
S4M0216A S4M0504A
CAUTION: If evaporator is replaced, add appropriate amount of compressor oil to evaporator. <Ref. to AC-25 REPLACEMENT, Compressor Oil.>
D: ASSEMBLY
S701632A02
Assemble in the reverse order of disassembly. CAUTION: Replace O-rings with new ones, and then apply compressor oil.
AC-37
FLEXIBLE HOSE
16. Flexible Hose

A: REMOVAL
S701286A18
S701286
CAUTION: When disconnecting/connecting hoses, do not apply excessive force them. Confirm that no torsion and excessive tension exist after installing. Seal the disconnected hose with a plug or vinyl tape to prevent contamination from entering. 1) Disconnect ground cable from battery. 2) Using refrigerant recovery system, discharge refrigerant. <Ref. to AC-19 OPERATION, Refrigerant Recovery Procedure.> 3) Remove hose attaching bolts (C). 4) Disconnect hose from evaporator unit. 5) Disconnect hose from compressor. 6) Remove low-pressure hose (A) from the vehicle. 7) Remove hose attaching bolts (D). 8) Disconnect hose from compressor. 9) Disconnect hose from condenser. 10) Disconnect high-pressure hose (B) from the vehicle.
S4M0217A
B: INSTALLATION
S701286A11
CAUTION: When disconnecting/connecting hoses, do not apply an excessive force them. Confirm that no torsion and excessive tension exist after installing. Seal the disconnected hose with a plug or vinyl tape to prevent contamination from entering. 1) Install in the reverse order of removal. 2) Charge refrigerant. <Ref. to AC-20 OPERATION, Refrigerant Charging Procedure.>
C: INSPECTION
S701286A10
NOTE: If cracking, damage, or swelling is found on a hose, replace it with a new one.
S4M0494A
AC-38
RELAY AND FUSE

S701287A10
17. Relay and Fuse

A: LOCATION
S701287A13
S701287
B: INSPECTION
B4M2308A S4M0546A
(A) (B) (C) (D) (E) (F)
A/C fuse Main fan relay Sub fan relay A/C relay Main fan fuse Sub fan fuse
(3) (4): Continuity exists. (1) (2): No continuity While applying battery voltage to the cable between (3) and (4), check continuity between (1) and (2). If no continuity exists, replace the relay with a new one.
AC-39
PRESSURE SWITCH (DUAL SWITCH)
18. Pressure Switch (Dual Switch)

S701555
A: INSPECTION
S701555A10
1) Connect the manifold gauge to the service valve on the high-pressure side. 2) Remove the pressure switch harness connector. Using a circuit tester, inspect the ON-OFF operation of the pressure switch.
G4M0654
Terminal
Operation
High-pressure side line pressure Increasing to 2,940200 kPa (29.982.04 kg/cm2, 426.329.0 psi): LHD model 2,650200 kPa (27.022.04 kg/cm2, 38429 psi): RHD model Decreasing to 17725 kPa (1.800.25 kg/cm2, 25.63.6 psi): Increasing to Less than 216 kPa (2.2 kg/cm2, 31 psi): Decreasing to 2,350200 kPa (23.972.04 kg/cm2, 34129 psi): LHD model 1,471200 kPa (152.04 kg/cm2, 213 29 psi): RHD model
Turns OFF. High and low pressure switch 12 Turns ON.
AC-40
AIR VENT GRILLE

S701284A11
19. Air Vent Grille

A: REMOVAL
S701284A18
S701284
B: INSTALLATION
S701284A1803
1. CENTER AIR VENT GRILLE

1) Remove center panel. 2) Loosen screw to remove grille.
C: INSPECTION
S701284A10
The direction and amount of air should be adjusted smoothly. The adjustment should be kept in each position.
S4M0517
2. SIDE AIR VENT GRILLE
S701284A1804
1) Remove grille using sharp-edged screwdriver.
B4M2314
CAUTION: Wrap screwdriver with vinyl tape to prevent damage to interior parts.
AC-41
HEATER DUCT
20. Heater Duct

A: REMOVAL
S701556A18
S701556
1) Remove front seat. <Ref. to SE-5 REMOVAL, Front Seat.> 2) Remove heater unit. <Ref. to AC-26 REMOVAL, Heater Unit.> 3) Remove front side sill cover. 4) Pull off floor mat to remove heater duct.
S4M0518
B: INSTALLATION
S701556A11
AC-42
HEATER VENT DUCT
21. Heater Vent Duct

A: REMOVAL
S701557A18
S701557
2) Remove screws. 3) Remove heater vent duct.
1) Remove instrument panel. <Ref. to EI-31 REMOVAL, Instrument Panel.>
S4M0519
B: INSTALLATION
S701557A11
AC-43
GENERAL DIAGNOSTICS
S701278
22. General Diagnostics

A: INSPECTION
S701278A10
Symptom
Repair order Fuse Blower motor relay Blower motor Blower motor resister Blower switch Wire harness Blower motor Refrigerant Fuse Air conditioning relay Magnet clutch Compressor Pressure switch A/C switch Blower switch Wire harness V-Belt Magnet clutch Compressor Refrigerant V-Belt Magnet clutch Compressor Pressure switch A/C switch Blower switch Wire harness Heater duct Heater vent duct Engine coolant Blower switch Heater core Engine coolant Mode actuator Wire harness Mode actuator Air flow switch Wire harness Air inlet select switch FRESH/RECIRC actuator Wire harness
Blower motor
Doesnt move.
Strange noise.
Doesnt move. Compressor
Strange noise
Cold air not emitted.
Warm air not emitted.
Temperature of air from vents does not change.
Unable to switch blow vents.
Unable to switch suction vents.
AC-44
AIRBAG SYSTEM
AB
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Page General Description.....................................................................................2 Airbag Connector ........................................................................................8 Inspection Locations After a Collision .......................................................10 Driver s Airbag Module ..............................................................................12 Passenger s Airbag Module ......................................................................14 Side Airbag Module ...................................................................................15 Main Harness ............................................................................................16 Side Airbag Harness .................................................................................17 Airbag Control Module ..............................................................................18 Side Airbag Sensor ...................................................................................19 Roll Connector...........................................................................................20 Front Sub Sensor ......................................................................................21 Front Sub Sensor Harness .......................................................................22 Disposal of Airbag Module (Deploying While Installed in Vehicle) ...........23 Disposal of Airbag Module (Deploying After Removal from Vehicle) .......27
Airbag System
GENERAL DESCRIPTION
S802001
A: COMPONENT
1. SRS AIRBAG
S802001A05 S802001A0501
S5M0418A
(1) Combination switch ASSY with roll connector (2) TORX bolt T30 (3) Airbag module ASSY (Driver) (4) Airbag module ASSY (Passenger) (5) Airbag control module (6) TORX bolt T40 (7) Side airbag sensor
(8) (9) (10) (11) (12) (13) (14) (15)
Side airbag module Side airbag harness (RH) Side airbag harness (LH) Airbag main harness Front sub sensor (RH) Front sub sensor harness (RH) Front sub sensor harness (LH) Front sub sensor (LH)
Tightening torque: Nm (kgf-m, ft-lb) T1: 4.4 (0.45, 3.3) T2: 7.4 (0.75, 5.4) T3: 10 (1.0, 7.2) T4: 20 (2.0, 14.5) T5: 25 (2.5, 18.1)
AB-2

S802001A03
Airbag System
When servicing a vehicle, be sure to turn the ignition switch OFF, disconnect the ground cable from the battery, and wait for more than 20 seconds before starting work. The airbag system is fitted with a backup power source. If the airbag system is serviced within 20 seconds after the ground cable is disconnected, it may inflate.
When checking, use a test harness. Do not directly apply the tester probe to any connector terminal of the airbag.
G5M0293
G5M0292
If sensors, airbag module, airbag control module and harness are deformed or damaged, replace them with new genuine parts.
G5M0291
Do not use the airbag parts from other vehicles. Always replace defective parts with new parts. Never re-use a deployed airbag. When checking the system, be sure to use a digital circuit tester. Use of an analog circuit tester may cause the airbag to activate erroneously.
G5M0294
Do not check continuity of the driver, passenger and side airbag modules.
G5M0302
AB-3
Airbag System
GENERAL DESCRIPTION
Install the wire harness securely with the specified clips to avoid interference or tongled up with other parts.
Do not allow water or oil to come in contact with the connector terminals. Do not touch the connector terminals.
G5M0298
G5M0297
Either of the airbag modules for driver, passenger or side, must not be disassembled.
When painting or performing sheet metal work on the front part of the vehicle, including the front wheel apron, front fender, and front side frame, remove the front sub sensors and wire harness of the airbag system. When painting or performing sheet metal work on the side of the vehicle, including the side sill, center pillar, and front and rear doors, remove the side airbag sensors and wire harness of the airbag system.
G5M0299
If any damage, opening, or rust is found on the airbag system wire harness, do not attempt to repair using soldering equipment. Be sure to replace the faulty harness with a new genuine part.
G5M0310
G5M0296
AB-4
GENERAL DESCRIPTION
Do not drop the airbag modulator parts, subject them to high temperature over 93C (199F), or let water, oil, or grease get on them; otherwise, the internal parts may be damaged and reliability greatly lowered.
Airbag System
The removed front seat with the airbag module must be kept at least 200 mm (8 in) away from walls and other objects.
B5M1072A
When storing a removed airbag module, do not place any objects on it or pile airbag modules on top of each other. If the airbag inflates for some reason when it is placed with its pad side facing downward or under any object, a serious accident may result.
G5M0295
AB-5
Airbag System
GENERAL DESCRIPTION
G5M0604
AB-6

1. SPECIAL TOOLS
ILLUSTRATION
S801001A1703 S802001A17
Airbag System
TOOL NUMBER 98299FC030
DESCRIPTION DEPLOYMENT ADAPTER A
REMARKS Used for deploying the airbag module. Used with DEPLOYMENT TOOL (98299PA030).
B5M1114
98299PA030
DEPLOYMENT TOOL
Used for deploying the airbag module. Used with DEPLOYMENT ADAPTER A (98299FC030).
B5M1115
2. GENERAL TOOL
S802001A1701
TOOL NAME TORX T30 TORX T40 (Tamper resistant type)
REMARKS Used for removal/installation of drivers airbag module Used for removal/installation of airbag control module
AB-7
Airbag System
AIRBAG CONNECTOR
S802659
2. Airbag Connector
A: OPERATION
S802659A16
How to connect:
Holding the connector, and push it in carefully until a connecting sound is heard. CAUTION: Be sure to insert the connector in until it locks. Then pull on it gently to make sure that it is locked.
1. DRIVER S AIRBAG, PASSENGER S AIRBAG, SIDE AIRBAG S802659A1605 How to disconnect:

1) Push lock arm (A). 2) With lock arm (A) pushed in, move slide lock (B) in the direction of the arrow.
B5M1155
B5M1153A
2. FRONT SUB-SENSOR, SIDE AIRBAG SENSOR S802659A1603 How to disconnect:

1) Holding outer part (A), pull it in the direction of the arrow. CAUTION: When pulling, be sure to hold onto the connector and not the wire.
3) With slide lock (B) pulled, remove lock arm (A) to its original position, and then pull in the direction of the arrow and separate the connector. CAUTION: When pulling, be sure to hold onto the connector and not the wire.
B5M1154 RE0014
AB-8
AIRBAG CONNECTOR
How to connect:
Holding the connector, and push it in carefully until a connecting sound is heard. CAUTION: Outer (A) moves back, and so do not put your hand on the outer part. Be sure to insert the connector in until it locks. Then pull on it gently to make sure that it is locked.
Airbag System
RE0015
AB-9
Airbag System
INSPECTION LOCATIONS AFTER A COLLISION

4. AIRBAG CONTROL MODULE
S802306A1004
3. Inspection Locations After a Collision

S802306
A: INSPECTION
S802306A10
If the vehicle is involved in a collision on any side, even if it is a slight collision, be sure to check the following system parts.
Check for the following, and replace damaged parts with new parts. Control module is cracked or deformed. Mounting bracket is cracked or deformed. Connector is scratched or deformed. Airbag is deployed. Side airbag is deployed.
1. AIRBAG MODULE (DRIVER)
S802306A1001
1) Check for the following, and replace damaged parts with new parts. Airbag module is cracked or deformed. Harness and/or connector is cracked, deformed or open. Lead wire is exposed. 2) When installing a new driver s airbag module, check the following. If necessary, install a new airbag module and steering wheel. The steering wheel is in the way, making it difficult to install the airbag module. The clearance between the driver s airbag module and steering wheel is not constant. When steering wheel deformation in axial and radial directions exceed limits. Deformation limit: Axial direction play A Less than 6 mm (0.24 in) Radial direction play L Less than 7 mm (0.28 in)
5. FRONT SUB SENSOR
S802306A1005
If the front section of vehicle as shown in the figure is damaged:
G5M0311
Check for the following, and replace damaged parts with new parts. Front sub sensor is cracked or deformed. Mounting bracket is cracked or deformed. Connector is scratched or cracked. Airbag is deployed.
6. FRONT SUB SENSOR HARNESS
S802306A1006
Check for the following, and replace damaged parts with new parts. Harness is open, lead wire is exposed, and corrugated tube is noticeably cracked. Connector is scratched or cracked.
B5M0096A
2. AIRBAG MODULE (PASSENGER)
S802306A1002
Check for the following, and replace damaged parts with new parts. Airbag module is cracked or deformed. Harness and/or connector is cracked, deformed or open. Lead wire is exposed. Mounting bracket is cracked or deformed.
3. AIRBAG MODULE (SIDE)
S802306A1003
Check for the following, and replace damaged parts with new parts. Front seat is damaged or deformed. Harness and/or connector is cracked, deformed or open. Lead wire is exposed.
AB-10

7. SIDE AIRBAG SENSOR
S802306A1007
Airbag System
11. STEERING SHAFT
S802306A1011
If the side section of vehicle as shown in the figure is damaged:
Check for the following, and replace damaged parts with new parts. The clearance between capsule (A) and tip of column bracket (B) on steering column upper side should be within specifications. Specifications: Clearance of expand plate: L More than 15 mm (0.59 in)
B5M0514
Check for the following, and replace damaged parts with new parts. Side airbag sensor is cracked or deformed. Mounting bracket is cracked or deformed. Connector is scratched or cracked. Side airbag is deployed. (operating side)
8. SIDE AIRBAG SENSOR HARNESS

S802306A1008
9. MAIN HARNESS
S802306A1009
S5M0213B
If necessary, replace them with new parts.
10. ROLL CONNECTOR
S802306A1010
Check for the following, and replace damaged parts with new parts. Combination switch or steering roll connector is cracked or deformed.
AB-11
Airbag System
DRIVER S AIRBAG MODULE

S802307
4. Driver s Airbag Module

A: CAUTION
S802307A03
Do not check continuity of the airbag module (driver, passenger, and side).
When disconnecting and connecting the airbag connector, be sure to turn the ignition switch OFF, disconnect the ground cable from the battery, and wait for more than 20 seconds before starting work.
G5M0302
Do not use the airbag system and pretensioners on other vehicles. When replacing parts, be sure to replace them with new parts.
B: REMOVAL
G5M0292
S802307A18
The airbag module (driver, passenger, and side) must not be disassembled. The airbag module cannot be used again once inflated.
1) Position front wheels straight ahead. (After moving a vehicle more than 5 m (16 ft) with front wheels positioned straight ahead, make sure that the vehicle moves straight ahead). 2) Turn ignition switch OFF. 3) Disconnect the ground cable from the battery, and wait for at least 20 seconds before starting work. 4) Using TORX BIT T30, remove two TORX bolts on side of steering wheel.
G5M0299
After removal, keep the airbag module with the pad facing upward on a dry, clean, and flat surface away from heat and light sources, and moisture and dust.
H5M0662A
5) Disconnect airbag connector on back of airbag module, and then remove airbag module.
G5M0301
H5M0664
AB-12
DRIVER S AIRBAG MODULE

6) Refer to CAUTION for handling of a removed airbag module. <Ref. to AB-3 CAUTION, General Description.>
Airbag System
C: INSTALLATION
S802307A11
1) Install in the reverse order of removal. CAUTION: Do not allow harness and connectors to interfere or get tangled up with other parts.
D: INSPECTION
S802307A10
Check for the following, and replace damaged parts with new parts. Airbag module, harness, connector, and mounting bracket are damaged.
AB-13
Airbag System
PASSENGER S AIRBAG MODULE

Do not check continuity of the airbag module (driver, passenger, and side) with airbag removed from the vehicle.
5. Passenger s Airbag Module

S802308
A: CAUTION
S802308A03
When disconnecting and connecting the airbag connector, be sure to turn the ignition switch OFF, disconnect the ground cable from the battery, and wait for more than 20 seconds before starting work.
G5M0302
B: REMOVAL
S802308A18
G5M0292
1) Turn ignition switch OFF. 2) Disconnect the ground cable from the battery, and wait for at least 20 seconds before starting work. 3) Remove glove box. <Ref. to EI-28 REMOVAL, Glove Box.> 4) Detach airbag connector from support beam bracket, and then disconnect airbag connector. 5) Remove seven bolts, and then carefully remove airbag module.
G5M0299
After removal, keep the airbag module with the pad facing upward on a dry, clean, and flat surface away from heat and light sources, and moisture and dust.
S5M0215
6) Refer to CAUTION for handling of a removed airbag module. <Ref. to AB-3 CAUTION, General Description.>
C: INSTALLATION
S802308A11
Install in the reverse order of removal. CAUTION: Do not allow harness and connectors to interfere or get tangled up with other parts.
D: INSPECTION
G5M0301
S802308A10
Check for the following, and replace damaged parts with new parts. Airbag module, harness, connector, and mounting bracket are damaged.
AB-14
SIDE AIRBAG MODULE
Airbag System
6. Side Airbag Module

A: CAUTION
S802311A03
S802311
When disconnecting and connecting airbag connector, be sure to turn the ignition switch OFF, disconnect the ground cable from the battery, and wait for more than 20 seconds before starting work.
B5M1072A
B: REMOVAL
G5M0292
S802311A18
CAUTION: The side airbag module cannot be detached from the front seat assembly. When replacing side airbag module, replace front seat assembly. <Ref. to SE-5 REMOVAL, Front Seat.>
C: INSTALLATION D: INSPECTION
S802311A11
<Ref. to SE-5 INSTALLATION, Front Seat.>

S802311A10
Check for the following, and replace damaged parts with new parts. Front seat is deformed or damaged. Harness and/or connector is cracked, deformed or open. Lead wire is exposed.
G5M0299
Do not check continuity of the airbag module (driver, passenger, and side) with airbag removed from the vehicle.
G5M0302
AB-15
Airbag System
MAIN HARNESS
S802310
7. Main Harness
A: REMOVAL
S802310A18
S802310A11

S802310A10
1) Turn ignition switch OFF. 2) Disconnect the ground cable from the battery and wait for at least 20 seconds before starting work. 3) Remove instrument panel. <Ref. to EI-31 REMOVAL, Instrument Panel Assembly.> 4) Disconnect connector from airbag control module.
Check for the following, and replace damaged parts with new parts. Harness and/or connector is damaged.
S5M0216
5) Disconnect body harness connector (B31) from airbag connector (ABI) located at front pillar lower (driver side).
S5M0217A
6) Disconnect front sub sensor connector (yellow) from airbag main harness located at front pillar (both sides). 7) Detach clips (A) from steering support beam, and remove main harness.
H5M0933B
AB-16
SIDE AIRBAG HARNESS
Airbag System
8. Side Airbag Harness

A: REMOVAL
S802309A18
S802309
1) Turn ignition switch OFF. 2) Disconnect the ground cable from the battery, and wait for at least 20 seconds before starting work. 3) Remove front seat. <Ref. to SE-5 REMOVAL, Front Seat.> 4) Remove console box. <Ref. to EI-30 REMOVAL, Console Box.> 5) Roll up floor mat, and then disconnect two 12-pin yellow connectors from airbag control module. 6) Disconnect connector from side airbag sensor. <Ref. to AB-19 REMOVAL, Side Air Bag Sensor.> 7) Detach clips, and then remove side airbag harness.
S5M0307
S802309A11

S802309A10
Check for the following, and replace damaged parts with new parts. Harness and/or connector is damaged.
AB-17
Airbag System
AIRBAG CONTROL MODULE

S802302
9. Airbag Control Module

A: REMOVAL
S802302A18
CAUTION: Do not disassemble the airbag control module. If the airbag control module is deformed or if water damage is suspected, replace the airbag control module with a new genuine part. Do not drop the airbag control module. After removal, keep the airbag control module on a dry, clean surface away from moisture, heat, and dust. 1) Turn ignition switch OFF. 2) Disconnect the ground cable from the battery, and wait for at least 20 seconds before starting work. 3) Remove console box. <Ref. to EI-30 Removal, CONSOLE BOX.> 4) Disconnect connector from airbag control module. 5) Using T40 TORX bit (Tamper resistant type), remove four TORX bolts in the order shown in the figure.
S5M0219A
B: INSTALLATION
S802302A11
CAUTION: Use new TORX bolts during installation. Install in the reverse order of removal.
C: INSPECTION
S802302A10
Check for the following, and replace damaged parts with new parts. Control module, connector, and mounting bracket are damaged. Airbag is deployed. Side airbag is deployed.
AB-18
SIDE AIRBAG SENSOR
Airbag System
S802298A10
10. Side Airbag Sensor

A: REMOVAL
S802298A18
S802298
C: INSPECTION
1) Turn ignition switch OFF. 2) Disconnect the ground cable from the battery, and wait for at least 20 seconds before starting work. 3) Remove center pillar lower trim. <Ref. to EI-38, REMOVAL, Lower Inner Trim.> 4) Remove Outer Belt (FRONT). <Ref. to SB-6, OUTER BELT (FRONT), REMOVAL, Front Seat Belt.> 5) Remove two TORX bolts, and then detach side airbag sensor.
Check for the following, and replace damaged parts with new parts. Bracket connector for side airbag sensor is damaged.
S5M0308
B: INSTALLATION
S802298A11
CAUTION: Use new TORX nuts during installation. Install in the reverse order of removal.
AB-19
Airbag System
ROLL CONNECTOR
S802299
11. Roll Connector

A: REMOVAL
S802299A18
B: INSTALLATION
S802299A11
1) Turn ignition switch OFF. 2) Disconnect the ground cable from the battery, and wait for at least 20 seconds before starting work. 3) Remove instrument panel lower cover. 4) Disconnect airbag connector (AB3) and (AB8) below steering column.
1) Install combination switch assembly and steering column cover in the reverse order of removal. 2) Adjust centering roll connector. <Ref. to AB-20 ADJUSTMENT, Roll Connector.> 3) Install steering wheel and airbag module.
C: INSPECTION
S802299A10
Check for the following, and replace damaged parts with new parts. Combination switch and roll connector is cracked or deformed.
D: ADJUSTMENT
S802299A01
G5M0312
1) Check that front wheels are positioned in straight ahead direction. 2) Turn roll connector pin (A) clockwise until it stops. 3) Turn roll connector pin (A) counterclockwise approximately 2.65 turns until marks are aligned.
5) Remove driver s airbag module. <Ref. to AB-12, Driver s Airbag Module.> 6) Remove steering wheel. <Ref. to PS-27, REMOVAL, Steering Wheel.> 7) Remove steering column cover. 8) Remove screws, and then remove combination switch assembly.
H5M0663B
S5M0220
9) Remove lighting switch and wiper switch from roll connector.
B5M0940
AB-20
FRONT SUB SENSOR
Airbag System
12. Front Sub Sensor

A: REMOVAL
S802300A18
S802300
1) Turn ignition switch OFF. 2) Disconnect the ground cable from the battery, and wait for at least 20 seconds before starting work. 3) Remove front wheel and mud guard. <Ref. to EI-21 REMOVAL, Mud Guard.> 4) Disconnect connector from front sub sensor.
S5M0335
5) Remove front sub sensor.
S5M0336
S802300A11

S802300A10
Check for the following, and replace damaged parts with new parts. Front sub sensor, mounting bracket, and connector are damaged.
AB-21
Airbag System
FRONT SUB SENSOR HARNESS B: INSTALLATION C: INSPECTION

S802572A11
13. Front Sub Sensor Harness

S802572

S802572A18 S802572A10
A: REMOVAL
1) Turn ignition switch OFF. 2) Disconnect the ground cable from the battery, and wait for at least 20 seconds before starting work. 3) Remove front side sill cover, and then disconnect front sub sensor connector.
Check for the following, and replace damaged parts. Harness and/or connector is damaged.
B5M0517
4) Disconnect connector from front sub sensor. <Ref. to AB-21 REMOVAL, Front Sub Sensor.> 5) Remove wiring harness clips.
G5M0315
6) Remove grommet, and then detach front sub sensor harness.
G5M0316
AB-22
DISPOSAL OF AIRBAG MODULE (DEPLOYING WHILE INSTALLED IN VEHICLE)

Airbag System
14. Disposal of Airbag Module (Deploying While Installed in Vehicle)

S802573
A: OPERATION
S802573A16
CAUTION: Do not discard undeployed airbag module because it may cause serious personal injury when accidentally deployed. As a rule, the airbag module should be deployed while still installed in the vehicle. Do not remove it unless necessary. Deployment of the airbag module should be done on a flat place free from any possible danger. Avoid deploying outdoors during rainy or windy weather. Because deploying the airbag module causes a high explosive noise, be sure to warn people in the area, and do not allow anyone within a 5 m (16 ft) radius of the disposal site. Some smoke will be emitted from deployment of the airbag module. Therefore, it must be deployed in a well-ventilated place with no fire alarms nearby. Wear gloves, goggles, and earplugs during this operation. Wash your hands afterwards. After deployment, the airbag module will be especially hot. Leave it unattended for 40 minutes, and then discard it. Do not let water get on the deployed airbag module. Wrap the deployed airbag module in an airtight vinyl bag, and discard it. If circumstances do not permit airbag module deployment, contact a Subaru dealer.
5) Short terminal to alligator clip furnished as deployment tool (ST1). 6) Connect the deployment tool (ST1) and deployment adapter (ST2). ST1 98299PA030 DEPLOYMENT TOOL ST2 98299FC030 DEPLOYMENT ADAPTER A CAUTION: The deployment tool should be kept shorted until just before deployment of the airbag module.
S5M0309C
7) Connect deployment adapter (ST2) connector (2D) to airbag connector (AB3).
S5M0310A
S802573A1601
1) Turn ignition switch OFF. 2) Disconnect the ground cable from the battery, and wait for at least 20 seconds before starting work. 3) Remove lower cover. 4) Disconnect airbag connector (AB3) and (AB8) below steering column.
8) Extend the deployment tool to the limit, and make sure that the vehicle is empty. Close all windows, sunroof, and rear gate completely.
B5M1068
G5M0312
9) Move the battery at least 5 m (16 ft) from vehicle, and secure the nearby area. Connect the deployment tool alligator clip to the battery minus terminal.
AB-23

Airbag System
10) Connect the other terminal of the deployment tool to the battery plus terminal. Then, deploy the airbag module.
CAUTION: The deployment tool should be kept shorted until just before deployment of the airbag module.
G5M0531 S5M0309C
CAUTION: After deployment, the airbag module will be especially hot. Leave it unattended for 40 minutes, and then discard it. Do not let water get on the deployed airbag module. 11) Remove airbag module. <Ref. to AB-12 Driver s Airbag Module.> 12) Wrap the deployed airbag module in an airtight vinyl bag, and discard it.
7) Connect deployment adapter (ST2) connector (2D) to airbag connector (AB10).
S5M0311A
G5M0532
S802573A1602
1) Turn ignition switch OFF. 2) Disconnect the ground cable from the battery, and wait for at least 20 seconds before starting work. 3) Remove the glove box. <Ref. to EI-28, REMOVAL, Glove Box.> 4) Disconnect airbag connectors (AB9) and (AB10). 5) Short terminal to alligator clip furnished as deployment tool (ST1). 6) Connect the deployment tool (ST1) and deployment adapter (ST2). ST1 98299PA030 DEPLOYMENT TOOL ST2 98299FC030 DEPLOYMENT ADAPTER A
B5M1068
AB-24

Airbag System
G5M0531 S5M0309C
CAUTION: After deployment, the airbag module will be especially hot. Leave it unattended for 40 minutes, and then discard it. Do not let water get on the deployed airbag module. 11) Remove airbag module. <Ref. to AB-14 Passenger s Airbag Module.> 12) Wrap the deployed airbag module in an airtight vinyl bag, and discard it.
7) Connect deployment adapter (ST2) connector (2D) to side airbag module connector (yellow). CAUTION: Do not put any objects on the front seat.
S5M0313A
G5M0532
S802573A1603
1) Turn ignition switch OFF. 2) Disconnect the ground cable from the battery, and wait for at least 20 seconds before starting work. 3) Disconnect the side airbag module connector (yellow) under the front seat cushion. 4) Adjust both the front seat and front seat backrest to center positions. 5) Short terminal to alligator clip furnished as deployment tool (ST1). 6) Connect the deployment tool (ST1) and deployment adapter (ST2). ST1 98299PA030 DEPLOYMENT TOOL ST2 98299FC030 DEPLOYMENT ADAPTER A
B5M1068
AB-25

Airbag System
G5M0531
CAUTION: After deployment, the airbag module will be especially hot. Leave it unattended for 40 minutes, and then discard it. Do not let water get on the deployed airbag module. 11) Remove side airbag module. 12) Wrap the deployed airbag module in an airtight vinyl bag, and discard it.
G5M0532
AB-26
DISPOSAL OF AIRBAG MODULE (DEPLOYING AFTER REMOVAL FROM VEHICLE)

Airbag System
15. Disposal of Airbag Module (Deploying After Removal from Vehicle)

S802574
5) Bundle three wire automotive harnesses [each with a sectional area of 1.25 mm2 (0.00194 sq in) or more], and bind them twofold around the airbag module stay.
A: OPERATION
S802574A16
CAUTION: Do not discard undeployed airbag module because it may cause serious personal injury when accidentally deployed. As a rule, the airbag module should be deployed while still installed in the vehicle. Do not remove it unless necessary. Deployment of the airbag module should be done on a flat place free from any possible danger. Avoid deploying outdoors during rainy or windy weather. Do not damage the airbag module or drop it. Because deploying the airbag module causes a high explosive noise, be sure to warn people in the area, and do not allow anyone within a 5 m (16 ft) radius of the disposal site. Some smoke will be emitted from deployment of the airbag module. Therefore, it must be deployed in a well-ventilated place with no fire alarms nearby. Wear gloves, goggles, and earplugs during this operation. Wash your hands afterwards. After deployment, the airbag module will be especially hot. Leave it unattended for 40 minutes, and then discard it. Do not let water get on the deployed airbag module. Wrap the deployed airbag module in an airtight vinyl bag, and discard it. If circumstances do not permit airbag module deployment, contact a Subaru dealer.
H5M0736
S802574A1601
1) Turn ignition switch OFF. 2) Disconnect the ground cable from the battery, and wait for at least 20 seconds before starting work. 3) Remove airbag module. <Ref. to AB-12 Driver s Airbag Module.> 4) Install the removed bolts to airbag module.
S5M0309C
8) Connect deployment adapter (ST2) connector (2D) to airbag module. 9) Install airbag module with pad side facing upward on the wheel with the tire.
G5M0535 H5M0735
AB-27

Airbag System
10) Put three tires without the wheel on the tire installed with the airbag module. Put on an additional tire with the wheel, and then fasten them tight with rope.
13) Wrap the deployed airbag module in an airtight vinyl bag, and discard it.
G5M0532
G5M0536
S802574A1602
1) Turn ignition switch OFF. 2) Disconnect the ground cable from the battery, and wait for at least 20 seconds before starting work. 3) Remove airbag module. <Ref. to AB-14 Passenger s Airbag Module.> 4) Bundle three wire automotive harnesses [each with a sectional area of 1.25 mm2 (0.00194 sq in) or more], and route them through the airbag module bracket (A). Then, twist them for added strength.
G5M0537
S5M0312A
G5M0531
5) Short terminal to alligator clip furnished as deployment tool (ST1). 6) Connect the deployment tool (ST1) and deployment adapter (ST2). ST1 98299PA030 DEPLOYMENT TOOL ST2 98299FC030 DEPLOYMENT ADAPTER A
CAUTION: After deployment, the airbag module will be especially hot. Leave it unattended for 40 minutes, and then discard it. Do not let water get on the deployed airbag module.
AB-28

Airbag System
S5M0309C
G5M0537
7) Connect deployment adapter (ST2) connector (2D) to airbag module. 8) Install airbag module with pad side facing upward on 14 inch or greater size wheel with the tire.
G5M0531
G5M0613
9) Put three tires without the wheel on the tire installed with the airbag module. Put on an additional tire with the wheel on top, and then fasten them tight with rope.
CAUTION: After deployment, the airbag module will be especially hot. Leave it unattended for 40 minutes, and then discard it. Do not let water get on the deployed airbag module. 12) Wrap the deployed airbag module in an airtight vinyl bag, and discard it.
G5M0536
G5M0532
S802574A1603
1) Turn ignition switch OFF. 2) Disconnect the ground cable from the battery, and wait for at least 20 seconds before starting work.
AB-29

Airbag System
3) Remove front seat. <Ref. to SE-5 REMOVAL, Front Seat.> 4) Remove side airbag module. 5) Install nuts to side airbag module. 6) Bundle three wire automotive harnesses [each with a sectional area of 1.25 mm2 (0.00194 sq in) or more], and bind them twofold around the airbag module stay.
10) Install side airbag module on 14 inch or greater size tire without disk wheel.
S5M0317
S5M0316
Put two tires without the wheel (A) under the tire installed with the side airbag module (B). Put on an additional tire without disk wheel (C), and then put a tire with the wheel (D) on top. Fasten them tight with rope.
B5M0768A
11) Move the battery at least 5 m (16 ft) from the vehicle, and secure the nearby area. Connect the deployment tool alligator clip to the battery minus terminal.
S5M0309C
9) Connect deployment adapter (ST2) connector (2D) to airbag module.

G5M0537
AB-30

Airbag System
G5M0531
CAUTION: After deployment, the airbag module will be especially hot. Leave it unattended for 40 minutes, and then discard it. Do not let water get on the deployed airbag module. 13) Wrap the deployed airbag module in an airtight vinyl bag, and discard it.
G5M0532
AB-31
Airbag System
MEMO:
AB-32
SEAT BELT SYSTEM
SB
1. 2. 3. 4. 5. Page General Description.....................................................................................2 Inspection Locations After a Collision ........................................................5 Front Seat Belt ............................................................................................6 Rear Seat Belt.............................................................................................8 Disposal of Pretensioner ...........................................................................10
Seat Belt System
GENERAL DESCRIPTION
S801001
A: COMPONENT
S801001A05
1. FRONT SEAT BELT
S801001A0501
S5M0301A
(1) (2) (3) (4)
Adjuster anchor ASSY Anchor cover Webbing guide Inner belt ASSY
(5) Outer belt ASSY
SB-2
GENERAL DESCRIPTION
2. REAR SEAT BELT
S801001A0504
Seat Belt System
S5M0505A
(1) (2) (3) (4)
Outer seat belt RH Outer seat belt LH Inner seat belt LH Inner seat belt RH
(5) Outer seat belt CENTER (6) Anchor cover (7) Adjustable anchor ASSY
SB-3
Seat Belt System
GENERAL DESCRIPTION
S801001A03
B: CAUTION
Before removing pretensioner, be sure to rotate while pulling the safety lever to the right until it stops to set the lock position.
S5M0304A
Do not drop or apply any impact to the pretensioner. If oil, grease, or water gets on the pretensioner, wipe it off immediately with a dry cloth. Do not expose the pretensioner to high temperature or flame. Do not disassemble or attempt to repair the pretensioner. If it is dented, cracked, or deformed, replace it with a new one. Do not use the pretensioner parts from other vehicles. Always replace parts with new parts When handling a seat belt with a deployed pretensioner, wear gloves and goggles. Wash your hands afterwards. Do not re-use a seat belt with a deployed pretensioner again. Be sure to deploy pretensioner before disposal. <Ref. to SB-10 OPERATION Disposal of Pretensioner.> If the material gets in your eyes or on your skin during deployment, wash it away with clean water, and then consult a doctor.
SB-4
Seat Belt System
2. Inspection Locations After a Collision

S801306
A: INSPECTION
S801306A10
Check for the following, and then replace with new parts if necessary. Center pillar lower garnish is discolored or cracked. Wire harness and/or connector is damaged.
SB-5
Seat Belt System
FRONT SEAT BELT

S801303
3. Front Seat Belt

A: REMOVAL
S801303A18
5) Remove webbing guide.
1. OUTER BELT (FRONT)
S801303A1807
1) Fold backrest all the way forward, and then move front seat all the way forward. 2) Remove anchor cover and shoulder anchor bolt (A). 3) Remove center pillar cover (B) and center pillar lower trim. <Ref. to EI-38 REMOVAL, Lower Inner Trim.>
S5M0233
S5M0231B G5M0653
4) Rotate while pulling the safety lever to the right until it stops, then set the lock position. CAUTION: Once undeployed pretensioner has been removed from the vehicle body, do not move the safety lever until re-installation.
6) Remove lap anchor bolt. 7) Remove belt retractor and outer belt.
S5M0232
CAUTION: Do not drop or apply any impact to pretensioner. Pretensioner and bracket should be treated as an assembly. Do not attempt to disassemble it.
S5M0304A
SB-6
FRONT SEAT BELT

2. INNER BELT (FRONT)
S801303A1802
Seat Belt System
1) Disconnect connector. 2) Remove anchor bolt, and then detach inner belt.
S5M0234
B: INSTALLATION
S801303A11
S801303A1107
Install in the reverse order of removal. CAUTION: The parts on left and right are not identical. Before installation, make sure that the correct part is used. Be careful not to twist belts during installation.
S801303A1102
C: INSPECTION
S801303A10
S801303A1005
Check for the following, and replace with new parts if necessary. Pretensioner is cracked or deformed. Seat belt is slackened, bent, or frayed. Seat belt is abnormally wound or extended.
S801303A1002
Check for the following, and replace with new parts if necessary. Inner belt is deformed or damaged. Seat belt buckle is engaged improperly.
SB-7
Seat Belt System
REAR SEAT BELT

S801304
4. Rear Seat Belt

A: REMOVAL
S801304A18
3. OUTER BELT CENTER
S801304A1811
1. OUTER BELT SIDE
S801304A1809
CAUTION: When removing clip, use great care not to damage the roof trim. 1) Remove rear rail trim (I). 2) Remove strut cover (J). 3) Remove rear outer belt side anchor bolt. 4) Remove caps and screws then remove rear quarter upper trim (H).
1) Remove rear seat. <Ref. to SE-6 REMOVAL, Rear Seat.> 2) Remove side sill rear upper cover. <Ref. to EI-38 REMOVAL, Lower Inner Trim.> 3) Remove quarter trim. <Ref. to EI-39 REMOVAL, Rear Quarter Trim.> 4) Remove bolts, then detach outer belt side.
S5M0236
2. INNER BELT
S801304A1810
1) Remove the rear cushion. <Ref. to SE-6 REMOVAL, Rear Seat.> 2) Remove bolts, and then detach inner belt.
B5M1037A
5) Remove cover (B) while detaching snap lock carefully. Put the outer belt center tongue (A) out to the other side of the trim through the hole.
S5M0408
B5M0675A
6) Remove clips and hang down rear end of roof trim.
SB-8
REAR SEAT BELT

7) Disconnect harness and connector, and then remove outer belt center assembly.
Seat Belt System

S801304A10
C: INSPECTION
1. OUTER BELT SIDE
S801304A1009
Check for the following, and replace with new parts if necessary. Seat belt is slackened, bent, or frayed. Seat belt is abnormally wound or extended.
S801304A1010
S5M0411
Check for the following, and replace with new parts if necessary. Seat belt is slackened, bent, or frayed. Seat belt is abnormally wound or extended.
3. INNER BELT
S801304A1011
B: INSTALLATION
1. OUTER BELT SIDE
S801304A11
S801304A1109
Install in the reverse order of removal. CAUTION: During installation, make sure that seat belts are not twisted. After installation, make sure that seat belts can be smoothly extended and wound.
Check for the following, and replace with new parts if necessary. Inner belt is deformed or damaged. Seat belt buckle is engaged improperly.
S801304A1110
Install in the reverse order of removal. CAUTION: During installation, make sure that seat belts are not twisted. After installation, make sure that seat belts can be smoothly extended and wound.
3. INNER BELT
S801304A1111
Install in the reverse order of removal. CAUTION: During installation, make sure that seat belts are not twisted.
SB-9
Seat Belt System
DISPOSAL OF PRETENSIONER
S801305
5. Disposal of Pretensioner
A: CAUTION
S801305A03
B: OPERATION
S801305A16
Do not discard undeployed pretensioners, because they may cause serious personal injury when accidentally deployed. Deployment of the pretensioners should be done on a flat place free from any possible danger. Avoid deploying outdoors during rainy or windy weather. Do not drop or damage pretensioner. Because deploying the pretensioners causes a high-explosive noise, be sure to warn people in the area, and do not allow anyone within a 5-meter (16 ft) radius of the disposal site. Some smoke will be emitted after deployment of the pretensioners. Therefore, it must be deployed in a well-ventilated area with no smoke alarms nearby. Wear gloves, goggles, and earplugs during this operation. Wash your hands afterwards. After deployment, the pretensioner is especially hot. Leave it unattended for 40 minutes, and then discard it. Do not let water get on the deployed pretensioner. Wrap the deployed the pretensioner in an airtight vinyl bag, and then discard it.
1) Rotate while pulling the safety lever to the right until it stops, then set the lock position.
S5M0304A
2) Remove outer belt (FRONT). <Ref. to SB-6 OUTER BELT (FRONT), REMOVAL, Front Seat Belt.> 3) Mark an arrow on pretensioner which indicates vehicle front. WARNING: Never move the safety lever of pretensioner until instructed to do so.
B5M0493
SB-10
4) Cut the webbing of the pretensioner.
Seat Belt System
7) Rotate while pulling the safety lever to the left until it stops, then set the unlock position. CAUTION: Pay careful attention not to apply impact to the pretensioner with its safety system unlocked. It may deploy even with a slight impact.
B5M0494
5) Tie the pretensioner with a rope of a minimum 6 m (20 ft) so that the arrow on the pretensioner faces downward.
B5M0495
6) Pile three tires without disc wheels on a flat and rigid floor. Softly place the pretensioner in the tires with the arrow facing downward.
S5M0304A
8) Put a tire with disk wheel on the three tires so that the rope comes out of the wheel center as shown in the figure. Then, fix the four tires with another rope. WARNING: Pay careful attention not to apply impact to the pretensioner with its safety system unlocked. It may deploy even with a slight impact.
B5M0496
B5M0498
SB-11
Seat Belt System
9) Pull the rope on the pretensioner from a minimum 5 m (16 ft) away from the tires so that the pretensioner is lifted a minimum 400 mm (15.75 in) from the floor. CAUTION: Before pulling the rope, confirm the safety in the working area, and inform the people around you of the deployment.
B5M0499A
10) Release the rope to drop the pretensioner so that the pretensioner is deployed by impact. CAUTION: The pretensioner may not deploy if the safety system is locked completely or it falls in a direction different from the one shown by the arrow. In this case, repeat the procedure from the beginning paying attention not to apply impact to the pretensioner. After deployment, the pretensioner is extremely hot. Leave it unattended for 40 minutes. Do not let water get on the deployed pretensioner. 11) Wrap the deployed pretensioner in an airtight vinyl bag and discard it.
B5M0500
SB-12
LIGHTING SYSTEM
LI
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. Page General Description.....................................................................................2 Headlight and Tail Light System .................................................................4 Front Fog Light System.............................................................................14 Rear Fog Light System .............................................................................18 Turn Signal and Hazard Light System ......................................................22 Back-up Light System ...............................................................................28 Stop Light System .....................................................................................30 Interior Light System .................................................................................32 Headlight Beam Leveler System...............................................................38 Combination Switch (Light) .......................................................................40 Headlight Assembly...................................................................................42 Headlight Bulb ...........................................................................................44 Front Turn Signal Light Assembly .............................................................45 Front Turn Signal Light Bulb .....................................................................46 Parking Light Bulb .....................................................................................47 Front Fog Light Assembly .........................................................................48 Front Fog Light Bulb .................................................................................49 Rear Combination Light Assembly............................................................50 Rear Finisher Light Assembly ...................................................................51 Brake/Tail Light Bulb .................................................................................52 Back-up Light Bulb ....................................................................................53 Rear Turn Signal Light Bulb......................................................................54 Rear Fog Light Assembly..........................................................................55 Rear Fog Light Bulb ..................................................................................56 License Plate Light....................................................................................57 High-mounted Stop Light ..........................................................................58 Side Turn Signal Light...............................................................................59 Spot Light ..................................................................................................60 Room Light ................................................................................................61 Luggage Room Light.................................................................................62 Glove Box Light.........................................................................................63
Lighting System
GENERAL DESCRIPTION
S914001
Headlight Front turn signal light Side turn signal light Parking light Front fog light Rear fog light Rear combination light License plate light High-mounted stop light Room light Spot light Luggage room light
A: SPECIFICATIONS
S914001E49
Tail/Stop light Turn signal light Back-up light
12 V 60 W/55 W (Halogen) 12 V 21 W 12 V 5 W 12 V 5 W 12 V 51 W 12 V 21 W 12 V 5/21 W 12 V 21 W 12 V 16 W 12 V 5 W 12 V 10 W 12 V 8 W 12 V 8 W 12 V 5 W
B: PRECAUTIONS
S914001E59
Before disassembling or reassembling parts, always disconnect battery ground cable. When replacing radio, control module, and other parts provided with memory functions, record memory contents before disconnecting the battery ground cable. Otherwise, the memory will be erased. Reassemble in reverse order of disassembly, unless otherwise indicated. Adjust parts to the given specifications. Connect connectors and hoses securely during reassembly.
After reassembly, make sure functional parts operate smoothly. WARNING: Air bag system wiring harness is routed near electrical parts and switches. All air bag system wiring harnesses and connectors are yellow. Do not use electric test equipment on these circuits. Be careful not to damage the air bag system wiring harness when servicing electrical parts and switches.
C: PREPARATION TOOL
1. GENERAL TOOLS
Circuit Tester
S914001A1701
S914001A17
TOOL NAME
REMARKS Used for measuring resistance and voltage.
LI-2
GENERAL DESCRIPTION
MEMO:
Lighting System
LI-3
Lighting System
HEADLIGHT AND TAIL LIGHT SYSTEM

S914415
2. Headlight and Tail Light System

A: SCHEMATIC
S914415A21
1. HEADLIGHT LHD MODEL
S914415A2104
SL19-20
LI-4

2. HEADLIGHT RHD MODEL
S914415A2105
Lighting System
SR19-20
LI-5
Lighting System

S914415A2106
3. CLEARANCE LIGHT AND ILLUMINATION LIGHT LHD MODEL
SL21-20A
LI-6
Lighting System
SL21-20B
LI-7
Lighting System
SL21-20C
LI-8

4. CLEARANCE LIGHT AND ILLUMINATION LIGHT RHD MODEL
S914415A2107
Lighting System
SR21-20A
LI-9
Lighting System
SR21-20B
LI-10
Lighting System
SR21-20C
LI-11
Lighting System

S914415A10
B: INSPECTION
1. HEADLIGHT RELAY
S914415A1001
Check continuity between terminals when terminal No. 4 is connected to battery and terminal No. 3 is grounded.
When current flows. When current does not flow. Between terminals No. 1 and No. 2 Between terminals No. 1 and No. 2 Between terminals No. 3 and No. 4 Continuity exists. Continuity does not exist. Continuity exists.
S6M0048A
2. TAIL AND ILLUMINATION RELAY
S914415A1002
Check continuity between terminals (indicated in table below) when terminal No. 4 is connected to battery and terminal No. 3 is grounded.
S6M0048A
LI-12

MEMO:
Lighting System
LI-13
Lighting System
FRONT FOG LIGHT SYSTEM

S914473
3. Front Fog Light System

A: SCHEMATIC
S914473A21
1. FRONT FOG LIGHT LHD MODEL
S914473A2105
SL22-20
LI-14

2. FRONT FOG LIGHT RHD MODEL
S914473A2106
Lighting System
SR22-20
LI-15
Lighting System

S914473A10
B: INSPECTION
1. FRONT FOG LIGHT SWITCH
S914473A1001
B6M1583
Check continuity between terminals when operating the switch.

Switch position OFF ON Tester connection 3-5-6 Specified condition No continuity Continuity
S914473A1002
2. FRONT FOG LIGHT RELAY
S6M0048A
LI-16

MEMO:
Lighting System
LI-17
Lighting System
REAR FOG LIGHT SYSTEM

S914476
4. Rear Fog Light System

A: SCHEMATIC
S914476A21
1. REAR FOG LIGHT LHD MODEL
S914476A2102
SL30-20
LI-18

2. REAR FOG LIGHT RHD MODEL
S914476A2103
Lighting System
SR30-20
LI-19
Lighting System

S914476A10
B: INSPECTION
1. REAR FOG LIGHT SWITCH
S914476A1001
1) Turn ignition switch ON. 2) Turn on the headlight or front fog light. 3) Push the rear fog light switch and check if the rear fog light turns on.
2. REAR FOG LIGHT RELAY
S914476A1002
S6M0048A
LI-20

MEMO:
Lighting System
LI-21
Lighting System
TURN SIGNAL AND HAZARD LIGHT SYSTEM

S914481
5. Turn Signal and Hazard Light System

A: SCHEMATIC
S914481A21
LI-22

1. TURN SIGNAL LIGHT AND HAZARD LIGHT LHD MODEL
S914481A2102
Lighting System
SL26-20A
LI-23
Lighting System
SL26-20B
LI-24

2. TURN SIGNAL LIGHT AND HAZARD LIGHT RHD MODEL
S914481A2103
Lighting System
SR26-20A
LI-25
Lighting System
SR26-20B
LI-26
TURN SIGNAL AND HAZARD LIGHT SYSTEM B: INSPECTION

S914481A10
Lighting System
1. TURN SIGNAL SWITCH
S914481A1001
<Ref. to LI-40 REMOVAL, Combination Switch (Light).>
2. HAZARD SWITCH
S914481A1002
B6M1483

Switch position OFF ON Tester connection 6-7 1 - 3 - 4, 7 - 8 Specified condition Continuity Continuity
3. TURN SIGNAL & HAZARD MODULE

S914481A1003
B6M1584
Connect battery and turn signal light bulb to the module, as shown in the figure. The module is properly functioning if it blinks when power is supplied to the circuit.
LI-27
Lighting System
BACK-UP LIGHT SYSTEM

S914414
6. Back-up Light System

A: SCHEMATIC
S914414A21
1. BACK-UP LIGHT
S914414A2101
SG29-20
LI-28
BACK-UP LIGHT SYSTEM B: INSPECTION

S914414A10
Lighting System
1. BACK-UP LIGHT SWITCH (M/T)

Check continuity between terminals.
Switch position When shift lever is set in reverse position Other positions Tester connection Turbo engine model: 2 - 4 Non-turbo engine model: 1 - 2
S914414A1001
Specified condition Continuity No continuity

S914414A1002
2. INHIBITOR SWITCH (A/T)
B6M1485

Switch position When select lever is set in R position Other positions Tester connection Specified condition Continuity No continuity
1-2
LI-29
Lighting System
STOP LIGHT SYSTEM

S914417
7. Stop Light System

A: SCHEMATIC
1. STOP LIGHT
S914417A21 S914417A2103
SG25-20
LI-30
STOP LIGHT SYSTEM B: INSPECTION

S914417A10
Lighting System
1. STOP LIGHT SWITCH
S914417A1001
S6M0570A

Switch position When brake pedal is depressed When brake pedal is released Tester connection 1 - 2: Without cruise control 2 - 3: With cruise control Specified condition Continuity No continuity
LI-31
Lighting System
INTERIOR LIGHT SYSTEM

S914418
8. Interior Light System

A: SCHEMATIC
S914418A21
1. INTERIOR LIGHT LHD MODEL
S914418A2102
SL24-20A
LI-32
Lighting System
SL24-20B
LI-33
Lighting System

S914418A2103
2. INTERIOR LIGHT RHD MODEL
SR24-20A
LI-34
Lighting System
SR24-20B
LI-35
Lighting System

S914418A10
B: INSPECTION
1. DOOR SWITCH
S914418A1001

Switch position When door is open. When door is closed. Tester connection Specified condition Continuity 1 - ground No continuity
S914418A1002
2. REAR GATE LATCH SWITCH

Switch position When rear gate is open. When rear gate is closed. Tester connection
Specified condition Continuity
1-2 No continuity
LI-36

MEMO:
Lighting System
LI-37
Lighting System
HEADLIGHT BEAM LEVELER SYSTEM

S914493
9. Headlight Beam Leveler System

A: SCHEMATIC
S914493A21
1. HEADLIGHT BEAM LEVELER
S914493A2101
SG83-20
LI-38
HEADLIGHT BEAM LEVELER SYSTEM B: INSPECTION

S914493A10
Lighting System
1. HEADLIGHT BEAM LEVELER ACTUATOR S914493A1001

1) Turn on the headlights. 2) Confirm the headlight beam level is lowered by changing the switch position to 0 - 1 - 2 - 3 - 4 - 5.
2. HEADLIGHT BEAM LEVELER SWITCH

S914493A1002
Measure the resistance between headlight beam leveler switch terminals at each switch position.
S6M0558A
Switch position 0 1 2 3 4 5
Resistance 2.7 k 1.2 k 750 350 120 1 - 10
LI-39
Lighting System
COMBINATION SWITCH (LIGHT) C: INSPECTION

S914411A10
10. Combination Switch (Light)

S914411
A: REMOVAL
S914411A18
1) Remove instrument panel lower cover. <Ref. to EI-31 REMOVAL, Instrument Panel Assembly.> 2) Remove screws which secure upper column cover to lower column cover.
S6M0042
3) Disconnect connector from combination switch. 4) Remove screws which secure switch and remove switch.
B6M1560B
Move combination switch to respective positions and check continuity between terminals.
1. LIGHTING SWITCH
LHD model:
Switch position
S6M0046
S914411A1001
Tester connection 14 - 16 13 - 14 - 16
OFF Tail Head
Specified condition No continuity Continuity Continuity
B: INSTALLATION
S914411A11
RHD model:
Switch position OFF Tail Head Tester connection 9 - 15 9 - 14 - 15 Specified condition No continuity Continuity Continuity
S914411A1002
2. DIMMER AND PASSING SWITCH

LHD model:
Switch position Passing Low beam High beam Tester connection 7 - 8 - 16 16 - 17 7 - 16
Specified condition Continuity Continuity Continuity
LI-40
COMBINATION SWITCH (LIGHT)

RHD model:
Switch position Passing Low beam High beam Tester connection 1-2-9 9 - 10 2-9 Specified condition Continuity Continuity Continuity
Lighting System
3. TURN SIGNAL SWITCH

LHD model:
Switch position Left Neutral Right
S914411A1003
Tester connection 1-2 2-3
Specified condition Continuity No continuity Continuity
RHD model:
Switch position Left Neutral Right Tester connection 6-7 7-8
S914411A1004
Specified condition Continuity No continuity Continuity
4. PARKING SWITCH
Switch position OFF ON
Tester connection 2-4 1-4
Specified condition Continuity Continuity
LI-41
Lighting System
HEADLIGHT ASSEMBLY
S914409
11. Headlight Assembly

A: REMOVAL
S914409A18
B: INSTALLATION C: ADJUSTMENT
S914409A11

S914409A01
1) Remove duct (A) (when right side headlight is removed).
1. HEADLIGHT AIMING
S914409A0101
CAUTION: Turn off the light before adjusting headlight aiming. If the light is necessary to check aiming, do not turn on for more than two minutes. NOTE: Before checking the headlight aiming, be sure of the following: The area around the headlight has not sustained any accident, damage or other type of deformation. Vehicle is parked on level ground. The inflation pressure of tires is correct. Vehicles gas tank is fully charged. Bounce the vehicle several times to normalize the suspension. Make certain that someone is seated in the driver s seat. Turn the headlights on and then adjust the low beam pattern to the following positions on the screen.
S6M0533
S6M0532A
2) Disconnect headlight bulb connector.
3) Remove front grille. <Ref. to EI-10 REMOVAL, Front Grille.> 4) Remove screw (A) then remove front turn signal light while disconnecting connector. 5) Remove extension (B). <Ref. to EI-12, REMOVAL, Front Bumper.> 6) Remove bolts (C) which secure headlight and remove headlight.
NOTE: Set the headlight leveler switch to 0 position. Adjust vertical aim (A) first, then horizontal aim (B).
S6M0426A
S6M0534A
LI-42
HEADLIGHT ASSEMBLY
Lighting System
S6M0535A
This illustration is for LHD model. The pattern for RHD model is symmetrically opposite.
W mm (in) 1,090 (42.91) H mm (in) Non-turbo model 710 (27.95) Turbo model 697 (27.44) h mm (in) at 3 m (10 ft) 30 (1.18)
LI-43
Lighting System
HEADLIGHT BULB
S914410
12. Headlight Bulb

A: REMOVAL
S914410A18
B: INSTALLATION
S914410A11
CAUTION: Because the tungsten halogen bulb operates at a high temperature, dirt and oil on the bulb surface reduces the bulbs service life. Hold the flange portion when replacing the bulb. Never touch the glass portion. Do not leave the headlight without a bulb for a long time. Dust, moisture, etc. entering the headlight may affect its the performance. 1) Remove duct (A) (when right side headlight is removed).
S6M0532A
2) Disconnect headlight bulb connector. 3) Remove back cover (A).
S6M0536A
4) Push to remove spring retainer (A) and then detach headlight bulb (B).
S6M0537A
LI-44
FRONT TURN SIGNAL LIGHT ASSEMBLY
Lighting System
13. Front Turn Signal Light Assembly

S914408
A: REMOVAL
S914408A18
1) Remove screw and disconnect connector, and then detach front turn signal light assembly.
S6M0538
B: INSTALLATION
S914408A11
LI-45
Lighting System
FRONT TURN SIGNAL LIGHT BULB
14. Front Turn Signal Light Bulb

S914412
A: REMOVAL
S914412A18
1) Remove front turn signal light assembly. <Ref. to LI-45, REMOVAL, Front Turn Signal Light Assembly.> 2) Turn the socket and remove the bulb.
S6M0539
B: INSTALLATION
S914412A11
LI-46
PARKING LIGHT BULB
Lighting System
15. Parking Light Bulb

A: REMOVAL
S914419A18
S914419
1) Remove headlight assembly. <Ref. to LI-42 REMOVAL, Headlight Assembly.> 2) Turn the socket and remove the bulb.
S6M0540
B: INSTALLATION
S914419A11
LI-47
Lighting System
FRONT FOG LIGHT ASSEMBLY
16. Front Fog Light Assembly

S914427
A: REMOVAL
S914427A18
1) Remove the two screws, then draw out the front fog light from front bumper.
S6M0085
2) Disconnect the connector.
B: INSTALLATION
S914427A11
LI-48
FRONT FOG LIGHT BULB
Lighting System
17. Front Fog Light Bulb

A: REMOVAL
S914428A18
S914428
1) Remove front fog light assembly. <Ref. to LI-48 REMOVAL, Front Fog Light Assembly.> 2) Remove front fog light bulb (A).
S6M0541A
B: INSTALLATION
S914428A11
LI-49
Lighting System
REAR COMBINATION LIGHT ASSEMBLY
18. Rear Combination Light Assembly

S914426
A: REMOVAL
S914426A18
1) Remove rear quarter upper and lower trim. <Ref. to EI-39 REMOVAL, Rear Quarter Trim.> 2) Remove nuts and disconnect connector.
S6M0045
3) Attach adhesive cloth tape to body area around rear combination light. 4) Using a standard screwdriver, carefully pry rear combination light off. CAUTION: Do not pry on the rear combination light forcefully as this may scratch the vehicle body.
B: INSTALLATION
S914426A11
Install in the reverse order of removal. CAUTION: Remove all traces of adhesive tape from body before installation. Attach butyl rubber tape to back of rear combination light before installing rear combination light on body for sealing purposes.
LI-50
REAR FINISHER LIGHT ASSEMBLY
Lighting System
19. Rear Finisher Light Assembly

S914429
A: REMOVAL
S914429A18
1) Remove rear gate trim access hole cover. 2) Remove the four nuts.
S6M0427
3) Detach rear finisher light while disconnecting connector. 4) Install in the reverse order of removal.
B: INSTALLATION
S914429A11
LI-51
Lighting System
BRAKE/TAIL LIGHT BULB

S914430
20. Brake/Tail Light Bulb

A: REMOVAL
S914430A18
1) Remove rear combination light cover. 2) Turn the socket and remove the bulb.
S6M0542
B: INSTALLATION
S914430A11
LI-52
BACK-UP LIGHT BULB
Lighting System
21. Back-up Light Bulb

A: REMOVAL
S914424A18
S914424
1) Remove rear gate trim access hole cover. 2) Turn the socket and remove the bulb.
S6M0543
B: INSTALLATION
S914424A11
LI-53
Lighting System
REAR TURN SIGNAL LIGHT BULB
22. Rear Turn Signal Light Bulb

S914421
A: REMOVAL
S914421A18
1) Remove rear combination light cover. 2) Turn the socket and remove the bulb.
S6M0544
B: INSTALLATION
S914421A11
LI-54
REAR FOG LIGHT ASSEMBLY
Lighting System
23. Rear Fog Light Assembly

S914422
A: REMOVAL
S914422A18
1) Disconnect connector from rear fog light. 2) Remove nuts and then detach rear fog light. NOTE: Take out rear fog light by pulling out it from behind the bumper.
S6M0429
B: INSTALLATION
S914422A11
LI-55
Lighting System
REAR FOG LIGHT BULB

S914423
24. Rear Fog Light Bulb

A: REMOVAL
S914423A18
1) Remove screw (A) and rear fog light lens (B).
S6M0545A
2) Remove the bulb.
B: INSTALLATION
S914423A11
LI-56
LICENSE PLATE LIGHT
Lighting System
25. License Plate Light

A: REMOVAL
S914420A18
S914420
1) Remove license plate light mounting screw (A) and then remove the lens (B)
S6M0546A
2) Remove the bulb.
B: INSTALLATION
S914420A11
LI-57
Lighting System
HIGH-MOUNTED STOP LIGHT
26. High-mounted Stop Light

S914425
A: REMOVAL
S914425A18
1) Remove cap (a) by prying on the edge with a screwdriver. 2) Remove screws (b) and then detach cover (c). 3) Remove screws (d) and then detach highmounted stop light while disconnecting connector.
B6M1343A
B: INSTALLATION
S914425A11
LI-58
SIDE TURN SIGNAL LIGHT
Lighting System
27. Side Turn Signal Light

A: REMOVAL
S914407A18
S914407
1) Pull out the light from body while pushing it in direction of vehicle front. 2) Disconnect harness connector and remove the light.
B6M1543
B: INSTALLATION
S914407A11
LI-59
Lighting System
SPOT LIGHT
S914398
28. Spot Light

A: REMOVAL
S914398A18
1) Remove spot light lens (A).
S6M0547A
2) Remove sunroof switch. <Ref. to SR-12, REMOVAL, Sunroof Switch.> 3) Remove spot light mounting screw (B).
S6M0548A
4) Disconnect harness connectors and remove spot light.
S914398A11

S914398A10

Switch position OFF ON Tester connection 1-2 Specified condition No continuity Continuity
LI-60
ROOM LIGHT
Lighting System
29. Room Light

A: REMOVAL
S914397
S914397A18
1) Remove lens (A) and room light mounting screws (B).
B6M1479A
2) Disconnect harness connectors and remove the light.
S914397A11

S914397A10
B6M1489A

Switch position OFF ON DOOR Tester connection 1-3 1-2 Specified condition No continuity Continuity Continuity
LI-61
Lighting System
LUGGAGE ROOM LIGHT

S914399
30. Luggage Room Light

A: REMOVAL
S914399A18
1) Remove lens (A) and luggage room light mounting screws (B).
B6M1480A
2) Disconnect harness connectors and remove luggage room light.
S914399A11

S914399A10
B6M1490A
Turn the switch each position and check continuity between terminals.
Switch position OFF ON DOOR Tester connection (A) - (C) (A) - (B) Specified condition No continuity Continuity Continuity
LI-62
GLOVE BOX LIGHT
Lighting System
31. Glove Box Light

A: REMOVAL
S914396A18
S914396
1) Remove glove box. <Ref. to EI-28 REMOVAL, Glove Box.> 2) Disconnect harness connector. 3) Remove glove box light.
S6M0549
B: INSTALLATION
S914396A11
LI-63
Lighting System
GLOVE BOX LIGHT
MEMO:
LI-64
WIPER AND WASHER SYSTEMS
WW
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Page General Description.....................................................................................2 Wiper and Washer System .........................................................................6 Combination Switch (Wiper)......................................................................10 Wiper Blade...............................................................................................12 Washer Tank and Motor ............................................................................13 Front Wiper Arm ........................................................................................14 Front Wiper Motor and Link ......................................................................15 Front Washer.............................................................................................17 Rear Wiper Arm.........................................................................................19 Rear Wiper Motor......................................................................................20 Rear Washer .............................................................................................21 Wiper Control Relay ..................................................................................23 Headlight Washer ......................................................................................24
Wiper and Washer Systems
GENERAL DESCRIPTION
S902001
A: SPECIFICATIONS
Front wiper motor Rear wiper motor Front washer motor Rear washer motor
S902001E49
Input Input Pump type Input Pump type Input

S902001A05
12 V 54 W or 12 V 42 W or Centrifugal 12 V 36 W or Centrifugal 12 V 36 W or
less less less less
B: COMPONENT
1. FRONT WIPER
S902001A0501
S6M0485A
(1) (2) (3) (4)
Wiper Wiper Wiper Wiper
rubber blade ASSY arm link
(5) Wiper motor
WW-2
GENERAL DESCRIPTION
2. REAR WIPER
S902001A0502
S6M0486A
(1) (2) (3) (4)
Wiper blade ASSY Wiper arm Wiper motor Pivot cap
(5) Wiper arm cover
Tightening torque: Nm (kgf-m, ft-lb) T1: 5.9 (0.6, 4.3) T2: 7.8 (0.8, 5.6)
WW-3
GENERAL DESCRIPTION
3. WASHER TANK
S902001A0503
S6M0564A
(1) (2) (3) (4) (5) (6)
Washer nozzle Washer hose Washer tank Washer tank cap Front washer motor Rear washer motor
S902001A03
(7) (8) (9) (10) (11) (12)
Grommet Headlight washer Motor bracket Headlight washer Headlight washer Headlight washer
motor case upper nozzle lower nozzle
(13) Clip (14) Joint valve

C: CAUTION
Reconnect connectors and hoses securely. After reconnecting, confirm that each function operates normally. Be careful that wire harnesses of airbag system pass near electrical parts and switches. Wire harnesses and connectors of all airbag system are yellow color. Do not use a tester on these circuits. Care must be taken when installing the piping hose so that no bending, jamming, etc. are caused. If even a little oil or grease such as silicon oil gets in the tank and washer passages, an oil film easily forms on the glass, causing the wiper to chatter and judder. Therefore, be careful not to let this happen.
WW-4
GENERAL DESCRIPTION
MEMO:
WW-5
WIPER AND WASHER SYSTEM

S902394
2. Wiper and Washer System

A: SCHEMATIC
S902394A21
1. WIPER AND WASHER (FRONT)
S902394A2101
SG50-20
WW-6

2. WIPER AND WASHER (REAR)
S902394A2102
SG51-20
WW-7

S902394A2107
3. HEADLIGHT WASHER
SG53-20
WW-8
WIPER AND WASHER SYSTEM B: INSPECTION

S902394A10
Symptom Wiper and washers do not operate.
Wipers do not operate in LO or HI.
Wipers do not operate in INT.
Washer motor does not operate.
Wipers do not operate when washer switch is ON. Washer fluid spray does not operate.
(1) (2) (3) (4) (1) (2) (3) (1) (2) (3) (1) (2) (3) (1) (2) (1)
Repair order Wiper fuse (F/B No. 14, 15) Combination switch Wiper motor Wire harness Combination switch Wiper motor Wire harness Combination switch Wiper motor Wire harness Washer switch Washer motor Wire harness Washer motor Wire harness Washer hose and nozzle
WW-9
COMBINATION SWITCH (WIPER) C: INSPECTION

S902395A10
3. Combination Switch (Wiper)

S902395
A: REMOVAL
S902395A18
Inspect the continuity between each connector terminal.
1) Loosen screw to remove a steering column cover.
S6M0042
2) Disconnect connectors from combination switches. 3) Loosen screw to remove combination switch.
S6M0137
LHD model:
Switch position
B6M1499
FRONT
B: INSTALLATION
S902395A11

REAR
OFF INT LO HI Washer ON Washer ON OFF ON Washer ON
Test connection 7 16 7 16 7 17 8 17 2 11 2 10 12 2 10 2 10 12
Specified condition Continuity Continuity Continuity Continuity Continuity Continuity No continuity Continuity Continuity
If continuity is not as specified, replace the switch. RHD model:

Switch position OFF INT LO HI Washer ON Washer ON OFF ON Washer ON Test connection 3 12 3 12 3 11 2 11 8 17 8 16 18 8 18 8 16 18 Specified condition Continuity Continuity Continuity Continuity Continuity Continuity No continuity Continuity Continuity
FRONT
REAR
If continuity is not as specified, replace the switch.
WW-10
COMBINATION SWITCH (WIPER)
Intermittent operation inspection 1) Turn the wiper switch to INT. 2) Adjust the intermittent control switch to MAX. 3) Apply battery voltage to switch terminals 16 and 2, and inspect the voltage of terminals 7 and 2. (Measure the voltage from after the second time the wiper stops.)
B6M1465A
If operation is not as specified, replace the switch.
WW-11
WIPER BLADE D: ASSEMBLY

S902392A02
4. Wiper Blade
A: REMOVAL
S902392
S902392A18
While pushing locking clip (A) up, pull out blade from arm to arrow direction.
1) Insert the wiper rubber onto the blade so that the stopper is in the position shown (at the bottom of the wiper arm).
B6M1497 B6M1570A
B: INSTALLATION
2) Make sure the wiper rubber is securely fastened to the pull stopper (A).
S902392A11
1) Install in the reverse order of removal. 2) Confirm that clip was locked securely.
C: DISASSEMBLY
S902392A06
Pull on side (A) of the wiper rubber stopper and remove the rubber from the blade assembly.
B6M1498A
E: INSPECTION
S902392A10
B6M1496A
1) When the wiper does not perform well, inspect the following: Make sure the movable part of the blade assembly moves smoothly. Make sure the wiper rubber is not deformed or damaged. 2) Replace with a new part if damage is found.
WW-12
WASHER TANK AND MOTOR

S902405A06
5. Washer Tank and Motor

A: REMOVAL
S902405A18
S902405
C: DISASSEMBLY
Remove bolt, and then pull out washer motor from tank.
1) Disconnect the ground cable from the battery. 2) Remove the two bolts, and then disconnect the connectors from washer motors.
S6M0563
B5M1464
D: ASSEMBLY
S902405A02
3) Lift the washer tank, and then disconnect the connector from headlight washer motor. Disconnect washer hoses.
1) Assemble in the reverse order of disassembly. 2) Confirm that water does not leak from installation area of motor.
E: INSPECTION
S902405A10
Apply battery voltage to the connector terminal of the washer motor and make sure the motor operates.
S6M0561
4) Disconnect the washer hose from the motor, and then detach the washer tank.
B6M1567
S6M0562
B: INSTALLATION
S902405A11
WW-13
FRONT WIPER ARM

S902404
6. Front Wiper Arm

A: REMOVAL
S902404A18
C: ADJUSTMENT
S902404A01
NOTE: The positions for RHD model are symmetrically opposite. 1) Open hood. 2) Remove cap. 3) Loosen nut to remove wiper arm.
NOTE: The positions for RHD model are symmetrically opposite. Operate wiper once. Align wiper blade to ceramic print point mark (A) of front window pane.
S6M0049B
S6M0050
B: INSTALLATION
S902404A11
NOTE: The positions for RHD model are symmetrically opposite. 1) Install in the reverse order of removal. 2) Operate wiper once. 3) Align wiper blade to ceramic print point mark (A) of front window pane.
S6M0049B
WW-14
FRONT WIPER MOTOR AND LINK
7. Front Wiper Motor and Link

S902406
5) Remove wiper link from service hole in front panel.
A: REMOVAL
S902406A18
NOTE: The positions for RHD model are symmetrically opposite. 1) Remove cowl panel. <Ref. to EI-25 REMOVAL, Cowl Panel.> 2) Disconnect connector of motor, and remove motor attaching bolts.
G6M0121
S902406A11

S902406A10
S6M0051
1) When battery is connected to terminal of connectors, confirm that motor operates at low speed.
3) Remove cowl cover, and remove the motor link nut on the back side of the motor.
S6M0055
S6M0052
2) When battery is connected to terminal of connectors, confirm that motor operates at high speed.
4) Remove bolts which secure sleeve unit.
S6M0056 S6M0053
WW-15
FRONT WIPER MOTOR AND LINK
3) Connect battery to terminals of connector, and remove terminal connection with motor rotated at low speed, and stop wiper motor through operation.
S6M0057
4) Connect battery and confirm that motor stops at automatic stop position after motor operates at low speed again.
S6M0058
WW-16
FRONT WASHER
8. Front Washer
A: LOCATION
S902401A13
S902401
S6M0559
B: REMOVAL
1. NOZZLE
S902401A18
C: INSTALLATION
1. NOZZLE
S902401A1101
S902401A11
S902401A1801
1) Remove the washer hose from the washer nozzle. 2) Open the clips on the underside of the hood with a thin screwdriver or other tool, and remove the washer nozzle.
1) Install in the reverse order of removal. 2) Adjust the position of the washer liquid sprayer. <Ref. to WW-18 ADJUSTMENT, Front Washer.>
D: INSPECTION
S902401A10
Make sure the nozzle and hose are not clogged. Make sure the hose is not bent.
B6M1505
WW-17
FRONT WASHER
E: ADJUSTMENT
S902401A01
NOTE: Adjustment positions for left-handed vehicle. Carry out left-right symmetry for adjustment positions for right-handed vehicle. 1) Turn wiper switch to OFF position. 2) When vehicle stops, adjust washer injection position as shown in the figure. Injection position: A: 410 mm (16.14 in) B: 150 mm (5.91 in) C: 370 mm (14.57 in) D: 530 mm (20.87 in)
S6M0165A
WW-18
REAR WIPER ARM
9. Rear Wiper Arm

A: REMOVAL
S902402A18
S902402
1) Raise wiper arm cover. 2) Loosen nut to remove wiper arm.
S6M0061
B: INSTALLATION
S902402A11
1) Install in the reverse order of removal. 2) Adjust the position of the wiper blade. <Ref. to WW-19, ADJUSTMENT, Rear Wiper Arm.>
C: ADJUSTMENT
S902402A01
1) Operate rear wiper once. 2) Adjust wiper blade to original position as shown in figure. Original position: A: 305 mm (1.180.20 in)
S6M0059A
WW-19
REAR WIPER MOTOR

S902532
10. Rear Wiper Motor

A: REMOVAL
S902532A18
C: INSPECTION
S902532A10
1) Remove rear wiper arm. <Ref. to WW-19, REMOVAL, Rear Wiper Arm.> 2) Remove rear gate lower trim. <Ref. to EI-42 REMOVAL, Rear Gate Trim.> 3) Unclip clip of harness and disconnect connector of wiper motor. 4) Loosen bolts to remove wiper motor assembly. CAUTION: Be careful not to damage O-ring when removing wiper motor assembly.
1) Connect battery to wiper motor connector and confirm that wiper motor operates.
S6M0072
2) Connect battery to terminal of connector and remove terminal connections with motor rotated, and stop wiper motor through operation.
S6M0062
B: INSTALLATION
S902532A11

S6M0073
3) Connect battery and confirm that motor stops at automatic stop position after motor operates at low speed again.
S6M0074
WW-20
REAR WASHER
11. Rear Washer

A: LOCATION
S902400A13
S902400
S6M0560
B: REMOVAL
1. NOZZLE
S902400A18
C: INSTALLATION
1. NOZZLE
S902400A1101
S902400A11
S902400A1801
1) Remove the high-mount stop light. <Ref. to LI-58 REMOVAL, High Mount Stop Light.> 2) Remove the washer hose from the washer nozzle. 3) Open the clips on the underside of the hood with a thin screwdriver or other tool, and remove the washer nozzle.
1) Install in the reverse order of removal. 2) Adjust the position of the washer liquid sprayer. <Ref. to WW-22 ADJUSTMENT, Rear Washer.>
D: INSPECTION
S902400A10
Make sure the nozzle and hose are not clogged. Make sure the hose is not bent.
B6M1505
WW-21
REAR WASHER
E: ADJUSTMENT
S902400A01
1) Turn wiper switch to OFF position. 2) When vehicle stops, adjust washer injection position as shown in the figure. Injection position: A: 60 mm (2.36 in) B: 60 mm (2.36 in)
S6M0320A
WW-22
WIPER CONTROL RELAY
12. Wiper Control Relay

A: REMOVAL
1. WAGON
S902403A18 S902403A1801
S902403
3) Measure the voltage when the wiper relay is operated.
1) Remove right quarter lower trim.<Ref. to EI-39 REMOVAL, Rear Quarter Trim.> 2) Remove quarter pocket. 3) Loosen nut to remove control unit.
B6M1523A
If operation is not as specified, replace the switch.
S6M0488
B: INSTALLATION
1. WAGON
S902403A1101
S902403A11
C: INSPECTION
1. WAGON
S902403A1001
S902403A10
1) Disconnect the connector from the wiper control relay. 2) Connect the positive (+) lead from the battery to terminal 8 and the negative () lead to terminal 6. Connect the positive (+) lead from the voltmeter to terminal 3 and negative lead to ground.
BO0276
WW-23
HEADLIGHT WASHER
S902736
13. Headlight Washer

A: REMOVAL
S902736A18
B: INSTALLATION
S902736A11
1) Disconnect the ground cable from the battery. 2) Remove the front grille. <Ref. to EI-10, REMOVAL, Front Grille.> 3) Draw out headlight washer hose. 4) Disconnect hose (A) from valve (B). NOTE: Washer fluid may drain from valve. Put a pan under the valve, then disconnect valve from hose while pinching the hose edge.
S5M0394A
5) Remove nozzle cover (A).
S5M0395A
6) Push the three pawls to remove outer nozzle (A). Then, pull out inner nozzle (B). NOTE: Before pushing the outer nozzle pawls, cover the bumper to avoid scratches.
S5M0396A
WW-24
ENTERTAINMENT
ET
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Page General Description.....................................................................................2 Radio System ..............................................................................................4 Cigarette Lighter System.............................................................................9 Accessory Power Socket System .............................................................10 Radio Body ................................................................................................11 Front Speaker............................................................................................12 Rear Speaker ............................................................................................13 Antenna .....................................................................................................14 Antenna Amplifier ......................................................................................15 Cigarette Lighter........................................................................................16 Accessory Power Socket ..........................................................................17
Entertainment
GENERAL DESCRIPTION
S901001
A: CAUTION
S901001A03
Before disassembling or reassembling parts, always disconnect battery ground cable. When replacing radio, control module, and other parts provided with memory functions, record memory contents before disconnecting the battery ground cable. Otherwise, the memory will be erased. Reassemble in reverse order of disassembly, unless otherwise indicated. Adjust parts to the given specifications. Connect connectors and hoses securely during reassembly. After reassembly, make sure functional parts operate smoothly.
B: PREPARATION TOOL
1. GENERAL TOOLS
TOOL NAME Circuit Tester Conductive Silver Composition (DUPONT NO. 4817 or equivalent)
S901001A1701
S901001A17
REMARKS Used for measuring resistance and voltage. Used for repairing antenna wire.
ET-2
GENERAL DESCRIPTION
MEMO:
Entertainment
ET-3
Entertainment
RADIO SYSTEM
S901467
2. Radio System
A: SCHEMATIC
1. RADIO LHD MODEL
S901467A21
S901467A2103
SL76-20A
ET-4
RADIO SYSTEM
Entertainment
SL76-20B
ET-5
Entertainment
RADIO SYSTEM
S901467A2104
2. RADIO RHD MODEL
SR76-20A
ET-6
RADIO SYSTEM
Entertainment
SR76-20B
ET-7
Entertainment
RADIO SYSTEM
S901467A10
B: INSPECTION
Symptom No power coming in (No display and no sound from speakers) (1) (2) (3) A specific speaker does not operate. (1) (2) Radio generates noise with engine running (1) (2) (3) (4) AM and FM modes are weak or noisy (1) (2) (3) (4)
Repair order Check fuse and power supply for radio. Check radio ground. Remove radio for repair. Check speaker. Check output circuit between radio and speaker. Check radio ground. Check generator. Check ignition coil. Remove radio for repair. Check antenna. Check antenna amplifier. Check radio ground. Remove radio for repair.
ET-8
CIGARETTE LIGHTER SYSTEM
Entertainment
3. Cigarette Lighter System

A: SCHEMATIC
S901494A21
S901494
1. CIGARETTE LIGHTER
S901494A2101
SG97-20
ET-9
Entertainment
ACCESSORY POWER SOCKET SYSTEM

S901785
4. Accessory Power Socket System

A: SCHEMATIC
S901785A21
1. ACCESSORY POWER SOCKET
S901785A2101
SG90-20
ET-10
RADIO BODY
Entertainment
5. Radio Body
A: REMOVAL
S901469
S901469A18
1) Remove console box. <Ref. to EI-30 REMOVAL, Console Box.> 2) Remove AT cover (AT model). 3) Remove center panel. 4) Remove fitting screws, and slightly pull radio out from center console.
S5M0048A
5) Disconnect electric connectors and antenna feeder cord.
B: INSTALLATION
S901469A11
ET-11
Entertainment
FRONT SPEAKER
S901466
6. Front Speaker
A: REMOVAL
S901466A18
1) Remove front door trim. <Ref. to EI-26 REMOVAL, Front Door Trim.> 2) Remove front speaker mounting screws.
S6M0568
3) Disconnect harness connector and remove front speaker.
B: INSTALLATION
S901466A11
ET-12
REAR SPEAKER
Entertainment
7. Rear Speaker
A: REMOVAL
S901470A18
S901470
1) Remove rear door trim. <Ref. to EI-27> REMOVAL, Rear Door Trim. 2) Remove rear speaker mounting screws.
S6M0569
3) Disconnect harness connector and remove rear speaker.
B: INSTALLATION
S901470A11
ET-13
Entertainment
ANTENNA
S901463
8. Antenna
B: REPAIR
S901463A10
S901463A19
A: INSPECTION
Check continuity between antenna terminal and each antenna wire. If an antenna wire is OK, continuity should exist. If an antenna wire is broken, no continuity should exist. NOTE: When checking continuity, wind a piece of tin foil around the tip of the tester probe and press the foil against the wire with your finger.
1) Clean antenna wire and the surrounding area with a cloth dampened by alcohol. 2) Paste a thin masking film on glass along the broken wire. 3) Deposit conductive silver composition (DUPONT NO. 4817) on the broken portion with a drawing pen.
G6M0138
4) Dry out the deposited portion. 5) After repair has been completed, check repaired wire for continuity.
B6M1494A
To locate the broken point, move the probe along the antenna wire.
B6M1495
ET-14
ANTENNA AMPLIFIER
Entertainment
9. Antenna Amplifier
A: REMOVAL
S901460A18
S901460
1) Remove rear quarter lower trim. <Ref. to EI-39 REMOVAL, Rear Quarter Trim.> 2) Disconnect harness connector and terminal. 3) Remove mounting screw and detach antenna amplifier.
S6M0507
S901460A11

S901460A10
S6M0508A
Measure resistance between terminal and amplifier body.

Tester connection A Amplifier B Amplifier a Amplifier Resistance More than 100 k More than 100 k More than 100 k
ET-15
Entertainment
CIGARETTE LIGHTER
S901461
10. Cigarette Lighter

A: REMOVAL
S901461A18
1) Remove center panel. <Ref. to ET-11 REMOVAL, Radio Body.> 2) Disconnect harness connectors and remove cigarette lighter.
S6M0509
B: INSTALLATION
S901461A11
ET-16
ACCESSORY POWER SOCKET
Entertainment
11. Accessory Power Socket

A: REMOVAL
S901786A18
S901786
1) Remove rear quarter lower trim. <Ref. to EI-39, REMOVAL, Rear Quarter Trim.> 2) Disconnect harness connectors and remove accessory power socket.
S6M0566
B: INSTALLATION
S901786A11
ET-17
Entertainment
ACCESSORY POWER SOCKET
MEMO:
ET-18
COMMUNICATION SYSTEM
COM
1. 2. 3. 4. Page General Description.....................................................................................2 Horn System................................................................................................3 Horn.............................................................................................................5 Horn Switch .................................................................................................6
Communication System
GENERAL DESCRIPTION
S904001
A: PREPARATION TOOL
1. GENERAL TOOLS
S904001A1701
S904001A17
TOOL NAME REMARKS Circuit Tester Used for measuring resistance and voltage.
COM-2
HORN SYSTEM
2. Horn System
A: SCHEMATIC
1. HORN
S904436A2101
S904436
S904436A21
SG74-20
COM-3
HORN SYSTEM
S904436A10
B: INSPECTION
1. HORN RELAY
S904436A1001
S6M0048A
COM-4
HORN
3. Horn
S904437
A: REMOVAL
S904437A18
1) Remove horn bracket mounting bolt (A). 2) Disconnect harness connector and remove horn assembly (B).
S6M0506A
S904437A11

S904437A10
With 12 V direct current supply between horn terminal and case ground, check that the horn sounds properly.
B6M1492
COM-5
HORN SWITCH
S904434
4. Horn Switch
A: REMOVAL
S904434A18
WARNING: Before servicing, be sure to read the notes in the AB section for proper handling of the driver airbag module. <Ref. to AB-3 CAUTION, General Description.> 1) Remove the driver s airbag module. <Ref. to AB-12 Driver s Airbag Module.> 2) Remove horn switch from steering wheel as shown.
S6M0095
S904434A11

S904434A10
B6M1493
Switch position Tester connection Specified condition When horn Continuity switch is pushed. 1Body ground When horn switch is not No continuity pushed.
COM-6
GLASS/WINDOWS/MIRRORS
GW
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. Page General Description.....................................................................................2 Power Window System ...............................................................................9 Rear Window Defogger System................................................................19 Windshield Wiper Deicer System..............................................................23 Remote Control Mirror System .................................................................25 Front Door Glass.......................................................................................28 Front Regulator and Motor Assembly .......................................................31 Rear Door Glass .......................................................................................32 Rear Regulator and Motor Assembly........................................................34 Windshield Glass.......................................................................................35 Rear Gate Glass .......................................................................................38 Rear Quarter Glass ...................................................................................39 Roof Window Glass...................................................................................41 Inner Rearview Mirror................................................................................42 Power Window Control Switch..................................................................43 Rear Window Defogger Switch .................................................................46 Rear Window Defogger.............................................................................48 Outer Mirror Assembly ..............................................................................49 Outer Mirror ...............................................................................................51 Remote Control Mirror Switch...................................................................52 Wiper Deicer..............................................................................................54 Wiper Deicer Switch..................................................................................55
Glass/Windows/Mirrors
GENERAL DESCRIPTION
S905001
A: COMPONENT
S905001A05
GW-2
GENERAL DESCRIPTION
1. FIXED GLASS
S905001A0506
S5M0497A
(1) (2) (3) (4)
Windshield glass Dam rubber Molding Rearview mirror mount
(5) (6) (7) (8)
Side molding Rear quarter glass Locate pin Rear quarter garnish
(9) Rear gate glass (10) Spring
GW-3
GENERAL DESCRIPTION
S905001A0503
2. FRONT DOOR GLASS
S5M0509A
(1) (2) (3) (4)
Door sash (Front) Glass Door sash (Rear) Regulator ASSY
(5) Motor ASSY
GW-4
GENERAL DESCRIPTION
3. REAR DOOR GLASS
S905001A0504
S5M0510A
(1) (2) (3) (4)
Door sash (Front) Glass Door sash (Rear) Regulator ASSY
(5) Motor ASSY
GW-5
GENERAL DESCRIPTION
4. MIRRORS
S905001A0505
S5M0457A
(1) Outer mirror (2) Inner rearview mirror
(3) Mount (4) Spring
(5) Mirror
GW-6

S905001A03
When electrical connectors are disconnected, always conduct an operational check after connecting them again. Avoid impact and damage to the glass.
GW-7
GENERAL DESCRIPTION
S905001A17
C: PREPARATION TOOL
TOOL NAME Circuit Tester Piano Wire Windshield Knife
REMARKS Used for checking voltage and continuity. Used for window glass removal. Used for window glass removal.
GW-8
POWER WINDOW SYSTEM
2. Power Window System

A: SCHEMATIC
S905456A21
S905456
GW-9
POWER WINDOW SYSTEM

S905456A2101
1. POWER WINDOW LHD MODEL
SL70-20A
GW-10
POWER WINDOW SYSTEM
SL70-20B
GW-11
POWER WINDOW SYSTEM
SL70-20C
GW-12
POWER WINDOW SYSTEM
SL70-20D
GW-13
POWER WINDOW SYSTEM

S905456A2102
2. POWER WINDOW RHD MODEL
SR70-20A
GW-14
POWER WINDOW SYSTEM
SR70-20B
GW-15
POWER WINDOW SYSTEM
SR70-20C
GW-16
POWER WINDOW SYSTEM
SR70-20D
GW-17
POWER WINDOW SYSTEM

S905456A10
B: INSPECTION
Symptom All power windows does not operate. (1) (2) (3) (4) (1) (2) (3) (4) (1)
One window does not operate. Window Lock does not operate.
Repair order Fuse (SBF-6) (F/B No. 18) Power window circuit breaker Power window relay Wire harness Power window main switch Power window sub switch Power window motor Wire harness Power window main switch
GW-18
REAR WINDOW DEFOGGER SYSTEM
3. Rear Window Defogger System

A: SCHEMATIC
S905455A21
S905455
GW-19

S905455A2102
1. REAR WINDOW DEFOGGER LHD MODEL
SL52-20
GW-20

2. REAR WINDOW DEFOGGER RHD MODEL
S905455A2103
SR52-20
GW-21

S905455A10
B: INSPECTION
Symptom (1) (2) (3) (4) (5) (6)
Rear window defogger does not operate.
Repair order Fuse (M/B No. 1) Rear defogger relay Defogger switch Rear defogger condenser Deffogger wire Wire harness
GW-22
WINDSHIELD WIPER DEICER SYSTEM
4. Windshield Wiper Deicer System

A: SCHEMATIC
S905457A21
S905457
1. WINDSHIELD WIPER DEICER
S905457A2101
SG78-20
GW-23
WINDSHIELD WIPER DEICER SYSTEM

S905457A10
B: INSPECTION
Symptom Wiper deicer does not operate. (1) (2) (3) (4)
Repair order Fuse (F/B No. 18, 19) Wiper deicer relay Wiper deicer switch Wire harness
GW-24
REMOTE CONTROL MIRROR SYSTEM
5. Remote Control Mirror System

A: SCHEMATIC
S905458A21
S905458
1. REMOTE CONTROL MIRROR LHD MODEL
S905458A2102
SL79-20
GW-25
REMOTE CONTROL MIRROR SYSTEM

S905458A2103
2. REMOTE CONTROL MIRROR RHD MODEL
SR79-20
GW-26
REMOTE CONTROL MIRROR SYSTEM B: INSPECTION

S905458A10
Symptom All function does not operate. (1) (2) (3) (1) (2) (3) (1) (2) (3) Fuse (F/B No. 4) Mirror switch Wire harness Mirror switch Mirror motor Wire harness Mirror switch Mirror heater Wire harness
Repair order
One side of the mirror motor does not operate.
Mirror heater does not operate.
GW-27
FRONT DOOR GLASS

S905452
6. Front Door Glass

A: REMOVAL
S905452A18
7) Operate the power window switch to move glass to the position shown in the figure, and then remove the two nuts from service holes.
1) Remove door trim. <Ref. to EI-26, REMOVAL, Front Door Trim.> 2) Remove sealing cover. <Ref. to EB-13, REMOVAL, Front Sealing Cover.> 3) Remove inner remote. <Ref. to SL-27, REMOVAL, Front Inner Remote.> 4) Remove inner stabilizer.
B5M1046
8) Take out glass door panel upward.
B5M1044
5) Remove outer mirror. <Ref. to REMOVAL, Outer Mirror Assembly.> 6) Remove gusset.
GW-49,
B5M1047
CAUTION: Do not turn regulator in the closing direction after removal of the glass. Otherwise gear may be disengaged. Avoid impact and damage to the glass.
B: INSTALLATION
S905452A11
1) Install in the reverse order of removal. CAUTION: Make sure that glass stay is placed securely in sash. 2) Adjust front door glass. <Ref. to GW-29, ADJUSTMENT, Front Door Glass.>
B5M1045
GW-28
FRONT DOOR GLASS C: ADJUSTMENT

S905452A01
NOTE: Before adjustment, ensure that all adjusting bolts of stabilizer, upper stopper, and sash are loose and door glass is raised so that it is in contact with weatherstrip. 1) Temporarily tighten one adjusting bolt on one side of rear sash at the midpoint of slotted hole in the inner panel. 2) Temporarily tighten regulator B-channel in a position slightly lower than midpoint of slotted hole. 3) Lower door glass 10 to 15 mm (0.39 to 0.59 in) from fully closed position. While applying outward pressure of 45.04.9 N (4.590.50 kgf, 10.121.10 lb) (F) to upper edge of glass above midpoint of two outer stabilizers, press inner stabilizer until it just touches the glass, then secure it.
5) For adjustment of upper and lower ends of center pillar, loosen adjusting nut (A).
S5M0197B
6) Adjust so that upper and lower ends of center pillar are the same size.
G5M0421
4) For adjustment of clearance between front and rear glasses, loosen nuts (A), and move glass sash back and forward until clearance becomes the value shown.
G5M0639
S5M0199B
7) For glass stroke adjustment, close door, raise glass until positional relationship between glass and weatherstrip becomes as shown. And secure the glass so that upper stopper lightly touches the glass holder.
S5M0200A S5M0198A
GW-29
FRONT DOOR GLASS

11) After adjustments, tighten nuts. 12) After adjustment of glass, if there is a gap between outer lip of gusset and glass surface, adjust the gap with adjusting bolt (A) in lower fitting part of gusset to prevent generation of wind noise. 13) During adjustments, loosen other three clamping bolts.
8) After stabilizer adjustment, carry out glass crimp adjustment. First, visually ensure positional relationship between retainer & molding and glass of the roof side, and then begin with rear sash adjustment. Adjust two adjusting bolts alternately step by step to obtain dimensions shown below (cross-section A). NOTE: If two nuts are loosened at the same time, sash moves back and forth. Therefore, when one nut is adjusted, secure the other. 9) Make the same adjustment of two adjusting bolts of rear sash.
S5M0513A
14) After adjustment, tighten bolts and nuts.
S5M0200A
CAUTION: Do not tilt sash bracket to inner panel during adjustment. Otherwise smooth regulator operation cannot be achieved.
S5M0201A
10) Make adjustment of front sash in the same manner as that of rear sash. CAUTION: Although front and rear sashes must, as a rule, be adjusted in the same manner, in some door installation, the adjustment in a different manner may be required. However, adjustment of one sash to the maximum amount and the other to the minimum amount is not permitted. Such adjustment may result in application of excessive load to regulator.
GW-30
FRONT REGULATOR AND MOTOR ASSEMBLY
7. Front Regulator and Motor Assembly

S905449
A: REMOVAL
S905449A18
1) Remove door trim. <Ref. to EI-26, REMOVAL, Front Door Trim.> 2) Remove sealing cover. <Ref. to EB-13, REMOVAL, Front Sealing Cover.> 3) Remove inner remote. <Ref. to SL-27, REMOVAL, Front Inner Remote.> 4) Remove door glass. <Ref. to GW-28, REMOVAL, Front Door Glass.> 5) Disconnect electrical connector. 6) Loosen four bolts and two nuts to pull out regulator assembly.
B5M1049
7) Loosen screws to remove motor assembly.
B5M1050
B: INSTALLATION
S905449A11
1) Install in the reverse order of removal. 2) Adjust front door glass. <Ref. to GW-29, ADJUSTMENT, Front Door Glass.>
C: INSPECTION
S905449A10
1) Make sure that power window motor rotates properly when battery voltage is applied to terminals of motor connector. 2) Change polarity of battery connections to terminals to ensure that motor rotates in reverse direction.
GW-31
REAR DOOR GLASS

S905450
8. Rear Door Glass

A: REMOVAL
S905450A18
B: INSTALLATION
S905450A11
1) Install in the reverse order of removal. CAUTION: Make sure that glass stay is placed securely in sash. 2) Adjust rear door glass. <Ref. to GW-32, ADJUSTMENT, Rear Door Glass.>
1) Remove door trim. <Ref. to EI-27, REMOVAL, Rear Door Trim.> 2) Remove sealing cover. <Ref. to EB-16, REMOVAL, Rear Sealing Cover.> 3) Remove stabilizer.
C: ADJUSTMENT
S905450A01
NOTE: Rear door glass, as a rule, should be adjusted in the same manner as front glass, although they are different in dimension. Special notes for rear glass are given below. 1) Adjust glass position using the following dimensions as a guide line.
B5M1044
4) Operate power window switch to move glass as shown in the figure, and remove two nuts.
S5M0384A
B5M1046
5) Loosen two screws to remove weatherstrip.
CAUTION: If dimensions are smaller than the given dimensions, glass may get caught in weatherstrip during lifting/lowering operation. In the worst case, it may cause glass not to be opened fully. After adjustment, move glass up and down to check whether it is caught. 2) Adjust crimp of glass using the following dimensions as a guide line.
B5M1051
6) Pull out glass. CAUTION: Avoid impact and damage to the glass.
S5M0385A
CAUTION: If crimp of rear glass is higher than necessary, glass may get caught in weatherstrip of center pillar corner, resulting in early
GW-32
REAR DOOR GLASS

wear of weatherstrip. Be careful when adjusting. After adjustment, move glass up and down to check whether it is caught.
GW-33
REAR REGULATOR AND MOTOR ASSEMBLY B: INSTALLATION

S905451A11
9. Rear Regulator and Motor Assembly

S905451
A: REMOVAL
S905451A18
1) Install in the reverse order of removal. 2) Adjust rear door glass. <Ref. to GW-32, ADJUSTMENT, Rear Door Glass.>
1) Remove door trim. <Ref. to EI-27, REMOVAL, Rear Door Trim.> 2) Remove sealing cover. <Ref. to EB-16, REMOVAL, Rear Sealing Cover.> 3) Remove door glass. <Ref. to GW-32, REMOVAL, Rear Door Glass.> 4) Secure bolts using screwdriver to remove front sash adjusting nut.
C: INSPECTION
S905451A10
1) Make sure that power window motor rotates properly when battery voltage is applied to terminals of motor connector. 2) Change polarity of battery connections to terminals to ensure that motor rotates in reverse direction.
B5M1052
5) Remove front sash. 6) Disconnect electrical connector. 7) Loosen four bolts and two nuts to remove regulator assembly.
B5M1049
8) Loosen screws to remove motor assembly.
B5M1050
GW-34
WINDSHIELD GLASS
10. Windshield Glass

A: REMOVAL
S905448A18
S905448
1. USING WINDSHIELD KNIFE
S905448A1801
1) Remove cowl panel. <Ref. to EI-25, REMOVAL, Cowl Panel.> 2) Remove front side molding and upper front molding. 3) Tape body side of the circumference of windshield glass for protection. 4) Apply sufficient amount of soapy water to adhesive layer. 5) Insert windshield knife into the adhesive layer. 6) While holding the knife edge and windshield glass edge at a right angle, move windshield knife in parallel to windshield glass edge along face and edge of windshield glass to cut the adhesive layer. CAUTION: Do not twist windshield knife. Cutting of adhesive layer shall be started with wider gap between windshield glass and body.
G5M0412
2. USING PIANO WIRE
S905448A1802
1) Remove cowl panel. <Ref. to EI-25, REMOVAL, Cowl Panel.> 2) Remove roof molding and upper front molding. 3) Tape the body side of the circumference of windshield glass for protection. 4) Make a hole in adhesive layer using drill or knife. 5) Pass piano wire through the hole, and attach securely both the wire ends to pieces of wood.
G5M0494
6) Pull the wire ends alternately to cut off the adhesive layer. CAUTION: Do not tightly pull the piano wire against the windshield glass edge. Be careful not to damage interior and exterior parts. When removal is made with area close to instrument panel, place a protection plate over it. Pay particular attention to the removal. Do not cross piano wires. Otherwise they may be cut.
G5M0418
NOTE: Because matching pins are bonded to the corners of glass, use piano wire to cut the pin.
GW-35
WINDSHIELD GLASS
S905448A11
B: INSTALLATION
9) Apply primer to adhesive layer of body. CAUTION: Primer once attached to the painted surface of the body and internal trim is hard to wipe off. Mask the circumference of such areas. Let primer dry for about ten minutes before installing the glass. Do not touch surface coated with primer.
1) Clean external circumference of windshield glass with alcohol or white gasoline. 2) Remove adhesive layer on the body using cutter knife to obtain smooth face 2 mm (0.08 in) thick. CAUTION: Be careful not to damage the body and paint surface.
G5M0495 G5M0553
3) Clean body with alcohol or white gasoline to remove thoroughly chips, dusts, and dirts from body face. 4) Place glass on body. 5) Adjust glass position to make uniform clearance between body and glass in four corners. 6) Place matching pins and body on glass.
10) Cut off cartridge nozzle tip and set it in sealant gun as shown.
G5M0408
11) Apply adhesive to glass end surface as shown. 12) Fit matching pins using suction rubber cup to install windshield glass.
G5M0407
7) Remove glass from body. 8) Apply primer to adhesive layer of glass using sponge.
G5M0409
13) Lightly press windshield glass for tight fit.
GW-36
WINDSHIELD GLASS
14) Remove adhesive overflowing from outside of glass until it becomes level with outer height of glass. Then, add adhesive to portions that need it, and clean with alcohol or white gasoline.
G5M0496
15) First, press-fit upper front window molding and last, roof molding.
G5M0417
CAUTION: When door is opened/closed after glass is bonded, always lower door glass and then open/close it carefully. Move vehicle slowly. 16) After completion of all work, allow vehicle to stand for about 24 hours. NOTE: For minimum drying time and time the vehicle must be left standing before driving after bonding, follow instructions or instruction manual from the adhesive manufacturer. 17) After curing of adhesive, pour water on external surface of vehicle to check that there are no water leaks. CAUTION: When a vehicle is returned to the user, tell him or her that the vehicle should not be subjected to heavy impact for at least three days. 18) Install cowl panel. <Ref. INSTALLATION, Cowl Panel.> to EI-25,
GW-37
REAR GATE GLASS

S905376
11. Rear Gate Glass

A: REMOVAL
S905376A18
2) Install glass in the same procedure as for windshield glass. <Ref. to GW-36, INSTALLATION, Windshield Glass.>
1) Remove real wiper motor. <Ref. to WW-20, REMOVAL, Rear Wiper Motor.> 2) Remove electrical connector from rear defogger terminal. 3) Remove glass in the same procedure as for windshield glass. <Ref. to GW-35, REMOVAL, Windshield Glass.> NOTE: A matching pin is cemented to corners of the glass on the compartment side. Use a piano wire when cutting each pin.
S5M0209A S5M0511A
(1) (2) (3)
Body panel Glass Matching pin

S905376A11
3) About one hour after installation, conduct a leak test. CAUTION: When door is opened/closed after glass is bonded, always lower door glass and then open/close it carefully. Move vehicle slowly. 4) After completion of all work, allow vehicle to stand for about 24 hours. NOTE: For minimum drying time and time the vehicle must be left standing before driving after bonding, follow instructions or instruction manual from the adhesive manufacturer. CAUTION: When a vehicle is returned to the user, tell him or her that the vehicle should not be subjected to heavy impact for at least three days. 5) Connect rear defogger terminals. 6) Install rear wiper. <Ref. to INSTALLATION, Rear Wiper Motor.> WW-20,
B: INSTALLATION
1) Install a new rubber strip (A) by aligning it with the end of the rear gate glass (B).
S5M0208B
GW-38
REAR QUARTER GLASS
12. Rear Quarter Glass

A: REMOVAL
S905453A18
S905453
1) Remove rear quarter molding on corner. 2) Remove glass in the same procedure as for windshield glass. <Ref. to GW-35, REMOVAL, Windshield.>
S5M0388A
B: INSTALLATION
S905453A11
7) Apply primer to surface of body to be adhered. CAUTION: If primer has dropped on body finish, it is hard to wipe it off. So protect with masking. Primer must not project from black frame of glass. After applying primer, let it dry naturally for about 10 minutes.
1) Using a putty knife, etc., cut layer of adhesive stick firmly to body and finish it into a smooth surface of about 2 mm (0.08 in) in thickness. CAUTION: Be careful not to damage body finish.
G5M0497
2) Remove chips, dirt and dust from body surface. 3) Clean body wall surface and upper surface of adhesive layer with a solvent such as alcohol or white gasoline. 4) Remove dirt and dust from surface of glass to be adhered. 5) Clean surface of glass to be adhered with alcohol or white gasoline. 6) Using a sponge, apply primer to surface of glass to be adhered.
G5M0495
8) Cut nozzle tip as shown in the figure.
G5M0414
9) Open cartridge and put it into a gun with nozzle attached. 10) Apply adhesive uniformly to all sides of adhesion surface while operating gun along glass end face. 11) Hold glass with rubber suction cups.
GW-39
REAR QUARTER GLASS
12) Mount glass on body with matching pins (A) aligned.
S5M0211B
13) Attach quickly and press all sides lightly. CAUTION: When door is opened/closed after glass is bonded, always lower door glass and then open/close it carefully. Move vehicle slowly. 14) After completion of all work, allow vehicle to stand for about 24 hours. NOTE: For minimum drying time and time the vehicle must be left standing before driving after bonding, follow instructions or instruction manual from the adhesive manufacturer. 15) After curing of adhesive, pour water on external surface of vehicle to check that there are no water leaks. CAUTION: When a vehicle is returned to the user, tell him or her that the vehicle should not be subjected to heavy impact for at least three days.
GW-40
ROOF WINDOW GLASS
13. Roof Window Glass

A: REMOVAL
S905339A18
S905339
<Ref. to SR-7, REMOVAL, Sunroof Lid.>
B: INSTALLATION C: ADJUSTMENT
S905339A11
<Ref. to SR-7, INSTALLATION, Sunroof Lid.>

S905339A01
<Ref. to SR-7, ADJUSTMENT, Sunroof Lid.>
GW-41
INNER REARVIEW MIRROR

S905340
14. Inner Rearview Mirror

A: REMOVAL
S905340A18
NOTE: The spring cannot be reused. Prepare a new spring before removal. 1) Turn mirror base 90 degrees clockwise or counterclockwise to remove it.
B5M1059
2) Remove spring from mirror base.
B5M1060
CAUTION: Be careful not to damage the mirror surface.
S905340A11

S905340A10
Do not let mirror be damaged.
GW-42
POWER WINDOW CONTROL SWITCH
15. Power Window Control Switch

S905621
2. SUB-SWITCH
S903621A1802
A: REMOVAL
1. MAIN SWITCH
S903621A18
1) Remove door trim. <Ref. to EI-27, REMOVAL, Rear Door Trim.> 2) Remove screws and sub-switch.
S903621A1801
1) Release two hooks (A) of switch panel to remove power window main switch. 2) Disconnect electrical connector from power window main switch.
S5M0494
B: INSTALLATION
1. MAIN SWITCH 2. SUB-SWITCH
S903621A11
S903621A1101

S903621A1102
S5M0512A
C: INSPECTION
S903621A10
1. MAIN SWITCH (LHD MODEL)

Driver s switch: Switch position AUTO UP UP OFF DOWN AUTO DOWN Front passenger s switch: Switch position UP OFF DOWN
S903621A1003

Tester connection 12 1, 2 7 12 1, 2 7 127 12 2, 1 7 12 2, 1 7 Specified condition Continuity Continuity Continuity Continuity Continuity
Tester connection 12 5, 6 7 567 12 6, 5 7
GW-43
Rear left switch: Switch position UP OFF DOWN Rear right switch: Switch position UP OFF DOWN
Tester connection 12 9, 10 7 9 10 7 12 10, 9 7
If NG, replace the main switch.
2. MAIN SWITCH (RHD MODEL)

Driver s switch: Switch position AUTO UP UP OFF DOWN AUTO DOWN Front passenger s switch: Switch position UP OFF DOWN Rear left switch: Switch position UP OFF DOWN Rear right switch: Switch position UP OFF DOWN
S903621A1004

Tester connection 7 16, 15 2 7 16, 15 2 16 15 2 7 15, 16 2 7 15, 16 2 Specified condition Continuity Continuity Continuity Continuity Continuity
Tester connection 7 3, 4 2 342 7 4, 3 2
If NG, replace the main switch.
3. SUB-SWITCH (FRONT)
Front passenger s door switch: Switch position UP OFF DOWN
S903621A1005

Tester connection 8 3 5, 4 7 4 7, 6 5 8 3 7, 6 5 Specified condition Continuity Continuity Continuity
If NG, replace the sub-switch.
GW-44

4. SUB-SWITCH (REAR)
Rear door switch: Switch position UP OFF DOWN Tester 6 1 6 connection 5, 1 4 4, 2 5 4, 2 5
S903621A1006

If NG, replace the sub-switch.
GW-45
REAR WINDOW DEFOGGER SWITCH
16. Rear Window Defogger Switch

S905559
A: REMOVAL
S905559A18
1) Remove center air vent grille. <Ref. to AC-41, REMOVAL, Air Vent Grille.> 2) Pull out switch and disconnect the connector.
S5M0495
B: INSTALLATION
S905559A11
GW-46
REAR WINDOW DEFOGGER SWITCH C: INSPECTION

S905559A10
1) Turn ignition switch ON. 2) Check continuity between terminals on the wire harness side with connectors connected. Connector & terminal (i18) No. 6 (+) No. 8 ():
S5M0514A
IGN SW ON ON
Tester connection (i18)6 (i18)8 68
Specified condition 10V 14V 0V
GW-47
REAR WINDOW DEFOGGER

S905341
17. Rear Window Defogger

A: INSPECTION
S905341A10
B: REPAIR
S905341A11
CAUTION: When wiping stain on glass off with cloth, use a dry and soft cloth and move it in the direction of the heat wire extension to avoid damage to the heat wire. 1) Turn ignition switch to ON. 2) Turn defogger switch to ON. 3) Wrap tips of tester pins with aluminum foil to avoid damage to heat wire.
1) Clean broken portion with alcohol or white gasoline. 2) Mask both side of wire with thin film. 3) Apply conductive silver composition (DUPONT No. 4817) to broken portion.
G6M0138
4) After repair, check wire.
G6M0136
4) Measure voltage at wire center with DC voltmeter. Standard voltage: Approx. 6 volts
B5M1053A
Voltage Approx. 6 V Approx. 12 V or 0 V
Criteria OK Broken
NOTE: If the measured value is 12 volts, heat wire is open between wire center and positive (+) end. If zero volt, heat wire is open between wire center and ground. 5) Apply positive lead of voltmeter to positive terminal of voltmeter, and then move negative lead along the wire up to the negative terminal end. If voltage changes from zero to several volts during movement of lead, heat wire is open at the voltage change point.
GW-48
OUTER MIRROR ASSEMBLY
18. Outer Mirror Assembly

A: REMOVAL
S905338A18
S905338
1) Remove door trim. <Ref. to EI-26, REMOVAL, Front Door Trim.> 2) Pull off sealing cover to disconnect mirror electrical connector.
B5M1054
3) Loosen screws to remove mirror assembly.
B5M1055
B: INSTALLATION
S905338A11
GW-49
OUTER MIRROR ASSEMBLY

S905338A10
C: INSPECTION
Check to ensure that rearview mirror moves properly when battery voltage is applied to terminals.
Mirror heater not-equipped model: Switch position OFF UP DOWN LEFT RIGHT Terminal connection 1 (+) 3 () 3 (+) 1 () 2 (+) 3 () 3 (+) 2 ()
If NG, replace the mirror.

Mirror heater equipped model: Switch position OFF UP DOWN LEFT RIGHT Terminal connection 2 (+) 4 () 4 (+) 2 () 3 (+) 4 () 4 (+) 3 ()
If NG, replace the mirror.
GW-50
OUTER MIRROR
19. Outer Mirror

A: REPLACEMENT
S905658
S905658A20
1) Remove the door mirror assembly. <Ref. to GW-49, REMOVAL, Outer Mirror Assembly.> 2) Warm the area around the mirror holder with a hair drier until the edges of the mirror holder become soft (about 2 or 3 minutes with a 1,000 W drier.) 3) Use a flat-bladed screwdriver without sharp edges to lift the mirror out of the mirror holder. (Also remove the connector from the back of mirrors with heaters.)
B5M1144A
4) Warm the area around the mirror holder with a hair drier until the edges of the mirror holder become soft (about 2 or 3 minutes with a 1,000 W drier.) 5) Remove the backing of the new two-sided tape, and push the mirror in to install it. CAUTION: Unless the mirror holder is warmed sufficiently, the mirror holder edges may be damaged or the mirror cracked.
GW-51
REMOTE CONTROL MIRROR SWITCH
20. Remote Control Mirror Switch

S905342
A: REMOVAL
S905342A18
Using a thin flat-bladed screwdriver, remove the switch and disconnect the connector.
S5M0496
B: INSTALLATION
S905342A11
GW-52
REMOTE CONTROL MIRROR SWITCH C: INSPECTION

S905342A10
Move rearview mirror switch to each position and check continuity between terminals.
B5M1132
Change over switch left position: Switch position NEUTRAL UP DOWN LEFT RIGHT Change over switch right position: Switch position NEUTRAL UP DOWN LEFT RIGHT Tester connection All terminals 6 4, 2 1 6 2, 4 1 8 4, 2 1 8 2, 4 1 Specified condition No continuity Continuity Continuity Continuity Continuity Tester connection All terminals 7 4, 2 1 7 2, 4 1 9 4, 2 1 9 2, 4 1 Specified condition No continuity Continuity Continuity Continuity Continuity
If NG, replace the switch.
GW-53
WIPER DEICER
S905622
21. Wiper Deicer

A: INSPECTION
S905622A10
Refer to INSPECTION under Rear Window Defogger. <Ref. to GW-48, INSPECTION, Rear Window Defogger.>
B: REPAIR
S905622A11
Refer to REPAIR under Rear Window Defogger. <Ref. to GW-48, REPAIR, Rear Window Defogger.
GW-54
WIPER DEICER SWITCH
22. Wiper Deicer Switch

A: REMOVAL
S905623A18
S905623
1) Remove lower cover. 2) Disconnect the connector and remove the switch.
S5M0044A
S905623A11

S905623A10
Move wiper deicer switch to each position and check continuity between terminals.
Switch position OFF ON Tester connection 35 Specified condition No continuity Continuity
If NG, replace the switch.
GW-55
WIPER DEICER SWITCH
MEMO:
GW-56
BODY STRUCTURE
BS
1. 2. 3. Page General Description.....................................................................................2 Datum Points...............................................................................................3 Datum Dimensions ....................................................................................15
Body Structure
GENERAL DESCRIPTION
S906001
A: PREPARATION TOOL
TOOL NAME Tram tracking gauge Tape measure
S906001A17
REMARKS Used for measuring dimension. Used for measuring dimension
BS-2
DATUM POINTS
Body Structure
2. Datum Points
A: LOCATION
S906540A13
S906540
NOTE: Datum points are specified for body repair. Guide holes, locators, and indents are provided to facilitate panel replacement and to increase alignment accuracy. Both right and left reference points are symmetrical.
BS-3
Body Structure
DATUM POINTS
S906540A1301
1. ROOM SECTION
S5M0073B
(1) Radiator panel (UPR) repair bolt hole M8 (Right) (2) Radiator panel (UPR) repair bolt hole M8 (Left) (3) Fender attaching bolt hole M6 (Symmetrical) (4) Repair locator 8 mm (0.31 in) dia. (Symmetrical) (5) Radiator panel side gauge hole 24 mm (0.94 in) dia. (Symmetrical) (6) Front bumper mounting hole 14 16 mm (0.55 0.63 in) dia. (Symmetrical) (7) Front crossmember attaching bolt hole 12.4 mm (0.488 in) dia. (Symmetrical) (8) Fender attaching bolt hole M6 (Symmetrical) (9) Front strut mounting hole 9.5 mm (0.374 in) dia. (Symmetrical)
(10) Hood hinge attaching bolt hole M8 (Symmetrical) (11) Cowl panel mounting hole 6 mm (0.24 in) dia. (Symmetrical) (12) Roof inner trim attaching bolt hole 8 mm (0.31 in) dia. (13) Fender attaching bolt hole M6 (Symmetrical) (14) Front pillar gauge hole 20 mm (0.79 in) dia. (Symmetrical) (15) Wax coat hole 20 mm (0.79 in) dia. (Symmetrical) (16) Retainer attaching square hole 7 mm (0.28 in) (Symmetrical) (17) Sun visor attaching hole 17 mm (0.67 in) dia. (Symmetrical) (18) Retainer attaching square hole 7 mm (0.28 in) (Symmetrical) (19) Retainer attaching square hole 7 mm (0.28 in) (Symmetrical)
(20) Center pillar gauge hole 12 mm (0.47 in) dia. (Symmetrical) (21) Belt anchor attaching bolt hole 11.1 mm (7/16 in) dia. (Symmetrical) (22) Wax coat hole, 20 mm (0.79 in) dia. (Symmetrical) (23) Rear door switch attaching hole 20 mm (0.79 in) dia. (Symmetrical) (24) Retainer attaching square hole 7 mm (0.28 in) (Symmetrical) (25) Spare tire attaching bolt hole M8 (26) Air draw hole 7 mm (0.28 in) dia. (Symmetrical) (60) Fender attaching bolt hole M6 (Symmetrical) (64) Door switch attaching hole 13.5 mm (0.531 in) dia. (Symmetrical) (67) Front glass attaching hole Right 6.5 mm (0.256 in) dia. Left 6.5 10 mm (0.256 0.39 in) dia.
BS-4
DATUM POINTS
2. REAR SECTION
S906540A1302
Body Structure
S5M0074A
(27) Rear pillar (Inner) harness and hose clip attaching hole 7 mm (0.28 in) dia. (Symmetrical) (34) Rear skirt gauge hole 20 mm (0.79 in) dia. (Symmetrical) (36) Rear quarter bumper side gauge hole 20 mm (0.79 in) dia. (Left) (37) Rear quarter bumper side gauge hole 20 mm (0.79 in) dia. (Right) (38) Instrument panel attaching square hole 22 34.5 mm (0.87 1.358 in) (Right) (39) Steering support beam attaching bolt hole M8 (Symmetrical) (40) Front pillar (Inner) gauge hole 10 mm (0.39 in) dia. (Symmetrical) (41) Floor mat attaching clip hole 8 mm (0.31 in) dia. (Symmetrical) (42) Rear quarter glass attaching hole 8 15 mm (0.31 0.59 in) dia. (Symmetrical)
(43) Pad attaching square hole 9 mm (0.35 in) dia. (Symmetrical) (44) Rear quarter glass attaching hole 8 mm (0.31 in) dia. (Symmetrical) (45) Rear locator hollow 4 mm (0.16 in) dia. (46) Rear strut mounting hole 10 mm (0.39 in) dia. (Symmetrical) (47) Rear gate stay attaching bolt hole M8 (Symmetrical) (48) Inner trim clip attaching hole 8 20 mm (0.31 0.79 in) dia. (Symmetrical) (49) Rear combination light mounting hole 8 mm (0.31 in) dia. (Symmetrical) (61) Side rail (Inner) gauge hole 10 mm (0.39 in) dia. (Symmetrical) (65) Repair location hole 12 mm (0.47 in) dia. (Symmetrical)
(70) Buffer attaching hole M6 (Symmetrical) (71) Bumper face attaching square hole 8 9 mm (0.31 0.35 in) (72) Bumper face attaching square hole 8 9 mm (0.31 0.35 in) (Symmetrical) (73) Head console bracket gauge hole 8 mm (0.31 in) dia. (74) Inner system carrier attaching bolt hole 8 mm (0.31 in) (Symmetrical) (75) Inner system carrier attaching bolt hole 8 mm (0.31 in) (Symmetrical) (76) Head console bracket gauge hole 8 mm (0.31 in) dia.
BS-5
Body Structure
DATUM POINTS
S906540A1303
3. UNDERBODY SECTION
S5M0075A
(50) Radiator panel (LWR) frame gauge hole 15 mm (0.59 in) dia. (Symmetrical) (51) Front side frame gauge hole 20 mm (0.79 in) dia. (Symmetrical) (52) Front crossmember attaching hole 12.4 mm (0.488 in) dia. (Symmetrical)
(53) Front suspension attaching bolt hole M14 (54) Side frame gauge hole 20 mm (0.79 in) dia. (Symmetrical) (55) Repair location hole 12 mm (0.47 in) dia. (Symmetrical) (56) Side frame gauge hole 15 mm (0.59 in) dia. (Symmetrical)
(57) Rear differential attaching bolt hole M12 (Symmetrical) (58) Rear suspension attaching bolt hole M12 (Symmetrical) (59) Rear side frame gauge hole 15 mm (0.59 in) dia. (Symmetrical)
BS-6
DATUM POINTS
Body Structure
S5M0076A
S5M0077A
S5M0079A S5M0078A
S5M0080A
S5M0081A
S5M0083B S5M0082A
BS-7
Body Structure
DATUM POINTS
S5M0085A S5M0084A
S5M0087A S5M0086A
S5M0088A
S5M0089A
S5M0091A S5M0090A
BS-8
DATUM POINTS
Body Structure
S5M0092A
S5M0093A
S5M0095A S5M0094A
S5M0097A S5M0096A
S5M0098A
S5M0099A
BS-9
Body Structure
DATUM POINTS
S5M0100A
S5M0101A
S5M0102A
S5M0103A
S5M0104A
S5M0105B
S5M0106A S5M0107A
BS-10
DATUM POINTS
Body Structure
S5M0108A
S5M0109A
S5M0110A S5M0111A
S5M0113A S5M0112A
S5M0114A S5M0115A
BS-11
Body Structure
DATUM POINTS
S5M0116A
S5M0117A
S5M0516A S5M0118A
S5M0120A
S5M0121A
S5M0122A
S5M0123B
BS-12
DATUM POINTS
Body Structure
S5M0124A
S5M0125A
S5M0126B
S5M0127A
S5M0129A S5M0128A
S5M0130A S5M0131A
BS-13
Body Structure
DATUM POINTS
S5M0132A
S5M0133A
S5M0134A
S5M0135A
S5M0136A
BS-14
DATUM DIMENSIONS
Body Structure
3. Datum Dimensions
A: MEASUREMENT
S906337A14
S906337
Refer to LOCATION for details on measurement points. <Ref. to BS-3, LOCATION, Datum Points.> NOTE: Using a tram tracking gauge, measure all the dimensions. When using a tape measure, carefully measure dimensions without letting the tape measure sag or twist. Measure the linear dimensions between CENTERS of holes. Suffixes RH and LH indicate right-hand and left-hand.
G5M0122
Measure at the center of the circle around the outside of the body panel.
B5M1133A
BS-15
Body Structure
DATUM DIMENSIONS
S906337A1401
1. FRONT STRUCTURE
S5M0137A
Point to point (11) R to (1) (11) L to (1) (11) R to (2) (11) L to (2) (11) R to (9) R (11) L to (9) L (11) R to (6) R (11) L to (6) L (11) R to (3) R (11) L to (3) L (10) R to (3) R (10) L to (3) L (10) R to (10) L (3) R to (3) L (5) R to (5) L (4) R to (4) L (5) R to (4) L (5) L to (4) R (60) R to (13) R (60) L to (13) L (60) R to (14) R (60) L to (14) L (10) R to (3) L
Dimension 852 (33.54) 913 (35.94) 960 (37.80) 865 (34.06) 392 (15.43) 392 (15.43) 926 (36.46) 926 (36.46) 891 (35.08) 891 (35.08) 917 (36.10) 917 (36.10) 1,374 (54.09) 1,338 (52.68) 924 (36.38) 1,296 (51.02) 1,176 (46.30) 1,176 (46.30) 1,174 (46.22) 1,174 (46.22) 1,076 (42.36) 1,076 (42.36) 1,637 (64.45)
Point to point (10) R to (8) R (10) L to (8) L (11) L to (9) R (11) R to (9) L (9) R to (9) L (11) L to (6) R (11) R to (6) L (6) R to (6) L (6) R to (10) L (6) L to (10) R (8) R to (3) R (8) L to (3) L (10) L to (3) R (8) R to (8) L (8) R to (10) L (8) L to (10) R (3) R to (8) L (3) L to (8) R (7) R to (7) L (7) R to (6) L (7) L to (6) R (7) R to (10) L (7) L to (10) R
Unit: mm (in) Dimension 390 (15.35) 390 (15.35) 659 (25.94) 659 (25.94) 966 (38.03) 1,059 (41.69) 1,059 (41.69) 914 (35.98) 1,549 (60.98) 1,549 (60.98) 528 (20.79) 528 (20.79) 1,637 (64.45) 1,396 (54.96) 1,438 (56.61) 1,438 (56.61) 1,465 (57.68) 1,465 (57.68) 860 (33.86) 982 (38.66) 982 (38.66) 1,302 (51.26) 1,302 (51.26)
BS-16
DATUM DIMENSIONS
Body Structure
S5M0141A
Point to point (11) to (A) (11) to (B)
Dimension 909.9 (35.82) 915 (36.02)
Point to point (11) to (C) (11) to (D)
Unit: mm (in) Dimension 1,097.7 (43.22) 1,022 (40.24)
BS-17
Body Structure
DATUM DIMENSIONS
S906337A1402
2. CENTER STRUCTURE
S5M0138B
BS-18
DATUM DIMENSIONS
3. WINDSHIELD AND DOORS
S906337A1403
Body Structure
S5M0139A
BS-19
Body Structure
DATUM DIMENSIONS
Unit: mm (in) Dimension 859 (33.82) 859 (33.82) 845 (33.27) 845 (33.27) 885 (34.84) 885 (34.84) 1,147 (45.16) 1,147 (45.16) 1,157 (45.55) 1,530 (60.24) 1,530 (60.24) 1,447 (56.97) 1,447 (56.97) 1,140 (44.88) 1,140 (44.88) 733 (28.86) 733 (28.86) 1,568 (61.73) 1,568 (61.73) 1,212 (47.72) 1,298 (51.10) 944 (37.17) 944 (37.17) 1,332 (52.44) 1,332 (52.44)
Point to point (14) L to (18) L (14) R to (18) R (13) L to (64) L (13) R to (64) R (20) L to (24) L (20) R to (24) R (20) L to (36) (20) R to (37) (42) L to (44) L (42) R to (44) R (11) R to (12) (11) L to (12) (67) R to (67) L (11) R to (67) R (11) L to (67) L (12) to (67) L (12) to (67) R (12) to (10) L (12) to (10) R (21) R to (21) L (15) R to (15) L (22) R to (22) L (39) R to (39) L (40) R to (40) L (11) L to (17) R (11) R to (17) L
Dimension 1,453 (57.20) 1,453 (57.20) 944 (37.17) 944 (37.17) 947 (37.28) 947 (37.28) 1,484 (58.43) 1,488 (58.58) 769 (30.28) 769 (30.28) 918 (36.14) 918 (36.14) 1,045 (41.14) 1,006 (39.61) 1,006 (39.61) 525 (20.67) 525 (20.67) 1,027 (40.43) 1,027 (40.43) 1,322 (52.05) 1,453 (57.20) 1,453 (57.20) 1,392 (54.80) 1,402 (55.20) 1,168 (45.98) 1,168 (45.98)
Point to point (16) L to (64) L (16) R to (64) R (20) L to (23) L (20) R to (23) R (19) L to (23) L (19) R to (23) R (11) L to (67) R (11) R to (67) L (41) to (38) (41) to (39) R (41) to (39) L (41) to (40) R (41) to (40) L (41) to (15) R (41) to (15) L (41) to (22) R (41) to (22) L (41) to (26) R (41) to (26) L (41) to (25) (41) to (12) (41) to (21) R (41) to (21) L (41) to (17) R (41) to (17) L
BS-20
DATUM DIMENSIONS
4. COMPARTMENT
S906337A1404
Body Structure
S5M0140A
Point to point (45) to (48) L (45) to (48) R (45) to (47) L (45) to (47) R (47) R to (47) L (49)R to (49) L (34) R to (34) L (48) R to (46) R (48) L to (46) L (70) R to (70) L (61) R to (75) R (61) L to (75) L (17) R to (75) R (17) L to (75) L (45) to (71)
Dimension 862 (33.94) 862 (33.94) 876 (34.49) 876 (34.49) 1,426 (56.14) 1,479 (58.23) 945 (37.20) 992 (39.06) 992 (39.06) 1,218 (47.95) 447 (17.60) 447 (17.60) 1,137 (44.76) 1,137 (44.76) 913 (35.94)
Point to point (41) to (65) R (41) to (65)L (41) to (45) (41) to (43) R (41) to (43) L (41) to (48) L (41) to (48) R (65) R to (65) L (17) R to (76) (17) L to (76) (72) R to (72) L (74) R to (75) R (74) L to (75) L (17) R to (73) (17) L to (73)
Unit: mm (in) Dimension 1,131 (44.53) 1,131 (44.53) 1,569 (61.77) 1,435 (56.50) 1,435 (56.50) 1,576 (62.05) 1,576 (62.05) 1,267 (49.88) 627 (24.68) 680 (26.77) 1,111 (43.74) 480 (18.90) 480 (18.90) 518 (20.39) 476 (18.74)
BS-21
Body Structure
DATUM DIMENSIONS
MEMO:
BS-22
INSTRUMENTATION/DRIVER INFO
IDI
1. 2. 3. 4. 5. 6. 7. 8. Page General Description.....................................................................................2 Combination Meter System.........................................................................4 Combination Meter Assembly ...................................................................15 Speedometer .............................................................................................17 Tachometer................................................................................................18 Fuel Gauge................................................................................................19 Water Temperature Gauge........................................................................20 Ambient Sensor.........................................................................................21
Instrumentation/Driver Info
GENERAL DESCRIPTION
S907001
A: SPECIFICATIONS
S907001E49
Speedometer Temperature gauge Fuel gauge Tachometer Turn signal indicator light Charge indicator light Oil pressure indicator light ABS warning light CHECK ENGINE warning light (Malfunction indicator light) HI-beam indicator light Door open warning light Combination meter Seat belt warning light Brake fluid and parking brake warning light FWD indicator light AIRBAG warning light Meter illumination light AT OIL TEMP. warning light LO indicator light HOLD indicator light POWER indicator light Rear differential oil temperature warning light Immobilizer indicator light Low fuel warning light LCD back light
Electric pulse type Thermistor cross coil type Resistance cross coil type Electric impulse type 14 V 1.4 W 14 V 1.4 W 14 V 1.4 W 14 V 1.4 W 14 V 1.4 W 14 V 1.4 W LED 14 V 1.4 W 14 V 1.4 W 14 V 1.4 W 14 V 1.4 W 14 V 3 W, 1.4 W 14 V 1.4 W 14 V 1.4 W 14 V 1.4 W 14 V 1.4 W 14 V 1.4 W LED 14 V 1.4 W 14 V 1.4 W
IDI-2

S907001A03
Be careful not to damage meters and instrument panel. Be careful not to damage meter glasses. Make sure that electrical connector is connected securely. After installation, make sure that each meter operates normally. Use gloves to avoid damage and getting fingerprints on the glass surface and meter surfaces. Do not apply excessive force to circuit plate. Do not drop or otherwise apply impact.
S907001A17
C: PREPARATION TOOL
1. GENERAL TOOLS
Circuit Tester
S907001A1701
TOOL NAME
IDI-3
COMBINATION METER SYSTEM

S907607
2. Combination Meter System

A: SCHEMATIC
S907607A21
1. COMBINATION METER
S907607A2101
SG6420A
IDI-4

2. OUTSIDE TEMPERATURE INDICATOR LHD MODEL
S907607A2103
SL96-20
IDI-5

S907607A2104
3. OUTSIDE TEMPERATURE INDICATOR RHD MODEL
SR96-20
IDI-6
COMBINATION METER SYSTEM B: INSPECTION

S907607A10
CAUTION: When measuring voltage and resistance of the ECM, TCM, or each sensor, use a tapered pin with a diameter of less than 0.64 mm (0.025 in) in order to avoid poor contact. Do not insert the pin more than 2 mm (0.08 in).
1. SYMPTOM CHART
S907607A1007
Symptom Combination meter assembly does not operate.
Repair order (1) Power supply (2) Ground circuit
Speedometer does not operate.
(1) (MT) Vehicle speed sensor (AT) Transmission control module (2) Harness (3) Speedometer
Tachometer does not operate.
(1) Engine control module (2) Harness (3) Tachometer
Fuel gauge does not operate.
(1) Fuel level sensor (2) Harness (3) Fuel gauge (1) Engine coolant temperature sensor (2) Harness (3) Water temperature gauge
Water temperature gauge does not operate.
Outside temperature indicator does not operate.
(1) Ambient sensor (2) Harness (3) Combination meter
Reference <Ref. to IDI-8 CHECK POWER SUPPLY AND GROUND CIRCUIT, INSPECTION, Combination Meter System.> MT: <Ref. to IDI-9 CHECK VEHICLE SPEED SENSOR, INSPECTION, Combination Meter System.> AT: <Ref. to IDI-10 CHECK TRANSMISSION CONTROL MODULE, INSPECTION, Combination Meter System.> <Ref. to IDI-11 CHECK ENGINE CONTROL MODULE, INSPECTION, Combination Meter System.> <Ref. to IDI-12 CHECK FUEL LEVEL SENSOR, INSPECTION, Combination Meter System.> <Ref. to IDI-13 CHECK ENGINE COOLANT TEMPERATURE SENSOR, INSPECTION, Combination Meter System.> <Ref. to IDI-14 CHECK OUTSIDE TEMPERATURE INDICATOR, INSPECTION, Combination Meter System.>
IDI-7
2. CHECK POWER SUPPLY AND GROUND CIRCUIT S907607A1001

No. 1 Step CHECK POWER SUPPLY FOR COMBINATION METER. 1) Remove combination meter. <Ref. to IDI-15 REMOVAL, Combination Meter Assembly.> 2) Disconnect combination meter harness connector. 3) Turn ignition switch to ON. 4) Measure voltage between combination meter connector (i10) and chassis ground. Connector & terminal (i10) No. 1 (+) Chassis ground (): CHECK POWER SUPPLY FOR COMBINATION METER. Measure voltage between combination meter connector (i10) and chassis ground. Connector & terminal (i10) No. 2 (+) Chassis ground (): CHECK GROUND CIRCUIT OF COMBINATION METER. 1) Turn ignition switch to OFF. 2) Measure resistance of harness between combination meter connector (i10) and chassis ground. Connector & terminal (i10) No. 3 (+) Chassis ground (): Check Yes Is the voltage more than 10 Go to step 2. V? No Check harness for open or short between fuse and combination meter.
Check harness for open or short between ignition relay and combination meter.
Replace combina- Repair wiring hartion meter printed ness. circuit.
IDI-8

3. CHECK VEHICLE SPEED SENSOR
S907607A1002
No. 1
Step CHECK VEHICLE SPEED SENSOR. 1) Set the vehicle on a free roller, or lift-up the vehicle and support it with safety stands. 2) Remove the combination meter with harness connector. WARNING: Be careful not to get caught in the running wheels. 3) Drive the vehicle at a speed greater than 20 km/h (12 MPH). 4) Measure voltage between combination meter connector (i10) and chassis ground. Connector & terminal (i10) No. 7 (+) Chassis ground (): CHECK VEHICLE SPEED SENSOR POWER SUPPLY. 1) Turn ignition switch to OFF. 2) Disconnect vehicle speed sensor harness connector. 3) Turn ignition switch to ON. 4) Measure voltage between vehicle speed sensor connector (B17) and engine ground. Connector & terminal (B17) No. 3 (+) Engine ground (): CHECK HARNESS BETWEEN VEHICLE SPEED SENSOR AND ENGINE GROUND. 1) Turn ignition switch to OFF. 2) Measure resistance between vehicle speed sensor connector (B17) and engine ground. Connector & terminal (B17) No. 2 (+) Engine ground (): CHECK HARNESS BETWEEN VEHICLE SPEED SENSOR AND COMBINATION METER. 1) Disconnect connector from combination meter. 2) Measure resistance between vehicle speed sensor harness connector and combination meter harness connector. Connector & terminal (B17) No. 1 (i10) No. 7:
Check Yes No Is the voltage less than 1 V Check speedom- Go to step 2. more than 4? eter. <Ref. to IDI-17 REMOVAL, Speedometer.>
Check harness for open or short between ignition relay and vehicle speed sensor.
Go to step 4.
Replace vehicle speed sensor.
IDI-9
4. CHECK TRANSMISSION CONTROL MODULE S907607A1008

No. 1 Step CHECK TRANSMISSION CONTROL MODULE SIGNAL. 1) Set the vehicle on a free roller, or lift-up the vehicle and support it with safety stands. WARNING: Be careful not to get caught in the running wheels. 2) Drive the vehicle faster than 10 km/h (6 MPH). 3) Measure voltage between transmission control module connector (B55) and chassis ground. Connector & terminal (B56) No. 17 (+) Chassis ground (): CHECK HARNESS BETWEEN TRANSMISSION CONTROL MODULE AND COMBINATION METER. 1) Turn ignition switch to OFF. 2) Disconnect connector from transmission control module and combination meter. 3) Measure resistance between transmission control module harness connector (B55) and combination meter harness connector (i10). Connector & terminal (B56) No. 17 (i10) No. 7: Check Yes Is the voltage less than 1 V Go to step 2. more than 4 V? No Check transmission control module. <Ref. to AT-2 Basic Diagnostic Procedure.>
Repair wiring harCheck speed ness. meter. <Ref. to IDI-17 REMOVAL, Speedometer.>
IDI-10

5. CHECK ENGINE CONTROL MODULE
S907607A1004
No. 1
Step Check CHECK ENGINE CONTROL MODULE SIG- Is the voltage 0 13 V or more? NAL. 1) Start the engine. 2) Measure voltage between engine control module connector (B84, B134 or B136) and engine ground. Connector & terminal SOHC model: (B134) No. 30 (+) Engine ground (): SOHC without OBD model: (B84) No. 6 (+) Engine ground (): DOHC turbo model: (B136) No. 9 (+) Engine ground ():
Yes Go to step 2.
Is the resistance less than CHECK HARNESS BETWEEN COMBINA10 ? TION METER AND ENGINE CONTROL MODULE. 1) Turn ignition switch to OFF. 2) Disconnect connector from engine control module and combination meter. 3) Measure resistance between engine control module harness connector (B84, B134 or B136) and combination meter harness connector (i11). Connector & terminal SOHC model: (B134) No. 30 (i10) No. 8: SOHC without OBD model: (B84) No. 6 (+) (i10) No. 8: DOHC turbo model: (B136) No. 9 (+) (i10) No. 8:
Check tachometer. <Ref. to IDI-18 REMOVAL, Tachometer.>
No Check engine control module. <Ref. to EN(SOHC)-2, Basic Diagnostic Procedure.>, <Ref. to EN(SOHCw/ oOBD)-2, Basic Diagnostic Procedure.> or <Ref. to EN(DOHC TURBO)-2, Basic Diagnostic Procedure.> Repair wiring harness.
IDI-11

S907607A1005
6. CHECK FUEL LEVEL SENSOR

No. 1
Step CHECK FUEL LEVEL SENSOR. 1) Remove fuel level sensor. <Ref. to FU(SOHC)-64, REMOVAL, Fuel Level Sensor.>, <Ref. to FU(SOHCw/oOBD)-52, REMOVAL, Fuel Level Sensor.> or <Ref. to FU(DOHC TURBO)-62, REMOVAL, Fuel Level Sensor.> 2) Measure resistance between fuel level sensor terminals when setting the float to FULL and EMPTY position. Terminals No. 3 No. 5: CHECK FUEL SUB LEVEL SENSOR. 1) Remove fuel sub level sensor. <Ref. to FU(SOHC)-65, REMOVAL, Fuel Sub Level Sensor.>, <Ref. to FU(SOHCw/oOBD)-53, REMOVAL, Fuel Sub Level Sensor.> or <Ref. to FU(DOHC TURBO)-63, REMOVAL, Sub Fuel Level Sensor.> 2) Measure resistance between fuel sub level sensor terminals when setting the float to FULL and EMPTY position. Terminals No. 1 No. 2: CHECK HARNESS BETWEEN FUEL SUB LEVEL SENSOR AND COMBINATION METER. 1) Disconnect connector from combination meter. 2) Measure resistance between fuel sub level sensor harness connector terminal and combination meter harness connector terminal. Connector & terminal (R59) No. 1 (i11) No. 10: CHECK HARNESS BETWEEN FUEL LEVEL SENSOR AND FUEL SUB LEVEL SENSOR. Measure resistance between fuel level sensor harness connector terminal and fuel sub level sensor harness connector terminal. Connector & terminal (R58) No. 3 (R59) No. 2: CHECK FUEL LEVEL SENSOR GROUND CIRCUIT. Measure resistance between fuel level sensor harness connector terminal and chassis ground. Connector & terminal (R58) No. 5 Chassis ground:
Check Is the resistance 0.5 to 2.5 (FULL) and 50 to 52 (EMPTY)?
Yes Go to step 2.
No Replace the fuel level sensor.
Is the resistance 0.5 to 2.5 (FULL) and 42 to 44 (EMPTY)?
Go to step 3.
Replace the fuel sub level sensor.
Go to step 4.
Go to step 5.
Check fuel gauge. Repair wiring harness. <Ref. to IDI-19, REMOVAL, Fuel Gauge.>
IDI-12

7. CHECK ENGINE COOLANT TEMPERATURE SENSOR S907607A1006
No. 1 Step CHECK ENGINE COOLANT TEMPERATURE SENSOR. Check engine coolant temperature sensor. <Ref. to EN(SOHC)-122, DTC P0117ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT LOW INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>, <Ref. to EN(SOHCw/oOBD)-70, DTC21 ENGINE COOLANT TEMPERATURE SENSOR, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> or <Ref. to EN(DOHC TURBO)-130, DTC P0117ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT LOW INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).> CHECK HARNESS BETWEEN ENGINE COOLANT TEMPERATURE SENSOR AND COMBINATION METER. 1) Turn ignition switch to OFF. 2) Disconnect connector from engine coolant temperature sensor and combination meter. 3) Measure resistance between engine coolant temperature sensor harness connector (E8) and combination meter harness connector (i12). Connector & terminal (E8) No. 3 (i12) No. 13: Check Is engine coolant temperature sensor OK?
Yes Go to step 2.
No Replace engine coolant temperature sensor.
Check water tem- Repair wiring harness. perature gauge. <Ref. to IDI-20 REMOVAL, Water Temperature Gauge.>
IDI-13
8. CHECK OUTSIDE TEMPERATURE INDICATOR S907607A1009

No. 1 Step CHECK POWER SUPPLY FOR AMBIENT SENSOR. 1) Turn ignition switch OFF. 2) Disconnect connector from ambient sensor. 3) Turn ignition switch ON. 4) Measure voltage between ambient sensor harness connector terminal and chassis ground. Connector & terminal (F78) No. 2 (+) Chassis ground (): CHECK AMBIENT SENSOR. 1) Turn ignition switch OFF. 2) Remove ambient sensor. 3) Check ambient sensor. <Ref. to IDI-21 INSPECTION, Ambient Sensor.> CHECK HARNESS BETWEEN AMBIENT SENSOR AND COMBINATION METER. 1) Disconnect connector from combination meter. 2) Measure resistance between ambient sensor harness connector terminal and combination meter harness connector terminal. Connector & terminal (F78) No. 1 (i10) No. 4: (F78) No. 2 (i10) No. 5: CHECK OUTSIDE TEMPERATURE INDICATOR. 1) Connect combination meter harness connector. 2) Connect a resistor (3.0 k) between terminals of ambient sensor harness connector. 3) Turn ignition switch ON and check the outside temperature indicator display. Check Is the voltage more than 4 V? Yes Go to step 2. No Check harness for open or short between ambient sensor and combination meter.
Is the ambient sensor OK?
Go to step 3.
Replace the ambient sensor.
Go to step 4.
Is the outside temperature indicator indicating 25C (77F)?
Check poor contact in ambient sensor harness connector.
Replace combination meter printed circuit.
IDI-14
COMBINATION METER ASSEMBLY
S907335A11
3. Combination Meter Assembly

S907335
B: INSTALLATION
Install in the reverse order of removal. CAUTION: Make sure that electrical connector is connected securely. Make sure that each meter operates normally.
A: REMOVAL
S907335A18
1) Disconnect ground cable from battery. 2) Set tilt steering at the lowest position. 3) Remove screws and detach meter visor.
C: DISASSEMBLY
S907335A06
CAUTION: Use gloves to avoid damage and getting fingerprints on the glass surface and meter surfaces. 1) Disengage claw (F) to remove case (B) from back cover (A). 2) Disengage claw (G) to remove meter glass (E), reflector (D), and window plate (C) from inner case.
S6M0076A
4) Remove screws of combination meter and pull out the meter toward you.
S6M0511A
S6M0077
5) Disconnect connector in the upper area of combination meter to remove meter. CAUTION: Be careful not to damage meter or instrument panel. Pay particular attention to avoid damaging the meter glass.
3) Pull up claw (A) of combination meter printed circuit with combination pliers. Push out speedometer assembly (B) and tachometer assembly (C) using hole (D). 4) Pull up claw in the center of combination meter printed circuit and remove combination meter printed circuit from case (F).
S6M0512A
IDI-15
COMBINATION METER ASSEMBLY

S907335A0601
1. BULB REPLACEMENT
S6M0565A
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24)
Check engine Oil pressure Charge Seat belt (RHD) AT oil temp. Brake Tachometer Turn RH Airbag warning light HI-beam Turn LH Speedometer FWD Seat belt (LHD) ABS AWD LO R. DIFF TEMP Low fuel Speedometer and fuel gauge Odometer and trip meter HOLD Outside air temperature display POWER Tachometer and temperature gauge
S907335A02
D: ASSEMBLY
IDI-16
SPEEDOMETER
4. Speedometer
A: REMOVAL
S907608A18
S907608
Disassemble combination meter, and then remove speedometer and fuel gauge assembly. <Ref. to IDI-15 DISASSEMBLY, Combination Meter Assembly.>
S907608A11

S907608A10
Measure resistance between speedometer terminals.
B6M1232A
Tester connection Terminals SIN+ SIN Terminals COS+ COS
Resistance 2008 2008
If NG, replace speedometer and fuel gauge assembly. If OK, replace combination meter printed circuit.
IDI-17
TACHOMETER
5. Tachometer
A: REMOVAL
S907609
S907609A18
Disassemble combination meter, and then remove tachometer and water temperature gauge assembly. <Ref. to IDI-15 DISASSEMBLY, Combination Meter Assembly.>
S907609A11

S907609A10
Measure resistance between tachometer terminals.
B6M1232A
Tester connection Terminals SIN+ SIN Terminals COS+ COS
Resistance 2008 2008
If NG, replace tachometer and water temperature gauge assembly. If OK, replace combination meter printed circuit.
IDI-18
FUEL GAUGE
6. Fuel Gauge
A: REMOVAL
S907610
S907610A18
Disassemble combination meter, and then remove speedometer and fuel gauge assembly. <Ref. to IDI-15 DISASSEMBLY, Combination Meter Assembly.>
S907610A11

S907610A10
Measure resistance between fuel gauge terminals.
B6M1233A
Tester connection Terminals IGN GND Terminals IGN UNIT Terminals UNIT GND
Resistance 17010 3510 13610
If NG, replace speedometer and fuel gauge assembly. If OK, replace combination meter printed circuit.
IDI-19
WATER TEMPERATURE GAUGE

S907611
7. Water Temperature Gauge

A: REMOVAL
S907611A18
Disassemble combination meter, and then remove tachometer and water temperature gauge assembly. <Ref. to IDI-15 DISASSEMBLY, Combination Meter Assembly.>
S907611A11

S907611A10
Measure resistance between fuel gauge terminals.
B6M1233A
Tester connection Terminals IGN GND Terminals IGN UNIT Terminals UNIT GND
Resistance 20810 5610 26410
If NG, replace tachometer and water temperature gauge assembly. If OK, replace combination meter printed circuit.
IDI-20
AMBIENT SENSOR
8. Ambient Sensor
A: REMOVAL
S907644A18
S907644
1) Disconnect ground cable from battery. 2) Disconnect ambient sensor connector. 3) Remove ambient sensor (A) from radiator lower panel.
S6M0510A
S907644A11

S907644A10
Measure resistance between ambient sensor terminals.
B6M1537
Tester connection 12
Resistance 3.0 k/25C (77F)
If NG, replace the ambient sensor.
IDI-21
AMBIENT SENSOR
MEMO:
IDI-22
SEATS
SE
1. 2. 3. Page General Description.....................................................................................2 Front Seat....................................................................................................5 Rear Seat ....................................................................................................6
Seats
GENERAL DESCRIPTION
S908001
A: COMPONENT
1. FRONT SEAT
S908001A05 S908001A0501
S5M0440A
(1) (2) (3) (4) (5) (6) (7)
Lumbar lever Lumbar cover Lumbar unit Headrest Backrest Cushion Cushion frame
(8) (9) (10) (11) (12) (13) (14)
Lifter dial Hinge cover OUT Reclining lever Hinge ASSY Hinge spring cover Slide rail ASSY IN Connecting wire
(15) Slide rail ASSY OUT (16) Bracket

Tightening torque: Nm (kgf-m, ft-lb) T1: 18 (1.8, 13) T2: 52 (5.3, 38)
SE-2
GENERAL DESCRIPTION
2. REAR SEAT
S908001A0505
Seats
S5M0508A
(1) (2) (3) (4) (5) (6)
Backrest RH Backrest LH Headrest OUTSIDE Headrest CENTER Hinge RH Hinge CENTER
(7) (8) (9) (10) (11)
Hinge LH Cushion Striker Cap Webbing guide
SE-3
Seats
GENERAL DESCRIPTION
S908001A03
B: CAUTION
Take care not to contaminate or damage seat surface. While loading to or unloading to vehicle, take care not to contact body. When removing front seat from a side airbag loaded vehicle, follow cautions given in the airbag section.
SE-4
FRONT SEAT
Seats
2. Front Seat
A: REMOVAL
S908343
S908343A18
1) While operating button (located on top of backrest), lift headrest out with hand placed between backrest and headrest.
CAUTION: When removing seat from vehicle, take care not to damage body, seat, or trim. After the front seat has been removed from side airbag equipped vehicle, store it as instructed in AIRBAG REPAIR SECTION. <Ref. to AB-15, CAUTION, Side Airbag Module.>
B: INSTALLATION
S908343A11
1) While operating button (located on top of backrest), lift headrest out by placing your hand between backrest and headrest.
S5M0303
2) Pull reclining lever back to fold backrest all the way forward. While pulling slide adjuster lever, move seat all the way forward. 3) Remove bolt cover at rear end of slide rail. 4) Remove bolts securing seat rear.
S5M0303
S5M0366
2) Pull reclining lever back to fold backrest all the way forward. Pull slide adjuster lever and move lower slide rail all the way backward. 3) Position seat in compartment and align the holes on the seat with the holes on the vehicle body side. 4) Secure the front of seat using inward and outward bolts (A) and (B) in that order. 5) While pulling slide adjuster lever, move seat all the way forward. 6) Secure the rear of seat using inward and outward bolts (C) and (D).
5) While pulling slide adjuster lever, slide seat all the way back. 6) Remove bolts securing front of seat.
S5M0227A
G5M0344
7) While disconnecting side airbag connector, detach front seat. (Side airbag equipped vehicle) and inner belt connector.
7) Connect inner belt connector. 8) Connect side airbag connector. (Side airbag equipped model) 9) Install bolt cover on rear end of slide rail. 10) Install headrest on backrest. CAUTION: Confirm that seat can move smoothly and be locked securely at any position.
SE-5
Seats
REAR SEAT
S908350
3. Rear Seat
A: REMOVAL
S908350A18
1) Remove bolts securing hinges (located at front of cushion) to body. 2) Slightly raise front of cushion while pushing down on cushion in the direction of A. With cushion held in that position, move it forward until it is unhooked.
S5M0228A
3) Remove rear quarter lower trim. <Ref. to EI-39, REMOVAL, Rear Quarter Trim.> 4) Remove bolts and nuts.
S5M0407
5) Detach backrest.
B: INSTALLATION
S908350A11
SE-6
SECURITY AND LOCKS
SL
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. Page General Description.....................................................................................2 Door Lock Control System ..........................................................................8 Keyless Entry System ...............................................................................14 Front Inner Remote ...................................................................................27 Front Outer Handle ...................................................................................28 Front Door Latch Assembly.......................................................................29 Front Door Lock Actuator ..........................................................................30 Rear Inner Remote....................................................................................31 Rear Outer Handle ....................................................................................32 Rear Door Latch Assembly .......................................................................33 Rear Door Lock Actuator...........................................................................34 Rear Gate Outer Handle ...........................................................................35 Rear Gate Latch Assembly .......................................................................36 Rear Gate Latch Lock Actuator.................................................................37 Front Hood Lock Assembly .......................................................................38 Remote Openers .......................................................................................39 Ignition Key Lock.......................................................................................40 Key Lock Cylinders ...................................................................................41 Immobilizer Control Module ......................................................................42 Immobilizer Antenna..................................................................................43 Keyless Entry Control Module...................................................................44 Keyless Transmitter...................................................................................45
Security and Locks
GENERAL DESCRIPTION
S909001
A: SPECIFICATIONS B: COMPONENT
S909001E49 S909001A05
1. DOOR LOCK ASSEMBLY
S909001A0501
S5M0444A
(1) (2) (3) (4) (5)
Inner remote ASSY Bell crank Auto-door lock actuator Door latch Striker
(6) Door outer handle (7) Key cylinder
Tightening torque: Nm (kgf-m, ft-lb) T1: 6.4 (0.65, 4.7) T2: 7.4 (0.75, 5.4) T3: 14 (1.4, 10.1)
SL-2
GENERAL DESCRIPTION
2. REAR GATE LOCK
S909001A0502
Security and Locks
S5M0445A
(1) (2) (3) (4)
Key cylinder Rear gate latch Striker Rear gate outer handle
(5) Rear gate actuator
SL-3
Security and Locks
GENERAL DESCRIPTION
S909001A0503
3. HOOD LOCK AND REMOTE OPENERS
S5M0446A
(1) Hood lock ASSY (2) Lever ASSY (3) Cable
(4) Pull handle ASSY
SL-4
GENERAL DESCRIPTION
4. IMMOBILIZER SYSTEM
S909001A0509
Security and Locks
S6M0413A
(1) Antenna (2) Immobilizer indicator light (LED bulb)
(3) Immobilizer control module (IMM ECM): LHD model (4) Transponder
NOTE: IMM ECM location for RHD model is symmetrically opposite.
SL-5
Security and Locks
GENERAL DESCRIPTION
S909001A0505
5. KEYLESS ENTRY SYSTEM
S5M0447A
(1) Keyless entry control module
(2) Rear gate latch switch
(3) Door switch
C: CAUTION
S909001A03
Before disassembling or reassembling parts, always disconnect battery ground cable. When repairing radio, control module, etc. which are provided with memory functions, record memory contents before disconnecting battery ground cable. Otherwise, these contents are cancelled upon disconnection. Reassemble parts in reverse order of disassembly procedure unless otherwise indicated. Adjust parts to specifications contained in this manual if so designated. Connect connectors and hoses securely during reassembly. After reassembly, ensure functional parts operate smoothly. Airbag system wiring harness is routed near the electrical parts and switch. All airbag system wiring harness and connectors are colored yellow. Do not use electrical test equipment on these circuits. Be careful not to damage Airbag system wiring harness when servicing the ignition key cylinder.
SL-6

1. SPECIAL TOOLS
ILLUSTRATION
S909001A1701 S909001A17
Security and Locks
DESCRIPTION PULLER
REMARKS Used for removing trim clip
B5M1120
2. GENERAL TOOLS
Circuit Tester Drill
S909001A1702
TOOL NAME
REMARKS Used for measuring resistance and voltage. Used for replacing ignition key lock.
SL-7
Security and Locks
DOOR LOCK CONTROL SYSTEM

S909348
2. Door Lock Control System

A: SCHEMATIC
S909348A21
1. DOOR LOCK CONTROL LHD MODEL
S909348A2106
SL73-20
SL-8

2. DOOR LOCK CONTROL RHD MODEL
S909348A2107
Security and Locks
SR73-20
SL-9
Security and Locks

S909348A10
B: INSPECTION
1. SYMPTOM CHART
S909348A1001
Symptom The door lock control system does not operate.
Reference 1. Check the fuse. <Ref. to SL-10 CHECK FUSE, INSPECTION, Door Lock Control System.> 2. Check the power supply and ground circuit for <Ref. to SL-11 CHECK POWER the keyless entry control module. SUPPLY AND GROUND CIRCUIT, INSPECTION, Door Lock Control System.> 3. Check the door lock switch and the circuit. <Ref. to SL-11 CHECK DOOR LOCK SWITCH AND CIRCUIT, INSPECTION, Door Lock Control System.> 4. Check the door lock actuator and the circuit. <Ref. to SL-12 CHECK DOOR LOCK ACTUATOR AND CIRCUIT, INSPECTION, Door Lock Control System.> The door lock switch (knob) does not Check the door lock switch and the circuit. <Ref. to SL-11 CHECK DOOR operate. LOCK SWITCH AND CIRCUIT, INSPECTION, Door Lock Control System.> A specific door lock actuator does not Check the door lock actuator and the circuit. <Ref. to SL-12 CHECK DOOR operate. LOCK ACTUATOR AND CIRCUIT, INSPECTION, Door Lock Control System.>
Repair order
2. CHECK FUSE
No. 1
S909348A1002
Step CHECK FUSE. Remove and visually check fuse No. 2 (in the main fuse box) and No. 3 (in the fuse and relay box).
Check Is the fuse blown (15A)?
Yes Replace the fuse with a new one.
No Check power supply and ground circuit. <Ref. to SL-11 CHECK POWER SUPPLY AND GROUND CIRCUIT, INSPECTION, Door Lock Control System.>
SL-10

3. CHECK POWER SUPPLY AND GROUND CIRCUIT S909348A1003
No. 1 Step CHECK POWER SUPPLY. 1) Disconnect the door lock timer or keyless entry control module harness connector. 2) Measure the voltage between the harness connector terminal and chassis ground. Connector & terminal (B176) No. 5 (+) Chassis ground (): (B176) No. 16 (+) Chassis ground (): CHECK GROUND CIRCUIT. Measure the resistance between the harness connector terminal and chassis ground. Connector & terminal (B176) No. 14 (+) Chassis ground (): Check Yes Is the voltage more than 10 Go to step 2. V?
Security and Locks
No Check the harness for open circuits or shorts between the keyless entry control module and the fuse.
Power supply and Repair harness. ground circuit is OK.
4. CHECK DOOR LOCK SWITCH AND CIRCUIT S909348A1004

No. 1 Step CHECK DOOR LOCK SWITCH CIRCUIT. 1) Disconnect the keyless entry control module harness connector. 2) Measure the resistance between the harness connector terminal and chassis ground when moving the driver s door lock knob to UNLOCK. Connector & terminal (B176) No. 7 (+) Chassis ground (): CHECK DOOR LOCK SWITCH CIRCUIT. Measure the resistance between the harness connector terminal and chassis ground when the driver s door lock knob is moved to LOCK. Connector & terminal (B176) No. 7 (+) Chassis ground (): CHECK DOOR LOCK SWITCH. 1) Disconnect the driver s door lock switch (actuator) harness connector. 2) Check the continuity between the door lock switch terminals when moving the door lock knob to UNLOCK. Terminal No. 1 No. 3: CHECK DOOR LOCK SWITCH. Check the continuity between the door lock switch terminals when moving the door lock knob to LOCK. Terminal No. 1 No. 3: Check Is the resistance less than 10 ? Yes Go to step 2. No Go to step 3.
Go to step 3.
The door lock switch is OK.
Does continuity exist?
Go to step 4.
Replace the door lock switch (actuator).
Does continuity exist?
Replace the door lock switch (actuator).
Check the harness for open circuits or shorts between the keyless entry control module and the door lock switch.
SL-11
Security and Locks
5. CHECK DOOR LOCK ACTUATOR AND CIRCUIT S909348A1005

No. 1 Step CHECK OUTPUT SIGNAL. Measure the voltage between the harness connector terminal and chassis ground when moving the door lock knob to LOCK. Connector & terminal (B176) No. 18 (+) Chassis ground (): CHECK OUTPUT SIGNAL. Measure the voltage between the harness connector terminal and chassis ground when moving the door lock knob to UNLOCK. Connector & terminal (B176) No. 17 (+) Chassis ground (): CHECK DOOR LOCK ACTUATOR. Check the door lock actuator. Front door lock actuator: <Ref. to SL-30 Front Door Lock Actuator.> Rear door lock actuator: <Ref. to SL-34 Rear Door Lock Actuator.> Rear gate latch lock actuator: <Ref. to SL-37 Rear Gate Latch Lock Actuator.> Check Yes Is the voltage more than 10 Go to step 2. V? No Replace the keyless entry control module.
Replace the keyless entry control module.
Is the door lock actuator OK?
Replace the door Check the harness for open cir- lock actuator. cuits or shorts between the keyless entry control module and the door lock actuator.
SL-12

MEMO:
Security and Locks
SL-13
Security and Locks
KEYLESS ENTRY SYSTEM

S909345
3. Keyless Entry System

A: SCHEMATIC
S909345A21
1. KEYLESS ENTRY LHD MODEL
S909345A2101
SL77-20A
SL-14
Security and Locks
SL77-20B
SL-15
Security and Locks
SL77-20C
SL-16

2. KEYLESS ENTRY RHD MODEL
S909345A2102
Security and Locks
SR77-20A
SL-17
Security and Locks
SR77-20B
SL-18
Security and Locks
SR77-20C
SL-19
Security and Locks

S909345A08
B: ELECTRICAL SPECIFICATION
B5M1141
Content Key warning switch Registration connector Door switch Empty Power supply Empty Door lock switch Empty Empty Empty Room light/Ignition switch illumination Turn signal light (Right) Turn signal light (Left) Ground Power supply (Hazard light) Power supply Door and rear gate lock actuator (Unlock) Door and rear gate lock actuator (Lock)
Terminal No. 1 (INPUT) 2 (INPUT) 3 (INPUT) 4 5 6 7 (INPUT) 8 9 10 11 (OUTPUT) 12 (OUTPUT) 13 (OUTPUT) 14 15 16 17 (OUTPUT) 18 (OUTPUT)
Measuring condition Battery voltage is present when inserting the key into the ignition switch. 0 V is present when connecting the registration connector. 0 V is present when any door is open. Battery voltage is constantly present. 0 V is present when driver s door is unlocked. 0 V is present when pressing the transmitter OPEN button. 0 V is present when any door is open. Battery voltage is present when pressing the transmitter OPEN or LOCK button. Battery voltage is present when pressing the transmitter OPEN or LOCK button. 0 V is constantly present. Battery voltage is constantly present. Battery voltage is constantly present. Battery voltage is present when pressing the transmitter OPEN button. Battery voltage is present when pressing the transmitter LOCK button.
SL-20
KEYLESS ENTRY SYSTEM C: INSPECTION

S909345A10
Security and Locks
1. SYMPTOM CHART
S909345A1001
Symptom None of the functions of the keyless entry system operate.
Repair order 1. Check the transmitter battery.
2. Check the fuse.
3. Check the keyless entry control module power supply and ground circuit.
4. Replace the keyless entry control module. The transmitter cannot be registered. 1. Check the transmitter battery.
2. Check the registration connector circuit.
3. Replace the keyless entry control module. 1. Check the transmitter battery. The door lock or unlock does not operate. NOTE: If the door lock control system does 2. Check the key warning switch. not operate when using the door lock switch, check the door lock control system. <Ref. to SL-10 3. Check the door switch. INSPECTION, Door Lock Control System.> 4. Replace the keyless entry control module. The hazard light does not operate. 1. Check the transmitter battery
2. Check the key warning switch.
3. Check the door switch.
4. Check the hazard light operation.
5. Replace the keyless entry control module.
Reference <Ref. to SL-22 CHECK TRANSMITTER BATTERY, INSPECTION, Keyless Entry System.> <Ref. to SL-22 CHECK FUSE, INSPECTION, Keyless Entry System.> <Ref. to SL-23 CHECK POWER SUPPLY AND GROUND CIRCUIT, INSPECTION, Keyless Entry system.> <Ref. to SL-44 Keyless Entry Control Module.> <Ref. to SL-22 CHECK TRANSMITTER BATTERY, INSPECTION, Keyless Entry System.> <Ref. to SL-23 CHECK REGISTRATION CONNECTOR CIRCUIT, INSPECTION, Keyless Entry System.> <Ref. to SL-44 Keyless Entry Control Module.> <Ref. to SL-22 CHECK TRANSMITTER BATTERY, INSPECTION, Keyless Entry System.> <Ref. to SL-24 CHECK KEY WARNING SWITCH, INSPECTION, Keyless Entry System.> <Ref. to SL-24 CHECK DOOR SWITCH, INSPECTION, Keyless Entry System.> <Ref. to SL- 44 Keyless Entry Control Module.> <Ref. to SL-22 CHECK TRANSMITTER BATTERY, INSPECTION, Keyless Entry System.> <Ref. to SL-24 CHECK KEY WARNING SWITCH, INSPECTION, Keyless Entry System.> <Ref. to SL-24 CHECK DOOR SWITCH, INSPECTION, Keyless Entry System.> <Ref. to SL-25 CHECK HAZARD LIGHT OPERATION, INSPECTION, Keyless Entry System.> <Ref. to SL-44 Keyless Entry Control Module.>
SL-21
Security and Locks

Symptom The room light and ignition switch illumination operation does not activate.

Repair order 1. Check the transmitter battery. Reference <Ref. to SL-22 CHECK TRANSMITTER BATTERY, INSPECTION, Keyless Entry System.> <Ref. to SL-26 CHECK ROOM LIGHT OPERATION, INSPECTION, Keyless Entry System.> <Ref. to SL-26 CHECK IGNITION SWITCH ILLUMINATION CIRCUIT, INSPECTION, Keyless Entry System.> <Ref. to SL-24 CHECK KEY WARNING SWITCH, INSPECTION, Keyless Entry System.> <Ref. to SL-24 CHECK DOOR SWITCH, INSPECTION, Keyless Entry System.> <Ref. to SL-44 Keyless Entry Control Module.>
2. Check the room light operation.
3. Check the ignition switch illumination circuit.
4. Check the key warning switch.
5. Check the door switch.
6. Replace the keyless entry control module.
2. CHECK TRANSMITTER BATTERY

No. 1
S909345A1011
Step CHECK TRANSMITTER BATTERY. 1) Remove the battery from the transmitter. <Ref. to SL-45 REMOVAL, Keyless Transmitter.> 2) Check the battery voltage. <Ref. to SL-45 INSPECTION, Keyless Transmitter.>
Check Is the battery voltage OK?
Yes No Further inspection Replace the transis necessary, refer mitter battery. to SYMPTOM CHART. <Ref. to SL-21 SYMPTOM CHART, INSPECTION, Keyless Entry System.>
3. CHECK FUSE
No. 1
S909345A1004
Step CHECK FUSE. Remove and visually check fuse No. 2 (in the main fuse box), No. 3 (in the fuse and relay box) and SBF-6 (in the main fuse box)
Check Is the fuse blown? (15 A and 30 A)
No Check power supply and ground circuit. <Ref. to SL-23 CHECK POWER SUPPLY AND GROUND CIRCUIT, INSPECTION, Keyless Entry system.>
SL-22

4. CHECK POWER SUPPLY AND GROUND CIRCUIT
No. 1 Step CHECK POWER SUPPLY. 1) Disconnect the keyless entry control module harness connector. 2) Measure the voltage between the harness connector terminal and chassis ground. Connector & terminal (B176) No. 5, No. 15, No. 16 (+) Chassis ground (): CHECK GROUND CIRCUIT. Measure the resistance between the harness connector terminal and chassis ground. Connector & terminal (B176) No. 14 (+) Chassis ground ():
S909345A1005
Security and Locks
No Check the harness for open circuits or shorts between the keyless entry control module and fuse.
The power supply Repair the harand ground circuit ness. are OK.
5. CHECK REGISTRATION CONNECTOR CIRCUIT

No. 1
S909345A1012
Step Check Yes REGISTRATION CONNECTOR INPUT VOLT- Is the voltage more than 10 Go to step 2. V? AGE INSPECTION 1) Disconnect registration connector. 2) Measure voltage between keyless entry control module harness connector and chassis ground. Connector & terminal (B176) No. 2 (+) Chassis ground (): Registration conREGISTRATION CONNECTOR INPUT VOLT- Is the voltage 0 V? nector circuit is AGE INSPECTION OK. 1) Connect registration connector. 2) Measure voltage between keyless entry control module harness connector and chassis ground. Connector & terminal (B176) No. 2 (+) Chassis ground ():
No Repair harness, and (or) connector.
Repair harness, and (or) connector.
SL-23
Security and Locks

S909345A1007
6. CHECK DOOR SWITCH

No. 1
Step CHECK DOOR SWITCH CIRCUIT. Measure the voltage between the keyless entry control module harness connector terminal and chassis ground. Connector & terminal (B176) No. 3 (+) Chassis ground (): CHECK DOOR SWITCH CIRCUIT. Measure the voltage between the keyless entry control module harness connector terminal and chassis ground. Connector & terminal (B176) No. 3 (+) chassis ground (): CHECK DOOR SWITCH. 1) Disconnect the door switch harness connector. 2) Check the continuity between the door switch terminal and chassis ground. Terminal Front LH No. 1 Chassis ground: Front RH No. 1 Chassis ground: Rear LH No. 1 Chassis ground: Rear RH No. 1 Chassis ground: Rear gate No. 1 No. 2: CHECK DOOR SWITCH. Check continuity between the door switch terminal and chassis ground. Terminal Front LH No. 1 Chassis ground: Front RH No. 1 Chassis ground: Rear LH No. 1 Chassis ground: Rear RH No. 1 Chassis ground: Rear gate No. 1 No. 2:
Check Is the voltage 0 V when each door and rear gate is opened?
Yes Go to step 2.
No Go to step 3.
Is the voltage more than 10 The door switch is Go to step 3. V when each door and rear OK. gate is closed?
Does continuity exist when the door switch is pushed?
Replace the door switch.
Go to step 4.
Does continuity exist when the door switch is released?
Check the harness for open circuits and shorts between the keyless entry control module and door switch.
Replace the door switch.
7. CHECK KEY WARNING SWITCH

No. 1
S909345A1008
Step CHECK FUSE. Remove and visually check fuse No. 6 (in the main fuse box). CHECK KEY WARNING SWITCH CIRCUIT. 1) Disconnect the keyless entry control module harness connector. 2) Insert the key into the ignition switch. (LOCK position) 3) Measure the voltage between the harness connector terminal and chassis ground. Connector & terminal (B176) No. 1 (+) chassis ground (): CHECK KEY WARNING SWITCH CIRCUIT. 1) Remove the key from the ignition switch. 2) Measure the voltage between the harness connector terminal and chassis ground. Connector & terminal (B176) No. 1 (+) chassis ground ():
Check Is the fuse blown? (15A)
No Go to step 2.
Go to step 4.
Is the voltage 0 V?
The key warning switch is OK.
Go to step 4.
SL-24

No. 4 Step Check Does continuity exist? CHECK KEY WARNING SWITCH. 1) Disconnect the key warning switch harness connector. 2) Insert the key into the ignition switch. (LOCK position) 3) Check the continuity between the key warning switch terminals. Terminal No. 1 No. 2: Does continuity exist? CHECK KEY WARNING SWITCH. 1) Remove the key from the ignition switch. 2) Check the continuity between the key warning switch terminals. Terminal No. 1 No. 2: Yes Go to step 5.
Security and Locks

No Replace key warning switch.
Replace key warning switch.
Check the following: Harness for open circuits or shorts between the key warning switch and fuse Harness for open circuits and shorts between the keyless entry control module and key warning switch
8. CHECK HAZARD LIGHT OPERATION

S909345A1013
No. 1
Step CHECK HAZARD LIGHT OPERATION. Make sure the hazard light blinks when hazard switch is turned ON. CHECK OUTPUT SIGNAL. 1) Remove the key from ignition switch. 2) Close all doors and rear gate. 3) Measure voltage between keyless entry control module harness connector terminal and chassis ground when LOCK or OPEN button of transmitter is pressed. Connector & terminal (B176) No. 12, No. 13 (+) Chassis ground ():
Check Does hazard light brink?
Yes Go to step 2.
No Check hazard light circuit.
Is the voltage more than 10 Check harness for Replace the keyless entry control V? open or short module. between keyless entry control module and turn signal lights.
SL-25
Security and Locks
9. CHECK ROOM LIGHT OPERATION

S909345A1010
No. 1
Step CHECK ROOM LIGHT OPERATION. Make sure the room light illuminates when the room light switch is turned ON. CHECK HARNESS BETWEEN ROOM LIGHT AND KEYLESS ENTRY CONTROL MODULE. 1) Disconnect the keyless entry control module harness connector and room light harness connector. 2) Measure the resistance between the keyless entry control module harness connector terminal and the room light harness connector terminal. Connector & terminal (B176) No. 11 (R52) No. 2:
Check Does the room light illuminate? Is the resistance less than 10 ?
Yes Go to step 2.
No Check the room light circuit.
The room light Check the haroperation circuit is ness for open cirOK. cuits or shorts between the keyless entry control module and room light.
10. CHECK IGNITION SWITCH ILLUMINATION CIRCUIT

No. 1 Step CHECK IGNITION SWITCH ILLUMINATION POWER SUPPLY. 1) Disconnect the ignition switch illumination harness connector. 2) Measure voltage between the ignition switch illumination harness connector terminal and chassis ground. Connector & terminal (B224) No. 1 (+) Chassis ground (): CHECK HARNESS BETWEEN IGNITION SWITCH ILLUMINATION AND KEYLESS ENTRY CONTROL MODULE. 1) Disconnect the keyless entry control module harness connector. 2) Measure the resistance between the keyless entry harness connector terminal and the ignition switch illumination harness connector. Connector & terminal (B176) No. 11 (B224) No. 2:
S909345A1014
No Check harness for open circuit or shorts between the ignition switch illumination and fuse.
Check the ignition Repair the harness. switch illumination. If NG, replace the ignition switch illumination.
SL-26
FRONT INNER REMOTE
Security and Locks
4. Front Inner Remote

A: REMOVAL
S909344A18
S909344
1) Remove the door trim. <Ref. to EI-26 REMOVAL, Front Door Trim.> 2) Remove the sealing cover. <Ref. to EB-13 REMOVAL, Front Sealing Cover.> 3) Remove the two rod joints. 4) Unlatch rod holder 5) Remove the front inner remote.
S5M0186
B: INSTALLATION
S909344A11
Install in the reverse order of removal. NOTE: Make sure the inner remote works properly after installation.
C: INSPECTION
S909344A10
1) Make sure the rod is not deformed. 2) Make sure the lever and rod work smoothly.
SL-27
Security and Locks
FRONT OUTER HANDLE

S909349
5. Front Outer Handle

A: REMOVAL
S909349A18
1) Remove the door trim. <Ref. to EI-26 REMOVAL, Front Door Trim.> 2) Remove the sealing cover. <Ref. to EB-13 REMOVAL, Front Sealing Cover.> 3) Remove the front inner remote. <Ref. to SL-27 REMOVAL, Front Inner Remote.> 4) Remove the two bolts. Remove the front outer handle (B).
S5M0189A
CAUTION: Do not use excessive force to remove the door panel. This will deform it.
B: INSTALLATION
S909349A11
Install in the reverse order of removal. NOTE: Make sure outer handle works properly after installation.
C: INSPECTION
S909349A10
SL-28
FRONT DOOR LATCH ASSEMBLY
Security and Locks
6. Front Door Latch Assembly

S909334
A: REMOVAL
S909334A18
1) Remove the front door trim. <Ref. to EI-26 REMOVAL, Front Door Trim.> 2) Remove the sealing cover. <Ref. to EB-13 REMOVAL, Front Sealing Cover.> 3) Remove the front inner remote. <Ref. to SL-27 REMOVAL, Front Inner Remote.> 4) Turn rod holder to disconnect joint between key lock and rod. 5) Turn rod holder to disconnect joint between outer handle and rod. 6) Turn rod holder to disconnect joint between crank and rod. 7) Remove the three screws and bolt.
S5M0189A
8) Disconnect the connector. Remove the front door latch assembly (A).
B: INSTALLATION
S909334A11
Install in the reverse order of removal. NOTE: Make sure parts work properly after installation.
C: INSPECTION
S909334A10
SL-29
Security and Locks
FRONT DOOR LOCK ACTUATOR

S909319
7. Front Door Lock Actuator

A: REMOVAL
S909319A18
1) Remove the front door latch assembly. <Ref. to SL-27 REMOVAL, Front Door Latch Assembly.> 2) Remove the bolt. Remove the front door lock actuator.
B5M0998
S909319A11

S909319A10
1) Disconnect the door lock actuator harness connector. 2) Connect the battery to the door lock actuator terminals.
B6M0135
Battery connection No. 2 (+) No. 4 () No. 4 (+) No. 2 ()
Actuator operation Unlocked Locked Locked Unlocked
If NG, replace the door lock actuator.
SL-30
REAR INNER REMOTE
Security and Locks
8. Rear Inner Remote

A: REMOVAL
S909321A18
S909321
1) Remove the rear door trim. <Ref. to EI-27 REMOVAL, Rear Door Trim.> 2) Remove the sealing cover. <Ref. to EB-16 REMOVAL, Rear Sealing Cover.> 3) Remove the two rod joints. 4) Remove the inner remote.
S5M0186
B: INSTALLATION
S909321A11
Install in the reverse order of removal. NOTE: Make sure the inner remote works properly after installation.
C: INSPECTION
S909321A10
1) Make sure the rod is not deformed. 2) Make sure the lever and rod work smoothly. 3) Make sure the child safety lock on rear doors work properly, when applicable.
SL-31
Security and Locks
REAR OUTER HANDLE

S909322
9. Rear Outer Handle

A: REMOVAL
S909322A18
1) Remove the rear door trim. <Ref. to EI-27 REMOVAL, Rear Door Trim.> 2) Remove the sealing cover. <Ref. to EB-16 REMOVAL, Rear Sealing Cover.> 3) Remove the rear inner remote. <Ref. to SL-31 REMOVAL, Rear Inner Remote.> 4) Remove the rear door latch assembly. <Ref. to SL-33 REMOVAL, Rear Door Latch Assembly.> 5) Remove the two bolts and nut. Remove the rear outer handle.
B5M1000
CAUTION: Do not use excessive force to remove the door panel. This will deform it.
B: INSTALLATION
S909322A11
Install in the reverse order of removal. NOTE: Make sure the outer handle works properly after installation.
C: INSPECTION
S909322A10
SL-32
REAR DOOR LATCH ASSEMBLY
Security and Locks
10. Rear Door Latch Assembly

S909320
A: REMOVAL
S909320A18
1) Remove the rear door trim. <Ref. to EI-27 REMOVAL, Rear Door Trim.> 2) Remove the sealing cover. <Ref. to EB-16 REMOVAL, Rear Sealing Cover.> 3) Remove the rear inner remote. <Ref. to SL-31 REMOVAL, Rear Inner Remote.> 4) Remove the three screws and bolt.
B5M1001
5) Disconnect the connector. Remove the rear door latch assembly.
B: INSTALLATION
S909320A11
C: INSPECTION
S909320A10
SL-33
Security and Locks
REAR DOOR LOCK ACTUATOR

S909323
11. Rear Door Lock Actuator

A: REMOVAL
S909323A18
1) Remove the rear door latch assembly. <Ref. to SL-33 REMOVAL, Rear Door Latch Assembly.> 2) Remove the bolt. Remove the rear door lock actuator.
B5M1002
B: INSTALLATION
S909323A11
Install in the reverse order of removal. NOTE: Make sure the lock works properly after installation.
C: INSPECTION
S909323A10
B6M0135
If NG, replace the door lock actuator.
SL-34
REAR GATE OUTER HANDLE
Security and Locks
12. Rear Gate Outer Handle

A: REMOVAL
S909626A18
S909626
1) Remove the rear gate lower trim. <Ref. to 42 REMOVAL, Rear Gate Trim.> 2) Disconnect rod (latch to outer handle) from outer handle (B). 3) Remove the four nuts used to hold outer handle (B) to the inside of rear gate and detach outer handle.
S5M0387A
B: INSTALLATION
S909626A11
Install in the reverse order of removal. NOTE: Make sure the outer handle works properly after installation.
C: INSPECTION
S909626A10
1) Inspect the rod for deformation. 2) Make sure the lever and rod move smoothly.
SL-35
Security and Locks
REAR GATE LATCH ASSEMBLY
13. Rear Gate Latch Assembly

S909316
A: REMOVAL
S909316A18
1) Remove the rear gate lower trim. <Ref. to EI-42 REMOVAL, Rear Gate Trim.> 2) Disconnect rod (latch to link) from latch (A). 3) Disconnect rod (latch to outer handle) from outer handle (B). 4) Remove bolts from latch (A).
S5M0387A
5) Disconnect rear gate switch connector from latch (A) and then detach the latch.
B: INSTALLATION
S909316A11
C: INSPECTION
S909316A10
SL-36
REAR GATE LATCH LOCK ACTUATOR
Security and Locks
14. Rear Gate Latch Lock Actuator

S909313
A: REMOVAL
S909313A18
1) Remove rear gate trim. <Ref. to EI-42 REMOVAL, Rear Gate Trim.> 2) Disconnect rod from key cylinder. 3) Loosen two bolts to remove rear gate actuator (E).
S5M0387A
B: INSTALLATION
S909313A11
Install in the reverse order of removal. NOTE: Make sure the lock works properly after installation.
C: INSPECTION
S909313A10
B6M0135
If NG, replace the rear gate latch lock actuator.
SL-37
Security and Locks
FRONT HOOD LOCK ASSEMBLY
15. Front Hood Lock Assembly

S909595
A: REMOVAL
S909595A18
1) Open the hood. 2) Remove the bolt. Remove the hood lock assembly. 3) Remove the release cable from the lock assembly.
S5M0148
B: INSTALLATION
S909595A11
Install in the reverse order of removal. CAUTION: Apply grease to parts that rub. Make sure the release cable works properly after installation.
C: ADJUSTMENT
S909595A01
Loosen the bolt. Adjust the lock assembly while moving it up and down.
B5M0752
D: INSPECTION
S909595A10
1) Check the striker for bending or abnormal wear. 2) Check the safety lever for improper movement. 3) Check other levers and the spring for rust formation and unsmooth movement.
SL-38
REMOTE OPENERS
Security and Locks

S909317A1803
16. Remote Openers

A: REMOVAL
S909317A18
S909317
2. FUEL FLAP OPENER
1. HOOD OPENER
S909317A1801
1) Remove the release cable from the hood lock. 2) Remove the bolt. Remove the opener lever.
1) Remove the rear seat. <Ref. to SE-6 REMOVAL, Rear Seat.> 2) Remove the center pillar lower trim and side sill cover on the passenger side. Remove the rear pillar lower trim. Pull back the floor mat. Remove the clip holding the cable. 3) Remove the bolt. Remove the opener pull handle.
S5M0149
S5M0291B
4) Remove the cable from the opener pull handle. 5) Remove the right rear quarter trim. <Ref. to EI-39 REMOVAL, Rear Quarter Trim.> 6) Rotate the fuel lock inside the quarter panel to left and remove.
B5M1067
B: INSTALLATION
1. HOOD OPENER
S909317A11
S909317A1101
2. FUEL FLAP OPENER
S909317A1103
C: INSPECTION
S909317A10
Make sure the fuel flap opens and closes smoothly.
SL-39
Security and Locks
IGNITION KEY LOCK

S909318
17. Ignition Key Lock

A: REPLACEMENT
S909318A20
1) Remove the battery ground cable. 2) Remove the steering column. <Ref. to DS-30 REMOVAL, Steering Column.> 3) Secure the steering column in a vise. Remove the bolt with a drill.
B5M1061
4) Remove the ignition key lock. 5) Use a new torn bolt. Tighten the torn bolt to the end of the thread.
S6M0162A
B: INSPECTION
S909318A10
1) Remove the instrument panel lower cover. 2) Remove the lower column cover. 3) Unfasten the holddown clip which secures the harness and disconnect the connector of the ignition switch from the body harness. 4) Turn the ignition key plate to each position and check the continuity between the terminals of the ignition connector.
Switch position LOCK ACC ON ST Tester connection Specified condition Continuity Continuity Continuity
No. 1 No. 2 No. 1 No. 2 No. 4 No. 1 No. 3 No. 4
If NG, replace the ignition switch.
SL-40
KEY LOCK CYLINDERS
Security and Locks
18. Key Lock Cylinders

A: REPLACEMENT
1. FRONT DOOR
S909326A20 S909326A2001
S909326
1) Remove the door trim. <Ref. to EI-26 REMOVAL, Front Door Trim.> 2) Pull back the sealing cover. 3) Remove the rod clamp. Remove the lock plate. Replace the key cylinder.
S5M0515
2. REAR GATE
S909326A2003
1) Remove the rear gate lower trim. <Ref. to EI-42 REMOVAL, Rear Gate Trim.> 2) Remove the rod clamp. Remove the lock plate. Replace the key cylinder (C).
S5M0387A
SL-41
Security and Locks
IMMOBILIZER CONTROL MODULE
19. Immobilizer Control Module

S909315
A: REMOVAL
S909315A18
NOTE: The following positions for removal and installation are for LHD models. The positions for RHD models are symmetrically opposite. 1) Disconnect GND cable from battery. 2) Remove instrument panel lower cover. <Ref. to EI-31 REMOVAL, Instrument Panel Assembly.> 3) Disconnect connector from immobilizer control module. 4) Remove immobilizer control module. DOHC Turbo and SOHC with OBD model:
H6M0712
SOHC without OBD model:
S6M0163
B: INSTALLATION
S909315A11
SL-42
IMMOBILIZER ANTENNA
Security and Locks
20. Immobilizer Antenna

A: REMOVAL
S909331A18
S909331
1) Disconnect GND cable from battery. 2) Remove instrument panel lower cover. <Ref. to EI-31 REMOVAL, Instrument Panel Assembly.> 3) Remove screws, separate upper column cover and lower column cover.
S6M0042
4) Disconnect immobilizer antenna connector (A) from immobilizer control module. 5) Remove immobilizer antenna (B). DOHC Turbo and SOHC with OBD model:
H6M0710A
SOHC without OBD model:
B6M0585B
B: INSTALLATION
S909331A11
SL-43
Security and Locks
KEYLESS ENTRY CONTROL MODULE
21. Keyless Entry Control Module

S909324
A: REMOVAL
S909324A18
1) Disconnect battery ground cable. 2) Remove instrument panel lower cover. <Ref. to EI-31 REMOVAL, Instrument Panel Assembly.> 3) Remove nut, then remove keyless entry control module (A) while disconnecting connector.
S6M0481A
4) Disconnect keyless entry control module.
B: INSTALLATION
S909324A11
SL-44
KEYLESS TRANSMITTER
Security and Locks
22. Keyless Transmitter

A: REMOVAL
S909325A18
S909325
If NG, replace the battery. (Use CR1620 or equivalent.)
1. TRANSMITTER BATTERY
Remove battery from transmitter.
D: REPLACEMENT
S909325A1801
S909325A20
1. TRANSMITTER REGISTRATION
S909325A2001
NOTE: To prevent static electricity damage to transmitter printed circuit board, touch steel area of building with hand to discharge static electricity carried on body or clothes before disassembling transmitter.
NOTE: A maximum of 3 transmitters can be registered for each individual vehicle. 1) Remove the side sill cover at the driver s side, then connect the registration connectors at the front pillar lower section. 2) Unlock the door lock. 3) Press any button of the transmitter twice to be registered. 4) The door lock will automatically lock and unlock in sequence. This indicates the completion of transmitter registration for the first transmitter. 5) If registration of a second transmitter is now to be carried out, press any button of that transmitter twice. 6) The door lock will automatically lock and unlock in sequence. This indicates the completion of transmitter registration for the second transmitter. 7) If registration of third transmitter is now to be carried out, repeat procedure of step 5) and 6). 8) Disconnect the registration connectors after the completion of all registration operations. After confirming the operation of the door lock using the newly registered transmitter(s), reinstall the side sill cover at the driver s side.
B5M1182
B: INSTALLATION
S909325A11
S909325A1101
C: INSPECTION
S909325A10
S909325A1001
1) Measure voltage between battery (+) terminal and () terminal. NOTE: Battery discharge occurs during measurement. Complete measurement within 5 seconds. During battery voltage measurement, voltage falls more than 1.8 volts in 3 seconds period.
S6M0291A
Tester connection (+) () Battery (+) termi- Battery () terminal nal
Voltage (V) More than 2
SL-45
Security and Locks
KEYLESS TRANSMITTER
MEMO:
SL-46
SUNROOF/T-TOP/CONVERTIBLE TOP (SUNROOF)
SR
1. 2. 3. 4. 5. 6. Page General Description.....................................................................................2 Sunroof Control System ..............................................................................5 Sunroof Lid ..................................................................................................7 Sunroof Assembly .......................................................................................8 Sunroof Motor............................................................................................10 Sunroof Switch ..........................................................................................12
Sunroof/T-top/Convertible Top (Sunroof)
GENERAL DESCRIPTION
S910001
A: COMPONENT
S910001A05
S5M0290A
SR-2
GENERAL DESCRIPTION
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) Glass lid Rear drain ASSY Frame ASSY Motor ASSY Drive unit Drain tube Harness Sunshade Garnish Frame bracket Cover Deflector Shim
SR-3
GENERAL DESCRIPTION
B: CAUTION
S910001A03
Before disassembling or reassembling parts, always disconnect battery ground cable. When replacing radio, control module, and other parts provided with memory functions, record memory contents before disconnecting the battery ground cable. Otherwise, the memory will be erased. Reassemble in reverse order of disassembly, unless otherwise indicated. Adjust parts to the given specifications. Connect connectors and hoses securely during reassembly. After reassembly, make sure functional parts operate smoothly.
C: PREPARATION TOOL
1. GENERAL TOOLS
S910001A1701
S910001A17
SR-4
SUNROOF CONTROL SYSTEM
2. Sunroof Control System

A: SCHEMATIC
1. SUNROOF
S910328A21 S910328A2101
S910328
SG75-20
SR-5
SUNROOF CONTROL SYSTEM
B: INSPECTION
Water leaks.
S910328A10
Symptom (1) (2) (3) (1) (2) (1) (2) (3) (4) (1) (2) (3) (4) (5) (6) (1) (2) (3) (4) (5) (6) (7) Check Check Check Check Check Check Check Check Check Check Check Check Check Check Check Check Check Check Check Check Check Check
Booming noise Abnormal motor noise
Failure of sunroof (Motor operates properly.)
Motor does not rotate or rotates improperly.
Checking order roof panel and sunroof lid for improper or poor sealing. drain tube for clogging. sunroof frame seal and body for improper fit. sunroof lid and roof panel for improper clearance. sunshade and roof trim for improper clearance. motor for looseness. gears and bearings for wear. cables for wear. cable pipe for deformities. guide rail for foreign particles. guide rail for improper installation. parts for mutual interference. cable slider for improper clinching. cable for improper installation. clutch adjustment nut for improper tightness. fuse for blow-out. switch for improper function. motor for incorrect terminal voltage. relay for improper operation. poor grounding system. harness for open or short and terminals for poor connections. limit switch for improper operation.
SR-6
SUNROOF LID

S910536A01
3. Sunroof Lid
A: REMOVAL
S910536
C: ADJUSTMENT
S910536A18
1) Completely close glass lid and open sunshade. 2) Detach the four covers (A) and then remove eight nuts.
1. ALIGNMENT OF HEIGHT BETWEEN SUNROOF LID AND ROOF PANEL S910536A0101

Loosen sunroof lid nuts and then adjust height by adding (max: four pieces) or extracting (max: two pieces) shims (A) (standard: two pieces) between sunroof lid (B) and roof panel (C). Difference in height between sunroof lid and roof panel 2.01.0 mm (0.0790.039 in)
S5M0292A
3) Carefully remove glass lid.
B: INSTALLATION
S910536A11
S5M0294C
SR-7
SUNROOF ASSEMBLY C: DISASSEMBLY

S910329A06
4. Sunroof Assembly
A: REMOVAL
S910329A18
S910329
1) Remove roof trim. <Ref. to EI-41, REMOVAL, Roof Trim.> 2) Remove sunroof lid. <Ref. to SR-7, REMOVAL, Sunroof Lid.> 3) Disconnect the four drain tubes (A) from sunroof frame. 4) Disconnect sunroof harness connector. 5) Remove bolts and nuts and then detach sunroof frame.
1) Remove sunroof frame. 2) Remove rail stoppers (A).
S5M0470A
3) Pull out the sunshade (B) from sunroof frame.
S5M0293A
B: INSTALLATION
S910329A11
Install in the reverse order of removal. CAUTION: Be careful not to snag harness. NOTE: Make sure to connect harness connector. When installing drain tube, insert it securely into drain pipe. Length A: 15 mm (0.59 in) or more
S5M0471A
D: ASSEMBLY
S910329A02
G5M0205
SR-8
SUNROOF ASSEMBLY E: INSPECTION

S910329A10
1. CHECK FOR MOVEMENT OF SUNSHADE S910329A1001

1) Place a cloth on sunshade, and attach a spring scale to sunshade edge using a cloth.
S5M0295
2) Pull spring scale to measure force required to move the sunshade. Force required to move sunshade: Less than 24.59.8 N (2.51.0 kgf, 5.52.2 lb) NOTE: Considerable effort is required to start sunshade moving, so take scale reading while sunroof panel is moving smoothly. 3) If force required exceeds specifications, check the sunroof glass lid, sunshade and deflector, and guide rail assembly for improper installation.
SR-9
SUNROOF MOTOR
5. Sunroof Motor
A: REMOVAL
S910537A18
S910537
CAUTION: Fully open sunroof when removing sunroof motor. When removing clip, use great care to not damage the roof trim. 1) Completely open the sunroof. 2) Remove roof trim. <Ref. to EI-41, REMOVAL, Roof Trim.> 3) Disconnect harness connector (A) and remove sunroof motor mounting screw (B) and nut (C).
S5M0472A
B: INSTALLATION
S910537A11
CAUTION: Never rotate the sunroof motor while removed. Be careful not to move the sunroof cable when installing sunroof motor. 1) Install sunroof motor. 2) Connect sunroof motor harness connector and then connect battery ground cable. 3) Operate the sunroof switch, and check the sunroof stop position. 4) Move sunroof to completely closed position.
SR-10
SUNROOF MOTOR
5) Check sunroof operation with the following procedure.
(1) (2) (3) (4) (5) Checking order Completely close sunroof. Open sunroof until it is almost completely open. Completely open sunroof. Close sunroof 500 mm (19.69 in) from completely open position. Completely close sunroof.
Switch position Closed Open Open Closed Closed
6) Install trim in the reverse order of removal.
SR-11
SUNROOF SWITCH
6. Sunroof Switch
A: REMOVAL
S910538A18
S910538
1) Disconnect ground cable from battery. 2) Remove sunroof switch panel (A).
S5M0458A
3) Disconnect harness connectors and remove sunroof switch.
S910538A11

S910538A10
B5M1058

Switch position Open Close Tester connection 34 13 Specified condition Continuity Continuity
SR-12
EXTERIOR/INTERIOR TRIM
EI
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. Page General Description.....................................................................................2 Front Grille.................................................................................................10 Front Under Cover.....................................................................................11 Front Bumper ............................................................................................12 Rear Bumper .............................................................................................19 Mud Guard ................................................................................................21 Protector ....................................................................................................22 Cowl Panel ................................................................................................25 Front Door Trim .........................................................................................26 Rear Door Trim..........................................................................................27 Glove Box..................................................................................................28 Roof Rail....................................................................................................29 Console Box ..............................................................................................30 Instrument Panel Assembly.......................................................................31 Upper Inner Trim .......................................................................................37 Lower Inner Trim .......................................................................................38 Rear Quarter Trim .....................................................................................39 Sun Visor...................................................................................................40 Roof Trim...................................................................................................41 Rear Gate Trim..........................................................................................42 Floor Mat ...................................................................................................43 Luggage Floor Mat ....................................................................................44
Exterior/Interior Trim
GENERAL DESCRIPTION
S911001
A: COMPONENT
1. FRONT BUMPER
S911001A05 S911001A0501
S5M0500A
(1) (2) (3) (4)
Bumper face Spacer E/A foam Back beam
(5) Beam upper (6) Plate (7) Bracket
Tightening torque: Nm (kgf-m, ft-lb) T1: 33 (3.4, 25) T2: 70 (7.1, 51)
EI-2
GENERAL DESCRIPTION
2. REAR BUMPER
S911001A0511
S5M0392A
(1) (2) (3) (4)
Bumper beam Cushion Lower center bracket Rear bumper plate
(5) (6) (7) (8)
Lower bracket Side upper bracket Bumper face Bumper side plate
EI-3
GENERAL DESCRIPTION
S911001A0504
3. SIDE PROTECTOR
S5M0393A
(1) Side protector (Front fender) (2) Side protector (Front door)
(3) Side protector (Rear door) (4) Side protector (Rear quarter)
(5) Side protector (Side sill)
EI-4
GENERAL DESCRIPTION
4. DOOR TRIM
S911001A0505
S5M0448A
(1) (2) (3) (4)
Gusset cover Weatherstrip Trim panel Pull handle
(5) (6) (7) (8)
Handle Pocket Speaker grille Upper trim
(9) Side trim (10) Lower trim
EI-5
GENERAL DESCRIPTION
S911001A0512
5. INNER TRIM
S5M0406A
(1) (2) (3) (4) (5)
Front pillar upper trim Center pillar upper trim Rear pillar upper trim Cover Pocket
(6) (7) (8) (9) (10)
Rear quarter lower trim Rear skirt trim Front pillar lower trim Center pillar cover Side sill rear upper cover
(11) (12) (13) (14)
Center pillar lower trim Side sill rear lower cover Side sill front upper cover Side sill front lower cover
EI-6
GENERAL DESCRIPTION
6. INSTRUMENT PANEL
S911001A0508
S5M0377A
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)
Pad & frame Grille side (D) Front def. grille Grille side (P) Grille vent (P) Glove box panel Glove box lid Knob Instrument panel center console BRKT (Radio) Center console cover
(12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22)
Pocket Panel center Center pocket lid Grille center Cup holder Side pocket Lower cover ASSY Meter visor Grille vent (D) Console cover Console lid
(23) (24) (25) (26) (27)
Rear cup holder Console box Console pocket Rear console BRKT Front cover
EI-7
GENERAL DESCRIPTION
S911001A0510
7. INNER ACCESSORIES
S5M0449A
(1) Hook (2) Sun visor
(3) Assist rail bracket (4) Assist grip (retractable)
(5) Assist grip (fixed)
EI-8
GENERAL DESCRIPTION B: PREPARATION TOOL

TOOL NAME Clip remover Adhesive remover Primer Infrared lamp Tow-sided tape Used Used Used Used Used for for for for for
S911001A17
REMARKS removal of trim. removal of side protector. installation of side protector. disassembly/assembly of side protector. installation of side protector.
EI-9
FRONT GRILLE
S911379
2. Front Grille
A: REMOVAL
S911379A18
1) Open hood. 2) Remove the four upper clips from the body panel. Push the part shown in the figure by using a screwdriver while lightly pulling the front grille.
S5M0401A
B: INSTALLATION
S911379A11
1) Attach all clips to front grille. 2) Align them with clip holes in body and push them into place.
EI-10
FRONT UNDER COVER
3. Front Under Cover

A: REMOVAL
S911372A18
S911372
1) Lift-up the vehicle. 2) Loosen bolts and clips to remove under cover.
S5M0402
B: INSTALLATION
S911372A11
EI-11
FRONT BUMPER
S911371
4. Front Bumper
A: REMOVAL
S911371A18
CAUTION: Handle bumper carefully to avoid damage to bumper face. Do not damage body during removal or installation of bumper. To avoid damage to bumper, lay removed bumper on sheet spread on the floor. Do not lay it directly on the floor. 1) Disconnect the ground cable from the battery. 2) Remove front fog light. <Ref. to LI-48, REMOVAL, Front Fog Light Assembly.> 3) Remove the front grille. <Ref. to EI-10, REMOVAL, Front Grille.> 4) Remove headlight washer nozzle. (Headlight washer equipped vehicle) <Ref. to WW-24, REMOVAL, Headlight Washer.> 5) Remove the extension of both sides.
7) Remove under cover. <Ref. to EI-11, REMOVAL, Front Under Cover.> 8) Remove the seven clips from under side of bumper.
S5M0153
9) Turn over the front mud guard of the front portion and then remove bolt.
S5M0154
S5M0152A
10) Remove bumper face and E/A foam. 11) Remove the four bolts and then detach the back beam.
6) Remove the seven clips and then detach plate (A).
S5M0398
S5M0397A
EI-12
FRONT BUMPER
12) Remove the four bolts and then detach the beam upper.
S5M0156
B: INSTALLATION
S911371A11
Install in the reverse order of removal. CAUTION: Handle bumper carefully to avoid damage to bumper face. Do not damage body during removal or installation of bumper.
EI-13
FRONT BUMPER
C: REPAIR
Process No.
S911371A19
1. COATING METHOD FOR PP BUMPER

Process name
S911371A1901
Job contents
Bumper mounting
Set bumper on paint worktable if required. Use paint worktable conforming to inner shape of bumper when possible.
G5M0164
2 3 4 5
Masking Degreasing, cleaning Primer paint Drying
Top coat paint (I)
Drying
Top coat paint (II)
9 10 11
Drying Inspection Masking removal
Mask specified part (black base) with masking tape. Use masking tape for PP (example, Nichiban No. 533, etc.). Clean all parts to be painted with white gasoline, normal alcohol, etc. to remove dirt, oil, fat, etc. Apply primer one to all parts to be painted, using air gun. Use primer (clear). Dry at normal temperature [10 to 15 min. at 20C (68F)]. In half-dried condition, PP primer paint is dissolved by solvent, e.g. thinner, etc. Therefore, if dust or dirt must be removed, use ordinary alcohol, etc. Solid color Metallic color Use section (block) paint for top coat. Use section (block) paint for top coat. Paint in use (for each color): Paint in use (for each color): Metallic paint Solid paint Hardener PB Hardener PB Thinner T-306 Thinner T-301 Mixing ratio: Mixing ratio: Main agent vs. hardener = 10:1 Main agent vs. hardener = 4:1 Viscosity: 10 13 sec/20C (68F) Viscosity: 10 13 sec/20C (68F) Film thickness: 15 20 Film thickness: 35 45 Spraying pressure: 245 343 kPa Spraying pressure: 245 343 kPa (2.5 3.5 kg/cm2, 36 50 psi) (2.5 3.5 kg/cm2, 36 50 psi) Dry at normal temperature [10 min. or more at Not required. 20C (68F)]. In half-dried condition, avoid dust, dirt. Apply a clear coat to parts with top coat paint (I), three times, at 5 7 minutes intervals. Paint in use: Metallic paint Hardener PB Thinner T-301 Not required. Mixing ratio: Clear vs. hardener = 6:1 Viscosity: 14 16 sec/20C (68F) Film thickness: 25 30 Spraying pressure: 245 343 kPa (2.5 3.5 kg/cm2, 36 50 psi) 60C (140F), 60 min. or 80C (176F), 30 min. If higher than 80C (176F), PP may be deformed. Keep maximum temperature of 80C (176F). Paint check. Remove masking in process No. 2.
EI-14
FRONT BUMPER
2. REPAIR INSTRUCTIONS FOR COLORED PP BUMPER
S911371A1902
NOTE: All PP bumpers are provided with a grained surface, and if the surface is damaged, it cannot normally be restored to its former condition. Damage limited to shallow scratches that cause only a change in the lustre of the base material or coating, can be almost fully restored. Before repairing a damaged area, explain this point to the customer and get an understanding about the matter. Repair methods are outlined below, based on a classification of the extent of damage.
Minor damage causing only a change in the lustre of the bumper due to a light touch
Almost restorable.
Process Process name No. 1 Cleaning 2 Sanding Job contents Clean the area to be repaired using water. Grind the repairing area with #500 sand paper Resin section Repeatedly apply wax to the affected area using a soft cloth (such as flannel). Recommended wax: NITTO KASEI Soft 99 TIRE WAX BLACK, or equivalent. Polish the waxed area with a clean cloth after 5 to 10 minutes.
in a feathering motion. Coated section Perform either the same operation as for the resin section or process No. 18 and subsequent operations in the (3) section, depending on the degree and nature of damage.
Finish
Deep damage caused by scratching fences, etc.

A dent cannot be repaired but a whitened or swelled part can be removed.
Process Process name No. 1 Cleaning Removal of dam2 aged area 3 Sanding 4 Finish Job contents Clean damaged area with water. Cut off protruding area, if any, due to collision, using a putty knife. Grind the affected area with #100 to #500 sand paper. Resin section Coated section Perform Process No. 12 and subsequent Same as Process No. 3 in the (1) section. operations in the (3) section.
EI-15
FRONT BUMPER
Deep damage such as a break or hole that requires filling

Much of the peripheral grained surface must be sacrificed for repair, and the degree of restoration is not really worth the expense. (The surface, however, will become almost flush with adjacent areas.) Recommended repair kit: PP Part Repair Kit (NRM)
Process Process name No. 1 Bumper removal 2 Part removal Job contents Remove bumper as required. Remove parts built into bumper as required.
Bumper placement
Place bumper on a paint worktable as required. It is recommended that contour of worktable accommodate internal shape of bumper.
G5M0164
Remove dust, oil, etc. from areas to be repaired and surrounding areas, using a suitable solSurface preparation vent (NRM No. 900 Precleno, white gasoline, or alcohol).
Cutting
If nature of damage are cracks or holes, cut a guide slit of 20 to 30 mm (0.79 to 1.18 in) in length along the crack or hole up to the bumper s base surface. Then, bevel or veeout the affected area using a knife or grinder.
G5M0165
6 7
Sanding (I) Cleaning
Grind beveled surface with sand paper (#40 to #60) to smooth finish. Clean the sanded surface with the same solvent as used in Process No. 4. Grind the side just opposite the beveled area with sand paper (#40 to #60) and clean using a solvent. Temporarily spot-weld the side, using a PP welding rod and heater gun.
Temporary welding
G5M0166
NOTE: Do not melt welding rod until it flows out. This results in reduced strength. Leave the welded spot unattended until it cools completely.
EI-16
FRONT BUMPER
Process No. Process name Job contents
Using a heater gun and PP welding rod, weld the beveled spot while melting the rod and damaged area.
Welding
G5M0167
NOTE: Melt the sections indicated by hatched area. Do not melt welding rod until it flows out, in order to provide strength. Always keep the heater gun 1 to 2 cm (0.4 to 0.8 in) away from the welding spot. Leave the welded spot unattended until it cools completely. Remove excess part of weld with a putty knife. If a drill or disc wheel is used instead of the knife, operate it at a rate lower than 1,500 rpm and grind the excess part little by little. A higher rpm will cause the PP substrate to melt from the heat.
10
Sanding (II)
G5M0168
11 12
Masking Cleaning/ degreasing
Sand the welded spot smooth with #240 sand paper. Mask the black substrate section using masking tape. Recommended masking tape: Nichiban No. 533 or equivalent Completely clean the entire coated area, using solvent similar to that used in Process No. 4. Apply a coat of primer to the repaired surface and its surrounding areas. Mask these areas, if necessary. Recommended primer: Mp/ 364 PP Primer NOTE: Be sure to apply one coat of primer at a spraying pressure of 245 to 343 kPa (2.5 to 3.5 kg/cm2, 36 to 50 psi) with a spray gun. Leave the repaired area unattended at 20C (68F) for 10 to 15 minutes until primer is halfdry. NOTE: If dirt or dust comes in contact with the coated area, wipe it off with a cloth dampended with alcohol. (Do not use thinner since the coated area tends to melt.) Apply a coat of primer surfacer to the repaired area two or three times at an interval of 3 to 5 minutes. Recommended surfacer: UPS 300 Flex Primer No. 303 UPS 300 Exclusive hardener NPS 725 Exclusive Reducer (thinner) Mixing ratio: 2 : 1 (UPS 300: No. 303) Viscosity: 12 14 sec/20C (68F) Coated film thickness: 40 50 Allow the coated surface to dry for 60 minutes at 20C (68F) [or 30 minutes at 60C (140F)]. Sand the coated surface and its surrounding areas using #400 sand paper and water. Same as Process No. 12.
13
Primer coating
14
Leave unattended.
15
Primer surfacer coating
16 17 18
Drying Sanding (III) Cleaning/ degreasing
EI-17
Process No. Process name
FRONT BUMPER
Job contents Solid color Use a block coating method. Recommended paint: Suncryl (SC) No. 307 Flex Hardener SC Reducer (thinner) Mixing ratio: 3 : 1 Suncryl (SC) vs. No. 307 Flex Hardener Viscosity: 11 13 sec/20C (68F) Coated film thickness: 40 50 Spraying thickness: 245 343 kPa (2.5 3.5 kg/cm2, 36 50 psi)
19
20
21
22 23 24 25 26
Metallic color Use a block coating method. Recommended paint: Suncryl (SC) No. 307 Flex Hardener SC Reducer (thinner) Top coat (I) Mixing ratio: 3 : 1 Suncryl (SC) vs. No. 307 Flex Hardener Viscosity: 11 13 sec/20C (68F) Coated film thickness: 20 30 Spraying thickness: 245 343 kPa (2.5 3.5 kg/cm2, 36 50 psi) Leave unattended at 20C (68F) for at least 10 minutes until the topcoated area is half-dry. Leave unattended. Not required. NOTE: Be careful to keep dust or dirt from coming in contact with the affected area. Apply a clear coat three times at an interval of 3 to 5 minutes. Recommended paint: SC710 Overlay Clear No. 307 Flex Hardener SC Reducer (thinner) Top coat (II) Not required. Mixing ratio: 3 : 1 Suncryl (SC) vs. No. 307 Flex Hardener Viscosity: 10 13 sec/20C (68F) Coated film thickness: 20 30 Spraying pressure: 245 343 kPa (2.5 3.5 kg/cm2, 36 50 psi) Allow the coated surface to dry at 20C (68F) for two hours or 60C (140F) for 30 minutes. Drying NOTE: Do not allow the temperature to exceed 80C (176F) since this will deform the PP substrate. Inspection Carefully check the condition of the repaired area. Masking removal Remove masking tape applied in Process No. 11 and 13. Parts installation Install parts on bumper in reverse order of removal. Bumper installation Install bumper.
EI-18
REAR BUMPER
5. Rear Bumper
A: REMOVAL
S911370A18
S911370
8) Remove rear bumper beam.
CAUTION: Handle bumper carefully to avoid damage to bumper face. Do not damage body during removal or installation of bumper. To avoid damage to bumper, lay removed bumper on sheet spread on the floor. Do not lay it directly on the floor. 1) Disconnect the ground cable from the battery. 2) Open rear gate. 3) Remove the five screws and the clip from the rear bumper.
S5M0399
4) Disconnect license plate light and rear fog light (if equipped) connectors. 5) Remove bolts and clips from under side of bumper.
S5M0157
6) Remove bumper face. 7) Remove bolts from bumper stay.
G5M0161
EI-19
REAR BUMPER
S911370A11
B: INSTALLATION
CAUTION: Handle bumper carefully to avoid damage to bumper face. Do not damage body during removal or installation of bumper. Install in the reverse order of removal.
C: REPAIR
S911370A19
Refer to front bumper repair. <Ref. to EI-12 REMOVAL, Front Bumper.>
EI-20
MUD GUARD
6. Mud Guard
A: REMOVAL
S911374
S911374A18
1) Jack-up the vehicle. 2) Remove screws and clips. Move mud guard toward the center of the body and remove mud guard.
S5M0166
B: INSTALLATION
S911374A11
Insert hook into body, and tighten it with screw and clip.
EI-21
PROTECTOR
S911380
7. Protector
A: REMOVAL
S911380A18
S5M0400A
(1) Side protector (Door) (2) Side protector (Side sill) (3) Side protector (Front fender)
(4) Side protector (Rear quarter) (5) Screw (6) Clip
(7) Clip
EI-22
PROTECTOR
1) Attach masking tape (A) on the upper painted area of the protector.
4) Attach plastic wrap (A) to adhesive remover coated areas and heat to 40 to 60C (104 to 140F) for 5 to 10 minutes using an infrared lamp (B). CAUTION: Do not overheat until plastic wrap is somewhat white.
S5M0501A
2) Release clip engagement using clip remover, and remove the protector while peeling off twosided tape.
S5M0503A
5) Using a plastic spatula, remove traces of twosided tape from body panel. 6) Remove masking tape and clean traces of twosided tape using a cloth dampened with white gasoline. 7) Similarly, clean traces of adhesive from twosided tape on side protector.
S5M0502
CAUTION: Make sure side protector is clean and free of adhesive remover. Clean if necessary.
NOTE: To increase adhesive remover strength, leave two-sided tape on body and side protector. If two-sided tape is too thick, use a putty knife to cut it thin so that adhesive remover is ready for use. If two-sided tape is hard to remove, heat to approximately 40C (104F). 3) Apply an even coat of adhesive remover to the two-sided tape. Recommended adhesive remover: SUMITOMO 3M4000 or equivalent CAUTION: Do not apply adhesive remover to lacquer base coated body panels.
B: INSTALLATION
S911380A11
1) Apply primer to original side protector (if used), and attach two-sided tape (A) to upper of side protectors as shown. Two-sided tape: Thickness; 1.2 mm (0.047 in) Width; 5 mm (0.20 in) Recommended primer: SUMITOMO 3MK-500 or equivalent Recommended two-sided tape: SUMITOMO 3M5305 or equivalent
S5M0504A
2) Using an infrared lamp, heat body panel to 40 to 60C (104 to 140F) and rear surface of side protector to 20 to 30C (68 to 86F).
EI-23
PROTECTOR
3) Remove tack paper from two-sided paper. While aligning clips with holes in body panel, attach two-sided tape to side protector and body panel with a force of more than 49 N (5 kg, 11 lb) with roller. Do not allow air to enter mating surface of the two. CAUTION: To maintain adhesive power, do not wash the vehicle for 24 hours after tape application. Push clip in securely using hands. (To prevent deformation, do not use excessive force.)
EI-24
COWL PANEL
8. Cowl Panel
A: REMOVAL
S911387
S911387A18
1) Remove cowl panel side.
S5M0167
2) Open hood. 3) Remove wiper arm. <Ref. to WW-14 REMOVAL, Wiper Arm.> 4) Lift cowl panel (RH), and then lift cowl panel (LH).
S5M0168A
B: INSTALLATION
S911387A11
EI-25
FRONT DOOR TRIM

S911356
9. Front Door Trim

A: REMOVAL
S911356A18
CAUTION: Do not apply excessive force to clip. Otherwise the clip may be broken. 1) Remove gusset cover (A), power window switch assembly (B) and pocket (C). 2) Remove screws, and then detach trim panel.
S5M0450A
B: INSTALLATION
S911356A11
EI-26
REAR DOOR TRIM
10. Rear Door Trim

A: REMOVAL
S911354A18
S911354
CAUTION: Do not apply excessive force to clip. Otherwise the clip may be broken. 1) Remove handle (A), pocket (B) and clips (C). 2) Remove screws, and then detach trim panel.
S5M0451A
B: INSTALLATION
S911354A11
EI-27
GLOVE BOX
S911558
11. Glove Box

A: REMOVAL
S911558A18
Loosen screws to remove glove box.
S5M0047A
B: INSTALLATION
S911558A11
EI-28
ROOF RAIL
12. Roof Rail

A: REMOVAL
S911383
S911383A18
1) Remove roof trim. <Ref. to EI-41 REMOVAL, Roof Trim.> 2) Remove seven mounting nuts and then detach roof rail carefully.
S5M0171A
B: INSTALLATION
S911383A11
Install in the reverse order of removal. CAUTION: Be careful not to scratch body panels with roof rail stud bolts when removing and installing them.
EI-29
CONSOLE BOX
S911382
13. Console Box

A: REMOVAL
S911382A18
B: INSTALLATION
S911382A11
1) Remove shift knob and drive select lever (MT model). 2) Remove console cover (A) and front cover (B).
S5M0297A
3) Remove console box.
S5M0043
EI-30
INSTRUMENT PANEL ASSEMBLY
14. Instrument Panel Assembly

S911381
5) Remove lower cover and then disconnect connector.
A: REMOVAL
S911381A18
Airbag system wiring harness is routed near combination meter. CAUTION: All airbag system wiring harness and connectors are colored yellow. Do not use electrical test equipment on these circuits. Be careful not to damage airbag system wiring harness when servicing the instrument panel. NOTE: The following positions for removal and installation are for LHD models. The positions for RHD models are symmetrically opposite. 1) Disconnect GND cable from battery. 2) Remove shift knob and drive select lever. (MT model) 3) Remove console cover (A) and front cover (B).
S5M0044A
6) Disconnect data link connector (A) from lower cover.
S5M0045A
7) Remove knee panel.
S5M0297A
4) Remove console box.
S5M0046
8) Remove glove box.
S5M0043
S5M0047A
EI-31

13) Disconnect temperature control cable and mode control cable from heater unit then disconnect recirc control cable from intake unit. NOTE: Do not move switch and link when installing.
9) Remove center panel and disconnect connector. 10) Remove audio.
S5M0048A
11) Remove two bolts and lower steering column.
G5M0278
S5M0049A
12) Set temperature control switch to FULL HOT, mode selector switch to DEF position and recirc switch to FRESH position.
EI-32

14) Disconnect harness connectors and then remove the installing bolts and nuts. CAUTION: Be sure to hold socket section and not harness when disconnecting. NOTE: Put matching mark, if necessary, for easy reassembly.
S5M0378A
EI-33
S5M0379A
EI-34

15) Remove front defroster grille and two bolts.
S5M0051
16) Remove instrument panel carefully from the body. CAUTION: Do not pull the harness when disconnecting the connector. Take care not to scratch the instrument panel and related parts. When storing removed instrument panel with passenger airbag module, place it standing up on the floor.
G5M0602
EI-35

S911381A11
B: INSTALLATION
Install in the reverse order of removal. CAUTION: Be careful not to snag the harness. Make sure to connect harness connector. Take care not to scratch the instrument panel and related parts. NOTE: When setting the instrument panel into position, push the two pins into grommet on the body panel.
S5M0052A
EI-36
UPPER INNER TRIM
15. Upper Inner Trim

A: REMOVAL
S911384A18
S911384
1) Remove front mole (A). 2) Remove front pillar upper trim (B). 3) Remove center pillar cover (C). 4) Detach front seat belt shoulder anchor. 5) Loosen screws to remove center pillar upper trim (D).
S5M0452A
B: INSTALLATION
S911384A11
Install in the reverse order of removal. CAUTION: Be sure to securely hook pawls of inner trim panel to body flange. NOTE: When installing center pillar upper trim and front pillar upper trim, be sure to set front mole as shown in figure.
B5M0673A
EI-37
LOWER INNER TRIM

S911369
16. Lower Inner Trim

A: REMOVAL
S911369A18
1) Remove front pillar lower trim (A). 2) Remove side sill front upper cover (B). 3) Remove rear seat cushion <Ref. to SE-6 REMOVAL, Rear Seat.>, then remove side sill rear upper cover (C). 4) Remove center pillar cover (D). 5) Remove front seat belt shoulder anchor. 6) Loosen screws to remove center pillar upper trim (E). 7) Remove center pillar lower trim (F).
S5M0453A
B: INSTALLATION
S911369A11
Install in the reverse order of removal. CAUTION: Be sure to securely hook pawls of inner trim panel to body flange.
EI-38
REAR QUARTER TRIM
S911358A11
17. Rear Quarter Trim

A: REMOVAL
S911358A18
S911358
B: INSTALLATION
Install in the reverse order of removal. CAUTION: Be sure to securely hook pawls of inner trim panel to body flange. NOTE: When installing rear quarter upper trim, be sure to set rear mole as shown in the figure.
1) Remove rear rail trim (A). 2) Remove strut cover (B). 3) Remove rear seat belt anchor. 4) Remove caps and screws, and then remove rear quarter upper trim (C). 5) Remove rear skirt trim (D). 6) Remove luggage floor mat. <Ref. to EI-44, REMOVAL, Luggage Floor Mat.> 7) Remove rear quarter lower trim (E).
B5M0673A
S5M0412B
EI-39
SUN VISOR
S911359
18. Sun Visor

A: REMOVAL
S911359A18
Remove mounting screws then detach sun visor (A) and hook (B).
S5M0454A
B: INSTALLATION
S911359A11
EI-40
ROOF TRIM
19. Roof Trim

A: REMOVAL
S911360
S911360A18
8) Remove cover (B) while detaching snap lock carefully. Put the rear seat belt tongue (A) out to the other side of the trim through the hole.
CAUTION: When removing clip, use great care not to damage the roof trim. 1) Disconnect ground cable from battery. 2) Remove head console.
B5M0675A
9) Remove clips and then remove roof trim.
S5M0243
3) Remove sun visor and hook of both sides. <Ref. to EI-40, REMOVAL, Sun Visor.> 4) Remove assist grips (A).
S5M0413
B: INSTALLATION
S911360A11
B5M1025A
5) Remove upper inner trim. <Ref. to EI-37, REMOVAL, Upper Inner Trim.> 6) Remove rear quarter trim. <Ref. to EI-39, REMOVAL, Rear quarter Trim.> 7) Detach sunroof garnish (A). (Sunroof equipped model)
S5M0305B
EI-41
REAR GATE TRIM

S911357
20. Rear Gate Trim

A: REMOVAL
S911357A18
CAUTION: Be careful not to damage clips or their holes. Remove rear gate inner handle (A) from rear gate and then detach trim panel.
S5M0386A
B: INSTALLATION
S911357A11
EI-42
FLOOR MAT
21. Floor Mat

A: REMOVAL
S911362
S911362A18
1) Remove front seats. <Ref. to SE-5 REMOVAL, Front Seat.> 2) Remove rear seat cushion. <Ref. to SE-6 REMOVAL, Rear Seat.> 3) Remove console box. <Ref. to EI-30 Console Box.> 4) Remove front pillar lower trim, side sill rear upper cover and center pillar lower trim. <Ref. to EI-38 REMOVAL, Lower Inner Trim.> 5) Remove clips from floor mat. NOTE: When pulling out edge, do not pull mat alone; pull mat together with edge. Ply off two steel clips on side sill front cover and one on side sill rear cover using screwdriver. 6) Remove mat hook. 7) Remove mat from toe board area. 8) Remove mat from rear heater duct. 9) Roll mat, and then take it out of opened rear door.
S5M0240
B: INSTALLATION
S911362A11
Install in the reverse order of removal. NOTE: Secure mat firmly with hook and Velcro tape. Insert mat edge firmly into the groove of side sill cover.
EI-43
LUGGAGE FLOOR MAT

S911353
22. Luggage Floor Mat

A: REMOVAL
S911353A18
Remove clips, then detach rear floor mats and boxes.
S5M0241
B: INSTALLATION
S911353A11
EI-44
EXTERIOR BODY PANELS
EB
1. 2. 3. 4. 5. 6. 7. 8. Page General Description.....................................................................................2 Front Hood ..................................................................................................9 Fender Panel.............................................................................................10 Front Door Panel .......................................................................................11 Front Sealing Cover ..................................................................................13 Rear Door Panel .......................................................................................14 Rear Sealing Cover...................................................................................16 Rear Gate Panel .......................................................................................17
Exterior Body Panels
GENERAL DESCRIPTION
S913001
A: SPECIFICATIONS
S913001E49
S5M0380A
EB-2

1. FRONT HOOD
S913001A05
S913001A0501
S5M0442A
(1) (2) (3) (4)
Front hood Striker Hinge Seal
(5) Front hood stay
Tightening torque: Nm (kg-m, ft-lb) T1: 24.5 (2.5, 18.1) T2: 33 (3.4, 25)
EB-3
GENERAL DESCRIPTION
S913001A0502
2. FRONT DOOR PANEL
S5M0506A
(1) (2) (3) (4) (5) (6)
Gusset Weatherstrip Stabilizer (Outer) Stabilizer (Inner) Door panel Checker
(7) Sealing cover (8) Lower hinge (9) Upper hinge
Tightening torque: Nm (kgf-m, ft-lb) T1: 7.35 (0.75, 5.4) T2: 13 (1.3, 9.4) T3: 25 (2.5, 18) T4: 30 (3.1, 22) T5: 32 (3.3, 24)
EB-4
GENERAL DESCRIPTION
3. REAR DOOR PANEL
S913001A0503
S5M0507A
(1) (2) (3) (4) (5) (6)
Weatherstrip Stabilizer (Outer) Stabilizer (Inner) Door panel Plate Sealing cover
(7) Checker (8) Lower hinge (9) Upper hinge
Tightening torque: Nm (kgf-m, ft-lb) T1: 7.35 (0.75, 5.4) T2: 25 (2.5, 18) T3: 30 (3.1, 18) T4: 32 (3.3, 24)
EB-5
GENERAL DESCRIPTION
S913001A0505
4. REAR GATE PANEL
S5M0443B
(1) (2) (3) (4)
Gas stay Hinge Rear gate Stopper
(5) Buffer cover (6) Buffer (Back door)
Tightening torque: Nm (kg-m, ft-lb) T1: 7.5 (0.76, 5.5) T2: 14 (1.4, 10.1) T3: 25 (2.5, 18.1)
EB-6

S913001A03
Exterior body panels are heavy. Do not drop and damage the panels. During removal and installation, do not damage the panel painting surface. While removing mounting bolts, using assistance devices such as a support jack will help support the panel. Be careful not to lose small parts.
EB-7
GENERAL DESCRIPTION
S913001A17
D: PREPARATION TOOL
1. SPECIAL TOOLS
ILLUSTRATION
S913001A1701
DESCRIPTION WRENCH
REMARKS Used for removing and installing door hing.
B5M1117
2. GENERAL TOOL
Support Jack
S913001A1702
TOOL NAME
REMARKS Used for supporting door panel.
EB-8
FRONT HOOD
2. Front Hood
A: REMOVAL
S913367
S913367A18
1) Open front hood to remove washer nozzles. 2) Remove bolts to detach hood from hinges.
G5M0137
B: INSTALLATION
S913367A11
1) Install in the reverse order of removal. 2) Adjust clearance between hood and fender. Clearance must be equal at both sides.
C: ADJUSTMENT
S913367A01
1) Use hinge mounting holes to align front hood longitudinally and laterally.
G5M0137
2) Adjust height at front end of hood. <Ref. to SL-38 ADJUSTMENT, Front Hood Lock Assembly.> 3) Rotate hood buffer to adjust lateral height.
G5M0141
EB-9
FENDER PANEL
S913368
3. Fender Panel
A: REMOVAL
S913368A18
1) Disconnect ground () cable from battery. 2) Remove side protectors and fender protectors. <Ref. to EI-22, REMOVAL, Protector.> 3) Remove mud guard. <Ref. to EI-21 REMOVAL, Mud Guard.> 4) Remove front bumper face. <Ref. to EI-12 REMOVAL, Front Bumper.> 5) Remove headlights. <Ref. to LI-42 REMOVAL, Headlight Assembly.> 6) Remove bolts to remove front fender.
S5M0165
B: INSTALLATION
S913368A11
1) Install in the reverse order of removal. 2) When fender panel is installed, clearance between fender panel and hood or front fender must be equal.
EB-10
FRONT DOOR PANEL
4. Front Door Panel

A: REMOVAL
S913366A18
S913366
10) Remove checker bolts.
1) Disconnect () cable from battery. 2) Remove front door trim. <Ref. to EI-26 REMOVAL, Front Door Trim.> 3) Remove outer mirror assembly. <Ref. to GW-49 REMOVAL, Outer Mirror Assembly.> 4) Remove front door glass. <Ref. to GW-28, REMOVAL, Front Door Glass.> 5) Remove front door regulator and motor. <Ref. to GW-31 REMOVAL, Front Regulator and Motor.> 6) Remove front door latch assembly. <Ref. to SL-29 REMOVAL, Front Door Latch Assembly.> 7) Remove front outer handle. <Ref. to SL-28 REMOVAL, Front Outer Handle.> 8) Remove front pillar lower trim to disconnect connector from body harness.
S5M0183
11) Remove door-side bolts for upper and lower hinges to remove door.
G5M0385
12) Using special tool, remove body-side bolts for upper and lower hinges, and remove door hinges. ST 925610000 DOOR HINGE WRENCH
B5M0726
9) Put wooden block on jack and place jack under door. Support door with a jack to protect it from damage.
B5M0933A
S5M0518
CAUTION: During removal and installation of doors, do not damage body. Doors are heavy. Be careful not to drop and damage them.
B: INSTALLATION
S913366A11
1) Install in the reverse order of removal. 2) Apply grease to sliding area of door hinges.
EB-11
FRONT DOOR PANEL

S913366A01
C: ADJUSTMENT
1) Using special tool, loosen body-side bolts of upper and lower hinges to align the position of front door panel longitudinally and vertically. ST 925610000 DOOR HINGE WRENCH
B5M0933A
2) Loosen door-side bolts of upper and lower hinges to align the position of front door panel vertically and laterally at the front end.
G5M0385
3) Loosen screw (A) and lightly tap striker (B) using plastic hammer to adjust striker to align the position of front door panel vertically and laterally at the rear end.
B5M0934A
CAUTION: Do not use impact wrench. Welding area on striker nut plate is easily broken.
EB-12
FRONT SEALING COVER
5. Front Sealing Cover

A: REMOVAL
S913564A18
S913564
1) Remove front door trim. <Ref. to EI-26 REMOVAl, Front Door Trim.> 2) Remove front speaker. <Ref. to EI-12 REMOVAL, Front Speaker.> 3) Using a spatula, remove sealer. CAUTION: Carefully remove sealer. Excessive force will easily break the cover. If cover gets broken, replace it with a new one.
G5M0391
B: INSTALLATION
S913564A11
1) Install in the reverse order of removal. 2) When replacing sealing cover, use CEMEDINE 5430L sealer. 3) Press sealer-applied area firmly to prevent any floating on surface. Sealer: CEMEDINE 5430L or equivalent CAUTION: Apply a uniform bead of sealer. Attach sealing cover, keeping it from becoming wrinkled. Breaks in the bead will allow water leakage and contamination.
C: INSPECTION
S913564A10
If sealing cover is damaged, replace it with a new one.
EB-13
REAR DOOR PANEL

S913364
6. Rear Door Panel

A: REMOVAL
S913364A18
9) Remove checker bolts.
1) Disconnect () cable from battery. 2) Remove rear door trim. <Ref. to EI-27 REMOVAL, Rear Door Trim.> 3) Remove rear door glass. <Ref. to GW-32, REMOVAL, Rear Door Glass.> 4) Remove rear door regulator and motor assembly. <Ref. to GW-34 REMOVAL, Rear Regulator and Motor Assembly.> 5) Remove rear outer handle. <Ref. to SL-32 REMOVAL, Rear Outer Handle.> 6) Remove center pillar lower trim. <Ref. to EI-38 REMOVAL, Lower Inner Trim.> 7) Remove seatbelt bracket and blind plug. Disconnect connector of door harness and remove door hinge nut.
S5M0183
10) Remove door-side bolts for upper and lower hinges to remove door.
G5M0385
11) Using special tool, remove body-side bolts for upper and lower hinges, and remove door hinges.
B5M1062
8) Put a wooden block on the jack and place the jack under the door. Support the door with the jack to protect it.
CAUTION: During removal and installation of doors, do not damage body. Doors are heavy. Be careful not to drop and damage them.
B: INSTALLATION
S913364A11
1) Install in the reverse order of removal. 2) Apply grease to sliding area of door hinges.
S5M0518
EB-14
REAR DOOR PANEL C: ADJUSTMENT

S913364A01
1) Using special tool, loosen body-side bolts of upper and lower hinges to align the position of rear door panel longitudinally and vertically.
B5M0933A
2) Loosen door-side bolts of upper and lower hinges to align the position of rear door panel vertically and laterally at front-end.
G5M0385
3) Loosen screw (A) and lightly tap striker (B) using plastic hammer to adjust striker to align the position of front door panel vertically and laterally at the rear end.
B5M0934A
CAUTION: Do not use an impact wrench. The welding area on the striker nut plate is easily broken.
EB-15
REAR SEALING COVER

S913565
7. Rear Sealing Cover

A: REMOVAL
S913565A18
1) Remove rear door trim. <Ref. to EI-27 REMOVAL, Rear Door Trim.> 2) Remove rear speaker. <Ref. to ET-13 REMOVAL, Rear Speaker.> 3) Using a spatula, remove sealer. CAUTION: Carefully remove sealer. Excessive force will easily break the cover. If cover gets broken, replace it with a new one.
G5M0391
B: INSTALLATION
S913565A11
1) Install in the reverse order of removal. 2) When replacing sealing cover, use CEMEDINE 5430L sealer. 3) Press sealer-applied area firmly to prevent any floating on surface. Sealer: CEMEDINE 5430L or equivalent CAUTION: Apply an uniform bead of sealer. Attach sealing cover, keeping it from becoming wrinkled. Breaks in the bead will allow water leakage and contamination.
C: INSPECTION
S913565A10
If sealing cover gets damaged, replace it with a new one.
EB-16
REAR GATE PANEL
8. Rear Gate Panel

A: REMOVAL
S913363A18
S913363
1. REAR GATE PANEL
CAUTION: When the rear gate is released, it may hit and damage the body. To prevent this, place a shop cloth between body and gate.
S913363A1801
1) Open rear gate. 2) Remove rear gate outer handle. <Ref. to SL-35 REMOVAL, Rear Gate Outer Handle.> 3) Remove rear gate latch assembly. <Ref. to SL-36 REMOVAL, Rear Gate Latch Assembly.> 4) Remove rear gate key lock cylinders. <Ref. to SL-41 REMOVAL, Key Lock Cylinders.> 5) Remove rear wiper. <Ref. to WW-20 REMOVAL, Rear Wiper Motor.> 6) Disconnect connectors of rear wiper, rear defogger, and other lighting devices. 7) Disconnect washer hose. 8) Remove rubber duct (A) connection, and pull out harness and washer hose from rear gate.
2. GAS STAY
S913363A1802
1) Open rear gate. Using a jack to support the rear gate.
BO0262
CAUTION: After gas stay is removed, rear gate cannot stay open. Supporting the rear gate with a jack, remove the bolts. Do not damage piston rods and oil seals. Never disassemble cylinders: They contain gas. 2) Loosen bolts to remove gas stay from rear gate.
B5M0733A
B: INSTALLATION
S913363A11
9) Using a support, support the rear gate while removing gas stay mounting bolts. 10) Loosen rear gate bolts to remove rear gate.
1. REAR GATE PANEL
S913363A1101
1) Install in the reverse order of removal. 2) Install rear gate panel with uniform clearance to body. CAUTION: Do not damage painted surfaces of body and rear gate.
2. GAS STAY
S913363A1102
Install in the reverse order of removal. CAUTION: Do not confuse right and left sides of gas stay. After supporting rear gate with a jack, start operation.
BO0262
S5M0206
EB-17
REAR GATE PANEL

S913363A07
C: DISPOSAL
1. GAS STAY
S913363A0701
CAUTION: Gas is colorless, odorless, and harmless. However, gas pressure may spray cutting powder or oil. Be sure to wear dust-resistant goggles. 1) Cover with a vinyl case as shown in the figure.
BO0264
CAUTION: Prevent the vinyl case from being caught by drill cutting edge 2) Lift body side slightly with piston rods fully extended, and secure body side on vise stand. Drill a hole in 2 to 3 mm (0.08 to 0.12 in) diameter at a point 10 to 200 mm (0.39 to 7.87 in) from door side, and bleed gas stay completely.
BO0263
EB-18
CRUISE CONTROL SYSTEM
CC
1. 2. 3. 4. 5. 6. 7. 8. 9. Page General Description.....................................................................................2 Actuator (Turbo Model) ...............................................................................5 Actuator (Non-turbo Model).........................................................................7 Cruise Control Module ................................................................................8 Cruise Control Main Switch.........................................................................9 Cruise Control Command Switch..............................................................10 Stop and Brake Switch..............................................................................11 Clutch Switch.............................................................................................12 Inhibitor Switch ..........................................................................................13
Cruise Control System
GENERAL DESCRIPTION
S912001
A: COMPONENT
1. TURBO MODEL
S912001A05 S912001A0501
S6M0487A
(1) Actuator (2) Inhibitor switch (AT) (3) Cruise control main switch
(4) Cruise control command switch (5) Cruise control module (6) Stop and brake switch
(7) Clutch switch (MT)
CC-2
GENERAL DESCRIPTION
2. NON-TURBO MODEL
S912001A0502
S6M0106A
(1) Actuator (with valves) (2) Inhibitor switch (AT) (3) Cruise control main switch
NOTE: Electrical component location are for LHD vehicles. Cruise control actuator and cruise control module location for RHD vehicles are symmetrically opposite.
CC-3
GENERAL DESCRIPTION
B: CAUTION
S912001A03
Before disassembling or reassembling parts, always disconnect the battery ground cable. When repairing the radio, control module and other parts with memory functions, make note of the memory before disconnecting the battery ground cable. All memory will be erased. Reassemble parts in the reverse order of disassembly unless otherwise indicated. Adjust parts to specifications specified in this manual. Connect connectors and hoses securely during reassembly. After reassembly, ensure functional parts operate properly.
C: PREPARATION TOOL
1. GENERAL TOOLS
S912001A1701
S912001A17
CC-4
ACTUATOR (TURBO MODEL)

S912753A11
2. Actuator (Turbo Model)

A: REMOVAL
S912753A18
S912753
B: INSTALLATION
Install in the reverse order of removal. Tightening torque: 7.4 Nm (0.75 kgf-m, 5.4 ft-lb) NOTE: (A): Must be adjusted when cable end outer is fixed in place, so that gap between throttle cam and lever is 0 1 mm (0 0.04 in). (Must be attached while throttle cam is being pulled by wire cable.) (B): Must be coated evenly on cam end inner connection. (C): Cover must be inserted securely, until tip of cable touches cover stopper.
CAUTION: Be careful not to apply excessive load to the wire cable when adjusting and/or installing; otherwise, the actuator may be deformed or damaged. Do not bend cable sharply with a radius less than 100 mm (3.94 in); otherwise, cable may bend permanently, resulting in poor performance. When installing cable, be careful not to sharply bend or pinch the inner cable; otherwise, the cable may break. 1) Remove clip bands from cruise control cable. 2) Loosen nut which secures cruise control cable end to throttle cam and then remove cable from throttle cam.
B6M1213A
S6M0088
3) Remove actuator attaching bolts. 4) Remove actuator while disconnecting connector.
CC-5
ACTUATOR (TURBO MODEL)

S912753A10
C: INSPECTION
B6M1568
Measure resistance between cruise control actuator terminals.

Tester connection 41 42 45 36 Resistance () Approx. 5 Approx. 5 Approx. 5 Approx. 39
If NG, replace cruise control actuator.
CC-6
ACTUATOR (NON-TURBO MODEL)
3. Actuator (Non-turbo Model)

S912754
5) Disconnect cruise control vacuum hose from intake manifold.
A: REMOVAL
S912754A18
1) Remove air intake chamber.
S6M0089
S6M0007
6) Remove actuator attaching bolts. 7) Disconnect connector from actuator, then remove the actuator.
2) Remove air intake chamber stay. 3) Remove clip bands from cruise control cable.
S6M0090
S6M0087
B: INSTALLATION
S912754A11
4) Remove cruise control cable end from throttle cam.
Install in the reverse order of removal. Tightening torque: 7.4 Nm (0.75 kgf-m, 5.4 ft-lb) CAUTION: When inserting vacuum hose to intake manifold, apply sealant to the fitting hose. Fluid packing: THREE BOND 1105 or equivalent CAUTION: Be careful not to apply excessive load to the wire cable when adjusting and/or installing; otherwise, the actuator may be deformed or damaged. Do not bend cable sharply with a radius less than 100 mm (3.94 in); otherwise, cable may bend permanently, resulting in poor performance. When installing cable, be careful not to sharply bend or pinch the inner cable; otherwise, the cable may break.
S6M0088
CC-7
CRUISE CONTROL MODULE

S912500
4. Cruise Control Module

A: REMOVAL
S912500A18
1) Remove front pillar lower trim.
S6M0097
2) Disconnect connector from cruise control module. 3) Remove bolt, then remove cruise control module.
S6M0098
B: INSTALLATION
S912500A11
CC-8
CRUISE CONTROL MAIN SWITCH

S912498A10
5. Cruise Control Main Switch

S912498
C: INSPECTION
A: REMOVAL
S912498A18
1) Remove screws and clip from instrument panel lower cover. 2) Remove panel lower cover.
S6M0091
3) Disconnect connector from cruise control main switch.

S6M0520A
Check continuity between cruise control main switch terminals.

S6M0092A
Tester connection 35 35
Specified condition No continuity Continuity
If NG, replace cruise control main switch.
4) Remove main switch by pushing it outward.
S6M0093
B: INSTALLATION
S912498A11
CC-9
CRUISE CONTROL COMMAND SWITCH

7) Disconnect horn and cruise control command switch connector, then remove cruise control command switch.
6. Cruise Control Command Switch

S912497
A: REMOVAL
S912497A18
WARNING: Before servicing, be sure to read the notes in the AB section for proper handling of the driver s airbag module. <Ref. to AB-3 CAUTION, General Description.> 1) Set front wheels in straight ahead position. 2) Turn ignition switch OFF. 3) Disconnect battery ground cable from battery and wait for at least 20 seconds before starting work. 4) Using TORX BIT T30 (Tamper resistant type), loosen two TORX bolts which secure driver s airbag module.
S6M0096
S912497A11
Install is in the reverse order of removal.

S912497A10
H5M0662A
5) Disconnect airbag module connector on back of airbag module. 6) Remove horn switch from steering wheel as shown.
B6M1406
Check continuity between cruise control command switch terminals.

Switch CANCEL SET/COAST RESUME/ ACCEL Position ON ON OFF ON OFF ON Tester conSpecified nection condition 1 (+) 2 () Continuity 1 (+) 3 () Continuity 13 No continuity 13 Continuity 12 No continuity 12 Continuity
If NG, replace cruise control command switch.

S6M0095
CC-10
STOP AND BRAKE SWITCH
7. Stop and Brake Switch

A: REMOVAL
S912496A18
S912496
Disconnect connector from switch, and then remove the switch. <Ref. to BR-60 REMOVAL, Stop Light Switch.>
S912496A11

S912496A10
S6M0567A
Check continuity brake switch (1) and stop light switch (2) between terminals.
Switch Brake Stop light Pedal Released Depressed Released Depressed Tester connection 14 14 23 23 Specified condition Continuity No continuity No continuity Continuity
If NG, replace stop and brake switch.
CC-11
CLUTCH SWITCH
S912258
8. Clutch Switch
A: REMOVAL
S912258A18
Disconnect the connector from the switch, and then remove the switch. <Ref. to CL-38 DISASSEMBLY, Clutch Pedal.>
S912258A11

S912258A10
G6M0184
Check continuity between clutch switch terminals.

Switch Clutch Pedal Released Depressed Tester connection 12 12 Specified condition Continuity No continuity
If NG, replace the clutch switch.
CC-12
INHIBITOR SWITCH
9. Inhibitor Switch
A: REMOVAL
S912243A18
S912243
Disconnect connector from switch, and then remove the switch. <Ref. to AT-29 REMOVAL, Inhibitor Switch.>
S912243A11
Installation is in the reverse order of removal.

S912243A10
B6M1530
Check continuity between inhibitor switch terminals.

Selector lever position P N Except P and N Tester connection Specified condition Continuity Continuity No continuity
7 12
If NG, replace inhibitor switch.
CC-13
INHIBITOR SWITCH
MEMO:
CC-14
AIRBAG SYSTEM (DIAGNOSTICS)
AB
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Page Basic Diagnostic Procedure ........................................................................2 Check List for Interview...............................................................................3 General Description.....................................................................................4 Electrical Components Location................................................................16 A/B Control Module I/O Signal..................................................................18 Airbag Connector ......................................................................................24 Airbag Warning Light Illumination Pattern.................................................26 Read Diagnostic Trouble Code .................................................................27 Inspection Mode ........................................................................................28 Clear Memory Mode..................................................................................29 Airbag Warning Light Failure ....................................................................30 List of Diagnostic Trouble Code................................................................36 Diagnostic Chart with Trouble Code .........................................................39
Airbag System (Diagnostics)

S002627
A: PROCEDURE
No. 1
S002501E45
Step Read Diagnostic Trouble Code. <Ref. to AB-27 Read Diagnostics Trouble Code.> Read Diagnostic Trouble Code. <Ref. to AB-27 Read Diagnostics Trouble Code.>
Check Is the normal code being detected? Is the trouble code being detected?
Yes No Finish the diagno- Go to step 2. sis. Go to step 3. Go to Airbag Warning Light Failure. <Ref. to AB-30 Airbag Warning Light Failure.> Finish the diagnosis.
Perform the diagnosis. 1) Judge the possible cause from List of Diagnostic Trouble Code <Ref. to AB-36 List of Diagnostic Trouble Code.>. 2) Inspect using Diagnostic Chart with Trouble Code. (DTC) 3) Repair the cause of the trouble. 4) Perform the clear memory mode. <Ref. to AB-29 Clear Memory Mode.> 5) Perform the inspection mode. <Ref. to AB-28 Inspection Mode.> 6) Read diagnostic trouble code.
Is the trouble code being detected?
Perform the procedure 1) to 5) in step 3.
AB-2

A: CHECK
Customer s Name
S002502A04
S002502
Inspector s Name
Date Vehicle Brought In
Registration No.
Odometer Reading
Km Vin No. Miles
Date Problem Occurred
Registration Year
Weather
Fine
Cloudy
Rainy
Snowy
Other:
Temperature
C (F)
Road Condition
Level road
Uphill
Downhill
Rough road
Other:
Vehicle Operation
Starting Idling Driving ( Constant Speed Acceleration Steering wheel turn Other:
Deceleration )
Details of Problem
Check Airbag Warning Light
Remains ON
Remains OFF
Check DTC
Normal Code
Trouble Code: (Code:
AB-3
GENERAL DESCRIPTION
S002001
A: CAUTION
S002001A03
When checking, use a test harness. Do not directly apply the tester probe to any connector terminal of the airbag.
When servicing a vehicle, be sure to turn the ignition switch OFF, disconnect the ground cable from the battery, and wait for more than 20 seconds before starting work. The airbag system is fitted with a backup power source. If the airbag system is serviced within 20 seconds after the ground cable is disconnected, it may inflate.
G5M0293
G5M0292
If sensors, airbag module, airbag control module and harness are deformed or damaged, replace them with new genuine parts. Do not use the airbag system on other vehicles. When replacing parts, be sure to replace them with new parts.
G5M0294
Do not check continuity of the airbag module (driver, passenger, and side).
G5M0291
When checking the system, be sure to use a digital circuit tester. Use of an analog circuit tester may cause the airbag to activate erroneously.
G5M0302
AB-4
GENERAL DESCRIPTION
Do not allow water or oil to come in contact with the connector terminals. Do not touch the connector terminals.
G5M0298
G5M0295
If any damage, opening or rust is found on the airbag system wire harness, do not attempt to repair using soldering equipment. Be sure to replace the faulty harness with a new genuine part.
G5M0299
Do not drop the airbag modulator parts, subject them to high temperature over 93C (199F), or let water, oil, or grease get on them; otherwise, the internal parts may be damaged and reliability greatly lowered.
G5M0296
Install the wire harness securely with the specified clips to avoid interference or tangled up with other parts.
G5M0297
AB-5
GENERAL DESCRIPTION
When painting or performing sheet metal work on the front part of the vehicle, including the front wheel apron, front fender, and front side frame, remove the front sub sensors and wire harness of the airbag system. When painting or performing sheet metal work on the side of the vehicle, including the side sill, center pillar, and front and rear doors, remove the side airbag sensors and wire harness of the airbag system.
G5M0310
B5M1072A
When storing a removed airbag module, do not place any objects on it or pile airbag modules on top of each other. If the airbag inflates for some reason when it is placed with its pad side facing downward or under any object, a serious accident may result.
AB-6
GENERAL DESCRIPTION
G5M0604
AB-7
GENERAL DESCRIPTION
Do not discard undeployed airbag modules. They could easily cause a serious accident if accidentally deployed.
B: INSPECTION
S002001A10
Before diagnosing, check the following items that might be related to the engine problem:
1. BATTERY
S002001A1001
Measure battery voltage and specific gravity of electrolyte. Standard voltage: 12V Specific gravity: Above 1.260
AB-8

S002001A17
CAUTION: Be sure to use specified test harness A, F, G, H and I or I2 when measuring voltage, resistance, etc. of AIRBAG system component parts.
1. TEST HARNESS A
S002001A1701
B5M0112A
AB-9
GENERAL DESCRIPTION
2. TEST HARNESS F
S002001A1702
S5M0247A
AB-10
GENERAL DESCRIPTION
3. TEST HARNESS G
S002001A1703
S5M0248A
AB-11
GENERAL DESCRIPTION
S002001A1704
4. TEST HARNESS H
B5M0553B
AB-12
GENERAL DESCRIPTION
5. TEST HARNESS I
S002001A1705
S5M0340A
AB-13
GENERAL DESCRIPTION
S002001A1706
6. TEST HARNESS I2
B5M0927A
AB-14
GENERAL DESCRIPTION
7. AIRBAG RESISTOR
S002001A1707
The airbag resistor is used during diagnostics. The airbag resistor has the same resistance as the airbag module and thus provides safety when used instead of the airbag module. It also makes it possible to finish, diagnostics in less time.
B5M0114A
AB-15

S002507

A: LOCATION
1. LHD MODEL
S002507A13 S002507A1301
S5M0460A
Connector No. Pole Color Male/ Female Connector No. Pole Color Male/ Female
(AB1) 7 Yellow Male
(AB2) 2 Yellow Male
(AB3) 2 Yellow Male
(AB6) 28 Yellow Female
(AB10) 2 Yellow Male
(AB11) 2 Blue Female
(AB12) 2 Blue Male
(AB15) 2 Blue Male
AB-16

2. RHD MODEL
S002507A1302
S5M0461A
Connector No. Pole Color Male/ Female Connector No. Pole Color Male/ Female
(AB1) 7 Yellow Male
(AB2) 2 Yellow Male
(AB3) 2 Yellow Male
(AB12) 2 Blue Male
(AB15) 2 Blue Male
AB-17
A/B CONTROL MODULE I/O SIGNAL

S002745
5. A/B Control Module I/O Signal

A: SCHEMATIC
S002745A21
1. AIRBAG LHD MODEL
S002745A2101
SL86-20A
AB-18
SL86-20B
AB-19
SL86-20C
AB-20

2. AIRBAG RHD MODEL
S002745A2102
SR86-20A
AB-21
SR86-20B
AB-22
SR86-20C
AB-23
AIRBAG CONNECTOR
S002659
6. Airbag Connector
A: OPERATION
S002659A16
How to connect:
Holding the connector, and push it in carefully until a connecting sound is heard. CAUTION: Be sure to insert the connector in until it locks. Then pull on it gently to make sure that it is locked.
1. DRIVER S AIRBAG, PASSENGER S AIRBAG, SIDE AIRBAG S002659A1607 How to disconnect:

1) Push lock arm (A). 2) With lock arm (A) pushed in, move slide lock (B) in the direction of the arrow.
B5M1155
B5M1153A
2. FRONT SUB-SENSOR, SIDE AIRBAG SENSOR S002659A1603 How to disconnect:

1) Holding outer part (A), pull it in the direction of the arrow. CAUTION: When pulling, be sure to hold onto the connector and not the wire.
3) With slide lock (B) pulled, remove lock arm (A) to its original position, and then pull in the direction of the arrow and separate the connector. CAUTION: When pulling, be sure to hold onto the connector and not the wire.
B5M1154 RE0014
AB-24
AIRBAG CONNECTOR
How to connect:
Holding the connector, and push it in carefully until a connecting sound is heard. CAUTION: Outer (A) moves back, and so do not put your hand on the outer part. Be sure to insert the connector in until it locks. Then pull on it gently to make sure that it is locked.
RE0015
AB-25
AIRBAG WARNING LIGHT ILLUMINATION PATTERN
7. Airbag Warning Light Illumination Pattern

S002629
A: INSPECTION
S002629A10
Keep the ignition switch ON, and confirm that the airbag warning light remains off approximately 6 seconds after being turned on.
B5M1096A
AB-26

S002508
A: OPERATION
S002508A16
1) Turn the ignition switch ON. 2) Connect the diagnosis terminal to diagnosis connector terminal No. 1 in the driver s seat lower cover area.
3) Read trouble code by identifying the way the air bag warning light flashes. The airbag warning light flashes a code corresponding to the faulty parts. The long segment (1.2 sec on) indicates a ten, and the short segment (0.3 sec on) indicates a one. NOTE: List of Diagnostic Trouble Code <Ref. to AB-36 List of Diagnostic Trouble Code.> Airbag Warning Light Failure <Ref. to AB-30 Airbag Warning Light Failure.>
B5M0115D
B5M0117A
4) Turn the ignition switch OFF, and disconnect the diagnosis terminal from the diagnosis connector terminal No 1. 5) Wind tape around the diagnosis terminal and return it to its original position.
AB-27
INSPECTION MODE
S002510
9. Inspection Mode
A: OPERATION
S002510A16
Recreate the circumstance by referring to the conditions described in the checklist.
AB-28
CLEAR MEMORY MODE

A: OPERATION
S002513A16
S002513
1) Turn the ignition switch ON. 2) Connect the diagnosis terminal A to diagnosis connector terminal No. 1 in the driver s seat lower cover area.
B5M0116D
3) While the warning light flashes, connect another diagnosis terminal B to diagnosis connector terminal No.2. 4) Once the memory is erased, the warning light returns to the normal flash rate (0.6 sec on). The failure to recover the normal flash rate indicates that trouble parts still remain. Having repaired such parts, erase the memory again and confirm that the normal flash rate has returned. 5) When the memory has been cleared, disconnect the diagnosis terminal from the diagnosis connector. 6) Wind tape around the diagnosis terminal and return it to its original position.
AB-29
AIRBAG WARNING LIGHT FAILURE

S002681
11. Airbag Warning Light Failure
A: AIRBAG WARNING LIGHT REMAINS ON.
S002681E28
DIAGNOSIS: Airbag warning light unit is faulty. Airbag control module to airbag warning light circuit is shorted or open. Grounding circuit is faulty. Airbag control module is faulty. (AB1) and (B31) are not connected properly. (AB6) is not connected properly to airbag control module. CAUTION: Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the ground cable from the battery, and wait more than 20 seconds before starting to work. Before replacing the airbag module, roll connector, control module, and sensor, reconnect each part and confirm that the warning light operates properly. When inspecting the airbag main harness, disconnect the airbag module connector of the driver and passenger seats for safety reasons.
AB-30

WIRING DIAGRAM:
S5M0462
No. 1
Step Check CHECK POOR CONTACT IN CONNECTORS Is the poor contact in double lock of connectors (AB1) AND (B31). (AB1) and (B31)? 1) Turn the ignition switch OFF, disconnect the battery ground cable, and wait more than 20 seconds. 2) Remove front pillar lower trim. (Driver s side) 3) Confirm that firm contact is secured between connectors (AB1) and (B31).
Yes Repair the body harness or replace airbag main harness.<Ref. to AB-16 Main Harness.>
No Go to step 2.
AB-31

No. 2

Check Is the airbag warning light turned off? Yes Go to step 4. No Go to step 3.
Step CHECK AIRBAG WARNING LIGHT. 1) Turn the ignition switch OFF, disconnect the battery ground cable, and wait more than 20 seconds. 2) Connect the connector (1A) in test harness A to the body harness connector (B31). 3) Connect the battery ground cable and turn the ignition switch ON. 4) Connect two connectors, (3A) and (4A) in test harness A. CHECK BODY HARNESS. Check the body harness. NOTE: After problem has been eliminated, disconnect connectors (3A) and (4A). CHECK POOR CONTACT. Confirm that firm contact is secured between the airbag control module and the connector (AB6). <Ref. to AB-18 Airbag Control Module.>
Is the anything unusual to body harness?
Repair the body harness.
Is the poor contact in connector (AB6)?
CHECK AIRBAG MAIN HARNESS. 1) Turn the ignition switch OFF, disconnect the battery ground cable, and wait more than 20 seconds. 2) Connect the connector (AB1) to (B31). 3) Disconnect connectors (AB3) and (AB8). 4) Remove glove box and disconnect connectors (AB10) and (AB9). 5) Disconnect the connector (AB6) from the airbag control module, and connect the connector (1I) in test harness I or I2. <Ref. to AB-18 Airbag Control Module.> 6) Connect the battery ground cable and turn the ignition switch ON. 7) Connect connectors (4I) and (5I) in test harness I or I2. NOTE: After problem has been eliminated, disconnect connectors (4I) and (5I). CHECK GROUNDING CIRCUIT. 1) Turn the ignition switch OFF, disconnect the battery ground cable, and wait more than 20 seconds. 2) Disconnect the connector (AB1) from the body harness connector (B31). 3) Connect the connector (1A) in test harness A to body harness connector (B31). 4) Measure the resistance between connector (5A) in test harness A and the chassis ground. Connector & terminal (5A) No. 17 Chassis ground: (5A) No. 18 Chassis ground:
Is the airbag warning light turned off?
Replace airbag main harness. <Ref. to AB-16 Main Harness.> or Replace the airbag control module. <Ref. to AB-18 Airbag Control Module.> Go to step 6. Replace airbag main harness. <Ref. to AB-16 Main Harness.>
Replace combination meter printed circuit. <Ref. to IDI-15 Combination Meter Assembly.> Go to step 5.
Go to step 7.
Repair bodygrounding circuit.
AB-32

No. 7 Step Check Is the resistance less than CHECK AIRBAG MAIN HARNESS. 10 ? 1) Connect the connector (AB1) to (B31). 2) Disconnect the connector (AB6) from the airbag control module, and connect the connector (1I) in test harness I or I2. <Ref. to AB-18 Airbag Control Module.> 3) Measure the resistance between connector (2I) in test harness I or I2 and the chassis ground. Connector & terminal (2I) No. 9 Chassis ground: (2I) No. 10 Chassis ground:

No Replace airbag main harness. <Ref. to AB-16 Main Harness.>
Yes Replace the airbag control module. <Ref. to AB-18 Airbag Control Module.>
AB-33

S002681E27
B: AIRBAG WARNING LIGHT REMAINS OFF.

DIAGNOSIS: Fuse No. 5 (in fuse box) is blown. Body harness circuit is open. Airbag warning light is faulty. Airbag main harness is faulty. Airbag control module is faulty.
CAUTION: Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the ground cable from the battery, and wait more than 20 seconds before starting to work. Before replacing the airbag module, roll connector, control module, and sensor, reconnect each part and confirm that the warning light operates properly. When inspecting the airbag main harness, disconnect the airbag module connector of the driver and passenger seats for safety reasons. WIRING DIAGRAM:
S5M0462
AB-34

No. 1 Step CHECK COMBINATION METER. Turn the ignition switch ON, and confirm that warning lights equipped in the combination meter are turned on. CHECK FUSE NO. 5 (IN MAIN FUSE BOX). Remove fuse No. 5 and perform visual inspection. CHECK AIRBAG WARNING LIGHT CIRCUIT (IN COMBINATION METER). 1) Turn the ignition switch OFF, disconnect the battery ground cable, and wait more than 20 seconds. 2) Disconnect the connector (AB1) from (B31). 3) Connect the battery ground cable and turn the ignition switch ON. CHECK AIRBAG MAIN HARNESS. 1) Turn the ignition switch OFF, disconnect the battery ground cable, and wait more than 20 seconds. 2) Connect the connector (AB1) to (B31). 3) Disconnect the connector (AB6) from the airbag control module. <Ref. to AB-18 Airbag Control Module.> 4) Connect the battery ground cable and turn the ignition switch ON. Check Do warning lights not for the airbag turn on?

No Repair combination meter power supply. <Ref. to IDI-4 Combination Meter System.> Go to step 3.
Yes Go to step 2.
Is fuse No. 5 (in main fuse box) blown?
Is the airbag warning light turned on?
Replace fuse No. 5. If fuse No. 5 blows again, go to step 3. Go to step 4. Replace airbag warning light bulb or combination meter printed circuit. <Ref. to IDI-15 Combination Meter Assembly.> Replace the airbag control module. <Ref. to AB-18 Airbag Control Module.> Replace airbag main harness. <Ref. to AB-16 Main Harness.>
Is the airbag warning light turned on?
AB-35

S002511

A: LIST
S002511A12
Trouble code/ Contents of troubles
Memory function
Contents of diagnosis Airbag main harness circuit is open, shorted or shorted to ground. Airbag module harness (driver) circuit is open, shorted or shorted to ground. Roll connector circuit is open, shorted or shorted to ground. Airbag control module is faulty. Driver s airbag module is faulty. Airbag main harness circuit is open, shorted or shorted to ground. Airbag module harness (passenger) circuit is open, shorted or shorted to ground. Airbag control module is faulty. Passenger s airbag module is faulty. Airbag main harness circuit (driver) is shorted to power supply. Airbag module harness (driver) is shorted to power supply. Roll connector is shorted to power supply. Airbag control module is faulty. Driver s airbag module is faulty. Airbag main harness circuit (passenger) is shorted to power supply. Airbag module harness (passenger) is shorted to power supply. Airbag control module is faulty. Passenger s airbag module is faulty. Airbag control module is faulty.
Index No.
11
Provided.
<Ref. to AB-39 TROUBLE CODE 11, Diagnostic Chart with Trouble Code.>
12
Provided.
15
Provided.
16
Provided.
<Ref. to AB-47 TROUBLE CODE 16, Diagnostic Chart with Trouble Code.> <Ref. to AB-48 TROUBLE CODE 21, Diagnostic Chart with Trouble Code.> <Ref. to AB-49 TROUBLE CODE 22, Diagnostic Chart with Trouble Code.> <Ref. to AB-50 TROUBLE CODE 23, Diagnostic Chart with Trouble Code.> <Ref. to AB-51 TROUBLE CODE 24, Diagnostic Chart with Trouble Code.> <Ref. to AB-53 TROUBLE CODE 25, Diagnostic Chart with Trouble Code.> <Ref. to AB-55 TROUBLE CODE 31, Diagnostic Chart with Trouble Code.>
21
Provided.
22
Provided.
Front airbag module is inflated.
23
Not provided.
(AB6), (AB17) and (AB18) are not connected properly to airbag control module. Airbag control module is faulty. Airbag main harness circuit is open. Fuse No. 11 (in joint box) is blown. Body harness circuit is open. Airbag control module is faulty. Airbag main harness circuit is open. Fuse No. 6 (in joint box) is blown. Body harness circuit is open. Front sub-sensor harness (RH) circuit is shorted. Front sub-sensor harness (RH) circuit is open. Front sub-sensor (RH) is faulty. Airbag control module is faulty.
24
Not provided.
25
Provided.
31
Provided.
AB-36

Trouble code/ Contents of troubles 32 Memory function Contents of diagnosis

Index No. <Ref. to AB-59 TROUBLE CODE 32, Diagnostic Chart with Trouble Code.> <Ref. to AB-63 TROUBLE CODE 41, Diagnostic Chart with Trouble Code.> <Ref. to AB-65 TROUBLE CODE 42, Diagnostic Chart with Trouble Code.> <Ref. to AB-67 TROUBLE CODE 45, Diagnostic Chart with Trouble Code.> <Ref. to AB-69 TROUBLE CODE 46, Diagnostic Chart with Trouble Code.> <Ref. to AB-71 TROUBLE CODE 51, Diagnostic Chart with Trouble Code.> <Ref. to AB-73 TROUBLE CODE 52, Diagnostic Chart with Trouble Code.> <Ref. to AB-74 TROUBLE CODE 53, Diagnostic Chart with Trouble Code.> <Ref. to AB-74 TROUBLE CODE 54, Diagnostic Chart with Trouble Code.> <Ref. to AB-74 TROUBLE CODE 55, Diagnostic Chart with Trouble Code.>
Provided.
Front sub-sensor harness (LH) circuit is shorted. Front sub-sensor harness (LH) circuit is open. Front sub-sensor (LH) is faulty. Airbag control module is faulty.
41
Provided.
Side airbag harness (RH) is faulty. Side airbag module (RH) is faulty. Airbag control module is faulty. Side airbag harness (LH) is faulty. Side airbag module (LH) is faulty. Airbag control module is faulty. Side airbag harness (RH) is shorted to power supply. Airbag control module is faulty. Side airbag harness (LH) is shorted to power supply. Airbag control module is faulty. Side airbag sensor (RH) is faulty. Side airbag harness (RH) is faulty. Airbag control module is faulty. Side airbag sensor (LH) is faulty. Side airbag harness (LH) is faulty. Airbag control module is faulty.
42
Provided.
45
Provided.
46
Provided.
51
Provided.
52
Provided.
53
Provided.
Side airbag sensor (RH) is faulty.
54
Provided.
Side airbag sensor (LH) is faulty.
55
Provided.
Side airbag module is inflated.
AB-37
MEMO:
AB-38
DIAGNOSTIC CHART WITH TROUBLE CODE
13. Diagnostic Chart with Trouble Code

A: TROUBLE CODE 11
S002630C38
S002630
DIAGNOSIS: Airbag main harness circuit is open, shorted or shorted to ground. Airbag module harness (Driver) circuit is open, shorted or shorted to ground. Roll connector circuit is open, shorted or shorted to ground. Driver s airbag module is faulty. Airbag control module is faulty. CAUTION: Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the ground cable from the battery, and wait more than 20 seconds before starting to work. Before replacing the airbag module, roll controller, control module, and sensor, reconnect each part and confirm that the warning light operates properly. When inspecting the airbag main harness, disconnect the driver s airbag module and passenger s airbag module connectors for safety reasons.
AB-39
WIRING DIAGRAM:
S5M0463
No. 1
Step Check Does the airbag warning CHECK DRIVERS AIRBAG MODULE. light operate properly? 1) Turn the ignition switch OFF, disconnect battery ground cable, and wait more than 20 seconds. 2) Remove the driver s airbag module. <Ref. to AB-12 Driver s Airbag Module.> 3) Connect the connector (1F) in test harness F to connector (AB7). 4) Connect airbag resistor to connector (3F) in test harness F. 5) Connect the battery ground cable and turn the ignition switch ON.
Yes Replace the driver s airbag module. <Ref. to AB-12 Driver s Airbag Module.>
No Go to step 2.
AB-40

No. 2 Step CHECK ROLL CONNECTOR. 1) Turn the ignition switch OFF, disconnect the battery ground cable, and wait more than 20 second. 2) Disconnect the test harness from the connector (AB7). 3) Remove the lower cover panel, disconnect the connector (AB3) from (AB8) and connect the connector (1F) in test harness F to connector (AB8). 4) Connect the airbag resistor to connector (3F) in test harness F. 5) Connect the battery ground cable and turn the ignition switch ON. CHECK AIRBAG MAIN HARNESS. 1) Turn the ignition switch OFF, disconnect the ground cable, and wait more than 20 seconds. 2) Disconnect the airbag resistor from the connector (3F) in test harness F. 3) Remove the glove box, <Ref. to AB-14 Passenger s Airbag Module.> and disconnect connectors (AB10) and (AB9). 4) Disconnect the connector (AB6) from the airbag control module, and connect the connector (1I) in test harness I or I2. <Ref. to AB-18 Airbag Control Module.> 5) Measure the resistance between connector (2I) in test harness I or I2 and the connector (3F) in test harness F. Connector & terminal (2I) No. 1 (3F) No. 3: (2I) No. 4 (3F) No. 4: CHECK AIRBAG MAIN HARNESS. Measure the resistance of the connector (2I) in test harness I or I2. Connector & terminal (2I) No. 1 No. 4: (2I) No. 4 Chassis ground: (2I) No. 1 Chassis ground: Check Does the airbag warning light operate properly?

No Go to step 3.
Yes Replace the roll connector. <Ref. to AB-20 Roll Connector.>
Go to step 4.
Replace airbag main harness. <Ref. to AB-16 Main Harness.>
Is the resistance more than Replace the air1 M? bag control module. <Ref. to AB-18 Airbag Control Module.>
AB-41
MEMO:
AB-42
DIAGNOSTIC CHART WITH TROUBLE CODE B: TROUBLE CODE 12

S002630C40
DIAGNOSIS: Airbag main harness circuit is open, shorted or shorted to ground. Airbag module harness (Passenger) circuit is open, shorted or shorted to ground. Passenger s airbag module is faulty. Airbag control module is faulty. CAUTION: Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the ground cable from the battery, and wait more than 20 seconds before starting to work. Before replacing the airbag module, roll connector, control module, and sensor, reconnect each part and confirm that the warning light operates properly. When inspecting the airbag main harness, disconnect the airbag module connector of the driver and passenger seats for safety reasons. WIRING DIAGRAM:
S5M0464
AB-43

No. 1

Check Does the airbag warning light operate properly? Yes Replace the passenger airbag module. <Ref. to AB-14 Passenger s Airbag Module.> No Go to step 2.
Step CHECK PASSENGERS AIRBAG MODULE. 1) Turn the ignition switch OFF, disconnect the battery ground cable, and wait more than 20 seconds. 2) Remove the glove box. 3) Disconnect the connector (AB10) from (AB9). 4) Connect the connector (1F) in test harness F to connector (AB9). 5) Connect the airbag resistor to connector (3F) in test harness F. 6) Connect the battery ground cable and turn the ignition switch ON. CHECK AIRBAG MAIN HARNESS. 1) Turn the ignition switch OFF, disconnect the battery ground cable, and wait more than 20 seconds. 2) Disconnect the airbag resistor from the connector (3F) in test harness F. 3) Remove lower cover and disconnect the connector (AB3) from (AB8). 4) Disconnect the connector (AB6) from the airbag control module, and connect the connector (1I) in test harness I or I2. <Ref. to AB-18 Airbag Control Module.> 5) Measure the resistance between connector (2I) in test harness I or I2 and the connector (3F) in test harness F. Connector & terminal (2I) No. 2 (3F) No. 3: (2I) No. 5 (3F) No. 4: CHECK AIRBAG MAIN HARNESS. Measure the resistance of the connector (2I) in test harness I or I2. Connector & terminal (2I) No. 2 No. 5: (2I) No. 2 Chassis ground: (2I) No. 5 Chassis ground:
Go to step 3.
Is the resistance more than Replace airbag 1 M? control module. <Ref. to AB-18 Airbag Control Module.>
AB-44
DIAGNOSTIC CHART WITH TROUBLE CODE C: TROUBLE CODE 15

S002630C41
DIAGNOSIS: Airbag main harness circuit (Driver) is shorted to the power supply. Airbag module harness (Driver) is shorted to the power supply. Roll connector is shorted to the power supply. Driver s airbag module is faulty. Airbag control module is faulty. CAUTION: Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the ground cable from the battery, and wait more than 20 seconds before starting to work. Before replacing the airbag module, roll connector, control module, and sensor, reconnect each part and confirm that the warning light operates properly. When inspecting the airbag main harness, disconnect the driver s airbag module and passenger s airbag module connectors for safety reasons. WIRING DIAGRAM:
S5M0463
AB-45

No. 1

Check Does the airbag warning light operate properly? Yes Replace the driver s airbag module. <Ref. to AB-12 Driver s Airbag Module.> No Go to step 2.
Step CHECK DRIVERS AIRBAG MODULE. 1) Turn the ignition switch OFF, disconnect the battery ground cable, and wait more than 20 seconds. 2) Remove the driver s airbag module. <Ref. to AB-12 Driver s Airbag Module.> 3) Connect the connector (AB7) to connector (1F) in test harness F. 4) Connect the airbag resistor to connector (3F) in test harness F. 5) Connect the battery ground cable and turn the ignition switch ON. CHECK ROLL CONNECTOR. 1) Turn the ignition switch OFF, disconnect the battery ground cable, and wait more than 20 seconds. 2) Disconnect the test harness from the connector (AB7). 3) Remove the lower cover panel and disconnect the connector (AB3) from (AB8). 4) Connect the connector (1F) in test harness F to connector (AB8). 5) Connect the airbag resistor to connector (3F) in test harness F. 6) Connect the battery ground cable and turn the ignition switch ON. CHECK AIRBAG MAIN HARNESS. 1) Turn the ignition switch OFF, disconnect the battery ground cable, and wait more than 20 seconds. 2) Disconnect the airbag resistor from the connector (3F) in test harness F. 3) Remove the glove box, and disconnect connectors (AB10) and (AB9). 4) Disconnect the connector (AB6) from the airbag control module, and connect the connector (1I) in test harness I or I2. <Ref. to AB-18 Airbag Control Module.> 5) Connect the battery ground cable and turn the ignition switch ON. (Engine OFF) 6) Measure the voltage between connector (2I) in test harness I or I2 and the chassis ground. Connector & terminal (2I) No. 4 (+) Chassis ground (): (2I) No. 1 (+) Chassis ground ():
Does the airbag warning light operate properly?
Replace the roll connector. <Ref. to AB-20 Roll Connector.>
Go to step 3.
Replace the airbag control module. <Ref. to AB-18 Airbag Control Module.>
AB-46
DIAGNOSTIC CHART WITH TROUBLE CODE D: TROUBLE CODE 16

S002630C42
DIAGNOSIS: Airbag main harness circuit (Passenger) is shorted to the power supply. Airbag module harness (Passenger) is shorted to the power supply. Passenger s airbag module is faulty. Airbag control module is faulty. CAUTION: Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the ground cable from the battery, and wait more than 20 seconds before starting to work. Before replacing the airbag module, roll connector, control module, and sensor, reconnect each part and confirm that the warning light operates properly. When inspecting the airbag main harness, disconnect the airbag module connector of the driver and passenger seats for safety reasons. WIRING DIAGRAM:
S5M0464
AB-47

No. 1

Check Does the airbag warning light operate properly? Yes Replace the passenger airbag module. <Ref. to AB-14 Passenger s Airbag Module.> No Go to step 2.
Step CHECK PASSENGERS AIRBAG MODULE. 1) Turn the ignition switch OFF, disconnect the battery ground cable, and wait more than 20 seconds. 2) Remove the glove box. 3) Disconnect the connector (AB10) from (AB9) 4) Connect the connector (1F) in test harness F to connector (AB9). 5) Connect the airbag resistor to connector (3F) in test harness F. 6) Connect the battery ground cable and turn the ignition switch ON. CHECK AIRBAG MAIN HARNESS. 1) Turn the ignition switch OFF, disconnect the battery ground cable, and wait more than 20 seconds. 2) Disconnect the airbag resistor from the connector (3F) in test harness F. 3) Remove the lower cover and disconnect the connector (AB3) from (AB8). 4) Disconnect the connector (AB6) from the airbag control module, and connect the connector (1I) in test harness I or I2. <Ref. to AB-18 Airbag Control Module.> 5) Measure the voltage between connector (2I) in test harness I or I2 and the chassis ground. Connector & terminal (2I) No. 2 Chassis ground: (2I) No. 5 Chassis ground:
S002630C45
E: TROUBLE CODE 21
DIAGNOSIS: Airbag control module is faulty. CAUTION: Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the ground cable from the battery, and wait more than 20 seconds before starting to work. Before replacing the airbag module, roll connector, control module, and sensor, reconnect each part and confirm that the warning light operates properly.
No. 1 Step CHECK IF TROUBLE CODE 21 IS INDICATED. Read Diagnostic Trouble Code. <Ref. to AB-27 Read Diagnostics Trouble Code.> Check Is airbag warning light trouble code 21 indicated? Yes Replace the airbag control module. <Ref. to AB-18 Airbag Control Module.> No Perform clear memory. <Ref. to AB-29 Clear Memory Mode.>
AB-48
DIAGNOSTIC CHART WITH TROUBLE CODE F: TROUBLE CODE 22

S002630C51
This code is indicated when the front airbag is in operation. Once this code is indicated, memory is not erasable; therefore replace the following parts. Airbag control module. <Ref. to AB-18 Airbag Control Module.> Driver s airbag module. <Ref. to AB-12 Driver s Airbag Module.> Passenger s airbag module. <Ref. to AB-14 Passenger s Airbag Module.> Front sub-sensor of both sides. <Ref. to AB-21 Front Sub Sensor.>
AB-49

S002630C56
G: TROUBLE CODE 23
DIAGNOSIS: (AB6), (AB17) and (AB18) are not connected properly to airbag control module. CAUTION: Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the ground cable from the battery, and wait more than 20 seconds before starting to work.
No. 1 Step CHECK POOR CONTACT IN CONNECTORS (AB6), (AB17) and (AB18). 1) Turn the ignition switch OFF, disconnect the battery ground cable, and wait more than 20 seconds. 2) Disconnect the connectors (AB6), (AB17) and (AB18) from the airbag control module. <Ref. to AB-18 Airbag Control Module.> Check Check if rust or damage appear on the harness connector and the control module connector. Yes No Go to step 2. Replace the airbag control module. <Ref. to AB-18 Airbag Control Module.> Replace airbag main harness. <Ref. to AB-16 Main Harness.> Replace side airbag harness. <Ref. to AB-17 Side Airbag Harness.> Finish the diagno- Replace the airsis. bag control module. <Ref. to AB-18 Airbag Control Module.>
CHECK POOR CONTACT IN CONNECTORS Does the airbag warning light operate properly? (AB6), (AB17) and (AB18). 1) Ensure that connectors are firmly reconnected. 2) Connect the battery ground cable and turn the ignition switch ON.
AB-50
DIAGNOSTIC CHART WITH TROUBLE CODE H: TROUBLE CODE 24

S002630C61
DIAGNOSIS: Airbag control module is faulty. Airbag main harness circuit is open. Fuse No, 11 (in joint box) is blown. Body harness circuit is open. CAUTION: Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the ground cable from the battery, and wait more than 20 seconds before starting to work. Before replacing the airbag module, roll connector, control module, and sensor, reconnect each part and confirm that the warning light operates properly. When inspecting the airbag main harness, disconnect the driver s airbag module and passenger s airbag module connectors for safety reasons. WIRING DIAGRAM:
B5M1101
AB-51

No. 1

Check Yes Is the voltage more than 10 Replace the airV? bag control module. <Ref. to AB-18 Airbag Control Module.> No Go to step 2.
Step CHECK AIRBAG CONTROL MODULE. 1) Turn the ignition switch OFF, disconnect the battery ground cable, and wait more than 20 seconds. 2) Disconnect the connector (AB6) from the airbag control module. <Ref. to AB-18 Airbag Control Module.> 3) Connect the connector (1I) in test harness I or I2 to connector (AB6). 4) Connect the battery ground cable and turn the ignition switch ON. 5) Measure the voltage between connector (2I) in test harness I or I2 and chassis ground. Connector & terminal (2I) No. 3 (+) Chassis ground (): CHECK AIRBAG MAIN HARNESS. 1) While checking control module, turn the ignition switch OFF and disconnect the battery ground cable. Wait more than 20 seconds before operation. 2) Disconnect the airbag connector (AB1) from the body harness (B31). 3) Connect the connector (2A) in test harness A to connector (AB1). 4) Measure the resistance between connector (5A) in test harness A and the connector (2I) in test harness I or I2. Connector & terminal (5A) No. 9 (2I) No. 3: CHECK AIRBAG MAIN HARNESS. Measure the following resistance with the above-mentioned condition maintained. Connector & terminal (5A) No. 9 Chassis ground: (2I) No. 3 Chassis ground: CHECK FUSE No. 11 (IN JOINT BOX). 1) Confirm that the ignition switch is turned OFF. 2) Remove fuse No. 11 (in joint box) and perform visual inspection.
Go to step 3.
Is fuse No. 11 blown?
Replace fuse No. 11. If fuse No. 11 blows again, repair the body harness.
Repair the body harness.
AB-52
DIAGNOSTIC CHART WITH TROUBLE CODE I: TROUBLE CODE 25

S002630C66
DIAGNOSIS: Airbag control module is faulty. Airbag main harness circuit is open. Fuse No. 6 (in joint box) is blown. Body harness circuit is open. CAUTION: Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the ground cable from the battery, and wait more than 20 seconds before starting to work. Before replacing the airbag module, roll connector, control module, and sensor, reconnect each part and confirm that the warning light operates properly. When inspecting the airbag main harness, disconnect the driver s airbag module and passenger s airbag module connectors for safety reasons. WIRING DIAGRAM:
B5M1102
AB-53

No. 1

Check Yes Is the voltage more than 10 Replace the airV? bag control module. <Ref. to AB-18 Airbag Control Module.> No Go to step 2.
Step CHECK AIRBAG CONTROL MODULE. 1) Turn the ignition switch OFF, disconnect the battery ground cable, and wait more than 20 seconds. 2) Disconnect the connector (AB6) from airbag control module. <Ref. to AB-18 Airbag Control Module.> 3) Connect the connector (1I) in test harness I or I2 to connector (AB6). 4) Connect the battery ground cable, and turn the ignition switch ON. 5) Measure the voltage between the connector (2I) in test harness I or I2 and the chassis ground. Connector & terminal (2I) No. 6 (+) Chassis ground (): CHECK AIRBAG MAIN HARNESS. 1) While checking control module, turn the ignition switch OFF and disconnect the battery ground cable. Wait more than 20 seconds before operation. 2) Disconnect the airbag connector (AB1) from the body harness (B31). 3) Connect the connector (2A) in test harness A to the airbag connector (AB1). 4) Measure the resistance between the connector (5A) in test harness A and the connector (2I) in test harness I or I2. Connector & terminal (5A) No. 1 (2I) No. 6: CHECK AIRBAG MAIN HARNESS. Measure the following resistance with the above-mentioned condition maintained. Connector & terminal (5A) No. 1 Chassis ground: (2I) No. 6 Chassis ground: CHECK FUSE NO. 6 (IN JOINT BOX). 1) Confirm that the ignition switch is turned OFF. 2) Remove No. 6 fuse (in joint box) and perform visual inspection.
Go to step 3.
Replace the airbag main harness. <Ref. to AB-16 Main Harness.>
Replace the airbag main harness. <Ref. to AB-16 Main Harness.> Repair the body harness.
Is fuse No. 6 blown?
Replace fuse No. 6. If fuse No. 6 is blown again, repair the body harness.
AB-54
DIAGNOSTIC CHART WITH TROUBLE CODE J: TROUBLE CODE 31

S002630C89
DIAGNOSIS: Front sub-sensor harness (RH) circuit is shorted. Front sub-sensor harness (RH) circuit is open. Front sub-sensor (RH) is faulty. Airbag control module is faulty. CAUTION: Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the ground cable from the battery, and wait more than 20 seconds before starting to work. Before replacing the airbag module, roll connector, control module, and sensor, reconnect each part and confirm that the warning light operates properly. When inspecting the airbag main harness, disconnect the driver s airbag module and passenger s airbag module connectors for safety reasons. WIRING DIAGRAM:
S5M0465
AB-55

No. 1

Check Is the resistance between 750 and 1 K? Yes Go to step 2. No Go to step 3.
Step CHECK FRONT SUB-SENSOR (RH) AND FRONT SUB-SENSOR HARNESS (RH). 1) Turn the ignition switch OFF, disconnect the battery ground cable, and wait more than 20 seconds. 2) Disconnect the connector (AB6) from the airbag control module , and connect the connector (1I) in test harness I or I2. <Ref. to AB-18 Airbag Control Module.> 3) Measure the resistance of the connector (3I) in test harness I or I2. Connector & terminal (3I) No. 2 No. 4: CHECK FRONT SUB-SENSOR (RH) AND FRONT SUB-SENSOR HARNESS (RH). Measure the resistance between connector (3I) in test harness I or I2 and the chassis ground. Connector & terminal (3I) No. 2 Chassis ground: (3I) No. 4 Chassis ground: CHECK AIRBAG MAIN HARNESS AND FRONT SUB-SENSOR HARNESS (RH). 1) Disconnect connector (AB16) from the front sub-sensor. <Ref. to AB-21 Front Sub Sensor.> 2) Connect connector (1H) in test harness H to connector (AB16). 3) Measure the resistance between connector (3I) in test harness I or I2 and connector (3H) in test harness H. Connector & terminal (3I) No. 2 (3H) No. 5: (3I) No. 4 (3H) No. 6: CHECK AIRBAG MAIN HARNESS AND FRONT SUB-SENSOR HARNESS (RH). Measure the resistance between connector (3I) in test harness I or I2 and the chassis ground. Connector & terminal (3I) No. 2 Chassis ground: (3I) No. 4 Chassis ground: CHECK AIRBAG MAIN HARNESS 1) Remove the instrument panel. <Ref. to EI-31 Instrument Panel Assembly.> 2) Disconnect connector (AB15) from (AB14), and connect connector (1F) in test harness F to connector (AB14). 3) Measure the resistance between connector (3I) in test harness I or I2 and connector (3F) in test harness F. Connector & terminal (3I) No. 2 (3F) No. 3: (3I) No. 4 (3F) No. 4:
Go to step 3.
Is the resistance less than 10?
Go to step 4.
Go to step 5.
Go to step 5.
Go to step 6.
AB-56

No. 6 Step CHECK AIRBAG MAIN HARNESS Measure the resistance between connector (3I) in test harness I or I2 and the chassis ground. Connector & terminal (3I) No. 2 Chassis ground: (3I) No. 4 Chassis ground: CHECK FRONT SUB-SENSOR HARNESS (RH). 1) Connect connector (2F) in test harness F to the connector (AB15). 2) Measure the resistance between connector (3H) in test harness H and connector (3F) in the test harness F. Connector & terminal (3F) No. 6 (3H) No. 5: (3F) No. 5 (3H) No. 6: CHECK FRONT SUB-SENSOR HARNESS (RH). Measure the resistance between connector (3H) in test harness H and connector (3F) in test harness F. Connector & terminal (3F) No. 6 (3H) No. 6: (3F) No. 5 (3H) No. 5: CHECK FRONT SUB-SENSOR HARNESS (RH). Measure the resistance between connector (3F) in test harness F and the chassis ground. Connector & terminal (3F) No. 6 Chassis ground: (3F) No. 5 Chassis ground: CHECK FRONT SUB-SENSOR (RH). 1) Connect connector (2H) in test harness H to front sub-sensor (RH). 2) Measure the resistance of the connector (3H) in test harness H. Connector & terminal (3H) No. 3 No. 4: CHECK FRONT SUB-SENSOR (RH). Measure the resistance between connector (3H) in test harness H and the chassis ground. Connector & terminal (3H) No. 3 Chassis ground: (3H) No. 4 Chassis ground:

No Replace airbag main harness. <Ref. to AB-16 Main Harness.>
Check Yes Is the resistance more than Go to step 7. 1 M?
Go to step 8.
Replace the front sub-sensor harness (RH) <Ref. to AB-22 Front Sub Sensor Harness.>
Replace the front sub-sensor harness (RH). <Ref. to AB-22, Front Sub Sensor Harness.>
Replace the front sub-sensor harness (RH) <Ref. to AB-22 Front Sub Sensor Harness.>
10
Is the resistance between 750 and 1 K?
Go to step 11.
Replace the front sub-sensor (RH) <Ref. to AB-21 Front Sub Sensor.>
11
Is the resistance more than Finish the diagno- Replace the front 1 M? sis. sub-sensor (RH) <Ref. to AB-21 Front Sub Sensor.>
AB-57
MEMO:
AB-58
DIAGNOSTIC CHART WITH TROUBLE CODE K: TROUBLE CODE 32

S002630C95
DIAGNOSIS: Front sub-sensor harness (LH) circuit is shorted. Front sub-sensor harness (LH) circuit is open. Front sub-sensor (LH) is faulty. Airbag control module is faulty. CAUTION: Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the ground cable from the battery, and wait more than 20 seconds before starting to work. Before replacing the airbag module, roll connector, control module, and sensor, reconnect each part and confirm that the warning light operates properly. When inspecting the airbag main harness, disconnect the driver s airbag module and passenger s airbag module connectors for safety reasons. WIRING DIAGRAM:
S5M0466
AB-59

No. 1

Check Is the resistance between 750 and 1 K? Yes Go to step 2. No Go to step 3.
Step CHECK FRONT SUB-SENSOR (LH) AND FRONT SUB-SENSOR HARNESS (RH). 1) Turn the ignition switch OFF, disconnect the battery ground cable, and wait more than 20 seconds. 2) Disconnect connector (AB6) from the airbag control module, and connect connector (1I) in the test harness I or I2 to connector (AB6). <Ref. to AB-18 Airbag Control Module.> 3) Measure the resistance of the connector (3I) in the test harness I or I2. Connector & terminal (3I) No. 1 No. 3: CHECK FRONT SUB-SENSOR (LH) AND FRONT SUB-SENSOR HARNESS (RH). Measure the resistance between connector (3I) in test harness I or I2 and the chassis ground. Connector & terminal (3I) No. 1 Chassis ground: (3I) No. 3 Chassis ground: CHECK AIRBAG MAIN HARNESS AND FRONT SUB-SENSOR HARNESS (LH). 1) Disconnect the connector (AB13) from the front sub-sensor. <Ref. to AB-21 Front Sub Sensor.> 2) Connect connector (1H) in test harness H to connector (AB13). 3) Measure the resistance between connector (3I) in test harness I or I2 and connector (3H) in test harness H. Connector & terminal (3I) No. 3 (3H) No. 5: (3I) No. 1 (3H) No. 6: CHECK AIRBAG MAIN HARNESS AND FRONT SUB-SENSOR HARNESS (LH). Measure the resistance between connector (3I) in test harness I or I2 and the chassis ground. Connector & terminal (3I) No. 3 Chassis ground: (3I) No. 1 Chassis ground: CHECK AIRBAG MAIN HARNESS. 1) Remove the instrument panel. <Ref. to EI-31 Instrument Panel Assembly.> 2) Disconnect connector (AB11) from (AB12), and connect connector (1F) in test harness F to (AB11). 3) Measure the resistance between connector (3I) in test harness I or I2 and connector (3F) in test harness F. Connector & terminal (3I) No. 3 (3F) No. 3: (3I) No. 1 (3F) No. 4:
Go to step 3.
Go to step 4.
Go to step 5.
Go to step 5.
Go to step 6.
Replace the airbag main harness. <Ref. to AB-16 Main Harness.>
AB-60

No. 6 Step CHECK AIRBAG MAIN HARNESS. Measure the resistance between connector (3I) in the test harness I or I2 and the chassis ground. Connector & terminal (3I) No. 3 Chassis ground: (3I) No. 1 Chassis ground: CHECK FRONT SUB-SENSOR HARNESS (LH). 1) Connect connector (2F) in test harness F to connector (AB12). 2) Measure the resistance between connector (3H) in test harness H and connector (3F) in test harness F. Connector & terminal (3F) No. 6 (3H) No. 5: (3F) No. 5 (3H) No. 6: CHECK FRONT SUB-SENSOR HARNESS (LH). Measure the resistance between connector (3H) in test harness H and connector (3F) in test harness F. Connector & terminal (3F) No. 6 (3H) No. 6: (3F) No. 5 (3H) No. 5: CHECK FRONT SUB-SENSOR HARNESS (LH). Measure the resistance between connector (3F) in test harness F and the chassis ground. Connector & terminal (3F) No. 6 Chassis ground: (3F) No. 5 Chassis ground: CHECK FRONT SUB-SENSOR (LH). 1) Connect connector (2H) in test harness H to front sub-sensor (LH). 2) Measure the resistance of the connector (3H) in test harness H. Connector & terminal (3H) No. 3 No. 4: CHECK FRONT SUB-SENSOR (LH). Measure the resistance between connector (3H) in test harness H and the chassis ground. Connector & terminal (3H) No. 3 Chassis ground: (3H) No. 4 Chassis ground:

No Replace the airbag main harness. <Ref. to AB-16 Main Harness.>
Check Yes Is the resistance more than Go to step 7. 1 M?
Go to step 8.
Replace the front sub-sensor harness (LH). <Ref. to AB-22 Front Sub Sensor Harness.>
Replace the front sub-sensor harness (LH). <Ref. to AB-22, Front Sub Sensor Harness.>
Replace the front sub-sensor harness (LH). <Ref. to AB-22 Front Sub Sensor Harness.>
10
Is the resistance between 750 and 1 K?
Go to step 11.
Replace the front sub-sensor (LH). <Ref. to AB-21 Front Sub Sensor.>
11
Is the resistance more than Finish the diagno- Replace the front 1 M? sis. sub-sensor (LH). <Ref. to AB-21 Front Sub Sensor.>
AB-61
MEMO:
AB-62
DIAGNOSTIC CHART WITH TROUBLE CODE L: TROUBLE CODE 41

S002630D28
DIAGNOSIS: Side airbag harness (RH) is faulty. Side airbag module (RH) is faulty. Airbag control module is faulty. CAUTION: Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the ground cable from the battery, and wait more than 20 seconds before starting to work. Before replacing the airbag module, roll connector, control module, and sensor, reconnect each part and confirm that the warning light operates properly. When inspecting the side airbag harness, disconnect the side airbag module connector for the safety reasons. WIRING DIAGRAM:
S5M0517
AB-63

No. 1

Check Does the airbag warning light operate properly? Yes No Replace front seat Go to step 2. with side airbag module (RH). <Ref. to SE-5 Front Seat.>
Step CHECK SIDE AIRBAG MODULE. 1) Turn the ignition switch OFF, disconnect the battery ground cable, and wait more than 20 seconds. 2) Disconnect connector (AB25) from (AB24), and connect connector (1F) in test harness F to (AB24). 3) Connect airbag resistor to connector (3F) in test harness F. 4) Connect the battery ground cable, and turn the ignition switch ON. CHECK SIDE AIRBAG HARNESS (RH). 1) Turn the ignition switch OFF, disconnect the battery ground cable, and wait more than 20 seconds. 2) Disconnect airbag resistor from test harness. 3) Disconnect the connector (AB18) from air bag control module. <Ref. to AB-18 Airbag Control Module.> 4) Connect connector (1I) in test harness I or I2 to connector (AB18). 5) Measure the resistance between connector (3I) in test harness I or I2 and connector (3F) in test harness F. Connector & terminal (3I) No. 7 (3F) No. 3: (3I) No. 9 (3F) No. 4: CHECK SIDE AIRBAG HARNESS (RH). Measure the resistance of the connector (3I) in test harness I or I2. Connector & terminal (3I) No. 7 No. 9: CHECK SIDE AIRBAG HARNESS (RH). Measure the resistance of the connector (3F) in test harness F. Connector & terminal (3F) No. 3 No. 4: CHECK SIDE AIRBAG HARNESS (RH). Measure the resistance between connector (3F) in test harness F and the chassis ground. Connector & terminal (3F) No. 3 Chassis ground: (3F) No. 4 Chassis ground: CHECK SIDE AIRBAG HARNESS (RH). Measure the resistance between connector (3I) in test harness I or I2 and the chassis ground. Connector & terminal (3I) No. 7 Chassis ground: (3I) No. 9 Chassis ground:
Go to step 3.
Replace side airbag harness. <Ref. to AB-17 Side Airbag Harness.>
Is the resistance more 1M?
Go to step 5.
Replace side airbag harness. <Ref. to AB-17 Side Airbag Harness.> Replace side airbag harness. <Ref. to AB-17 Side Airbag Harness.> Replace side airbag harness. <Ref. to AB-17 Side Airbag Harness.>
AB-64
DIAGNOSTIC CHART WITH TROUBLE CODE M: TROUBLE CODE 42

S002630D33
DIAGNOSIS: Side airbag harness (LH) is faulty. Side airbag module (LH) is faulty. Airbag control module is faulty. CAUTION: Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the ground cable from the battery, and wait more than 20 seconds before starting to work. Before replacing the airbag module, roll connector, control module, and sensor, reconnect each part and confirm that the warning light operates properly. When inspecting the side airbag harness, disconnect the side airbag module connector for the safety reasons. WIRING DIAGRAM:
S5M0468
AB-65

No. 1

Check Does the airbag warning light operate properly? Yes No Replace front seat Go to step 2. with side airbag module (LH). <Ref. to SE-5 Front Seat.>
Step CHECK SIDE AIRBAG MODULE. 1) Turn the ignition switch OFF, disconnect the battery ground cable, and wait more than 20 seconds. 2) Disconnect connector (AB20) from (AB19), and connect connector (1F) in test harness F to (AB19). 3) Connect airbag resistor to connector (3F) in test harness F. 4) Connect the battery ground cable, and turn the ignition switch ON. CHECK SIDE AIRBAG HARNESS (LH). 1) Turn ignition switch OFF, disconnect the battery ground cable, and wait more than 20 seconds. 2) Disconnect airbag resistor from the test harness. 3) Disconnect the connector (AB17) from the airbag control module. <Ref. to AB-18 Airbag Control Module.> 4) Connect connector (1I) in test harness I or I2 to connector (AB17). 5) Measure the resistance between connector (3I) in test harness I or I2 and connector (3F) in test harness F. Connector & terminal (3I) No. 10 (3F) No. 4: (3I) No. 12 (3F) No. 3: CHECK SIDE AIRBAG HARNESS (LH). Measure the resistance of the connector (3I) in test harness I or I2. Connector & terminal (3I) No. 10 No. 12: CHECK SIDE AIRBAG HARNESS (LH). Measure the resistance of the connector (3F) in test harness F. Connector & terminal (3F) No. 3 No. 4: CHECK SIDE AIRBAG HARNESS (LH). Measure the resistance between connector (3F) in test harness F and the chassis ground. Connector & terminal (3F) No. 3 Chassis ground: (3F) No. 4 Chassis ground: CHECK SIDE AIRBAG HARNESS (LH). Measure the resistance between connector (3I) in test harness I or I2 and the chassis ground. Connector & terminal (3I) No. 10 Chassis ground: (3I) No. 12 Chassis ground:
Go to step 3.
Replace side airbag harness. <Ref. to AB-17 Side Airbag Harness.> Replace side airbag harness. <Ref. to AB-17 Side Airbag Harness.> Replace side airbag harness. <Ref. to AB-17 Side Airbag Harness.>
Is the resistance more than Replace airbag 1 M? control module. <Ref. to AB-18 Airbag Control Module.>
AB-66
DIAGNOSTIC CHART WITH TROUBLE CODE N: TROUBLE CODE 45

S002630D45
DIAGNOSIS: Side airbag harness (RH) is shorted to power supply. Airbag control module is faulty. CAUTION: Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the ground cable from the battery, and wait more than 20 seconds before starting to work. Before replacing the airbag module, roll connector, control module, and sensor, reconnect each part and confirm that the warning light operates properly. When inspecting the side airbag harness, disconnect the side airbag module connector for the safety reasons. WIRING DIAGRAM:
S5M0517
AB-67

No. 1

Check Does airbag warning light operate properly? Yes No Replace front seat Go to step 2. with side airbag module (RH). <Ref. to SE-5 Front Seat.>
Step CHECK SIDE AIRBAG MODULE. 1) Turn the ignition switch OFF, disconnect the battery ground cable, and wait more than 20 seconds. 2) Disconnect the connector (AB25) from (AB24), and connect connector (1F) in test harness F to (AB24 ). 3) Connect airbag resistor to connector (3F) in test harness F. 4) Connect the battery ground cable, and turn the ignition switch ON. CHECK SIDE AIRBAG HARNESS (RH). 1) Turn the ignition switch OFF, disconnect the battery ground cable, and wait more than 20 seconds. 2) Disconnect airbag resistor from the test harness. 3) Disconnect the connector (AB18) from the airbag control module. <Ref. to AB-18 Airbag Control Module.> 4) Connect connector (1I) in test harness I or I2 to connector (AB18). 5) Connect the battery ground cable, and turn the ignition switch ON. 6) Measure the voltage between connector (3I) in test harness I or I2 and the chassis ground. Connector & terminal (3I) No. 7 (+) Chassis ground (): (3I) No. 9 (+) Chassis ground ():
AB-68
DIAGNOSTIC CHART WITH TROUBLE CODE O: TROUBLE CODE 46

S002630D50
DIAGNOSIS: Side airbag harness (LH) is shorted to power supply. Airbag control module is faulty. CAUTION: Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the ground cable from the battery, and wait more than 20 seconds before starting to work. Before replacing the airbag module, roll connector, control module, and sensor, reconnect each part and confirm that the warning light operates properly. When inspecting the side airbag harness, disconnect the side airbag module connector for the safety reasons. WIRING DIAGRAM:
S5M0468
AB-69

No. 1

Check Does airbag warning light operate properly? Yes No Replace front seat Go to step 2. with side airbag module (LH). <Ref. to SE-5 Front Seat.>
Step CHECK SIDE AIRBAG MODULE. 1) Turn the ignition switch OFF, disconnect the battery ground cable, and wait more than 20 seconds. 2) Disconnect connector (AB20) from (AB19), and connect connector (1F) in test harness F to (AB19). 3) Connect airbag resistor to connector (3F) in test harness F. 4) Connect the battery ground cable and turn the ignition switch ON. CHECK SIDE AIRBAG HARNESS (LH). 1) Turn the ignition switch OFF, disconnect the battery ground cable, and wait more than 20 seconds. 2) Disconnect airbag resistor from the test harness. 3) Disconnect the connector (AB17) from the airbag control module. <Ref. to AB-18 Airbag Control Module.> 4) Connect connector (1I) in test harness I or I2 to connector (AB17). 5) Connect the battery ground cable, and turn the ignition switch ON. 6) Measure the voltage between connector (3I) in test harness I or I2 and the chassis ground. Connector & terminal (3I) No. 10 (+) Chassis ground (): (3I) No. 12 (+) Chassis ground ():
AB-70
DIAGNOSTIC CHART WITH TROUBLE CODE P: TROUBLE CODE 51

S002630D60
DIAGNOSIS: Side airbag sensor (RH) is faulty. Side airbag harness (RH) is faulty. Airbag control module is faulty. CAUTION: Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the ground cable from the battery, and wait more than 20 seconds before starting to work. Before replacing the airbag module, roll connector, control module, and sensor, reconnect each part and confirm that the warning light operates properly. When inspecting the side airbag harness, disconnect the side airbag module connector for the safety reasons. WIRING DIAGRAM:
S5M0517
AB-71

No. 1

Check Is the resistance less than 10 ? Yes Go to step 2. No Replace side airbag harness. <Ref. to AB-17 Side Airbag Harness.>
Step CHECK SIDE AIRBAG HARNESS (RH). 1) Turn the ignition switch OFF, disconnect the battery ground cable, and wait more than 20 seconds. 2) Disconnect connector (AB25) from (AB24). 3) Disconnect connector (AB18) from the airbag control module. <Ref. to AB-18 Airbag Control Module.> 4) Connect connector (1I) in test harness I or I2 to the connector (AB18). 5) Disconnect connector (AB28) from the side airbag sensor (RH), and connect connector (1G) in test harness G to connector (AB28). 6) Measure the resistance between connector (3I) in test harness I or I2 and connector (3G) in test harness G. Connector & terminal (3I) No. 17 (3G) No. 2: (3I) No. 18 (3G) No. 1: (3I) No. 19 (3G) No. 5: (3I) No. 20 (3G) No. 4: CHECK SIDE AIRBAG HARNESS (RH). Measure the resistance between connector (3I) in test harness I or I2 and the chassis ground. Connector & terminal (3I) No. 17 Chassis ground: (3I) No. 18 Chassis ground: (3I) No. 19 Chassis ground: (3I) No. 20 Chassis ground:
Is the resistance more than Replace side air1 M? bag sensor (RH). <Ref. to AB-19 Side Airbag Sensor.> When sensor replacement is not OK, replace the airbag control module. <Ref. to AB-18 Airbag Control Module.>
AB-72
DIAGNOSTIC CHART WITH TROUBLE CODE Q: TROUBLE CODE 52

S002630D64
DIAGNOSIS: Side airbag sensor (LH) is faulty. Side airbag harness (LH) is faulty. Airbag control module is faulty. CAUTION: Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the ground cable from the battery, and wait more than 20 seconds before starting to work. Before replacing the airbag module, roll connector, control module, and sensor, reconnect each part and confirm that the warning light operates properly. When inspecting the side airbag harness, disconnect the side airbag module connector for the safety reasons. WIRING DIAGRAM:
S5M0468
AB-73

No. 1

Check Is the resistance less than 10 ? Yes Go to step 2. No Replace side airbag harness. <Ref. to AB-17 Side Airbag Harness.>
Step CHECK SIDE AIRBAG HARNESS (LH). 1) Turn the ignition switch OFF, disconnect the battery ground cable, and wait more than 20 seconds. 2) Disconnect connector (AB20) from (AB19). 3) Disconnect connector (AB17) from the airbag control module. <Ref. to AB-18 Airbag Control Module.> 4) Connect connector (1I) in test harness I or I2 to connector (AB17). 5) Disconnect connector (AB23) from the side airbag sensor (LH), and connect connector (1G) in test harness G to connector (AB23). 6) Measure the resistance between connector (3I) in test harness I or I2 and connector (3G) in test harness G. Connector & terminal (3I) No. 5 (3G) No. 4: (3I) No. 14 (3G) No. 5: (3I) No. 15 (3G) No. 1: (3I) No. 16 (3G) No. 2: CHECK SIDE AIRBAG HARNESS (RH). Measure the resistance between connector (3I) in test harness I or I2 and the chassis ground. Connector & terminal (3I) No. 5 Chassis ground: (3I) No. 14 Chassis ground: (3I) No. 15 Chassis ground: (3I) No. 16 Chassis ground:
Is the resistance more than Replace side air1 M? bag sensor (LH). <Ref. to AB-19 Side Airbag Sensor.> When sensor replacement is not OK, replace the airbag control module. <Ref. to AB-18 Airbag Control Module.>
R: TROUBLE CODE 53
S002630D69
DIAGNOSIS: Side airbag sensor (RH) is faulty. When Code 53 is displayed, the circuit within the side airbag sensor (RH) is faulty. Replace the side airbag sensor (RH). <Ref. to AB-19 Side Airbag Sensor.>
S: TROUBLE CODE 54
S002630D70
DIAGNOSIS: Side airbag sensor (LH) is faulty. When Code 54 is displayed, the circuit within the side airbag sensor (LH) is faulty. Replace the side airbag sensor (LH). <Ref. to AB-19 Side Airbag Sensor.>
T: TROUBLE CODE 55
S002630D73
This code is displayed when the side airbag is deployed. When this code is displayed, the memory cannot be erased. Replace the following parts. Airbag control module. <Ref. to AB-18 Airbag Control Module.> Front seat with side airbag module. (Operating side) <Ref. to SE-5 Front Seat.> Side airbag sensor. (Operating side) <Ref. to AB-19 Side Airbag Sensor.>
AB-74
CRUISE CONTROL SYSTEM (DIAGNOSTICS)
CC
1. 2. 3. 4. 5. 6. 7. 8. 9. Page Basic Diagnostic Procedure ........................................................................2 General Description.....................................................................................5 Electrical Components Location..................................................................8 Cruise Control Module I/O Signal .............................................................10 Subaru Select Monitor...............................................................................19 Diagnostics Chart with Symptom (Turbo Model) ......................................21 Diagnostics Chart with Trouble Code (Turbo Model)................................37 Diagnostics Chart with Symptom (Non-turbo Model) ...............................49 Diagnostics Chart with Trouble Code (Non-turbo Model).........................57
Cruise Control System (Diagnostics)

S003501

A: PROCEDURE
No. 1
S003501E45
Step Check Is cruise control main START DIAGNOSIS. switch turned ON? 1) Perform pre-inspection. <Ref. to CC-6 INSPECTION, General Description.> 2) Check cruise control main switch operation.
Yes Go to step 2.
2 3
PREPARE SUBARU SELECT MONITOR. PERFORM CRUISE CANCEL CONDITIONS DIAGNOSIS. Perform cruise cancel conditions diagnosis. <Ref. to CC-19 Subaru Select Monitor.> CHECK CRUISE CONTROL SET OPERATION. Check cruise control set operation.
Is the select monitor available? Is trouble code indicated?
Go to step 3. Go to Diagnostics Chart with Trouble Code.
No Go to symptom 1. Turbo model: <Ref. to CC-21 SYMPTOM CHART, Diagnostics Chart with Symptom (Turbo Model).> Non-turbo model: <Ref. to CC-49, SYMPTOM CHART, Diagnostics Chart with Symptom (Non-turbo Model).> Go to step 4. Go to step 4.
Can cruise control be set Go to step 5. while driving at 40 km/h (25 MPH)?
CHECK VEHICLE SPEED IS HELD WITHIN SET SPEED. Make sure vehicle speed is held within set speed.
Is vehicle speed held within Go to step 6. set speed 3 km/h (2 MPH) ?
Go to symptom 2. Turbo model: <Ref. to CC-21 SYMPTOM CHART, Diagnostics Chart with Symptom (Turbo Model).> Non-turbo model: <Ref. to CC-49, SYMPTOM CHART, Diagnostics Chart with Symptom (Non-turbo Model).> Go to symptom 3. Turbo model: <Ref. to CC-21 SYMPTOM CHART, Diagnostics Chart with Symptom (Turbo Model).> Non-turbo model: <Ref. to CC-49, SYMPTOM CHART, Diagnostics Chart with Symptom (Non-turbo Model).>
CC-2

No. 6 Step CHECK RESUME/ACCEL OPERATION. Check RESUME/ACCEL operation. Check Does vehicle speed increase or return to set speed after RESUME/ ACCEL switch has been pressed?

Yes Go to step 7. No Go to symptom 4. Turbo model: <Ref. to CC-21 SYMPTOM CHART, Diagnostics Chart with Symptom (Turbo Model).> Non-turbo model: <Ref. to CC-49, SYMPTOM CHART, Diagnostics Chart with Symptom (Non-turbo Model).> Go to symptom 5. Turbo model:<Ref. to CC-21 SYMPTOM CHART, Diagnostics Chart with Symptom (Turbo Model).> Non-turbo model: <Ref. to CC-49, SYMPTOM CHART, Diagnostics Chart with Symptom (Non-turbo Model).> Go to symptom 6. Turbo model: <Ref. to CC-21 SYMPTOM CHART, Diagnostics Chart with Symptom (Turbo Model).> Non-turbo model: <Ref. to CC-49, SYMPTOM CHART, Diagnostics Chart with Symptom (Non-turbo Model).>
CHECK SET/COAST OPERATION. Check SET/COAST operation.
Go to step 8. Does vehicle speed decrease after SET/COAST switch has been pressed?
CHECK CANCEL OPERATION. Check CANCEL operation.
Is cruise control released after CANCEL switch has been pressed?
Go to step 9.
CC-3

No. 9

Check Is cruise control released after brake pedal has been depressed? Yes Go to step 10. No Go to symptom 7. Turbo model: <Ref. to CC-21 SYMPTOM CHART, Diagnostics Chart with Symptom (Turbo Model).> Non-turbo model: <Ref. to CC-49, SYMPTOM CHART, Diagnostics Chart with Symptom (Non-turbo Model).> Go to symptom 8. Turbo model: <Ref. to CC-21 SYMPTOM CHART, Diagnostics Chart with Symptom (Turbo Model).> Non-turbo model: <Ref. to CC-49, SYMPTOM CHART, Diagnostics Chart with Symptom (Non-turbo Model).>
Step CHECK CRUISE CONTROL RELEASE OPERATION. Check cruise control release operation.
10
CHECK CRUISE CONTROL RELEASE OPERATION. Check cruise control release operation.
Finish the diagIs cruise control released after clutch pedal has been nostics. depressed? (MT)
CC-4
GENERAL DESCRIPTION
A: CAUTION
S003001A03
S003001
1. SUPPLEMENTAL RESTRAINT SYSTEM AIRBAG S003001A0301

Airbag system wiring harness is routed near the cruise control module and cruise control command switch.
CAUTION: All Airbag system wiring harness and connectors are colored yellow. Do not use electrical test equipment on these circuits. Be careful not to damage Airbag system wiring harness when servicing the cruise control module and cruise control command switch.
B: PREPARATION TOOL
1. SPECIAL TOOLS
ILLUSTRATION
S003001A1701
S003001A17
B2M3876
22771AA030
SELECT MONITOR KIT
B2M3877
2. GENERAL TOOLS
Circuit Tester
S003001A1702
TOOL NAME
CC-5
GENERAL DESCRIPTION
5. CABLE FREE PLAY
S003001A1006
C: INSPECTION
1. BATTERY
S003001A1002
S003001A10
Measure battery voltage and specific gravity of electrolyte. Standard voltage: 12 V, or more Specific gravity: Above 1.260
2. CRUISE CONTROL CABLE
S003001A1003
B6M0241A
Check that the throttle cam-to-lever clearance is within specifications. Throttle cam-to-lever clearance: 0 1 mm (0 0.04 in) If NG, adjust the clearance with the adjust nut. NOTE: Check that the cap is positioned in the groove.
S6M0099A
6. VACUUM HOSE (NON-TURBO MODEL)

S003001A1009
Check the cruise control cable installation. If NG, install the cable securely.
3. ACCELERATOR CABLE
S003001A1004
S6M0101A
S6M0099A
Check vacuum hose (which connects actuator and intake manifold). If NG, replace vacuum hose.
Check movement of the accelerator cable when the cruise control throttle is moved by hand. If NG, check throttle cam.
4. THROTTLE CAM
S003001A1005
Check that the throttle cam moves smoothly. If NG, repair throttle cam.
CC-6
GENERAL DESCRIPTION
7. ACTUATOR (NON-TURBO MODEL)
No. 1
S003001A1010
Step MEASURE RESISTANCE OF VALVE. 1) Disconnect connector from actuator. 2) Measure resistance between terminals of actuator. Terminals No. 2 No. 3: MEASURE RESISTANCE OF VALVE. Measure resistance between terminals of actuator. Terminals No. 2 No. 1: MEASURE RESISTANCE OF VALVE. Measure resistance between terminals of actuator. Terminals No. 2 No. 4: CHECK FOR LEAKAGE AND STICKING OF VALVES. 1) Disconnect connector from actuator. 2) Disconnect vacuum hose from actuator. 3) Connect vacuum pump. 4) Apply a vacuum pressure of 40.0 kPa (300 mmHg, 11.81 inHg) to actuator. 5) Make sure that cruise control cable moves smoothly when connecting + (positive) battery cable to terminal No. 2 and (negative) battery cable to terminals No. 1, 3 and 4 of actuator connector. CHECK FOR LEAKAGE AND STICKING OF VALVES. When the battery cable is disconnected from former condition, make sure the cable returns to its original position smoothly. CHECK CABLE MOVEMENT. 1) Connect + (positive) battery cable to terminal No. 2 and (negative) battery cable to terminals No. 1, 3 and 4 of actuator connector. 2) Apply a vacuum pressure of 40 kPa (300 mmHg, 11.81 inHg) to actuator. CHECK CABLE MOVEMENT. After step 6, disconnect (negative) battery cable from terminal 3 of actuator connector and remove vacuum pump. CHECK CABLE MOVEMENT. After step 7, disconnect (negative) battery cable from terminal 1 of actuator connector.
Check Is resistance less than 22 ?
Yes Go to step 2.
No Replace actuator. <Ref. to CC-7, REMOVAL, Actuator (Non-turbo Model).> Replace actuator. <Ref. to CC-7, REMOVAL, Actuator (Non-turbo Model).> Replace actuator. <Ref. to CC-7, REMOVAL, Actuator (Non-turbo Model).> Replace actuator. <Ref. to CC-7, REMOVAL, Actuator (Non-turbo Model).>
Go to step 3.
Go to step 4.
Does cruise control cable have a stroke of 35 mm (1.38 in) within 3 seconds?
Go to step 5.
Does cruise control cable Go to step 6. get back to its original position within 1.5 seconds?
Does cruise control perform Go to step 7. pull operation?
Replace actuator. <Ref. to CC-7, REMOVAL, Actuator (Non-turbo Model).> Replace actuator. <Ref. to CC-7, REMOVAL, Actuator (Non-turbo Model).>
Does cruise control perform Go to step 8. hold operation?
Does cruise control perform End of actuator release operation? inspection.
Replace actuator. <Ref. to CC-7, REMOVAL, Actuator (Non-turbo Model).> Replace actuator. <Ref. to CC-7, REMOVAL, Actuator (Non-turbo Model).>
CC-7

S003507

A: LOCATION
S003507A13
NOTE: Electrical component locations are for LHD vehicles. Cruise control actuator and cruise control module locations for RHD vehicles are symmetrically opposite.
1. TURBO MODEL
S003507A1301
S6M0487A
(1) Actuator (2) Inhibitor switch (AT) (3) Cruise control main switch
CC-8

2. NON-TURBO MODEL
S003507A1302
S6M0106A
(1) (2) (3) (4) (5) (6) (7)
Actuator (with valves) Inhibitor switch (AT) Cruise control main switch Cruise control command switch Cruise control module Stop and brake switch Clutch switch (MT)
CC-9
CRUISE CONTROL MODULE I/O SIGNAL

S003515
4. Cruise Control Module I/O Signal

1. TURBO MODEL
S003515A0801 S003515A08
G6M0015
Content Main light Inhibitor switch (AT)
Terminal No. 1 4
Motor B
Ground Motor A
6 7
RESUME/ACCEL switch
SET/COAST switch
10
Main power supply Ignition switch Motor C
11 12 13
Motor clutch
14
Cruise control main switch
15
Brake switch
16
Measuring conditions and I/O signals (ignition switch ON and engine idling) Battery voltage is present when main switch is turned OFF. 0 volt is present when main switch is turned ON. Battery voltage is present when selector lever is other than P or N position. 0 volt is present when selector lever is set to P or N position. ON-and-OFF (0-and-battery voltage) operation is alternately repeated while cruise control is operating. 0 volt is present when main switch is turned OFF. ON-and-OFF (0-and-battery voltage) operation is alternately repeated while cruise control is operating. 0 volt is present when main switch is turned OFF. Battery voltage is present when command switch is turned to RESUME/ ACCEL position. 0 volt is present when command switch is released. Battery voltage is present when command switch is turned to SET/COAST position. 0 volt is present when command switch is released. Battery voltage is present when main power is turned ON. 0 volt is present when main power is turned OFF. Battery voltage is present when ignition switch is turned ON. 0 volt is present when ignition switch is turned OFF. ON-and-OFF (0-and-battery voltage) operation is alternately repeated while cruise control is operating. 0 volt is present when main switch is turned OFF. ON-and-OFF (0-and-battery voltage) operation is alternately repeated while cruise control is operating. 0 volt is present when vehicle is stopped. Battery voltage is present during pressing the cruise control main switch, and then battery voltage is present while main switch is turned ON. 0 volt is present when main switch is turned OFF. Leave clutch pedal released (MT), while cruise control main switch is turned ON. Then check that; Battery voltage is present when brake pedal is released. 0 volt is present when brake pedal is depressed. Additionally only in MT vehicle, keep the cruise control main switch to ON and leave brake pedal released. Then check that; Battery voltage is present when clutch pedal is released. 0 volt is present when clutch pedal is depressed.
CC-10

Content Data link connector Data link connector Vehicle speed sensor (MT) TCM (AT) Terminal No. 17 18 19
Stop light switch
20
Measuring conditions and I/O signals (ignition switch ON and engine idling) Lift-up the vehicle until all four wheels are raised off ground, and then rotate any wheel manually. Approx. 5 and 0 volt pulse signals are alternately input to cruise control module. Turn ignition switch to OFF. Then check that; Battery voltage is present when brake pedal is depressed. 0 volt is present when brake pedal is released.
NOTE: Voltage at terminals 5, 7, 13 and 14 cannot be checked unless vehicle is driving by cruise control operation.
2. NON-TURBO MODEL
S003515A0802
G6M0015
Content Vent valve
Terminal No. 1
Measuring conditions and I/O signals (ignition switch ON and engine idling) Power supply is ON when vehicle is stopped. ON-and-OFF (0-and-battery voltage) operation is alternately repeated while cruise control is operating. Power supply is ON when vehicle is stopped. ON-and-OFF (0-and-battery voltage) operation is alternately repeated while cruise control is operating. Battery voltage is present when ignition switch is turned ON. 0 volt is present when ignition switch is turned OFF. Battery voltage is present when main power is turned ON. 0 volt is present when main power is turned OFF. Battery voltage is present when main power is turned ON. 0 volt is present when main power is turned OFF. Battery voltage is present when command switch is turned to SET/COAST position. 0 volt is present when command switch is released. Battery voltage is present when command switch is turned to RESUME/ ACCEL position. 0 volt is present when command switch is released.
Safety valve
Ignition switch Cruise control main switch Power supply to vacuum valve, vent valve, safety valve and indicator light SET/COAST switch
3 4 5
RESUME/ACCEL switch
CC-11

Content Brake switch

Terminal No. 8 Measuring conditions and I/O signals (ignition switch ON and engine idling) Set selector lever to any position other than P or N position (AT) / leave clutch pedal released (MT), while cruise control main switch is turned ON. Then check that; Battery voltage is present when brake pedal is released. 0 volt is present when brake pedal is depressed, or Battery voltage is present when clutch pedal is released (MT). 0 volt is present when clutch pedal is depressed (MT). Battery voltage is present when selector lever is in any position other than P or N position (AT). 0 volt is present when selector lever is set to P or N position (AT). Battery voltage is present when clutch pedal is released (MT). 0 volt is present when clutch pedal is depressed (MT). Battery voltage is present when selector lever is in any position other than P or N position (AT). 0 volt is present when selector lever is set to P or N position (AT). Power supply is ON when vehicle is stopped. ON-and-OFF (0-and-battery voltage) operation is alternately repeated while cruise control is operating. TCM emits a ground-level signal while driving vehicle at least 40 km/h (25 MPH) with SET switch ON. Lift-up the vehicle until all four wheels are raised off ground, and then rotate any wheel manually. Approx. 5 and 0 volt pulse signals are alternately input to cruise control module. Turn ignition switch to OFF. Then check that; Battery voltage is present when brake pedal is depressed. 0 volt is present when brake pedal is released.
Clutch switch (MT)/ Inhibitor switch (AT)
Vacuum valve
11
Set signal to transmission control module (AT) Ground Check connector/ OBD-II service connector Check connector/ OBD-II service connector Vehicle speed sensor 2 (MT) Automatic transmission control module (AT) Stop light switch
12 13 14 15 18
19
Ground 20 NOTE: Voltage at terminals 1, 2, 11 and 12 cannot be checked unless vehicle is driving by cruise control operation.
CC-12
CRUISE CONTROL MODULE I/O SIGNAL B: SCHEMATIC

S003515A21
1. CRUISE CONTROL TURBO MODEL
S003515A2107
SG71-20A
CC-13
SG71-20B
CC-14
SG71-20C
CC-15
2. CRUISE CONTROL NON-TURBO MODEL S003515A2108
SG71-21A
CC-16
SG71-21B
CC-17
SG71-21C
CC-18

A: OPERATION
1. GENERAL
S003503A16 S003503A1604
S003503
2. CRUISE CANCEL CONDITIONS DIAGNOSIS S003503A1605

The on-board diagnosis function of the cruise control system uses an external Subaru Select Monitor. The on-board diagnosis function operates in two categories, which are used depending on the type of problems; 1) Cruise cancel conditions diagnosis (1) This category of diagnosis requires actual vehicle driving in order to determine the cause, (as when cruise speed is cancelled during driving although cruise cancel condition is not entered). (2) Cruise control module memory stores the cancel condition (Code No.) which occurred during driving. When there are plural cancel conditions (Code No.), they are shown on the Subaru Select Monitor. CAUTION: The cruise control memory stores not only the cruise cancel which occurred (although cancel operation is not entered by the driver), but also the cancel condition input by the driver. The content of memory is cleared when ignition switch or cruise main switch is turned OFF. 2) Real-time diagnosis The real-time diagnosis function is used to determine whether or not the input signal system is in good order, according to signal emitted from switches, sensors, etc. (1) Vehicle cannot be driven at cruise speed because problem occurs in the cruise control system or its associated circuits. (2) Monitor the signal conditions from switches and sensors.
S2M0285
2) Connect diagnosis cable to Subaru Select Monitor. 3) Insert cartridge into Subaru Select Monitor.
S2M0286A
S2M2157
CC-19

3. REAL-TIME DIAGNOSIS
S003503A1606
5) Start engine and turn cruise control main switch to ON. 6) Turn Subaru Select Monitor switch to ON.
S2M0288A
7) On the Main Menu display screen, select the {All System Diagnosis} and press the [YES] key. NOTE: The diagnostic trouble code is also shown in the {Each System Check} mode. This mode is called up on the Cruise Control Diagnosis screen by selecting the item {Cancel Code(s) Display}. 8) Drive vehicle at least 30 km/h (19 MPH) with cruise speed set. 9) If cruise speed is canceled itself (without doing any cancel operations), a diagnostic trouble code will appear on select monitor display. CAUTION: A diagnostic trouble code will also appear when cruise cancel is effected by driver. Do not confuse. Have a co-worker ride in vehicle to assist in diagnosis during driving. NOTE: Diagnostic trouble code will be cleared by turning ignition switch or cruise control main switch to OFF.
1) Connect select monitor. 2) Turn ignition switch and cruise control main switch to ON. 3) Turn Subaru Select Monitor switch to ON. 4) On the Main Menu display screen, select the {Each System Check} and press the [YES] key. 5) On the System Selection Menu display screen, select the {Cruise Control} and press the [YES] key. 6) Press the [YES] key after displayed the information of engine type. 7) On the Cruise Control Diagnosis display screen, select the {Current Data Display & Save} and press the [YES] key. 8) Make sure that normal indication is displayed when controls are operated as indicated below: Depress/release the brake pedal. (Stop light switch and brake switch turn ON.) Turn ON the SET/COAST switch. Turn ON the RESUME/ACCEL switch. Depress/release the clutch pedal. (MT) Set the selector lever to P or N. (AT) NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. For detailed concerning diagnostic trouble codes, refer to the LIST OF DIAGNOSTIC TROUBLE CODE. <Ref. to CC-37 LIST OF DIAGNOSTIC TROUBLE CODE, Diagnostics Chart with Trouble Code (Turbo Model).> or <Ref. to CC-57, LIST OF DIAGNOSTIC TROUBLE CODE, Diagnostics Chart with Trouble Code (Non-turbo Model).>
CC-20
DIAGNOSTICS CHART WITH SYMPTOM (TURBO MODEL)

S003749
6. Diagnostics Chart with Symptom (Turbo Model)

A: SYMPTOM CHART
Symptom Cruise control main switch is not turned ON. 1
S003749F22
Repair area (1) Check power supply. (2) Check cruise control main switch.
Cruise control cannot be set.
(1) Check SET/COAST switch. (2) Check stop light switch and brake switch. (3) Check clutch switch (MT). (4) Check inhibitor switch (AT). (5) Check vehicle speed sensor. (6) Check motor drive system. (7) Check motor clutch drive system.
Vehicle speed is not held within set speed 3 km/h (2 MPH). 3
(1) Check vehicle speed sensor. (2) Check motor drive system. (3) Check motor clutch drive system.
Vehicle speed does not increase or does not return to set speed after RESUME/ ACCEL switch has been pressed.
(1) Check RESUME/ACCEL switch. (2) Check motor drive system. (3) Check motor clutch drive system.
Vehicle speed does not decrease after SET/COAST switch has been pressed. 5
(1) Check SET/COAST switch. (2) Check motor drive system. (3) Check motor clutch drive system.
Reference <Ref. to CC-23 CHECK POWER SUPPRY, Diagnostics Chart with Symptom (Turbo Model).> <Ref. to CC-25 CHECK CRUISE CONTROL MAIN SWITCH, Diagnostics Chart with Symptom (Turbo Model).> <Ref. to CC-29 CHECK CRUISE CONTROL COMMAND SWITCH, Diagnostics Chart with Symptom (Turbo Model).> <Ref. to CC-31 CHECK STOP LIGHT SWITCH AND BRAKE SWITCH, Diagnostics Chart with Symptom (Turbo Model).> <Ref. to CC-33 CHECK CLUTCH SWITCH (MT), Diagnostics Chart with Symptom (Turbo Model).> <Ref. to CC-35 CHECK INHIBITOR SWITCH (AT), Diagnostics Chart with Symptom (Turbo Model).> <Ref. to CC-39 DIAGNOSTIC TROUBLE CODE 22 VEHICLE SPEED SENSOR , Diagnostics Chart with Trouble Code (Turbo Model).> <Ref. to CC-43 DIAGNOSTIC TROUBLE CODE 35 AND 36 ACTUATOR MOTOR , Diagnostics Chart with Trouble Code (Turbo Model).> <Ref. to CC-45 DIAGNOSTIC TROUBLE CODE 37 ACTUATOR MOTOR CLUTCH , Diagnostics Chart with Trouble Code (Turbo Model).> <Ref. to CC-39 DIAGNOSTIC TROUBLE CODE 22 VEHICLE SPEED SENSOR , Diagnostics Chart with Trouble Code (Turbo Model).> <Ref. to CC-43 DIAGNOSTIC TROUBLE CODE 35 AND 36 ACTUATOR MOTOR , Diagnostics Chart with Trouble Code (Turbo Model).> <Ref. to CC-45 DIAGNOSTIC TROUBLE CODE 37 ACTUATOR MOTOR CLUTCH , Diagnostics Chart with Trouble Code (Turbo Model).> <Ref. to CC-29 CHECK CRUISE CONTROL COMMAND SWITCH, Diagnostics Chart with Symptom (Turbo Model).> <Ref. to CC-43 DIAGNOSTIC TROUBLE CODE 35 AND 36 ACTUATOR MOTOR , Diagnostics Chart with Trouble Code (Turbo Model).> <Ref. to CC-45 DIAGNOSTIC TROUBLE CODE 37 ACTUATOR MOTOR CLUTCH , Diagnostics Chart with Trouble Code (Turbo Model).> <Ref. to CC-29 CHECK CRUISE CONTROL COMMAND SWITCH, Diagnostics Chart with Symptom (Turbo Model).> <Ref. to CC-43 DIAGNOSTIC TROUBLE CODE 35 AND 36 ACTUATOR MOTOR , Diagnostics Chart with Trouble Code (Turbo Model).> <Ref. to CC-45 DIAGNOSTIC TROUBLE CODE 37 ACTUATOR MOTOR CLUTCH , Diagnostics Chart with Trouble Code (Turbo Model).>
CC-21

Reference <Ref. to CC-29 CHECK CRUISE CONTROL COMMAND SWITCH, Diagnostics Chart with Symptom (Turbo Model).> <Ref. to CC-43 DIAGNOSTIC TROUBLE CODE 35 AND 36 ACTUATOR MOTOR , Diagnostics Chart with Trouble Code (Turbo Model).> <Ref. to CC-45 DIAGNOSTIC TROUBLE CODE 37 ACTUATOR MOTOR CLUTCH , Diagnostics Chart with Trouble Code (Turbo Model).> <Ref. to CC-31 CHECK STOP LIGHT SWITCH AND BRAKE SWITCH, Diagnostics Chart Symptom (Turbo Model).> <Ref. to CC-43 DIAGNOSTIC TROUBLE CODE 35 AND 36 ACTUATOR MOTOR , Diagnostics Chart with Trouble Code (Turbo Model).> <Ref. to CC-45 DIAGNOSTIC TROUBLE CODE 37 ACTUATOR MOTOR CLUTCH , Diagnostics Chart with Trouble Code (Turbo Model).> <Ref. to CC-33 CHECK CLUTCH SWITCH (MT), Diagnostics Chart with Symptom (Turbo Model).> <Ref. to CC-43 DIAGNOSTIC TROUBLE CODE 35 AND 36 ACTUATOR MOTOR , Diagnostics Chart with Trouble Code (Turbo Model).> <Ref. to CC-45 DIAGNOSTIC TROUBLE CODE 37 ACTUATOR MOTOR CLUTCH , Diagnostics Chart with Trouble Code (Turbo Model).>
Symptom Repair area Cruise control is not released (1) Check CANCEL switch. after CANCEL switch has been pressed. (2) Check motor drive system. (3) Check motor clutch drive system. Cruise control is not released (1) Check stop light switch and brake switch. after brake pedal has been depressed. (2) Check motor drive system. (3) Check motor clutch drive system. Cruise control is not released (1) Check clutch switch. after clutch pedal has been depressed (MT). (2) Check motor drive system. (3) Check motor clutch drive system.
CC-22
DIAGNOSTICS CHART WITH SYMPTOM (TURBO MODEL) B: CHECK POWER SUPPLY

S003749F23
TROUBLE SYMPTOM: Cruise control can be set normally, but indicator does not come on. (When main switch is pressed.) WIRING DIAGRAM:
S6M0521
CC-23

No. 1

No Check fuse No. 18 (in fuse & relay box). Check harness for open or short between cruise control module and fuse & relay box. Power supply and Repair harness. ground circuit are OK.
Step Check Yes Is the voltage more than 10 Go to step 2. CHECK POWER SUPPLY. 1) Disconnect cruise control module harness V? connector. 2) Turn ignition switch ON. 3) Measure voltage between harness connector terminal and chassis ground. Connector & terminal (B94) No. 12 (+) Chassis ground (): Is the resistance less than CHECK GROUND CIRCUIT. Measure resistance between harness connec- 10 ? tor terminal and chassis ground. Connector & terminal (B94) No. 6 (+) Chassis ground ():
CC-24
DIAGNOSTICS CHART WITH SYMPTOM (TURBO MODEL) C: CHECK CRUISE CONTROL MAIN SWITCH
S003749F24
TROUBLE SYMPTOM: Cruise control main switch is not turned ON and cruise control cannot be set. NOTE: When the main relay (built-in cruise control module) operates, the main switch circuit is in normal condition. The main relay operation can be checked by hearing the operation sounds. This operation sounds will be heard when ignition switch and cruise control main switch is turned to ON.
CC-25
WIRING DIAGRAM:
S6M0521
CC-26

No. 1 Step CHECK CRUISE CONTROL MAIN SWITCH CIRCUIT. 1) Disconnect cruise control main switch harness connector. 2) Turn ignition switch ON. 3) Measure voltage between harness connector terminal and chassis ground. Connector & terminal (B161) No. 3 (+) Chassis ground (): CHECK CRUISE CONTROL MAIN SWITCH CIRCUIT. 1) Turn ignition switch OFF. 2) Disconnect cruise control module harness connector. 3) Measure resistance between cruise control module harness connector terminal and cruise control main switch harness connector terminal. Connector & terminal (B94) No. 15 (+) (B161) No. 5 (): (B94) No. 1 (+) (B161) No. 6 (): (B94) No. 11(+) (B161) No. 1 (): CHECK CRUISE CONTROL MAIN SWITCH. Remove and check cruise control main switch. <Ref. to CC-9 Cruise Control Main Switch.> Check Yes Is the voltage more than 10 Go to step 2. V?

No Check fuse No. 18 (in fuse & relay box). Check harness for open or short between cruise control main switch and fuse & relay box. Repair harness.
Go to step 3.
Is cruise control main switch OK?
Replace cruise control module.
Replace cruise control main switch.
CC-27
MEMO:
CC-28
DIAGNOSTICS CHART WITH SYMPTOM (TURBO MODEL) D: CHECK CRUISE CONTROL COMMAND SWITCH
TROUBLE SYMPTOM: Cruise control cannot be set. (Cancelled immediately.) WIRING DIAGRAM:
S003749F25
S6M0522
CC-29

No. 1

Check Yes Go to step 2. Is the voltage 0 V when SET/COAST switch is not pressed? Is the voltage more than 10 V when SET/ COAST switch is pressed? No Go to step 4.
Step CHECK SET/COAST SWITCH CIRCUIT. 1) Disconnect cruise control module harness connector. 2) Turn ignition switch ON. 3) Measure voltage between harness connector terminal and chassis ground when SET/ COAST switch is pressed and not pressed. Connector & terminal (B94) No. 10 (+) Chassis ground (): CHECK RESUME/ACCEL SWITCH CIRCUIT. Measure voltage between harness connector terminal and chassis ground when RESUME/ ACCEL switch is pressed and not pressed. Connector & terminal (B94) No. 9 (+) Chassis ground (): CHECK CANCEL SWITCH CIRCUIT. Measure voltage between harness connector terminal and chassis ground when CANCEL switch is pressed and not pressed. Connector & terminal (B94) No. 9 (+) Chassis ground (): (B94) No. 10 (+) Chassis ground (): CHECK POWER SUPPLY FOR COMMAND SWITCH. Check horn operation.
Is the voltage 0 V when RESUME/ACCEL switch is not pressed? Is the voltage more than 10 V when RESUME/ACCEL switch is pressed? Is the voltage 0 V when CANCEL switch is not pressed? Is the voltage more than 10 V when CANCEL switch is pressed? Does horn sound?
Go to step 3.
Go to step 4.
Cruise control command switch circuit is OK.
Go to step 4.
Go to step 5.
CHECK CRUISE CONTROL COMMAND SWITCH. Remove and check cruise control command switch. <Ref. to CC-10 Cruise Control Command Switch.>
Is cruise control command switch OK?
Check harness between cruise control command switch and cruise control module.
Check fuse No. 6 (in main fuse box). Check horn relay. <Ref. to COM-4 HORN RELAY, INSPECTION, Horn System.> Check harness for open or short between cruise control command switch and fuse & relay box. Replace cruise control command switch.
CC-30
DIAGNOSTICS CHART WITH SYMPTOM (TURBO MODEL) E: CHECK STOP LIGHT SWITCH AND BRAKE SWITCH
TROUBLE SYMPTOM: Cruise control cannot be set. WIRING DIAGRAM:
S003749F26
S6M0523
CC-31

No. 1

Check Yes Is the voltage more than 10 Go to step 2. V? No Check fuse No. 16 (in fuse & relay box). Check harness for open or short between stop light/brake switch and fuse & relay box. Check harness for open or short between stop light/brake switch and cruise control module (AT). Check clutch switch and the circuit (MT). Repair harness.
Step CHECK STOP LIGHT SWITCH AND BRAKE SWITCH CIRCUIT. 1) Disconnect stop light switch and brake switch harness connector. 2) Turn ignition switch ON. 3) Turn cruise control main switch ON. 4) Measure voltage between harness connector terminal and chassis ground. Connector & terminal (B65) No. 2 (+) Chassis ground (): CHECK STOP LIGHT SWITCH AND BRAKE SWITCH CIRCUIT. Measure voltage between harness connector terminal and chassis ground. Connector & terminal (B65) No. 1 (+) Chassis ground ():
CHECK STOP LIGHT SWITCH AND BRAKE SWITCH CIRCUIT. 1) Turn cruise control main switch and ignition switch OFF. 2) Disconnect cruise control module harness connector. 3) Measure resistance between cruise control module harness connector terminal and stop light switch and brake switch harness connector terminal. Connector & terminal (B94) No. 20 (+) (B65) No. 3 (): (B94) No. 16 (+) (B65) No. 4 (): CHECK STOP LIGHT SWITCH AND BRAKE SWITCH. Remove and check stop light switch and brake switch. <Ref. to CC-11 Stop and Brake Switch.>
Go to step 4.
Are stop light switch and brake switch OK?
Stop light switch and brake switch circuit are OK.
Replace stop light switch and brake switch.
CC-32
DIAGNOSTICS CHART WITH SYMPTOM (TURBO MODEL) F: CHECK CLUTCH SWITCH (MT)
S003749F27
S6M0523
CC-33

No. 1

Check Yes Is the voltage more than 10 Go to step 2. V? No Check harness for open or short between clutch switch and cruise control module.
Step CHECK CLUTCH SWITCH CIRCUIT. 1) Disconnect clutch switch harness connector. 2) Turn ignition switch ON. 3) Turn cruise control main switch ON. 4) Measure voltage between harness connector terminal and chassis ground. Connector & terminal (B107) No. 2 (+) Chassis ground (): CHECK CLUTCH SWITCH CIRCUIT. 1) Turn cruise control main switch and ignition switch OFF. 2) Disconnect stop light switch and brake switch harness connector. 3) Measure resistance between clutch switch harness connector terminal and stop light switch and brake switch harness connector terminal. Connector & terminal (B107) No. 1 (+) (B65) No. 1 (): CHECK CLUTCH SWITCH. Remove and check clutch switch. <Ref. to CC-12 Clutch Switch.>
Go to step 3.
Repair harness.
Is clutch switch OK?
Clutch switch circuit is OK.
Replace clutch switch.
CC-34
DIAGNOSTICS CHART WITH SYMPTOM (TURBO MODEL) G: CHECK INHIBITOR SWITCH (AT)
S003749F28
B6M1527
CC-35

No. 1

Check Yes Is the voltage more than 10 Go to step 2. V? No Check harness for open or short between inhibitor switch and cruise control module.
Step CHECK INHIBITOR SWITCH CIRCUIT. 1) Disconnect inhibitor switch harness connector. 2) Turn ignition switch ON. 3) Turn cruise control main switch ON. 4) Measure voltage between harness connector terminal and chassis ground. Connector & terminal (T7) No. 12 (+) Chassis ground (): CHECK INHIBITOR SWITCH CIRCUIT. 1) Turn cruise control main switch and ignition switch OFF. 2) Disconnect starter motor harness connector. 3) Measure resistance between inhibitor switch harness connector terminal and chassis ground. Connector & terminal (T7) No. 7 (+) (B14) No. 1 (): CHECK INHIBITOR SWITCH. Remove and check inhibitor switch. <Ref. to CC-13 Inhibitor Switch.>
Go to step 3.
Repair harness.
Is inhibitor switch OK?
Inhibitor switch circuit is OK.
Replace inhibitor switch.
CC-36
DIAGNOSTICS CHART WITH TROUBLE CODE (TURBO MODEL)

S003750
7. Diagnostics Chart with Trouble Code (Turbo Model)

A: LIST OF DIAGNOSTIC TROUBLE CODE
Diagnostic trouble code 21 Item Inner relay is seized.
S003750E40
Contents of diagnosis Cruise control module inner relay is seized when main switch is OFF.
Reference
22
Vehicle speed sensor
24
Cruise control module is abnormal.
25
Cruise control module is abnormal.
28
Wiring harness opened.
35
Motor drive system is abnormal.
36
Trouble of motor
<Ref. to CC-38 DIAGNOSTIC TROUBE CODE 21, 24, 25, AND 2A CRUISE CONTROL MODULE BUILT-IN RELAY, CPU RAM , Diagnostics Chart with Trouble Code (Turbo Model).> Vehicle speed signal changes more than 10 km/h (6 <Ref. to CC-39 DIAGMPH) within 350 ms. NOSTIC TROUBLE CODE 22 VEHICLE SPEED SENSOR , Diagnostics Chart with Trouble Code (Turbo Model).> Two vehicle speed values stored in cruise control mod<Ref. to CC-38 DIAGule memory are not the same. NOSTIC TROUBE CODE 21, 24, 25, AND 2A CRUISE CONTROL MODULE BUILT-IN RELAY, CPU RAM , Diagnostics Chart with Trouble Code (Turbo Model).> Two output values stored in cruise control module <Ref. to CC-38 DIAGmemory are not the same. NOSTIC TROUBE CODE 21, 24, 25, AND 2A CRUISE CONTROL MODULE BUILT-IN RELAY, CPU RAM , Diagnostics Chart with Trouble Code (Turbo Model).> Open wiring harness circuit is detected via control mod<Ref. to CC-42 DIAGule relay when main switch is ON. NOSTIC TROUBLE CODE 28 WIRING HARNESS OPENED , Diagnostics Chart with Trouble Code (Turbo Model).> Motor output circuit is open or shorted. <Ref. to CC-43 DIAG Motor drive circuit is open or shorted. NOSTIC TROUBLE CODE 35 AND 36 ACTUATOR MOTOR , Diagnostics Chart with Trouble Code (Turbo Model).> Motor turning speed is slow. <Ref. to CC-43, DIAGNOSTIC TROUBLE CODE 35 AND 36 ACTUATOR MOTOR , Diagnostics Chart with Trouble Code (Turbo Model).>
CC-37

Diagnostic trouble code 37
Item Motor clutch drive system is abnormal.
Contents of diagnosis Motor clutch output circuit is open or shorted. Motor clutch drive circuit is open or shorted.
Reference
38
39
2A
<Ref. to CC-45 DIAGNOSTIC TROUBLE CODE 37 ACTUATOR MOTOR CLUTCH , Diagnostics Chart with Trouble Code (Turbo Model).> <Ref. to CC-47 DIAGMotor drive shaft does not Motor drive gear engagement is not properly adjusted. engage properly. NOSTIC TROUBLE CODE 38 MOTOR DRIVE SHAFT DOES NOT ENGAGE PROPERLY. , Diagnostics Chart with Trouble Code (Turbo Model).> Motor is overloaded. Current flows through motor more frequently than under <Ref. to CC-48 DIAGnormal conditions. NOSTIC TROUBLE CODE 39 MOTOR IS OVERLOADED., Diagnostics Chart with Trouble Code (Turbo Model).> Cruise control module is Cruise control module self-diagnosis function senses <Ref. to CC-38 DIAGabnormal. abnormality. NOSTIC TROUBE CODE 21, 24, 25, AND 2A CRUISE CONTROL MODULE BUILT-IN RELAY, CPU RAM , Diagnostics Chart with Trouble Code (Turbo Model).>
B: DIAGNOSTIC TROUBLE CODE 21, 24, 25 AND 2A CRUISE CONTROL MODULE BUILT-IN RELAY, CPU RAM
S003750F29
DIAGNOSIS: Poor welding of built-in relay of cruise control module. Failure of built-in CPU RAM of cruise control module. TROUBLE SYMPTOM: Cruise control is canceled and memorized cruise speed is also canceled. Once cruise control is canceled, cruise control cannot be set until the ignition switch and cruise control main switch turns OFF, and then turns ON again. NOTE: Check input/output signal and vehicle speed signal with select monitor. When signals are in good condition, failure is in cruise control module. (Check power supply and ground conditions of cruise control module.)
CC-38
DIAGNOSTICS CHART WITH TROUBLE CODE (TURBO MODEL) C: DIAGNOSTIC TROUBLE CODE 22 VEHICLE SPEED SENSOR
S003750F30
DIAGNOSIS: Disconnection or short circuit of vehicle speed sensor system. TROUBLE SYMPTOM: Cruise control cannot be set. (Cancelled immediately.) WIRING DIAGRAM:
S6M0524
CC-39

No. 1 2

Step CHECK TRANSMISSION TYPE. CHECK HARNESS BETWEEN BATTERY AND VEHICLE SPEED SENSOR. 1) Disconnect harness connector from vehicle speed sensor. 2) Turn ignition switch to ON. 3) Measure voltage between vehicle speed sensor harness connector terminal and chassis ground. Connector & terminal (B17) No. 3 (+) Chassis ground (): CHECK HARNESS BETWEEN CRUISE CONTROL MODULE AND VEHICLE SPEED SENSOR. 1) Disconnect harness connector from cruise control module. 2) Measure resistance between vehicle speed sensor harness connector terminal and cruise control module harness connector terminal. Connector & terminal (B17) No. 1 (B94) No. 19: CHECK HARNESS BETWEEN VEHICLE SPEED SENSOR AND ENGINE GROUND. 1) Turn ignition switch to OFF. 2) Measure resistance between vehicle speed sensor harness connector terminal and engine ground. Connector & terminal (B17) No. 2 (+) Engine ground (): CHECK VEHICLE SPEED SENSOR. 1) Connect harness connector to vehicle speed sensor. 2) Set the vehicle on free roller, or lift-up the vehicle and support with safety stands. WARNING: Be careful not to be caught up by the running wheels. 3) Drive the vehicle at speed greater than 20 km/h (12 MPH). 4) Measure voltage between cruise control module harness connector terminal and chassis ground. Connector & terminal (B94) No. 19 (+) Chassis ground (): Check Yes Is the transmission type Go to step 2. MT? Is the voltage more than 10 Go to step 3. V? No Go to step 6. Check harness for open or short between ignition relay and vehicle speed sensor.
Go to step 4.
Repair harness.
Go to step 5.
Repair harness.
Is the voltage less than 1 V Replace cruise more than 4 V? control module. <Ref. to CC-8 Cruise Control Module.>
CC-40

No. 6 Step CHECK HARNESS BETWEEN CRUISE CONTROL MODULE AND TRANSMISSION CONTROL MODULE. 1) Disconnect harness connector from transmission control module and cruise control module. 2) Measure resistance between cruise control module harness connector terminal and transmission control module harness connector terminal. CAUTION: To measure the voltage and/or resistance, use a tapered pin with a diameter of less than 0.64 mm (0.025 in). Do not insert the pin more than 5 mm (0.20 in). Connector & terminal (B94) No. 19 (B56) No. 17: CHECK TRANSMISSION CONTROL MODULE. 1) Connect harness connector to transmission control module. 2) Set the vehicle on free roller, or lift-up the vehicle and support with safety stands. WARNING: Be careful not to be caught by the running wheels. 3) Drive the vehicle faster than 10 km/h (6 MPH). 4) Measure voltage between transmission control module harness connector terminal and chassis ground. CAUTION: To measure the voltage and/or resistance, use a tapered pin with a diameter of less than 0.64 mm (0.025 in). Do not insert the pin more than 5 mm (0.20 in). Connector & terminal (B56) No. 17 (+) Chassis ground (): Check Is the resistance less than 10 ? Yes Go to step 7.

No Repair harness connector between cruise control module and transmission control module.
Replace transmission control module. <Ref. to AT-48 Transmission Control Module (TCM).>
CC-41
D: DIAGNOSTIC TROUBLE CODE 28 WIRING HARNESS OPENED.

No. 1
S003750F31
Step Check CHECK BATTERY. Is battery specific gravity Measure battery specific gravity of electrolyte. more than 1.250? CHECK FUSES, CONNECTORS AND HARNESSES. Check the condition of the main and other fuses, and harnesses and connectors. Also check for proper grounding. Is there anything unusual about the appearance of main fuse, fuse, harness, connector and grounding?
Yes Go to step 2.
No Charge or replace battery. Go to step 2. End of inspection.
CC-42
DIAGNOSTICS CHART WITH TROUBLE CODE (TURBO MODEL) E: DIAGNOSTIC TROUBLE CODE 35 AND 36 ACTUATOR MOTOR
S003750F32
DIAGNOSIS: Open or poor contact of cruise control actuator motor. TROUBLE SYMPTOM: Cruise control cannot be set. (Cancelled immediately.) WIRING DIAGRAM:
S6M0525
CC-43

No. 1

Step CHECK POWER SUPPLY. 1) Turn ignition switch OFF. 2) Disconnect harness connector from cruise control actuator. 3) Turn ignition switch ON. 4) Turn cruise control main switch ON. 5) Measure voltage between cruise control actuator harness connector terminal and chassis ground. Terminals (B7) No. 4 (+) Chassis ground (): CHECK GROUND CIRCUIT OF ACTUATOR. Measure resistance between cruise control actuator harness connector terminal and chassis ground. Terminals (B7) No. 6 (+) Chassis ground (): MEASURE RESISTANCE OF ACTUATOR. Measure resistance of cruise control actuator motor. Terminals No. 4 No. 1: No. 4 No. 2: No. 4 No. 5: CHECK HARNESS BETWEEN ACTUATOR AND CRUISE CONTROL MODULE. 1) Disconnect harness connector from cruise control module. 2) Measure resistance between cruise control module harness connector terminal and cruise control actuator harness connector terminal. Connector & terminal (B7) No. 1 (B94) No. 7: CHECK HARNESS BETWEEN ACTUATOR AND CRUISE CONTROL MODULE. Measure resistance between cruise control module harness connector terminal and cruise control actuator harness connector terminal . Connector & terminal (B7) No. 5 (B94) No. 5: Check Yes Is the voltage more than 10 Go to step 2. V? No Check harness for open or short between cruise control main switch and cruise control actuator.
Go to step 3.
Repair harness.
Is resistance approximately Go to step 4. 5 ?
Replace cruise control actuator. <Ref. to CC-5, Actuator (Turbo Model).>
Go to step 5.
Repair harness.
Replace cruise control module. <Ref. to CC-8 Cruise Control Module.>
Repair harness.
CC-44
DIAGNOSTICS CHART WITH TROUBLE CODE (TURBO MODEL) F: DIAGNOSTIC TROUBLE CODE 37 ACTUATOR MOTOR CLUTCH
S003750F33
DIAGNOSIS: Open or poor contact of cruise control actuator motor clutch. TROUBLE SYMPTOM: Cruise control cannot be set. (Cancelled immediately.) WIRING DIAGRAM:
S6M0525
CC-45

No. 1

Step CHECK POWER SUPPLY. 1) Turn ignition switch OFF. 2) Disconnect harness connector from cruise control actuator. 3) Turn ignition switch ON. 4) Turn cruise control main switch ON. 5) Measure voltage between cruise control actuator harness connector terminal and chassis ground. Terminals (B7) No. 4 (+) Chassis ground (): CHECK GROUND CIRCUIT OF ACTUATOR. Measure resistance between cruise control actuator harness connector terminal and chassis ground. Terminals (B7) No. 6 Chassis ground: MEASURE RESISTANCE OF ACTUATOR CLUTCH. Measure resistance of cruise control actuator clutch. Terminals No. 3 No. 6: CHECK HARNESS BETWEEN ACTUATOR AND CRUISE CONTROL MODULE. 1) Disconnect harness connector from cruise control module. 2) Measure resistance between cruise control module harness connector terminal and cruise control actuator harness connector terminal. Connector & terminal (B7) No. 2 (B94) No. 13: CHECK HARNESS BETWEEN ACTUATOR AND CRUISE CONTROL MODULE. Measure resistance between cruise control module harness connector terminal and cruise control actuator harness connector terminal. Connector & terminal (B7) No. 3 (B94) No. 14: Check Yes Is the voltage more than 10 Go to step 2. V? No Check harness for open or short between cruise control main switch and cruise control actuator.
Go to step 3.
Repair harness.
Is resistance approximately Go to step 4. 39 ?
Replace cruise control actuator. <Ref. to CC-5, Actuator (Turbo Model).> Repair harness.
Go to step 5.
Repair harness.
CC-46
DIAGNOSTICS CHART WITH TROUBLE CODE (TURBO MODEL) G: DIAGNOSTIC TROUBLE CODE 38 MOTOR DRIVE SHAFT DOES NOT ENGAGE PROPERLY.
No. 1 Step CHECK ACTUATOR MOTOR. 1) Disconnect harness connector from cruise control actuator. 2) Remove cruise control actuator from mounting bracket. 3) Pull cable by hand to check for looseness or status of inner gear engagement. Check Are foreign particles caught in inner gear or does inner gear engage and disengage improperly?
S003750F34
Yes Replace cruise control actuator. <Ref. to CC-5, Actuator (Turbo Model).>
No Check the cruise control cable adjustment. <Ref. to CC-6 CABLE FREE PLAY, INSPECTION, General Description.>
CC-47
H: DIAGNOSTIC TROUBLE CODE 39 MOTOR IS OVERLOADED.

No. 1
S003750F35
Step Check Is current more than 10A? CHECK THE OPERATING CURRENT TO ACTUATOR MOTOR. 1) Connect Subaru Select Monitor to data link connector. 2) Try to drive the vehicle while operating the cruise control system. 3) Check the operation current to the cruise control actuator motor.
Yes Replace cruise control module. <Ref. to CC-8 Cruise Control Module.>
No Check the power supply circuit. <Ref. to CC-23, CHECK POWER SUPPLY, Diagnostics Chart with Symptom (Turbo Model).>
CC-48
DIAGNOSTICS CHART WITH SYMPTOM (NON-TURBO MODEL)

S003751
8. Diagnostics Chart with Symptom (Non-turbo Model)

A: SYMPTOM CHART
Symptom Cruise control main switch is not turned ON. 1
S003751F22
Repair area (1) Check power supply. (2) Check cruise control main switch.
Cruise control cannot be set.
(1) Check SET/COAST switch.
(2) Check stop light switch and brake switch. (3) Check clutch switch (MT). 2
(4) Check inhibitor switch (AT). (5) Check vehicle speed sensor. (6) Check actuator.
Vehicle speed is not held within set speed 3 km/h (2 MPH). 3
(1) Check vehicle speed sensor. (2) Check actuator.
Vehicle speed does not increase or does not return to set speed after RESUME/ ACCEL switch has been pressed.
(1) Check RESUME/ACCEL switch.
(2) Check actuator.
Vehicle speed does not decrease after SET/COAST switch has been pressed. 5
(1) Check SET/COAST switch.
(2) Check actuator.
Reference <Ref. to CC-51 CHECK POWER SUPPLY, Diagnostics Chart with Symptom (Non-turbo Model).> <Ref. to CC-53 CHECK CRUISE CONTROL MAIN SWITCH, Diagnostics Chart with Symptom (Non-turbo Model).> <Ref. to CC-66 DIAGNOSTIC TROUBLE CODE 14 SET/COAST SWITCH, RESUME/ACCEL SWITCH AND CANCEL SWITCH , Diagnostics Chart with Trouble Code (Non-turbo Model).> <Ref. to CC-59 DIAGNOSTIC TROUBLE CODE 11 BRAKE SWITCH AND STOP LIGHT SWITCH , Diagnostics Chart with Trouble Code (Non-turbo Model).> <Ref. to CC-61 DIAGNOSTIC TROUBLE CODE 12 CLUTCH SWITCH AND INHIBITOR SWITCH , Diagnostics Chart with Trouble Code (Non-turbo Model).> <Ref. to CC-61 DIAGNOSTIC TROUBLE CODE 12 CLUTCH SWITCH AND INHIBITOR SWITCH , Diagnostics Chart with Trouble Code (Non-turbo Model).> <Ref. to CC-63, DIAGNOSTIC TROUBLE CODE 13 AND 24 SPEED SENSOR SYSTEM , Diagnostics Chart with Trouble Code (Non-turbo Model).> <Ref. to CC-68 DIAGNOSTIC TROUBLE CODE 21, 22 AND 23 VACUUM VALVE, VENT 2 VALVE AND VENT 1 VALVE , Diagnostics Chart with Trouble Code (Non-turbo Model).> <Ref. to CC-63, DIAGNOSTIC TROUBLE CODE 13 AND 24 SPEED SENSOR SYSTEM , Diagnostics Chart with Trouble Code (Non-turbo Model).> <Ref. to CC-68 DIAGNOSTIC TROUBLE CODE 21, 22 AND 23 VACUUM VALVE, VENT 2 VALVE AND VENT 1 VALVE , Diagnostics Chart with Trouble Code (Non-turbo Model).> <Ref. to CC-66 DIAGNOSTIC TROUBLE CODE 14 SET/COAST SWITCH, RESUME/ACCEL SWITCH AND CANCEL SWITCH ,Diagnostics Chart with Trouble Code (Non-turbo Model).> <Ref. to CC-68 DIAGNOSTIC TROUBLE CODE 21, 22 AND 23 VACUUM VALVE, VENT 2 VALVE AND VENT 1 VALVE , Diagnostics Chart with Trouble Code (Non-turbo Model).> <Ref. to CC-66 DIAGNOSTIC TROUBLE CODE 14 SET/COAST SWITCH, RESUME/ACCEL SWITCH AND CANCEL SWITCH ,Diagnostics Chart with Trouble Code (Non-turbo Model).> <Ref. to CC-68 DIAGNOSTIC TROUBLE CODE 21, 22 AND 23 VACUUM VALVE, VENT 2 VALVE AND VENT 1 VALVE , Diagnostics Chart with Trouble Code (Non-turbo Model).>
CC-49

Reference <Ref. to CC-66 DIAGNOSTIC TROUBLE CODE 14 SET/COAST SWITCH, RESUME/ACCEL SWITCH AND CANCEL SWITCH ,Diagnostics Chart with Trouble Code (Non-turbo Model).> <Ref. to CC-68 DIAGNOSTIC TROUBLE CODE 21, 22 AND 23 VACUUM VALVE, VENT 2 VALVE AND VENT 1 VALVE , Diagnostics Chart with Trouble Code (Non-turbo Model).> <Ref. to CC-59 DIAGNOSTIC TROUBLE CODE 11 BRAKE SWITCH AND STOP LIGHT SWITCH , Diagnostics Chart with Trouble Code (Non-turbo Model).> <Ref. to CC-68 DIAGNOSTIC TROUBLE CODE 21, 22 AND 23 VACUUM VALVE, VENT 2 VALVE AND VENT 1 VALVE , Diagnostics Chart with Trouble Code (Non-turbo Model).> <Ref. to CC-61 DIAGNOSTIC TROUBLE CODE 12 CLUTCH SWITCH AND INHIBITOR SWITCH , Diagnostics Chart with Trouble Code (Non-turbo Model).> <Ref. to CC-68 DIAGNOSTIC TROUBLE CODE 21, 22 AND 23 VACUUM VALVE, VENT 2 VALVE AND VENT 1 VALVE , Diagnostics Chart with Trouble Code (Non-turbo Model).>
Symptom Repair area Cruise control is not released (1) Check CANCEL switch. after CANCEL switch has been pressed. 6 (2) Check actuator.
Cruise control is not released (1) Check stop light switch after brake pedal has been and brake switch. depressed. (2) Check actuator.
Cruise control is not released (1) Check clutch switch. after clutch pedal has been depressed (MT). (2) Check actuator.
CC-50
DIAGNOSTICS CHART WITH SYMPTOM (NON-TURBO MODEL) B: CHECK POWER SUPPLY

S003751F23
TROUBLE SYMPTOM: Cruise control can be set normally, but indicator does not come on. (When main switch is pressed.) WIRING DIAGRAM:
S6M0526
CC-51

No. 1

No Check fuse No. 18 (in fuse & relay box). Check harness for open or short between cruise control module and fuse & relay box. Power supply and Repair harness. ground circuit are OK.
Step Check Yes Is the voltage more than 10 Go to step 2. CHECK POWER SUPPLY. 1) Disconnect cruise control module harness V? connector. 2) Turn ignition switch ON. 3) Measure voltage between harness connector terminal and chassis ground. Connector & terminal (B94) No. 3 (+) Chassis ground (): Is the resistance less than CHECK GROUND CIRCUIT. Measure resistance between harness connec- 10 ? tor terminal and chassis ground. Connector & terminal (B94) No. 13, No. 20 (+) Chassis ground ():
CC-52
DIAGNOSTICS CHART WITH SYMPTOM (NON-TURBO MODEL) C: CHECK CRUISE CONTROL MAIN SWITCH
S003751F24
TROUBLE SYMPTOM: Cruise control main switch is not turned ON and cruise control cannot be set. NOTE: When the main relay (built-in cruise control module) operates, the main switch circuit is in normal condition. The main relay operation can be checked by hearing the operation sounds. This operation sounds will be heard when ignition switch and cruise control main switch is turned to ON.
CC-53
WIRING DIAGRAM:
S6M0526
CC-54

No. 1 Step CHECK CRUISE CONTROL MAIN SWITCH CIRCUIT. 1) Disconnect cruise control main switch harness connector. 2) Turn ignition switch ON. 3) Measure voltage between harness connector terminal and chassis ground. Connector & terminal (B161) No. 3 (+) Chassis ground (): CHECK CRUISE CONTROL MAIN SWITCH CIRCUIT. 1) Turn ignition switch OFF. 2) Disconnect cruise control module harness connector. 3) Measure resistance between cruise control module harness connector terminal and cruise control main switch harness connector terminal. Connector & terminal (B94) No. 4 (+) (B161) No. 5 (): (B94) No. 5 (+) (B161) No. 1 (): (B161) No. 6 (+) Chassis ground: CHECK CRUISE CONTROL MAIN SWITCH. Remove and check cruise control main switch. <Ref. to CC-9 Cruise Control Main Switch.> Check Yes Is the voltage more than 10 Go to step 2. V?

No Check fuse No. 18 (in fuse & relay box). Check harness for open or short between cruise control main switch and fuse & relay box. Repair harness.
Go to step 3.
Is cruise control main switch OK?
Replace cruise control module.
Replace cruise control main switch.
CC-55
MEMO:
CC-56
DIAGNOSTICS CHART WITH TROUBLE CODE (NON-TURBO MODEL)

S003752
9. Diagnostics Chart with Trouble Code (Non-turbo Model)

A: LIST OF DIAGNOSTIC TROUBLE CODE
Diagnostic code 11 Item BRAKE SW/STOP SW
S003752E40
Contents of diagnosis Input signals from brake switch OFF, stop light switch ON (Brake pedal is depressed.)
Index No.
12
13
14
21
22
23
<Ref. to CC-59 DIAGNOSTIC TROUBLE CODE 11 BRAKE SWITCH AND STOP LIGHT SWITCH , Diagnostics Chart with Trouble Code (Non-turbo Model).> <Ref. to CC-61 DIAGNOSCLUTCH SW/INHIBITOR SW Input signals from clutch switch OFF (MT), or TIC TROUBLE CODE 12 inhibitor switch P or N (AT) [Clutch pedal is depressed (MT), or selector lever is CLUTCH SWITCH AND INHIBITOR SWITCH , set to P or N position (AT).] Diagnostics Chart with Trouble Code (Non-turbo Model).> LOW SPEED LIMIT Low-speed control limiter <Ref. to CC-63 DIAGNOSTIC TROUBLE CODE 13 AND 24 VEHICLE SPEED SENSOR SYSTEM , Diagnostics Chart with Trouble Code (Nonturbo Model).> CANCEL SW Input signal from cancel switch <Ref. to CC-66 DIAGNOS(faulty SET/COAST switch or RESUME/ACCEL TIC TROUBLE CODE 14 switch) SET/COAST SWITCH, RESUME/ACCEL SWITCH AND CANCEL SWITCH , Diagnostics Chart with Trouble Code (Non-turbo Model).> VACUUM VALVE Faulty vacuum valve or valve drive system <Ref. to CC-68 DIAGNOSTIC TROUBLE CODE 21, 22 AND 23 VACUUM VALVE, VENT 2 VALVE AND VENT 1 VALVE , Diagnostics Chart with Trouble Code (Non-turbo Model).> VENT 2 VALVE Faulty vent 2 valve or valve drive system <Ref. to CC-68 DIAGNOSTIC TROUBLE CODE 21, 22 AND 23 VACUUM VALVE, VENT 2 VALVE AND VENT 1 VALVE , Diagnostics Chart with Trouble Code (Non-turbo Model).> VENT 1 VALVE Faulty vent 1 valve or valve drive system <Ref. to CC-68 DIAGNOSTIC TROUBLE CODE 21, 22 AND 23 VACUUM VALVE, VENT 2 VALVE AND VENT 1 VALVE , Diagnostics Chart with Trouble Code (Non-turbo Model).>
CC-57

Diagnostic code 24 Item SPEED SENSOR

Contents of diagnosis Faulty vehicle speed sensor 2 (MT) or transmission control module (AT) Index No. <Ref. to CC-63 DIAGNOSTIC TROUBLE CODE 13 AND 24 VEHICLE SPEED SENSOR SYSTEM , Diagnostics Chart with Trouble Code (Nonturbo Model).> <Ref. to CC-70 DIAGNOSTIC TROUBLE CODE 25 CRUISE CONTROL MODULE BUILT-IN RELAY AND CPU RAM , Diagnostics Chart with Trouble Code (Non-turbo Model).>
25
CONTROL MODULE
Faulty CPU RAM included in cruise control module
CC-58
B: DIAGNOSTIC TROUBLE CODE 11 BRAKE SWITCH AND STOP LIGHT SWITCH

S003752H52
DIAGNOSIS: Failure or disconnection of the stop light switch and brake switch. WIRING DIAGRAM:
S6M0527
CC-59

No. 1

Step CHECK STOP LIGHT SWITCH AND BRAKE SWITCH CIRCUIT. 1) Disconnect stop light switch and brake switch harness connector. 2) Turn ignition switch ON. 3) Turn cruise control main switch ON. 4) Measure voltage between harness connector terminal and chassis ground. Connector & terminal (B65) No. 2 (+) Chassis ground (): CHECK STOP LIGHT SWITCH AND BRAKE SWITCH CIRCUIT. Measure voltage between harness connector terminal and chassis ground. Connector & terminal (B65) No. 1 (+) Chassis ground (): CHECK STOP LIGHT SWITCH AND BRAKE SWITCH CIRCUIT. 1) Turn cruise control main switch and ignition switch OFF. 2) Disconnect cruise control module harness connector. 3) Measure resistance between cruise control module harness connector terminal and stop light switch and brake switch harness connector terminal. Connector & terminal (B94) No. 5 (+) (B65) No. 4 (): (B94) No. 19 (+) (B65) No. 3 (): CHECK STOP LIGHT SWITCH AND BRAKE SWITCH. Remove and check stop light switch and brake switch. <Ref. to CC-11 Stop and Brake Switch.> Check Yes Is the voltage more than 10 Go to step 2. V? No Check fuse No. 16 (in fuse & relay box). Check harness for open or short between stop light/brake switch and fuse & relay box. Check harness for open or short between stop light/brake switch and cruise control module. Repair harness.
Go to step 4.
Are stop light switch and brake switch OK?
Stop light switch and brake switch circuit are OK.
Replace stop light switch and brake switch.
CC-60
C: DIAGNOSTIC TROUBLE CODE 12 CLUTCH SWITCH AND INHIBITOR SWITCH

S003752H53
DIAGNOSIS: Failure or disconnection of the clutch switch. (MT) Failure or disconnection of the inhibitor switch. (AT) WIRING DIAGRAM:
S6M0528
CC-61

No. 1

Step CHECK INHIBITOR SWITCH CIRCUIT (AT). 1) Disconnect inhibitor switch harness connector. 2) Turn ignition switch ON. 3) Turn cruise control main switch ON. 4) Measure voltage between harness connector terminal and chassis ground. Connector & terminal (T7) No. 12 (+) Chassis ground (): CHECK INHIBITOR SWITCH CIRCUIT (AT). 1) Turn cruise control main switch and ignition switch OFF. 2) Disconnect starter motor harness connector. 3) Measure resistance between inhibitor switch harness connector terminal and chassis ground. Connector & terminal (T7) No. 7 (+) (B14) No. 1 (): CHECK INHIBITOR SWITCH (AT). Remove and check inhibitor switch. <Ref. to CC-13 Inhibitor Switch.> CHECK CLUTCH SWITCH CIRCUIT (MT). 1) Disconnect clutch switch harness connector. 2) Turn ignition switch ON. 3) Turn cruise control main switch ON. 4) Measure voltage between harness connector terminal and chassis ground. Connector & terminal (B107) No. 2 (+) Chassis ground (): CHECK CLUTCH SWITCH CIRCUIT (MT). 1) Turn cruise control main switch and ignition switch OFF. 2) Disconnect stop light switch and brake switch harness connector. 3) Measure resistance between clutch switch harness connector terminal and stop light switch and brake switch harness connector terminal. Connector & terminal (B107) No. 1 (+) Chassis ground (): CHECK CLUTCH SWITCH (MT). Remove and check clutch switch. <Ref. to CC-12 Clutch Switch.> Check Yes Is the voltage more than 10 Go to step 2. V? No Check harness for open or short between inhibitor switch and cruise control module.
Go to step 3.
Repair harness.
Is inhibitor switch OK?
Inhibitor switch circuit is OK.
Replace inhibitor switch. Check harness for open or short between clutch switch and cruise control module.
Go to step 6.
Repair harness.
Is clutch switch OK?
Clutch switch circuit is OK.
Replace clutch switch.
CC-62
D: DIAGNOSTIC TROUBLE CODE 13 AND 24 VEHICLE SPEED SENSOR SYSTEM

S003752F52
DIAGNOSIS: Disconnection or short circuit of vehicle speed sensor (MT model) or transmission control module (AT model). WIRING DIAGRAM:
S6M0529
CC-63

No. 1 2

Step CHECK TRANSMISSION TYPE. CHECK HARNESS BETWEEN BATTERY AND VEHICLE SPEED SENSOR. 1) Disconnect harness connector from vehicle speed sensor. 2) Turn ignition switch to ON. 3) Measure voltage between vehicle speed sensor harness connector terminal and chassis ground. Connector & terminal (B17) No. 3 (+) Chassis ground (): CHECK HARNESS BETWEEN CRUISE CONTROL MODULE AND VEHICLE SPEED SENSOR. 1) Disconnect harness connector from cruise control module. 2) Measure resistance between vehicle speed sensor harness connector terminal and cruise control module harness connector terminal. Connector & terminal (B17) No. 1 (B94) No. 18: CHECK HARNESS BETWEEN VEHICLE SPEED SENSOR AND ENGINE GROUND. 1) Turn ignition switch to OFF. 2) Measure resistance between vehicle speed sensor harness connector terminal and engine ground. Connector & terminal (B17) No. 2 (+) Engine ground (): CHECK VEHICLE SPEED SENSOR. 1) Connect harness connector to vehicle speed sensor. 2) Set the vehicle on free roller, or lift-up the vehicle and support with safety stands. WARNING: Be careful not to be caught up by the running wheels. 3) Drive the vehicle at speed greater than 20 km/h (12 MPH). 4) Measure voltage between cruise control module harness connector terminal and chassis ground. Connector & terminal (B94) No. 18 (+) Chassis ground (): Check Yes Is the transmission type Go to step 2. MT? Is the voltage more than 10 Go to step 3. V? No Go to step 6. Check harness for open or short between ignition relay and vehicle speed sensor.
Go to step 4.
Repair harness.
Go to step 5.
Repair harness.
Is the voltage less than 1 more than 4 V?
CC-64

No. 6 Step CHECK HARNESS BETWEEN CRUISE CONTROL MODULE AND TRANSMISSION CONTROL MODULE. 1) Disconnect harness connector from transmission control module and cruise control module. 2) Measure resistance between cruise control module harness connector terminal and transmission control module harness connector terminal. CAUTION: To measure the voltage and/or resistance, use a tapered pin with a diameter of less than 0.64 mm (0.025 in). Do not insert the pin more than 5 mm (0.20 in). Connector & terminal (B94) No. 18 (B56) No. 17: CHECK TRANSMISSION CONTROL MODULE. 1) Connect harness connector to transmission control module. 2) Set the vehicle on free roller, or lift-up the vehicle and support with safety stands. WARNING: Be careful not to be caught by the running wheels. 3) Drive the vehicle faster than 10 km/h (6 MPH). 4) Measure voltage between transmission control module harness connector terminal and chassis ground. CAUTION: To measure the voltage and/or resistance, use a tapered pin with a diameter of less than 0.64 mm (0.025 in). Do not insert the pin more than 5 mm (0.20 in). Connector & terminal (B56) No. 17 (+) Chassis ground (): Check Is the resistance less than 10 ? Yes Go to step 7.

No Repair harness connector between cruise control module and transmission control module.
Replace transmission control module. <Ref. to AT-48 Transmission Control Module (TCM).>
CC-65
E: DIAGNOSTIC TROUBLE CODE 14 SET/COAST SWITCH, RESUME/ACCEL SWITCH AND CANCEL SWITCH
S003752H54
DIAGNOSIS: Short circuit inside the SET SW and RESUME SW. WIRING DIAGRAM:
S6M0530
CC-66

No. 1 Step CHECK SET/COAST SWITCH CIRCUIT. 1) Disconnect cruise control module harness connector. 2) Turn ignition switch ON. 3) Measure voltage between harness connector terminal and chassis ground when SET/ COAST switch is pressed and not pressed. Connector & terminal (B94) No. 6 (+) Chassis ground (): CHECK RESUME/ACCEL SWITCH CIRCUIT. Measure voltage between harness connector terminal and chassis ground when RESUME/ ACCEL switch is pressed and not pressed. Connector & terminal (B94) No. 7 (+) Chassis ground (): CHECK CANCEL SWITCH CIRCUIT. Measure voltage between harness connector terminal and chassis ground when CANCEL switch is pressed and not pressed. Connector & terminal (B94) No. 7 (+) Chassis ground (): (B94) No. 6 (+) Chassis ground (): CHECK POWER SUPPLY FOR COMMAND SWITCH. Check horn operation. Check Yes Go to step 2. Is the voltage 0 V when SET/COAST switch is not pressed? Is the voltage more than 10 V when SET/ COAST switch is pressed?

No Go to step 4.
Is the voltage 0 V when RESUME/ACCEL switch is not pressed? Is the voltage more than 10 V when RESUME/ACCEL switch is pressed? Is the voltage 0 V when CANCEL switch is not pressed? Is the voltage more than 10 V when CANCEL switch is pressed? Does horn sound?
Go to step 3.
Go to step 4.
Cruise control command switch circuit is OK.
Go to step 4.
Go to step 5.
CHECK CRUISE CONTROL COMMAND SWITCH. Remove and check cruise control command switch. <Ref. to CC-10 Cruise Control Command Switch.>
Is cruise control command switch OK?
Check harness between cruise control command switch and cruise control module.
Check fuse No. 6 (in main fuse box). Check horn relay. <Ref. to COM-4 HORN RELAY, INSPECTION, Horn System.> Check harness for open or short between cruise control command switch and main fuse box. Replace cruise control command switch.
CC-67
F: DIAGNOSTIC TROUBLE CODE 21, 22 AND 23 VACUUM VALVE, VENT 2 VALVE AND VENT 1 VALVE
S003752H55
DIAGNOSIS: Open or poor contact of vacuum valve, vent 2 valve and vent 1 valve. WIRING DIAGRAM:
S6M0531
CC-68

No. 1 Step MEASURE RESISTANCE OF VACUUM VALVE, VENT 2 VALVE AND VENT 1 VALVE. 1) Disconnect connector from actuator. 2) Measure resistance of vacuum valve, vent 2 valve and vent 1 valve. Terminals No. 2 No. 3: MEASURE RESISTANCE OF VACUUM VALVE, VENT 2 VALVE AND VENT 1 VALVE. Measure resistance of vacuum valve, vent 2 valve and vent 1 valve. Terminals No. 2 No. 1: MEASURE RESISTANCE OF VACUUM VALVE, VENT 2 VALVE AND VENT 1 VALVE. Measure resistance of vacuum valve, vent 2 valve and vent 1 valve. Terminals No. 2 No. 4: PERFORM A CIRCUIT TEST IN HARNESS BETWEEN ACTUATOR AND CRUISE CONTROL MODULE. 1) Disconnect connector from cruise control module. 2) Measure resistance of harness connector between cruise control module and actuator. Connector & terminal (B7) No. 1 (B94) No. 1: PERFORM A CIRCUIT TEST IN HARNESS BETWEEN ACTUATOR AND CRUISE CONTROL MODULE. Measure resistance of harness connector between cruise control module and actuator. Connector & terminal (B7) No. 2 (B94) No. 8: PERFORM A CIRCUIT TEST IN HARNESS BETWEEN ACTUATOR AND CRUISE CONTROL MODULE. Measure resistance of harness connector between cruise control module and actuator. Connector & terminal (B7) No. 3 (B94) No. 11: PERFORM A CIRCUIT TEST IN HARNESS BETWEEN ACTUATOR AND CRUISE CONTROL MODULE. Measure resistance of harness connector between cruise control module and actuator. Connector & terminal (B7) No. 4 (B94) No. 2: Check Is resistance less than 22 ? Yes Go to step 2.

No Replace actuator. <Ref. to CC-7, REMOVAL, Actuator (Non-turbo Model).>
Go to step 3.
Replace actuator. <Ref. to CC-7, REMOVAL, Actuator (Non-turbo Model).>
Go to step 4.
Replace actuator. <Ref. to CC-7, REMOVAL, Actuator (Non-turbo Model).>
Go to step 5.
Repair or replace wiring harness between actuator and cruise control module.
Go to step 6.
Go to step 7.
Replace cruise control module. <Ref. to CC-8 REMOVAL, Cruise Control Module.>
CC-69
G: DIAGNOSTIC TROUBLE CODE 25 CRUISE CONTROL MODULE BUILTIN RELAY AND CPU RAM
S003752H56
DIAGNOSIS: Poor welding of built-in relay of cruise control module. Failure of built-in CPU RAM of cruise control module. TROUBLE SYMPTOM: Cruise control is canceled and memorized cruise speed is also canceled. Once cruise control is canceled, cruise control cannot be set until the ignition switch and cruise control main switch turns OFF, and then turns ON again. NOTE: Check input/output signal and vehicle speed signal with select monitor. When signals are in good condition, failure is in cruise control module. (Check power supply and ground conditions of cruise control module.)
CC-70
IMMOBILIZER (DIAGNOSTICS)
IM
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Page Basic Diagnostic Procedure ........................................................................2 General Description.....................................................................................3 Electrical Components Location..................................................................5 Immobilizer Control Module I/O Signal .......................................................6 Subaru Select Monitor...............................................................................14 Read Diagnostic Trouble Code .................................................................16 Clear Memory Mode..................................................................................18 Diagnostics Chart for Immobilizer Indicator Light .....................................19 List of Diagnostic Trouble Code................................................................25 Diagnostics Chart with Trouble Code .......................................................26
Immobilizer (Diagnostics)

S009501
A: PROCEDURE
No. 1
S009501E45
2 3
Step CHECK ILLUMINATION OF IMMOBILIZER INDICATOR LIGHT. Turn ignition switch ON. CHECK ENGINE START. Turn ignition switch to START position. CHECK ILLUMINATION OF IMMOBILIZER INDICATOR LIGHT. 1) Turn ignition switch to OFF or ACC position. 2) Wait at least 60 seconds.
Check Does immobilizer indicator light illuminate?
Yes Go to step 2.
No Go to step 3.
Is the engine hard to start? Go to step 5. Does immobilizer indicator light blink? Go to step 4.
Go to step 3. Check immobilizer indicator light circuit. <Ref. to IM-19, CHECK IMMOBILIZER INDICATOR CIRCUIT, INSPECTION, Diagnostics Chart for Immobilizer Indicator Light.> Check key switch circuit. <Ref. to IM-22, CHECK KEY SWITCH CIRCUIT, INSPECTION, Diagnostics Chart for Immobilizer Indicator Light.> Repair the related parts.
CHECK ILLUMINATION OF IMMOBILIZER INDICATOR LIGHT. Remove key from ignition switch.
Does immobilizer indicator light begin to blink 5 seconds after the key is removed?
The immobilizer system is OK.
CHECK INDICATION OF DTC ON DISPLAY. 1) Turn ignition switch OFF. 2) Connect the Subaru Select Monitor to data link connector. <Ref. to IM-14, OPERATION, Subaru Select Monitor.> 3) Turn ignition switch and Subaru Select Monitor switch ON. 4) Read DTC on the display. PERFORM THE DIAGNOSIS. 1) Inspect using Diagnostics Chart with Trouble Code. <Ref. to IM-26, Diagnostics Chart with Trouble Code.> 2) Repair the trouble cause. 3) Perform clear memory mode. 4) Read DTC again.
Is trouble code indicated on Go to step 6. display?
Is trouble code indicated on Inspect using display? Diagnostic Chart with Trouble Code. <Ref. to IM-26, Diagnostics Chart with Trouble Code.>
Finish the diagnostics.
IM-2
GENERAL DESCRIPTION
A: CAUTION
S009001A03
S009001
CAUTION: Airbag system wiring harness is routed near the immobilizer control module. All airbag system wiring harness and connectors are colored yellow. Do not use electrical test equipment on these circuits. Be careful not to damage airbag system wiring harness when servicing the immobilizer control module. While diagnostic items are being checked, do not operate radios, portable telephones, etc. which emit electromagnetic waves near or inside the vehicle.
When repeatedly turning ignition ON or OFF while diagnostic items are being checked, it should be switched in cycles of ON for at least 5 seconds OFF for at least 8 seconds.
B6M0618A
If engine fails to start with a registered ignition key, detach ignition key from ignition switch and wait for approximately 1 second until immobilizer indicator light begins to flash. Start engine again. Before checking diagnostic items, obtain all keys for vehicle to be checked possessed by owner.
B6M0616
When ignition switch is being turned ON or OFF while diagnostic items are being checked, do not allow keys with different ID codes close to the ignition switch. If ignition key is in a key holder, remove it from holder before carrying out diagnoses.
B6M0617
IM-3
GENERAL DESCRIPTION
S009001A17
B: PREPARATION TOOL
1. SPECIAL TOOLS
ILLUSTRATION
S009001A1701
B2M3876
22771AA030
SELECT MONITOR KIT
B2M3877
2. GENERAL TOOLS
Circuit Tester
S009001A1702
TOOL NAME
IM-4

S009507
A: LOCATION
S009507A13
S6M0413A
(1) Antenna (2) Immobilizer indicator light (LED bulb)
(3) Immobilizer control module (IMM ECM) (4) Transponder
NOTE: IMM ECM location for RHD model is symmetrically opposite.
IM-5
IMMOBILIZER CONTROL MODULE I/O SIGNAL

S009517
4. Immobilizer Control Module I/O Signal

A: SCHEMATIC
S009517A21
1. IMMOBILIZER LHD WITH OBD MODEL
S009517A2103
SL91-20A
IM-6
SL91-20B
IM-7
2. IMMOBILIZER LHD WITHOUT OBD MODEL S009517A2104
SL91-21A
IM-8
SL91-21B
IM-9
3. IMMOBILIZER RHD WITH OBD MODEL

S009517A2105
SR91-20A
IM-10
SR91-20B
IM-11
4. IMMOBILIZER RHD WITHOUT OBD MODEL S009517A2106
SR91-21A
IM-12
SR91-21B
IM-13

S009503

A: OPERATION
S009503A16
CAUTION: Do not connect scan tools except for Subaru Select Monitor. 5) Turn ignition switch to ON (engine OFF) and Subaru Select Monitor switch to ON.

S2M0288A S2M0285
2) Connect diagnosis cable to Subaru Select Monitor. 3) Insert cartridge into Subaru Select Monitor. <Ref. to IM-4, SPECIAL TOOLS, PREPARATION TOOL, General Description.>
2. READ DIAGNOSTIC TROUBLE CODE (DTC) FOR ENGINE. S009503A1606

Refer to Read Diagnostic Trouble Code for information about how to indicate DTC. <Ref. to IM-16, Read Diagnostic Trouble Code.>
3. INTERFACE CHECK
S009503A1604
NOTE: Communication line between ECM and IMM ECM can be checked in System Operation Check Mode. This is referred to as interface check.
S2M0286A
1) Connect select monitor. 2) Set the System Operation Check Mode menu display screen then select Immobilizer System. 3) Screen indicates as shown.
S6M0210
S2M2157
IM-14

4) Start interface check. 5) Does Communication appear on screen? If YES. Go to step 6). If NO. Go to step 7). Line not Shorted
S6M0211
6) After diagnostic results, it is determined that short circuit is not a diagnostic item. This completes interface check. 7) If a problem is detected, repair. <Ref. to IM-27, DTC P1572 IMM CIRCUIT FAILURE (EXCEPT ANTENNA CIRCUIT) , Diagnostics Chart with Trouble Code.>
IM-15

S009508

A: OPERATION
S009508A16
S009508A1601
1) On the Main Menu display screen, select the {Each System Check} and press the [YES] key. 2) On the System Selection Menu display screen, select the {Engine Control System} and press the [YES] key. 3) Press the [YES] key after displayed the information of engine type. 4) On the Engine Diagnosis display screen, select the {Diagnostic Code(s) Display} and press the [YES] key. 5) On the Diagnostic Code(s) Display display screen, select the {Current Diagnostic Code(s)} or {History Diagnostic Code(s)} and press the [YES] key. NOTE: For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL. For detailed concerning diagnostic trouble codes, refer to the List of Diagnostic Trouble Code (DTC). <Ref. to IM-25, LIST, List of Diagnostic Trouble Code.>

No. 1 Step CHECK STATUS OF CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL). 1) Turn ignition switch to OFF. 2) Connect read memory connector. <Ref. to EN(SOHCw/oOBD)-10, LOCATION, Electrical Components Location.> 3) Turn ignition switch to ON.
S009508A1602
CHECK DIAGNOSTIC TROUBLE CODE (DTC).
No Check the following and repair if necessary. NOTE: Open or short circuit in engine control module power supply or ground line Open or short circuit in CHECK ENGINE malfunction indicator lamp Does the MIL indicate diag- Record diagnostic Complete read diagnostic trouble nostic trouble code (DTC)? trouble code (DTC). Then turn code. Turn ignition switch to OFF and ignition switch to disconnect read OFF, disconnect read memory con- memory connector. nector.
Yes Go to step 2.
IM-16
The CHECK ENGINE malfunction indicator lamp (MIL) flashes the code corresponding to the faulty parts. The long segment (1.3 seconds ON) indicates a ten, and the short segment (0.2 seconds ON) signifies one. And middle segment (0.5 seconds ON) means OK code. NOTE: For detailed concerning diagnostic trouble codes, refer to the List of Diagnostic Trouble Code (DTC). <Ref. to IM-25, LIST, List of Diagnostic Trouble Code.>
S2M1768A
IM-17
CLEAR MEMORY MODE

S009513

A: OPERATION
S009513A1601 S009513A16
5) When the Done and Turn Ignition Switch OFF are shown on the display screen, turn the Subaru Select Monitor and ignition switch to OFF. NOTE: After the memory has been cleared, the ISC must be initialized. To do this, turn the ignition switch to the ON position. Wait 3 seconds before starting the engine. For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.

1) On the Main Menu display screen, select the {2. Each System Check} and press the [YES] key. 2) On the System Selection Menu display screen, select the {Engine Control System} and press the [YES] key. 3) Press the [YES] key after displayed the information of engine type. 4) On the Engine Diagnosis display screen, select the {Clear Memory} and press the [YES] key.

No. 1 Step CHECK STATUS OF CHECK ENGINE MALFUNCTION INDICATOR LAMP (MIL). 1) Turn ignition switch to OFF. 2) Set shift lever to neutral position (MT vehicles), or set selector lever to P position (AT vehicles). 3) Connect test mode connector and read memory connector. 4) Turn ignition switch to ON.
S009513A1602
No Check the following and repair if necessary. NOTE: Open or short circuit in engine control module power supply or ground line Open or short circuit in CHECK ENGINE malfunction indicator lamp Does the MIL indicate diag- Record diagnostic Turn ignition CHECK DIAGNOSTIC TROUBLE CODE switch to OFF, nostic trouble code (DTC)? trouble code. (DTC). 1) Set selector lever N position, and then set <Ref. to IM-25, LIST, List of Repair the trouble Disconnect read memory connecDiagnostic Trouble Code.> cause. selector lever to P position again (AT tor and test mode vehicles only). connector. Com2) Start the engine. plete clear 3) Drive vehicle at speed greater than 11 memory mode. km/h (7 MPH) for at least one minute. 4) Warm-up engine above 2,000 rpm.
Yes Go to step 2.
IM-18
DIAGNOSTICS CHART FOR IMMOBILIZER INDICATOR LIGHT
8. Diagnostics Chart for Immobilizer Indicator Light

A: INSPECTION
S009641A10
S009641
1. CHECK IMMOBILIZER INDICATOR CIRCUIT

WIRING DIAGRAM (WITH OBD MODEL):
S009641A1001
S6M0513
IM-19
WIRING DIAGRAM (WITHOUT OBD MODEL):
S6M0514
IM-20

No. 1 Step CHECK IMMOBILIZER INDICATOR LIGHT COMES ON. 1) Turn ignition switch OFF. 2) Disconnect harness connector from IMM ECM. 3) Connect a resistor (750 ) between IMM ECM harness connector terminal No. 9 and chassis ground. CHECK IMM ECM GROUND CIRCUIT. Measure resistance between IMM ECM harness connector terminal and chassis ground. Connector & terminal With OBD: (B141) No. 2, No. 3 (+) Chassis ground (): Without OBD: (B141) No. 14, No. 15 (+) Chassis ground (): CHECK IMM ECM IGNITION CIRCUIT. 1) Turn ignition switch ON. (Engine OFF.) 2) Measure voltage between IMM ECM harness connector terminal and chassis ground. Connector & terminal With OBD: (B141) No. 12 (+) Chassis ground (): Without OBD: (B141) No. 4 (+) Chassis ground (): CHECK IMM ECM POWER SUPPLY CIRCUIT. 1) Turn ignition switch OFF. 2) Measure voltage between IMM ECM harness connector terminal and chassis ground. Connector & terminal With OBD: (B141) No. 10, No. 11 (+) Chassis ground (): Without OBD: (B141) No. 5, No. 6 (+) Chassis ground (): Check Does indicator light comes on? Yes Go to step 2.
No Go to step 5.
Go to step 3.
Repair open circuit of IMM ECM ground circuit.
Is the voltage more than 10 Go to step 4.. V?
Check harness for open or short between IMM ECM and ignition switch.
CHECK COMBINATION METER CIRCUIT. 1) Remove combination meter. <Ref. to IDI15, Combination Meter Assembly.> 2) Measure voltage between combination meter harness connector terminal and chassis ground. Connector & terminal (i10) No. 1 (+) Chassis ground (): Is the resistance less than CHECK COMBINATION METER CIRCUIT. 10 ? Measure resistance between IMM ECM harness connector terminal and combination meter harness connector terminal. Connector & terminal With OBD: (B141) No. 9 (i10) No. 18: Without OBD: (B141) No. 13 (+) (i10) No. 18:
Is the voltage more than 10 Replace IMM V? ECM <Ref. to SL-42, Immobilizer Control Module.> and then replace all ignition keys (including the transponder). Then perform teaching operation. Refer to teaching operation manual (Pub. No. S0820GZ). Is the voltage more than 10 Go to step 6. V?
Check harness for open or short between IMM ECM and fuse.
Check harness for open or short between combination meter and fuse.
Faulty LED bulb. Repair harness or Replace combina- connector. tion meter printed circuit. <Ref. to IDI-15, DISASSEMBLY, Combination Meter Assembly.>
IM-21

S009641A1002
2. CHECK KEY SWITCH CIRCUIT
WIRING DIAGRAM (WITH OBD MODEL):
S6M0515
IM-22

S6M0516
IM-23
No. 1

Check Yes Is the voltage more than 10 Go to step 2. V? No Check harness for open or short between key warning switch and fuse.
Step CHECK POWER SUPPLY CIRCUIT. 1) Disconnect harness connector from key warning switch. 2) Turn ignition switch ACC or LOCK position (The key inserted). 3) Measure voltage between key warning switch harness connector terminal and chassis ground. Connector & terminal (B74) No. 2 (+) Chassis ground (): CHECK KEY SWITCH. 1) Insert the ignition key to the ignition switch. (OFF or ACC position) 2) Check continuity between key warning switch connector terminals. Connector & terminal No. 1 No. 2: CHECK KEY SWITCH. 1) Remove the ignition key from the ignition switch. 2) Check continuity between key warning switch connector terminals. Connector & terminal No. 1 No. 2: CHECK HARNESS BETWEEN KEY SWITCH AND IMM ECM. 1) Disconnect harness connector from key warning switch. 2) Disconnect harness connector from IMM ECM. 3) Measure resistance between key warning switch harness connector terminal and IMM ECM harness connector terminal. Connector & terminal With OBD: (B74) No. 1 (B141) No. 4: Without OBD: (B74) No. 1 (B141) No. 9:
Dose continuity exist?
Go to step 3.
Does continuity exsit?
Go to step 4.
Replace IMM ECM <Ref. to SL-42, Immobilizer Control Module.> and then replace all ignition keys (including the transponder). Then perform teaching operation. Refer to teaching operation manual (Pub. No. S0820GZ).
Repair harness between key warning switch and IMM ECM.
IM-24

A: LIST
S009511A12
S009511
DTC Without With OBD OBD P1571
Item
Contents of diagnosis
Index No.
Reference Code Incompatibility
P1572
IMM Circuit Failure (Except Antenna Circuit)
P1574
Key Communication Failure
53 P0153 Use of Unregistered Key
P1576
EGI Control Module EEPROM
P1577
IMM Control Module EEPROM
P1570
ANTENNA
<Ref. to IM-26, DTC P1571 REFERENCE CODE INCOMPATIBILITY , Diagnostics Chart with Trouble Code.> <Ref. to IM-27, DTC P1572 IMM CIRCUIT FAILURE Communication failure between IMM (EXCEPT ANTENNA CIRCUIT) ECM and ECM , Diagnostics Chart with Trouble Code.> <Ref. to IM-33, DTC P1574 KEY COMMUNICATION FAILFailure of IMM ECM to verify key URE , Diagnostics Chart with (transponder) ID code Trouble Code.> <Ref. to IM-34, DTC P0153 INNCORRECT IMMOBILIZER Incorrect immobilizer key (Use of KEY (USE OF UNREGISunregistered key in IMM ECM) TERED KEY) , Diagnostics Chart with Trouble Code.> <Ref. to IM-34, DTC P1576 EGI CONTROL MODULE ECM malfunctioning EEPROM , Diagnostics Chart with Trouble Code.> <Ref. to IM-34, DTC P1577 IMM CONTROL MODULE IMM ECM malfunctioning EEPROM , Diagnostics Chart with Trouble Code.> <Ref. to IM-35, DTC P1570 Faulty antenna ANTENNA , Diagnostics Chart with Trouble Code.> Reference code incompatibility between IMM ECM and ECM
NOTE: When reading diagnostic trouble code except with SUBARU SELECT MONITOR, the item cannot be specified. Therefore diagnose for all items. When a diagnostic trouble code except for the above immobilizer trouble code has been output, carry out diagnosis for the engine trouble code. <Ref. to EN(SOHC)-80, List of Diagnostic Trouble Code (DTC).> or <Ref. to EN(SOHCw/oOBD)-65, List of Diagnostic Trouble Code (DTC).> or <Ref. to EN(DOHC TURBO)82, List of Diagnostic Trouble Code (DTC).>
IM-25
DIAGNOSTICS CHART WITH TROUBLE CODE

S009620
10. Diagnostics Chart with Trouble Code

DIAGNOSIS: Reference code incompatibility between IMM ECM and ECM
No. 1 Step PERFORM TEACHING OPERATION ON IGNITION KEY. Perform teaching operation on all keys of the vehicle. Refer to teaching operation manual.
A: DTC P1571 REFERENCE CODE INCOMPATIBILITY
S009620H45
Check Is teaching operation for all END keys completed?
Yes
No Replace ECM. <Ref. to FU(SOHC)-49, Engine Control Module.>, <Ref. to FU(SOHCw/ oOBD)-38, Engine Control Module.>, or <Ref. to FU(DOHC TURBO)-47, Engine Control Module.>, IMM ECM <Ref. to SL-42, Immobilizer Control Module.> and then replace all ignition keys (including the transponder). Then perform teaching operation. Refer to teaching operation manual (Pub. No. S0820GZ).
IM-26
S009620H46
B: DTC P1572 IMM CIRCUIT FAILURE (EXCEPT ANTENNA CIRCUIT)

DIAGNOSIS: Communication failure between IMM ECM and ECM WIRING DIAGRAM (WITH OBD MODEL):
S6M0517
IM-27
S6M0518
IM-28

No. 1 Step CHECK POWER SUPPLY CIRCUIT OF IMM ECM. 1) Turn ignition switch OFF. 2) Disconnect harness connector from IMM ECM. 3) Measure voltage between IMM ECM harness connector terminal and chassis ground. Connector & terminal With OBD: (B141) No. 10, No. 11 (+) Chassis ground (): Without OBD: (B141) No. 5, No. 6 (+) Chassis ground (): CHECK POWER SUPPLY CIRCUIT OF IMM ECM. 1) Turn ignition switch ON. (Engine OFF.) 2) Measure voltage between IMM ECM harness connector terminal and chassis ground. Connector & terminal With OBD: (B141) No. 12 (+) Chassis ground (): Without OBD: (B141) No. 4 (+) Chassis ground (): CHECK GROUND CIRCUIT OF IMM ECM. 1) Turn ignition switch OFF. 2) Measure resistance between IMM ECM harness connector terminal and chassis ground. Connector & terminal With OBD: (B141) No. 2, No .3 (+) Chassis ground (): Without OBD: (B141) No. 14, No. 15 (+) Chassis ground (): CHECK HARNESS BETWEEN IMM ECM AND ECM. 1) Disconnect harness connector from ECM and IMM ECM. 2) Measure resistance between IMM ECM harness connector terminal and ECM harness connector terminal. Connector & terminal With OBD (turbo): (B141) No. 1 (B135) No. 5: With OBD (LHD non-turbo): (B141) No. 1 (B135) No. 22: With OBD (RHD non-turbo): (B141) No. 1 (B135) No. 23: Without OBD: (B141) No. 10 (B84) No. 23: Check Yes Is the voltage more than 10 Go to step 2. V?
No Check harness for open or short between IMM ECM and fuse.
Check harness for open or short between IMM ECM and ignition switch.
Go to step 4.
Repair open circuit of IMM ECM ground circuit.
Go to step 5.
Repair open circuit of harness between IMM ECM and ECM.
IM-29
No. 5

Check Is the resistance less than 10 ? Yes Go to step 6. No Repair open circuit of harness between IMM ECM and ECM.
Step CHECK HARNESS BETWEEN IMM ECM AND ECM. Measure resistance between IMM ECM harness connector terminal and ECM harness connector terminal. Connector & terminal With OBD (turbo): (B141) No. 6 (+) (B135) No. 14 (): With OBD (LHD non-turbo): (B141) No. 6 (+) (B135) No. 23 (): With OBD (RHD non-turbo): (B141) No. 6 (B135) No. 22: Without OBD: (B141) No. 11 (B84) No. 31: CHECK HARNESS OF COMMUNICATION LINE. 1) Turn ignition switch ON. (Engine OFF.) 2) Measure voltage between IMM ECM harness connector terminal and chassis ground. Connector & terminal With OBD: (B141) No. 1, No. 6 (+) Chassis ground (): Without OBD: (B141) No. 10, No. 11 (+) Chassis ground (): CHECK HARNESS OF COMMUNICATION LINE. Measure voltage between ECM harness connector terminal and engine ground. Connector & terminal With OBD (turbo): (B135) No. 5, No. 14 (+) Chassis ground (): With OBD (non-turbo): (B135) No. 22, No. 23 (+) Chassis ground (): Without OBD: (B84) No. 23, No. 31 (+) Chassis ground (): CHECK ECM BY INTERFACE CHECK. 1) Connect harness connector to ECM. 2) Disconnect harness connector from IMM ECM. 3) Perform interface check. <Ref. to IM-14, INTERFACE CHECK, OPERATION, Subaru Select Monitor.>
Is the voltage 0 V?
Go to step 7.
Repair harness between IMM ECM and ECM, because there is short circuit in battery voltage line or ignition switch ON line.
Is the voltage 0 V?
Go to step 8.
Repair harness between IMM ECM and ECM, because there is short circuit in battery voltage line or ignition switch ON line.
Does Commun. Line Shorted to Ground appear on screen?
Go to step 9. Replace ECM. <Ref. to FU(SOHC)-49, Engine Control Module.>, <Ref. to FU(SOHCw/ oOBD)-38, Engine Control Module.>, or <Ref. to FU(DOHC TURBO)-47, Engine Control Module.> Then perform teaching operation. Refer to teaching operation manual (Pub. No. S0820GZ).
IM-30

No. 9 Step CHECK ECM BY INTERFACE CHECK. Perform interface check. Check Does Commun. Line Shorted to Battery appear on screen?
No Go to step 10.
10
CHECK ECM BY INTERFACE CHECK. Perform interface check.
Yes Replace ECM. <Ref. to FU(SOHC)-49, Engine Control Module.>, <Ref. to FU(SOHCw/ oOBD)-38, Engine Control Module.> or <Ref. to FU(DOHC TURBO)-47, Engine Control Module.> Then perform teaching operation. Refer to teaching operation manual (Pub. No. S0820GZ). Does Communication Line Replace IMM not Shorted appear on ECM <Ref. to screen? SL-42, Immobilizer Control Module.> and then replace all ignition keys (including the transponder). Then perform teaching operation. Refer to teaching operation manual (Pub. No. S0820GZ).
When Check (Time Out) appears on screen, perform interface check again.
IM-31
MEMO:
IM-32
DIAGNOSTICS CHART WITH TROUBLE CODE C: DTC P1574 KEY COMMUNICATION FAILURE
DIAGNOSIS: Failure of IMM ECM to verify key (transponder) ID code
No. 1 Step CHECK IMM ECM FUNCTION. Insert the key to ignition switch (LOCK position), measure changes in voltage between Antenna connector. Connector & terminal (B142) No. 1 No. 2: Check Yes Is the voltage 30 to 30 V? Go to step 2. (Approximately 0.1 second after inserting the key.) Is the voltage 0 V? (Approximately 1 second after inserting the key.)
S009620H47
CHECK IGNITION KEY (TRANSPONDER). 1) Remove the key from ignition switch. 2) Start engine using other keys that have undergone the teaching operation, furnished with vehicle.
Does engine start?
No Replace IMM ECM <Ref. to SL-42, Immobilizer Control Module.> and then replace all ignition keys (including the transponder). Then perform teaching operation. Refer to teaching operation manual (Pub. No. S0820GZ). Replace IMM Replace ignition key (including the ECM <Ref. to SL-42, Immobitransponder). lizer Control ModThen perform ule.> and then teaching operareplace all ignition tion. Refer to teaching operation keys (including manual (Pub. No. the transponder). Then perform S0820GZ). teaching operation. Refer to teaching operation manual (Pub. No. S0820GZ).
IM-33
D: DTC P0153 INCORRECT IMMOBILIZER KEY (USE OF UNREGISTERED KEY)

S009620H48
DIAGNOSIS: Use of unregistered key in IMM ECM

No. 1 Step PERFORM TEACHING OPERATION ON IGNITION KEY. Perform teaching operation on all keys of the vehicle. Refer to teaching operation manual (Pub. No. S0820GZ). PERFORM TEACHING OPERATION ON IGNITION KEY. Perform teaching operation on all keys with vehicle. Refer to teaching operation manual (Pub. No. S0820GZ). Check Is teaching operation for all END keys completed? Yes No Replace all ignition keys (including the transponder). Go to step 2. Replace IMM ECM <Ref. to SL-42, Immobilizer Control Module.> and then replace all ignition keys (including the transponder). Then perform teaching operation. Refer to teaching operation manual (Pub. No. S0820GZ).
Is teaching operation for all END keys completed?
E: DTC P1576 EGI CONTROL MODULE EEPROM

DIAGNOSIS: ECM malfunctioning
S009620H49
1. REPLACE ECM.
S009620H4901
Replace ECM. <Ref. to FU(SOCH)-49, Engine Control Module.>, <Ref. to FU(SOHCw/oOBD)-38, Engine Control Module.> or <Ref. to FU(DOHC TURBO)-47, Engine Control Module.> Then perform teaching operation. Refer to teaching operation manual (Pub. No. S0820GZ).
F: DTC P1577 IMM CONTROL MODULE EEPROM

DIAGNOSIS: IMM ECM malfunctioning
S009620H50
1. REPLACE IMM ECM.
S009620H5001
Replace IMM ECM <Ref. to SL-42, Immobilizer Control Module.> and then replace all ignition keys (including the transponder). Then perform teaching operation. Refer to teaching operation manual (Pub. No. S0820GZ).
IM-34
DIAGNOSTICS CHART WITH TROUBLE CODE G: DTC P1570 ANTENNA

DIAGNOSIS: Faulty antenna WIRING DIAGRAM (WITH OBD MODEL):
S009620H51
B6M1534
IM-35
S6M0519
IM-36

No. 1 2 Step CHECK ENGINE TYPE. CHECK ANTENNA CIRCUIT. 1) Turn ignition switch OFF. Disconnect harness antenna connector from IMM ECM. <Ref. to SL-43, Immobilizer Antenna.> 2) Measure resistance of antenna circuit. Connector & terminal (B142) No. 1 No. 2: CHECK ANTENNA CIRCUIT. Measure resistance between antenna harness connector and chassis ground. Connector & terminal (B142) No. 1 (+) Chassis ground (): CHECK ANTENNA CIRCUIT. Measure resistance between antenna harness connector and chassis ground. Connector & terminal (B142) No. 2 (+) Chassis ground (): CHECK ANTENNA CIRCUIT. 1) Turn ignition switch ON. (Engine OFF.) 2) Measure voltage between antenna harness connector and chassis ground. Connector & terminal (B142) No. 1 (+) Chassis ground (): CHECK ANTENNA CIRCUIT. Measure voltage between antenna harness connector and chassis ground. Connector & terminal (B142) No. 2 (+) Chassis ground (): CHECK IMM ECM FUNCTION. 1) Turn ignition switch OFF. 2) Connect antenna harness connector to IMM ECM. 3) Insert the key to ignition switch, measure changes in voltage between antenna harness connector. Connector & terminal (B142) No. 1 No. 2: Check Is the vehicle with OBD? Is the resistance less than 10 ? Yes Go to step 2. Go to step 3.
No Go to step 8. Replace antenna. <Ref. to SL-43, Immobilizer Antenna.>
Replace antenna. <Ref. to SL-43, Immobilizer Antenna.> Replace antenna. <Ref. to SL-43, Immobilizer Antenna.> Go to step 6.
Go to step 4.
Go to step 5.
Is the voltage 0 V?
Replace antenna. <Ref. to SL-43, Immobilizer Antenna.>
Is the voltage 0 V?
Go to step 7.
Replace antenna. <Ref. to SL-43, Immobilizer Antenna.> Replace IMM ECM <Ref. to SL-42, Immobilizer Control Module.> and then replace all ignition keys (including the transponder). Then perform teaching operation. Refer to teaching operation manual (Pub. No. S0820GZ). Replace antenna. <Ref. to SL-43, Immobilizer Antenna.>
Is the voltage 30 to 30 V? Go to step 15. (Approximately 0.1 second after inserting the key.) Is the voltage 0 V? (Approximately 1 second after inserting the key.)
CHECK ANTENNA CIRCUIT. 1) Turn ignition switch OFF. 2) Disconnect harness antenna connector. <Ref. to SL-43, Immobilizer Antenna.> 3) Measure resistance of antenna circuit. Connector & terminal (B142) No. 1 No. 2:
Go to step 9.
IM-37
No. 9

Check Is the resistance less than 10 ? Yes Go to step 10. No Repair harness between IMM ECM and antenna harness connector.
10
11
12
13
14
Step CHECK ANTENNA CIRCUIT. 1) Disconnect IMM ECM harness connector. 2) Measure resistance between IMM ECM harness connector terminal and antenna harness connector terminal. Connector & terminal (B141) No. 1 (B142) No. 2: (B141) No. 2 (B142) No. 1: CHECK ANTENNA CIRCUIT. Measure resistance between IMM ECM harness connector and chassis ground. Connector & terminal (B141) No. 1 (+) Chassis ground (): CHECK ANTENNA CIRCUIT. Measure resistance between IMM ECM harness connector and chassis ground. Connector & terminal (B141) No. 2 (+) Chassis ground (): CHECK ANTENNA CIRCUIT. 1) Turn ignition switch ON. (Engine OFF.) 2) Measure voltage between IMM ECM harness connector and chassis ground. Connector & terminal (B141) No. 1 (+) Chassis ground (): CHECK ANTENNA CIRCUIT. Measure voltage between IMM ECM harness connector and chassis ground. Connector & terminal (B141) No. 2 (+) Chassis ground (): CHECK IMM ECM FUNCTION. 1) Turn ignition switch OFF. 2) Connect antenna harness connector and IMM ECM harness connector. 3) Insert the key to ignition switch, measure changes in voltage between IMM ECM harness connector. Connector & terminal (B141) No. 1 No. 2:
Is the voltage 0 V?
Go to step 11. Repair harness between IMM ECM and antenna harness connector. Go to step 12. Repair harness between IMM ECM and antenna harness connector. Go to step 13. Repair harness between IMM ECM and antenna harness connector. Go to step 14.
Is the voltage 0 V?
15
CHECK IGNITION KEY (TRANSPONDER). 1) Remove key from ignition switch. 2) Start engine using other keys that have undergone the teaching operation, furnished with vehicle.
Repair harness between IMM ECM and antenna harness connector. Replace IMM Is the voltage 30 to 30 V? Go to step 15. ECM <Ref. to (Approximately 0.1 second SL-42, Immobiafter inserting the key.) Is lizer Control Modthe voltage 0 V? (Approxiule.> and then mately 1 second after replace all ignition inserting the key.) keys (including the transponder). Then perform teaching operation. Refer to teaching operation manual (Pub. No. S0820GZ). Replace IMM Does engine start? Replace ignition key (including the ECM <Ref. to SL-42, Immobitransponder). lizer Control ModThen perform ule.> and then teaching operareplace all ignition tion. Refer to teaching operation keys (including manual (Pub. No. the transponder). Then perform S0820GZ). teaching operation. Refer to teaching operation manual (Pub. No. S0820GZ).
IM-38
WIRING SYSTEM
WI
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. Page Basic Diagnostics Procedure ......................................................................3 Working Precautions .................................................................................13 Power Supply Routing...............................................................................14 Ground Distribution ...................................................................................28 Airbag System ...........................................................................................40 Air Conditioning System............................................................................46 Anti-lock Brake System .............................................................................50 A/T Control System ...................................................................................58 Audio System ............................................................................................84 Back-up Light System ...............................................................................88 Charging System.......................................................................................89 Clearance Light and Illumination Light System ........................................90 Combination Meter ....................................................................................96 Cruise Control System ..............................................................................98 Door Lock System...................................................................................104 Engine Electrical System ........................................................................106 Front Accessory Power Supply System..................................................164 Front Fog Light System...........................................................................166 Fuel Gauge System ................................................................................168 Full-Time Dual-Range System ................................................................170 Headlight Beam Leveler System.............................................................172 Headlight System ....................................................................................174 Headlight Washer System.......................................................................176 Horn System............................................................................................177 Immobilizer System .................................................................................178 In Compartment Light System ................................................................186 Keyless Entry System .............................................................................190 Oil Pressure and Temperature Gauge System.......................................196 Outside Temperature Display System.....................................................198 Parking Brake and Brake Fluid Level Warning System..........................200 Power Window System ...........................................................................202 Radiator Fan System ..............................................................................210 Rear Accessory Power Supply System...................................................211 Rear Differential Oil Temperature Warning System................................212 Rear Fog Light System ...........................................................................214 Rear Window Defogger System..............................................................216 Remote Controlled Rearview Mirror System ..........................................218 Seat Belt Warning System ......................................................................222 Seat Heater System ................................................................................224 Starter System.........................................................................................225 Stop Light System ...................................................................................226 Sunroof System.......................................................................................227 Turn Signal Light and Hazard Light System ...........................................228 Wiper and Washer System (Front) .........................................................232
Wiring System

45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. Wiper and Washer System (Rear) ..........................................................233 Wiper Deicer System ..............................................................................234 Overall Systems ......................................................................................236 Front Wiring Harness ..............................................................................238 Bulkhead Wiring Harness (In Engine Room)..........................................242 Bulkhead Wiring Harness (In Compartment) ..........................................254 Engine Wiring Harness and Transmission Cord.....................................260 Instrument Panel Wiring Harness ...........................................................266 Rear Wiring Harness...............................................................................270 Door Cord................................................................................................274 Rear Gate Cord.......................................................................................278
WI-2
BASIC DIAGNOSTICS PROCEDURE
Wiring System
1. Basic Diagnostics Procedure

S903627
3) Shift the positive probe to connector (B). The voltmeter will indicate no voltage.
A: BASIC PROCEDURES
1. GENERAL
S903627E3101
S903267E31
The most important purpose of diagnostics is to determine which part is malfunctioning quickly, to save time and labor.
2. IDENTIFICATION OF TROUBLE SYMPTOM S903627E3102

Determine what the problem is based on the symptom.
H6M0510A
3. PROBABLE CAUSE OF TROUBLE

S903627E3103
Look at the wiring diagram and check the systems circuit. Then check the switch, relay, fuse, ground, etc.
4) With test set-up held as it is, turn switch ON. The voltmeter will indicate a voltage and, at the same time, the light will come on. 5) The circuit is in good order. If a problem such as a lamp failing to light occurs, use the procedures outlined above to track down the malfunction.
4. LOCATION AND REPAIR OF TROUBLE

S903627E3104
2. CIRCUIT CONTINUITY CHECKS
S903627G5102
1) Using the diagnostics narrow down the causes. 2) If necessary, use a voltmeter, ohmmeter, etc. 3) Before replacing certain component parts (switch, relay, etc.), check the power supply, ground, for open wiring harness, poor connectors, etc. If no problems are encountered, check the component parts.
5. CONFIRMATION OF SYSTEM OPERATION S903267E3105

After repairing, ensure that the system operates properly.
1) Disconnect the battery terminal or connector so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. 2) Use an ohmmeter to check for diode continuity. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity.
B: BASIC INSPECTION
S903627G51
1. VOLTAGE MEASUREMENT
S903627G5101
1) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal and the positive lead to the connector or component terminal. 2) Contact the positive probe of the voltmeter on connector (A). The voltmeter will indicate a voltage.
G6M0207
WI-3
Wiring System

2) Ohmmeter method: Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors. When the ohmmeter indicates infinite, the wiring is open.
3) Symbol kk indicates that continuity exists between two points or terminals. For example, when a switch position is 3, continuity exists among terminals 1, 3 and 6, as shown in table below.
B6M0749
G6M0209
3. HOW TO DETERMINE AN OPEN CIRCUIT S903627G5103

1) Voltmeter Method: An open circuit is determined by measuring the voltage between respective connectors and ground using a voltmeter, starting with the connector closest to the power supply. The power supply must be turned ON so that current flows in the circuit. If voltage is not present between a particular connector and ground, the circuit between that connector and the previous connector is open.
4. HOW TO DETERMINE A SHORT CIRCUIT S903627G5104

1) Test lamp method: Connect a test lamp (rated at approximately 3 watts) in place of the blown fuse and allow current to flow through the circuit. Disconnect one connector at a time from the circuit, starting with the one located farthest from the power supply. If the test lamp goes out when a connector is disconnected, the wiring between that connection and the next connector (farther from the power supply) is shorted.
G6M0208 G6M0210
WI-4

2) Ohmmeter method: Disconnect all affected connectors, and check continuity between each connector and ground. When ohmmeter indicates continuity between a particular connector and ground, that connector is shorted.
Wiring System
G6M0211
WI-5
Wiring System

S903627G52
C: HOW TO READ WIRING DIAGRAMS

1. WIRING DIAGRAM
S903627G5201
The wiring diagram of each system is illustrated so that you can understand the path through which the electric current flows from the battery. Sketches and codes are used in the diagrams. They should read as follows: Each connector and its terminal position are indicated by a sketch of the connector in a disconnected state which is viewed from the front.
G6M0193
The number of poles or pins, presence of a lock, and pin number of each terminal are indicated in the sketch of each connector. In the sketch, the highest pole number refers to the number of poles which the connector has. For example, the sketch of the connector shown in figure indicates the connector has 9 poles.
Connector used in vehicle Sketch Connector shown in wiring diagram Symbol Number of poles
Numbered in order from upper right to lower left.
G6M0194
G6M0196
Numbered in order from upper left to lower right.
G6M0198 G6M0195 G6M0197
WI-6

When one set of connectors is viewed from the front side, the pole numbers of one connector are symmetrical to those of the other. When these two connectors are connected as a unit, the poles which have the same number are joined.
Wiring System
The following color codes are used to indicate the colors of the wires used.
Color code L B Y G R W Br Lg Gr P Or Lb V SA SB Color Blue Black Yellow Green Red White Brown Light green Gray Pink Orange Light Blue Violet Sealed (Inner) Sealed (Outer)
G6M0199
Electrical wiring harness: The connectors are numbered along with the number of poles, external colors, and mating connections in the accompanying list. The sketch of each connector in the wiring diagram usually shows the (A) side of the connector. The relationship between the wire color, terminal number and connector is described in figure. NOTE: A wire which runs in one direction from a connector terminal sometimes may have a different color from that which runs in the other direction from that terminal.
B6M1585A
In wiring diagram, connectors which have no terminal number refer to one-pole types. Sketches of these connectors are omitted intentionally.
MG-098
B6M1586A
WI-7
Wiring System

Each unit is directly grounded to the body or indirectly grounds through a harness ground terminal. Different symbols are used in the wiring diagram to identify the two grounding systems.
The wire color code, which consists of two letters (or three letters including Br or Lg), indicates the standard color (base color of the wire covering) by its first letter and the stripe marking by its second letter.
B6M1587A G6M0202
The table lists the nominal sectional areas and allowable currents of the wires. CAUTION: When replacing or repairing a wire, be sure to use the same size and type of the wire which was originally used. NOTE: The allowable current in the table indicates the tolerable amperage of each wire at an ambient temperature of 40C (104F). The allowable current changes with ambient temperature. Also, it changes if a bundle of more than two wires is used.
Nominal sectional area mm2 0.3 0.5 0.75 0.85 1.25 2 3 5 8 7/0.26 7/0.32 30/0.18 11/0.32 16/0.32 26/0.32 41/0.32 65/0.32 50/0.45 No. of strands/ strand diameter Outside diameter of finished wiring mm 1.8 2.2 (or 2.0) 2.6 (or 2.4) 2.4 (or 2.2) 2.7 (or 2.5) 3.1 (or 2.9) 3.8 (or 3.6) 4.6 (or 4.4) 5.5 Allowable current Amps/ 40C (104F) 7 12 16 16 21 28 38 51 67
The ground points shown in the wiring diagram refer to the following: NOTE: All wiring harnesses are provided with a ground point which should be securely connected.
B6M0747A
WI-8
Wiring System
Relays are classified as normally-open or normally-closed. The normally-closed relay has one or more contacts. The wiring diagram shows the relay mode when the energizing circuit is OFF.
B6M0748
WI-9
Wiring System
Each connector number shown in the wiring diagram corresponds to that in the wiring harness. The location of each connector in the actual vehicle is determined by reading the first character of the connector (for example, a F for F8, i for i16, etc.) and the type of wiring harness. The first character of each connector number refers to the area or system of the vehicle.
Symbol F B E T D i R Wiring harness and cord Front wiring harness Bulkhead wiring harness Engine wiring harness Transmission cord Door cord LH & RH, Rear door cord LH & RH Instrument panel wiring harness Rear wiring harness, Fuel tank cord, Roof cord, Rear gate code
B6M1561A
WI-10
BASIC DIAGNOSTICS PROCEDURE D: SYMBOLS IN WIRING DIAGRAMS

S903627G53
Wiring System
A number of symbols are used in each wiring diagram to easily identify parts or circuits.
B6M1562A
1. RELAY
S903627G5301
4. FUSE No. & RATING
G903627G5304
A symbol used to indicate a relay.
2. CONNECTOR-1
S903627G5302
The FUSE No. & RATING corresponds with that used in the fuse box (main fuse box, fuse and joint box).
The sketch of the connector indicates the one-pole types.
5. CONNECTOR-2
S903627G5305
3. WIRING CONNECTION
S903627G5303
Some wiring diagrams are indicated in foldouts for convenience. Wiring destinations are indicated where necessary by corresponding symbols (as when two pages are needed for clear indication).
Each connector is indicated by a symbol. Each terminal number is indicated in the corresponding wiring diagram in an abbreviated form. For example, terminal number C2 refers to No. 2 terminal of connector (C: F41) shown in the connector sketch.
WI-11
Wiring System

S903627G5306
6. CONNECTOR SKETCH
Each connector sketch clearly identifies the shape and color of a connector as well as terminal locations. Non-colored connectors are indicated in natural color. When more than two types of connector number are indicated in a connector sketch, it means that the same type connectors are used.
E: ABBREVIATION IN WIRING DIAGRAMS

S903627G54
7. GROUND
S903627G5307
Each grounding point can be located easily by referring to the corresponding wiring harness.
8. DIODE
S903627G5308
A symbol is used to indicate a diode.
9. WIRE TRACING ON EXTENDED WIRING DIAGRAMS S903627G5309

For a wiring diagram extending over at least two pages, a symbol (consisting of the same characters with arrows), facilitates wire tracing from one page to the next. A A, B B
10. SYMBOLS OF WIRE CONNECTION AND CROSSING S903627G5310
Abbr. ABS ACC A/C AD AT AU +B DN E F/B FL1.5 IG Illumi. LH Lo M M/B MG Mi OP PASS RH SBF ST SW UP WASH
Full name Antilock Brake System Accessory Air Conditioning Auto Down Automatic Transmission Auto Up Battery Down Ground Fuse & Joint Box Fusible link 1.5 mm2 Ignition Illumination Left Hand Low Motor Main Fuse Box Magnet Middle Optional Parts Passing Right Hand Slow Blow Fuse Starter Switch Up Washer
B6M1588A
11. POWER SUPPLY ROUTING
S903627G5311
A symbol is used to indicate the power supply in each wiring diagram. MB-5, MB-6, etc., which are used as powersupply symbols throughout the text, correspond with those shown in the POWER SUPPLY ROUTING in the wiring diagram. Accordingly, using the POWER SUPPLY ROUTING and wiring diagrams permits service personnel to understand the entire electrical arrangement of a system.
WI-12
WORKING PRECAUTIONS
Wiring System
2. Working Precautions
S903706
A: PRECAUTIONS WHEN WORKING WITH THE PARTS MOUNTED ON THE VEHICLE

S903706G38
1) When working under a vehicle which is jackedup, always be sure to use safety stands. 2) The parking brake must always be applied during working. Also, in automatic transmission vehicles, keep the select lever set to the P (Parking) range. 3) Be sure the workshop is properly ventilated when running the engine. Further, be careful not to touch the belt or fan while the engine is operating. 4) Be careful not to touch hot metal parts, especially the radiator and exhaust system immediately after the engine has been shut off.
5) Some connectors are provided with a lock. One type of such a connector is disconnected by pushing the lock, and the other, by moving the lock up. In either type the lock shape must be identified before attempting to disconnect the connector. To connect, insert the connector until it snaps and confirm that it is tightly connected.
B: PRECAUTIONS IN TROUBLE DIAGNOSIS AND REPAIR OF ELECTRIC PARTS

S903706G39
1) The battery cable must be disconnected from the batterys () terminal, and the ignition switch must be set to the OFF position, unless otherwise required by the diagnostics. 2) Securely fasten the wiring harness with clamps and slips so that the harness does not interfere with the body end parts or edges and bolts or screws. 3) When installing parts, be careful not to catch them on the wiring harness. 4) When disconnecting a connector, do not pull the wires, but pull while holding the connector body.
G6M0213
6) When checking continuity between connector terminals, or measuring voltage across the terminal and ground, always contact tester probe(s) on terminals from the wiring connection side. If the probe is too thick to gain access to the terminal, use mini test leads. To check waterproof connectors (which are not accessible from the wiring side), contact test probes on the terminal side being careful not to bend or damage the terminals.
G6M0212
G6M0214
7) Sensors, relays, electrical unit, etc., are sensitive to strong impacts. Handle them with care so that they are not dropped or mishandled.
WI-13
Wiring System
POWER SUPPLY ROUTING

S903465
3. Power Supply Routing

A: SCHEMATIC
1. LHD MODEL
S903465A21 S903465A2101
SL01-20A
WI-14
Wiring System
SL01-20B
WI-15
Wiring System
SL01-20C
WI-16
Wiring System
SL01-20D
WI-17
Wiring System
SL01-20E
WI-18

No. MB-1 MB-2 MB-3 MB-4 MB-5 MB-6 MB-7 MB-8 Load A/C relay holder Headlight RH Combination meter Headlight LH Horn Horn switch Hazard switch Key switch Keyless entry control module Transmission control module Diode (With rear fog light) Diode (lighting) Lighting switch Data link connector Engine control module Fuel pump relay Main relay Immobilizer control module Headlight washer module Power window circuit breaker ABS control module Combination meter Check connector Combination meter Hazard switch Headlight washer switch Mirror heater condenser Mirror heater LH Mirror heater RH Power window relay Seatbelt timer Speed warning module Vehicle speed sensor (MT) Engine control module (AT) Inhibitor switch (AT) Starter motor (AT) Combination meter Hazard switch Rear turn signal light RH Trailer connector Turn signal switch Combination meter Keyless entry control module Hazard switch Turn signal switch Rear turn signal light LH Parking switch Side turn signal light RH Front turn signal light RH Side turn signal light LH Front turn signal light LH Front clearance light LH Front clearance light RH Headlight leveler LH Headlight leveler RH License plate light Trailer connector No.
Wiring System
FB-8
FB-9
MB-9
FB-10 FB-11 FB-12 FB-13 FB-14 FB-15
MB-12 SBF-7 ALT-1
FB-16 FB-17
IG
FB-18
ST
FB-19
FB-1
FB-20 FB-21
FB-22
FB-2
FB-3 FB-4 FB-5
FB-23
FB-24 FB-25 FB-26 FB-27
FB-6
FB-7
Load Combination meter Radio Room light Keyless entry control module Key illumination light Clock Luggage room light Spot light Rear fog light relay Headlight leveling switch Illumination light Illumination control module Front fog light relay Front fog light switch Parking switch Lighting switch Parking switch Rear defogger switch Rear defogger Mirror heater relay Rear defogger Wiper deicer Wiper deicer time Back-up light switch (MT) Inhibitor switch (AT) ABS control module A/C relay holder Air conditioner relay A/C relay holder Mode control panel Blower motor relay Pressure switch Rear defogger switch Fuel pump relay Engine control module Ignition coil and ignitor Transmission control module Immobilizer control module Airbag control module Airbag control module Front washer motor Front wiper motor Front wiper switch Rear wiper motor Rear wiper intermittent module Noise killer Radio Clock Remote rearview mirror switch Seat heater/rear accessory power supply relay Front accessory power supply socket Rear fog light relay Seat heater/rear accessory power supply relay Stop light Stop light switch
WI-19
Wiring System
No. FB-28 FB-29 FB-30 FB-31 FB-32
Load ABS control module Front fog light relay Blower motor relay Keyless entry control module Wiper deicer relay
WI-20

2. RHD MODEL
S903465A2102
Wiring System
SR01-20A
WI-21
Wiring System
SR01-20B
WI-22
Wiring System
SR01-20C
WI-23
Wiring System
SR01-20D
WI-24
Wiring System
SR01-20E
WI-25
Wiring System
No. MB-1 MB-2 MB-3 MB-4 MB-5 MB-6 MB-7 MB-8

No. Load Combination meter Keyless entry control module Hazard switch Turn signal switch Trailer connector Side turn signal light LH Rear turn signal light LH Front turn signal light RH Parking switch Side turn signal light RH Front turn signal light RH Front turn signal light LH Front clearance light LH Front clearance light RH Headlight leveler LH Headlight leveler RH License plate light Trailer connector Rear fog light relay Headlight leveling switch Illumination light Illumination control module Front fog light relay Front fog light switch Parking switch Lighting switch Rear defogger switch Rear defogger Mirror heater relay Rear defogger Back-up light switch (MT) Inhibitor switch (AT) Wiper deicer Wiper deicer timer ABS control module A/C relay holder Air conditioner relay A/C relay holder Power window relay Mode control panel Blower motor relay Pressure switch Rear defogger switch Fuel pump relay Engine control module Ignition coil and ignitor Transmission control module Immobilizer control module Airbag control module Airbag control module Front washer motor Front wiper motor Front wiper switch Rear wiper motor Rear wiper intermittent module
MB-9
MB-10
MB-11
MB-12 SBF-7 ALT-1
IG
ST
FB-1
Load A/C relay holder Headlight RH Combination meter Headlight LH Horn Horn switch Hazard switch Key switch Keyless entry control module Transmission control module Diode (With rear fog light) Diode (lighting) Lighting switch Check connector Data link connector Engine control module Fuel pump relay Immobilizer control module Main relay Parking switch Combination meter Radio Room light Keyless entry control module Key illumination light Clock Luggage room light Spot light Headlight washer module Power window circuit breaker ABS control module Combination meter Check connector Combination meter Hazard switch Headlight washer switch Mirror heater condenser Mirror heater LH Mirror heater RH Power window relay Seatbelt timer Speed warning module Vehicle speed sensor (MT) Engine control module (AT) Inhibitor switch (AT) Starter motor (AT) Combination meter Trailer connector Rear turn signal light RH Hazard switch Turn signal switch Keyless entry control module
FB-2
FB-3 FB-4 FB-5 FB-6
FB-7
FB-9
FB-10 FB-11 FB-13 FB-14 FB-15
FB-16 FB-17
FB-18
FB-19
FB-20 FB-21
FB-22
WI-26

No. FB-23 Load Noise killer Radio Clock Remote rearview mirror switch Seat heater/rear accessory power supply relay Front accessory power supply socket Rear fog light relay Seat heater/rear accessory power supply relay Stop light Stop light switch ABS control module Front fog light relay Blower motor relay Keyless entry control module Wiper deicer relay
Wiring System
FB-24 FB-25 FB-26 FB-27 FB-28 FB-29 FB-30 FB-31 FB-32
WI-27
Wiring System
GROUND DISTRIBUTION
S903472
4. Ground Distribution
A: SCHEMATIC
S903472A21
SG04-20A
WI-28
GROUND DISTRIBUTION
Wiring System
SG04-20B
WI-29
Wiring System
GROUND DISTRIBUTION
SG04-20C
WI-30
GROUND DISTRIBUTION
Wiring System
SG04-20D
WI-31
Wiring System
GROUND DISTRIBUTION
SG04-20E
WI-32
GROUND DISTRIBUTION
Wiring System
SG04-20F
WI-33
Wiring System
GROUND DISTRIBUTION
SG04-20G
WI-34
GROUND DISTRIBUTION
Wiring System
SG04-20H
WI-35
Wiring System
GROUND DISTRIBUTION
SG04-20I
WI-36
GROUND DISTRIBUTION
Wiring System
SG04-20J
WI-37
Wiring System
GROUND DISTRIBUTION
SG04-20K
WI-38
GROUND DISTRIBUTION
Wiring System
SG04-20L
WI-39
Wiring System
AIRBAG SYSTEM
S903491
5. Airbag System
A: SCHEMATIC
1. LHD MODEL
S903491A21 S903491A2101
SL86-20A
WI-40
AIRBAG SYSTEM
Wiring System
SL86-20B
WI-41
Wiring System
AIRBAG SYSTEM
SL86-20C
WI-42
AIRBAG SYSTEM
2. RHD MODEL
S903491A2102
Wiring System
SR86-20A
WI-43
Wiring System
AIRBAG SYSTEM
SR86-20B
WI-44
AIRBAG SYSTEM
Wiring System
SR86-20C
WI-45
Wiring System
AIR CONDITIONING SYSTEM

S903471
6. Air Conditioning System

A: SCHEMATIC
1. LHD MODEL
S903471A21 S903471A2111
SL45-20A
WI-46
Wiring System
SL45-20B
WI-47
Wiring System

S903471A2112
2. RHD MODEL
SR45-20A
WI-48
Wiring System
SR45-20B
WI-49
Wiring System
ANTI-LOCK BRAKE SYSTEM

S903484
7. Anti-lock Brake System

A: SCHEMATIC
1. LHD MODEL
S903484A21 S903484A2101
SL82-20A
WI-50
Wiring System
SL82-20B
WI-51
Wiring System
SL82-20C
WI-52
Wiring System
SL82-20D
WI-53
Wiring System

S903484A2102
2. RHD MODEL
SR82-20A
WI-54
Wiring System
SR82-20B
WI-55
Wiring System
SR82-20C
WI-56
Wiring System
SR82-20D
WI-57
WIRING SYSTEM
WI
Wiring System

WI-2
Wiring System
A/T CONTROL SYSTEM

S903485
8. A/T Control System

A: SCHEMATIC
S903485A21
1. LHD NON-TURBO MODEL WITH OBD
S903485A2110
SL41-20A
WI-58
A/T CONTROL SYSTEM
Wiring System
SL41-20B
WI-59
Wiring System
A/T CONTROL SYSTEM
SL41-20C
WI-60
A/T CONTROL SYSTEM
Wiring System
SL41-20D
WI-61
Wiring System
A/T CONTROL SYSTEM

S903485A2111
2. LHD NON-TURBO MODEL WITHOUT OBD
SL41-21A
WI-62
A/T CONTROL SYSTEM
Wiring System
SL41-21B
WI-63
Wiring System
A/T CONTROL SYSTEM
SL41-21C
WI-64
A/T CONTROL SYSTEM
Wiring System
SL41-21D
WI-65
Wiring System
A/T CONTROL SYSTEM
SL41-21E
WI-66
A/T CONTROL SYSTEM

3. LHD TURBO MODEL
S903485A2112
Wiring System
SL41-22A
WI-67
Wiring System
A/T CONTROL SYSTEM
SL41-22B
WI-68
A/T CONTROL SYSTEM
Wiring System
SL41-22C
WI-69
Wiring System
A/T CONTROL SYSTEM
SL41-22D
WI-70
A/T CONTROL SYSTEM

4. RHD NON-TURBO MODEL WITH OBD
S903485A2113
Wiring System
SR41-20A
WI-71
Wiring System
A/T CONTROL SYSTEM
SR41-20B
WI-72
A/T CONTROL SYSTEM
Wiring System
SR41-20C
WI-73
Wiring System
A/T CONTROL SYSTEM
SR41-20D
WI-74
A/T CONTROL SYSTEM

5. RHD NON-TURBO MODEL WITHOUT OBD
S903485A2114
Wiring System
SR41-21A
WI-75
Wiring System
A/T CONTROL SYSTEM
SR41-21B
WI-76
A/T CONTROL SYSTEM
Wiring System
SR41-21C
WI-77
Wiring System
A/T CONTROL SYSTEM
SR41-21D
WI-78
A/T CONTROL SYSTEM
Wiring System
SR41-21E
WI-79
Wiring System
A/T CONTROL SYSTEM

S903485A2115
6. RHD TURBO MODEL
SR41-22A
WI-80
A/T CONTROL SYSTEM
Wiring System
SR41-22B
WI-81
Wiring System
A/T CONTROL SYSTEM
SR41-22C
WI-82
A/T CONTROL SYSTEM
Wiring System
SR41-22D
WI-83
Wiring System
AUDIO SYSTEM
S903486
9. Audio System
A: SCHEMATIC
1. LHD MODEL
S903486A2101
S903486A21
SL76-20A
WI-84
AUDIO SYSTEM
Wiring System
SL76-20B
WI-85
Wiring System
AUDIO SYSTEM
S903486A2102
2. RHD MODEL
SR76-20A
WI-86
AUDIO SYSTEM
Wiring System
SR76-20B
WI-87
Wiring System
BACK-UP LIGHT SYSTEM

S903414
10. Back-up Light System

A: SCHEMATIC
S903414A21
SG29-20
WI-88
CHARGING SYSTEM
Wiring System
11. Charging System

A: SCHEMATIC
S903487A21
S903487
SG02-20
WI-89
Wiring System
CLEARANCE LIGHT AND ILLUMINATION LIGHT SYSTEM

S903489
12. Clearance Light and Illumination Light System

A: SCHEMATIC
1. LHD MODEL
S903489A21 S903489A2101
SL21-20A
WI-90
Wiring System
SL21-20B
WI-91
Wiring System
SL21-20C
WI-92

2. RHD MODEL
S903489A2102
Wiring System
SR21-20A
WI-93
Wiring System
SR21-20B
WI-94
Wiring System
SR21-20C
WI-95
Wiring System
COMBINATION METER
S903488
13. Combination Meter

A: SCHEMATIC
S903488A21
SG64-03
WI-96
COMBINATION METER
MEMO:
Wiring System
WI-97
Wiring System

S903495
14. Cruise Control System

A: SCHEMATIC
S903495A21
1. NON-TURBO MODEL
S903495A2109
SG71-21A
WI-98
Wiring System
SG71-21B
WI-99
Wiring System
SG71-21C
WI-100

2. TURBO MODEL
S903495A2110
Wiring System
SG71-20A
WI-101
Wiring System
SG71-20B
WI-102
Wiring System
SG71-20C
WI-103
Wiring System
DOOR LOCK SYSTEM

S903490
15. Door Lock System

A: SCHEMATIC
S903490A21
1. LHD WITH KEYLESS ENTRY MODEL
S903490A2105
SL73-20
WI-104
DOOR LOCK SYSTEM

2. RHD WITH KEYLESS ENTRY MODEL
S903490A2106
Wiring System
SR73-20
WI-105
WIRING SYSTEM
WI
Wiring System

WI-2
Wiring System
ENGINE ELECTRICAL SYSTEM

S903482
16. Engine Electrical System

A: SCHEMATIC
S903482A21
1. LHD SOHC MODEL
S903482A2121
SL10-20A
WI-106
Wiring System
SL10-20B
WI-107
Wiring System
SL10-20C
WI-108
Wiring System
SL10-20D
WI-109
Wiring System
SL10-20E
WI-110
Wiring System
SL10-20F
WI-111
Wiring System
SL10-20G
WI-112
Wiring System
SL10-20H
WI-113
Wiring System
SL10-20I
WI-114

2. LHD SOHC W/O OBD MODEL
S903482A2120
Wiring System
SL10-21A
WI-115
Wiring System
SL10-21B
WI-116
Wiring System
SL10-21C
WI-117
Wiring System
SL10-21D
WI-118
Wiring System
SL10-21E
WI-119
Wiring System
SL10-21F
WI-120
Wiring System
SL10-21G
WI-121
Wiring System
SL10-21H
WI-122
Wiring System
SL10-21I
WI-123
Wiring System

S903482A2122
3. LHD DOHC TURBO MODEL
SL10-22A
WI-124
Wiring System
SL10-22B
WI-125
Wiring System
SL10-22C
WI-126
Wiring System
SL10-22D
WI-127
Wiring System
SL10-22E
WI-128
Wiring System
SL10-22F
WI-129
Wiring System
SL10-22G
WI-130
Wiring System
SL10-22H
WI-131
Wiring System
SL10-22I
WI-132
Wiring System
SL10-22J
WI-133
Wiring System
SL10-22K
WI-134

4. RHD SOHC MODEL
S903482A2124
Wiring System
SR10-20A
WI-135
Wiring System
SR10-20B
WI-136
Wiring System
SR10-20C
WI-137
Wiring System
SR10-20D
WI-138
Wiring System
SR10-20E
WI-139
Wiring System
SR10-20F
WI-140
Wiring System
SR10-20G
WI-141
Wiring System
SR10-20H
WI-142
Wiring System
SR10-20I
WI-143
Wiring System

S903482A2123
5. RHD SOHC W/O OBD MODEL
SR10-21A
WI-144
Wiring System
SR10-21B
WI-145
Wiring System
SR10-21C
WI-146
Wiring System
SR10-21D
WI-147
Wiring System
SR10-21E
WI-148
Wiring System
SR10-21F
WI-149
Wiring System
SR10-21G
WI-150
Wiring System
SR10-21H
WI-151
Wiring System
SR10-21I
WI-152

6. RHD DOHC TURBO MODEL
S903482A2125
Wiring System
SR10-22A
WI-153
Wiring System
SR10-22B
WI-154
Wiring System
SR10-22C
WI-155
Wiring System
SR10-22D
WI-156
Wiring System
SR10-22E
WI-157
Wiring System
SR10-22F
WI-158
Wiring System
SR10-22G
WI-159
Wiring System
SR10-22H
WI-160
Wiring System
SR10-22I
WI-161
Wiring System
SR10-22J
WI-162
Wiring System
SR10-22K
WI-163
Wiring System
FRONT ACCESSORY POWER SUPPLY SYSTEM

S903664
17. Front Accessory Power Supply System

A: SCHEMATIC
S903664A21
SG97-20
WI-164
FRONT ACCESSORY POWER SUPPLY SYSTEM

MEMO:
Wiring System
WI-165
Wiring System

S903473
18. Front Fog Light System

A: SCHEMATIC
1. LHD MODEL
S903473A21 S903473A2101
SL22-20
WI-166

2. RHD MODEL
S903473A2102
Wiring System
SR22-20
WI-167
Wiring System
FUEL GAUGE SYSTEM

S903046
19. Fuel Gauge System

A: SCHEMATIC
1. LHD MODEL
S903046A21 S903046A2105
SL61-20
WI-168
FUEL GAUGE SYSTEM

2. RHD MODEL
S903046A2106
Wiring System
SR61-20
WI-169
Wiring System
FULL-TIME DUAL-RANGE SYSTEM

S903492
20. Full-Time Dual-Range System

A: SCHEMATIC
1. LHD MODEL
S903492A21 S903492A2101
SL38-20
WI-170
FULL-TIME DUAL-RANGE SYSTEM

2. RHD MODEL
S903492A2102
Wiring System
SR38-20
WI-171
WIRING SYSTEM
WI
Wiring System

WI-2
Wiring System

S903493
21. Headlight Beam Leveler System

A: SCHEMATIC
S903493A21
SG83-20
WI-172

MEMO:
Wiring System
WI-173
Wiring System
HEADLIGHT SYSTEM
S903474
22. Headlight System

A: SCHEMATIC
1. LHD MODEL
S903474A21 S903474A2101
SL19-20
WI-174
HEADLIGHT SYSTEM
2. RHD MODEL
S903474A2102
Wiring System
SR19-20
WI-175
Wiring System
HEADLIGHT WASHER SYSTEM

S903746
23. Headlight Washer System

A: SCHEMATIC
S903746A21
SG53-20
WI-176
HORN SYSTEM
Wiring System
24. Horn System

A: SCHEMATIC
S903436
S903436A21
SG74-20
WI-177
Wiring System
IMMOBILIZER SYSTEM
S903346
25. Immobilizer System

A: SCHEMATIC
S903346A21
1. LHD MODEL WITH OBD
S903346A2103
SL91-20A
WI-178
IMMOBILIZER SYSTEM
Wiring System
SL91-20B
WI-179
Wiring System
IMMOBILIZER SYSTEM
S903346A2104
SL91-21A
WI-180
IMMOBILIZER SYSTEM
Wiring System
SL91-21B
WI-181
Wiring System
IMMOBILIZER SYSTEM
S903346A2105
3. RHD MODEL WITH OBD
SR91-20A
WI-182
IMMOBILIZER SYSTEM
Wiring System
SR91-20B
WI-183
Wiring System
IMMOBILIZER SYSTEM
S903346A2106
SR91-21A
WI-184
IMMOBILIZER SYSTEM
Wiring System
SR91-21B
WI-185
Wiring System
IN COMPARTMENT LIGHT SYSTEM

S903665
26. In Compartment Light System

A: SCHEMATIC
1. LHD MODEL
S903665A21 S903665A2101
SL24-20A
WI-186
Wiring System
SL24-20B
WI-187
Wiring System

S903665A2102
2. RHD MODEL
SR24-20A
WI-188
Wiring System
SR24-20B
WI-189
Wiring System

S903345
27. Keyless Entry System

A: SCHEMATIC
1. LHD MODEL
S903345A21 S903345A2101
SL77-20A
WI-190
Wiring System
SL77-20B
WI-191
Wiring System
SL77-20C
WI-192

2. RHD MODEL
S903345A2102
Wiring System
SR77-20A
WI-193
Wiring System
SR77-20B
WI-194
Wiring System
SR77-20C
WI-195
Wiring System
OIL PRESSURE AND TEMPERATURE GAUGE SYSTEM

S903725
28. Oil Pressure and Temperature Gauge System

A: SCHEMATIC
1. LHD MODEL
S903725A21 S903725A2101
SL66-20
WI-196
OIL PRESSURE AND TEMPERATURE GAUGE SYSTEM

2. RHD MODEL
S903725A2102
Wiring System
SR66-20
WI-197
Wiring System
OUTSIDE TEMPERATURE DISPLAY SYSTEM

S903668
29. Outside Temperature Display System

A: SCHEMATIC
1. LHD MODEL
S903668A21 S903668A2191
SL96-20
WI-198
OUTSIDE TEMPERATURE DISPLAY SYSTEM

2. RHD MODEL
S903668A2102
Wiring System
SR96-20
WI-199
Wiring System
PARKING BRAKE AND BRAKE FLUID LEVEL WARNING SYSTEM

S903478
30. Parking Brake and Brake Fluid Level Warning System

A: SCHEMATIC
S903478A21
SG60-20
WI-200
PARKING BRAKE AND BRAKE FLUID LEVEL WARNING SYSTEM

MEMO:
Wiring System
WI-201
Wiring System
POWER WINDOW SYSTEM

S903456
31. Power Window System

A: SCHEMATIC
1. LHD MODEL
S903456A21 S903456A2101
SL70-20A
WI-202
POWER WINDOW SYSTEM
Wiring System
SL70-20B
WI-203
Wiring System
POWER WINDOW SYSTEM
SL70-20C
WI-204
POWER WINDOW SYSTEM
Wiring System
SL70-20D
WI-205
Wiring System
POWER WINDOW SYSTEM

S903456A2102
2. RHD MODEL
SR70-20A
WI-206
POWER WINDOW SYSTEM
Wiring System
SR70-20B
WI-207
Wiring System
POWER WINDOW SYSTEM
SR70-20C
WI-208
POWER WINDOW SYSTEM
Wiring System
SR70-20D
WI-209
Wiring System
RADIATOR FAN SYSTEM

S903480
32. Radiator Fan System

A: SCHEMATIC
S903480A21
SG14-20
WI-210
REAR ACCESSORY POWER SUPPLY SYSTEM
Wiring System
33. Rear Accessory Power Supply System

A: SCHEMATIC
S903670A21
S903670
SG90-20
WI-211
Wiring System
REAR DIFFERENTIAL OIL TEMPERATURE WARNING SYSTEM

S903747
34. Rear Differential Oil Temperature Warning System

A: SCHEMATIC
S903747A21
SG94-20
WI-212
REAR DIFFERENTIAL OIL TEMPERATURE WARNING SYSTEM

MEMO:
Wiring System
WI-213
Wiring System

S903476
35. Rear Fog Light System

A: SCHEMATIC
1. LHD MODEL
S903476A21 S903476A2101
SL30-20
WI-214

2. RHD MODEL
S903476A2102
Wiring System
SR30-20
WI-215
Wiring System

S903455
36. Rear Window Defogger System

A: SCHEMATIC
1. LHD MODEL
S903455A21 S903455A2101
SL52-20
WI-216

2. RHD MODEL
S903455A2102
Wiring System
SR52-20
WI-217
Wiring System
REMOTE CONTROLLED REARVIEW MIRROR SYSTEM

S903459
37. Remote Controlled Rearview Mirror System

A: SCHEMATIC
S903459A21
WI-218

1. LHD MODEL
S903459A2101
Wiring System
SL79-20
WI-219
Wiring System

S903459A2102
2. RHD MODEL
SR79-20
WI-220

MEMO:
Wiring System
WI-221
Wiring System
SEAT BELT WARNING SYSTEM

S903483
38. Seat Belt Warning System

A: SCHEMATIC
1. LHD MODEL
S903483A21 S903483A2101
SL87-20
WI-222
SEAT BELT WARNING SYSTEM

2. RHD MODEL
S903483A2102
Wiring System
SR87-20
WI-223
Wiring System
SEAT HEATER SYSTEM

S903462
39. Seat Heater System

A: SCHEMATIC
S903462A21
SG84-20
WI-224
STARTER SYSTEM
Wiring System
40. Starter System

A: SCHEMATIC
S903439A21
S903439
SG03-20
WI-225
Wiring System
STOP LIGHT SYSTEM

S903417
41. Stop Light System

A: SCHEMATIC
S903417A21
SG25-20
WI-226
WIRING SYSTEM
WI
Wiring System

WI-2
SUNROOF SYSTEM
Wiring System
42. Sunroof System

A: SCHEMATIC
S903440A21
S903440
SG75-20
WI-227
Wiring System
TURN SIGNAL LIGHT AND HAZARD LIGHT SYSTEM

S903481
43. Turn Signal Light and Hazard Light System

A: SCHEMATIC
1. LHD MODEL
S903481A21 S903481A2101
SL26-20A
WI-228
Wiring System
SL26-20B
WI-229
Wiring System

S903481A2102
2. RHD MODEL
SR26-20A
WI-230
Wiring System
SR26-20B
WI-231
Wiring System
WIPER AND WASHER SYSTEM (FRONT)

S903442
44. Wiper and Washer System (Front)

A: SCHEMATIC
S903442A21
SG50-20
WI-232
WIPER AND WASHER SYSTEM (REAR)
Wiring System
45. Wiper and Washer System (Rear)

A: SCHEMATIC
S903443A21
S903443
SG51-20
WI-233
Wiring System
WIPER DEICER SYSTEM

S903444
46. Wiper Deicer System

A: SCHEMATIC
S903444A21
SG78-20
WI-234
WIPER DEICER SYSTEM

MEMO:
Wiring System
WI-235
Wiring System
OVERALL SYSTEMS
S903672
47. Overall Systems

A: LOCATION
1. LHD MODEL
S903672A13 S903672A1307
S6M0262A
(1) (2) (3) (4) (5) (6)
Front wiring harness Engine wiring harness Bulkhead wiring harness Instrument panel center harness Front door cord RH Instrument panel meter harness
(7) (8) (9) (10) (11) (12)
Rear door cord RH Rear wiring harness Roof cord Fuel tank cord Rear gate cord Rear door cord LH
(13) (14) (15) (16)
Combination switch cord Front door cord LH Transmission cord Panel-center harness
WI-236
OVERALL SYSTEMS
2. RHD MODEL
S903672A1308
Wiring System
S6M0263A
(1) (2) (3) (4) (5) (6)
Front wiring harness Engine wiring harness Bulkhead wiring harness Instrument panel center harness Front door cord RH Instrument panel meter harness
(7) (8) (9) (10) (11) (12)
Rear door cord RH Rear wiring harness Roof cord Fuel tank cord Rear gate cord Rear door cord LH
(13) (14) (15) (16)
Combination switch cord Front door cord LH Transmission cord Panel-center harness
WI-237
Wiring System
FRONT WIRING HARNESS

S903445
48. Front Wiring Harness

A: LOCATION
1. LHD MODEL
Connector Pole Color 2 2 1 2 3 2 2 2 2 2 3 1 1 3 4 4 4 2 2 4 2 3 6 1 8 9 7 8 20 F45 16 F46 F47 F49 F51 20 1 31 2 # # # # # B-4 B-4 C-2 B-2 B-2 Gray Black # Black # Black Black Gray Black Black # Black # Green # # # Green # # # # Black # # Brown Gray White #
S903445A13 S903445A1302
No. F3 F4 F5 F6 F7 F16 F17 F19 F21 F22 F23 F24 F25 F26 F27 F28 F31 F32 F33 F34 F35 F36 F37 F38 F39 F40 F41 F44
Area B-1 B-1 C-1 C-1 C-1 D-1 C-2 C-3 D-3 D-3 C-2 B-2 B-2 C-2 A-3 A-4 A-3 B-3 B-3 C-3 B-3 C-3 C-3 C-4 B-3 B-4 C-4 B-4 B-4
No.
Connecting to Name Front turn signal light RH Front clearance light RH Horn Front fog light RH Headlight RH Sub fan motor Radiator main fan motor Front turn signal light LH Front fog light LH Front clearance light LH Headlight LH A/C compressor Generator A/C fuse (Relay holder) A/C sub fan relay (Relay holder) A/C relay (Relay holder) Front washer motor Rear washer motor SBF holder (ABS)
No. F54 F55 F57 F58 F59 F60
Connector Pole Color 2 12 2 3 3 16 # # Blue Black Black #
Area C-4 C-4 B-3 C-2 D-1 B-2
No.
R48
E3
F61 F62 F63 F64 F65 F66 F67 F68 F75
20 6 6 1 4 4 2 4 24
Black # # # # # # Black Black
C-2 B-1 B-1 B-2 A-3 A-4 A-4 B-4 B-3
E2 F63 F62
Connecting to Name Side turn signal light LH Rear harness Headlight washer motor Headlight leveler LH Headlight leveler RH Engine wiring harness (DOHC turbo model) Engine wiring harness (DOHC turbo model) Shield joint connector (ABS)
F76 F78
6 2
Black Black
B-4 D-1
ABS motor ground Front fog light relay (Relay holder) Radiator main fan relay (Relay holder) FWD switch (Relay holder) M/B Bulkhead wiring harB209 ness (DOHC turbo model) Bulkhead wiring harB210 ness (DOHC turbo model) Outside temperature sensor
M/B
#: Non-colored
F/B Bulkhead wiring harness Bulkhead wiring harB62 ness (DOHC turbo model) Bulkhead wiring harB62 ness (SOHC model) Bulkhead wiring harB108 ness Horn ABS control module Side turn signal light RH B61
WI-238
Wiring System
S6M0489
WI-239
Wiring System

S903445A1303
2. RHD MODEL
No. F2 F3 F4 F5 F6 F7 F16 F17 F19 F21 F22 F23 F24 F25 F26 F27 F28 F31 F34 F35 F39 F41 F44 F45 F47 F49 F51 F58 F59 F62 F63 F64 F65 F66 F67 F78 #: Non-colored
Connector Pole Color 22 Blue 2 Gray 2 Black 1 # 2 Black 3 # 2 Black 2 Black 2 Gray 2 Black 2 Black 3 # 1 Black 1 # 3 Green 4 # 4 # 4 # 4 # 2 # 8 Black 7 Gray 6 # 14 # 1 # 31 # 2 # 3 Black 3 Black 6 # 6 # 1 # 4 # 4 # 2 # 2 Black
Area B-3 B-1 B-1 C-1 C-1 C-2 C-1 C-2 C-3 D-2 D-3 C-2 C-2 B-2 C-2 A-3 A-3 A-3 C-3 B-3 B-3 B-3 B-2 B-3 C-2 B-2 B-2 C-2 C-1 C-1 B-1 B-2 A-3 A-4 A-4 D-1
No. B100
Connecting to Name Bulkhead wiring harness (ABS) Front turn signal light RH Front clearance light RH Horn Front fog light RH Headlight RH Sub fan motor Radiator main fan motor Front turn signal light LH Front fog light LH Front clearance light LH Headlight LH A/C compressor Generator A/C fuse (Relay holder) A/C sub fan relay (Relay holder) A/C relay (Relay holder) SBF holder (ABS) M/B F/B
B61 B62
Bulkhead wiring harness Horn ABS control module Side turn signal light RH Headlight leveler LH Headlight leveler RH
F63 F62
Shield joint connector (ABS) ABS motor ground Front fog light relay (Relay holder) Radiator main fan relay (Relay holder) FWD switch (Relay holder) Outside temperature sensor
WI-240
Wiring System
S6M0490
WI-241
Wiring System
BULKHEAD WIRING HARNESS (IN ENGINE ROOM)

S903438
49. Bulkhead Wiring Harness (In Engine Room)

A: LOCATION
S903438A13
1. LHD NON-TURBO MODEL WITH OBD

No. B2 B6 B7 B8 B10 B11 B12 B14 B15 B16 B17 B20 B21 B22 B24 B25 B29 #: Non-colored Connector Pole Color 3 Black 2 Brown 4 Gray 6 # 2 Brown 20 Black 12 # 1 Black 2 Brown 2 Gray 3 Black 10 Gray 20 Gray 16 Brown 2 Gray 2 Brown 2 Gray Area B-1 B-2 B-2 B-2 B-2 C-3 B-3 C-3 B-3 B-3 B-2 C-3 B-1 C-1 B-3 C-3 C-3
S903438A1308
No.
Connecting to Name Pressure sensor ABS front sensor RH Cruise control actuator Front wiper motor A/C pressure switch Transmission (AT) Starter (Magnet) ABS front sensor LH Brake fluid level switch Vehicle speed sensor (MT) Engine wiring harness Engine wiring harness Back-up light switch (MT) Neutral position switch (MT) Lo (AWD) indicator light switch (MT)
T4 T3
E1 E2 E3 T1 T2 T8
WI-242
Wiring System
S6M0491
WI-243
Wiring System

S903438A1309

No. B6 B7 B8 B10 B11 B12 B14 B15 B16 B17 B18 B20 B24 B25 B29 B84 B138 B139 B155 #: Non-colored Connector Pole Color 2 Brown 4 Gray 6 # 2 Brown 20 Black 12 # 1 Black 2 Brown 2 Gray 3 Black 4 Gray 6 Gray 2 Gray 2 Brown 2 Gray 34 Black 2 Gray 2 Gray 3 # Area B-2 B-2 B-2 B-2 C-3 B-3 C-3 B-3 B-3 B-2 C-2 B-1 B-3 C-3 C-3 C-1 C-2 C-2 B-2
No.
Connecting to Name ABS front sensor RH Cruise control actuator Front wiper motor A/C pressure switch Transmission (AT) Starter (Magnet) ABS front sensor LH Brake fluid level switch Vehicle speed sensor (MT) Oxygen sensor (Catalytic converter equipped vehicle) Engine wiring harness (AT) Back-up light switch (MT) Neutral position switch (MT) Lo (AWD) indicator light switch (MT) Engine control module Joint connector (E/G) CO resistor (Catalytic converter equipped vehicle)
T4 T3
E1 T1 T2 T8 B139 B138
WI-244
Wiring System
S6M0492
WI-245
Wiring System

S903438A1310
3. LHD TURBO MODEL

No. B3 B6 B7 B8 B10 B11 B12 B14 B15 B16 B17 B18 B19 B20 B127 B128 B279 #: Non-colored
Connector Pole Color 5 Black 2 Brown 6 Black 6 # 2 Brown 20 Black 12 # 1 Black 2 Brown 2 Gray 4 Black 4 Gray 4 # 10 # 2 Gray 4 Gray 2 Gray
Area B-2 B-2 B-2 A-2 A-2 C-3 A-3 B-3 B-3 A-3 B-2 A-1 A-3 B-2 B-1 B-2 C-1
No.
Connecting to Name Mass air flow sensor ABS front sensor RH Cruise control actuator Front wiper motor A/C pressure switch Transmission (AT) Starter (Magnet) ABS front sensor LH Brake fluid level switch Vehicle speed sensor (MT) Front oxygen (A/F) sensor Oxygen sensor Engine wiring harness Wastgate control solenoid valve Transmission (MT) Exhaust temperature sensor
T4 T3
T5 E1 T9
WI-246
Wiring System
S6M0493
WI-247
Wiring System

S903438A1311
4. RHD NON-TURBO MODEL WITH OBD

No. B2 B6 B7 B8 B10 B11 B12 B14 B15 B16 B17 B20 B21 B22 B24 B25 B29 B143 B144 B145 B146 B147 B148 B149 B186 #: Non-colored Connector Pole Color 3 Black 2 Brown 4 Gray 6 # 2 Brown 20 Black 12 # 1 Black 2 Brown 2 Gray 3 Black 10 Gray 20 Gray 16 Brown 2 Gray 2 Brown 2 Gray 3 # 6 Black 1 # 2 Green 2 # 2 # 2 Blue 4 Black Area B-1 B-2 B-3 B-3 B-4 B-3 B-3 B-3 C-3 B-2 C-2 C-2 B-2 B-2 C-2 C-2 C-3 C-3 B-4 C-4 C-3 C-3 B-4 C-3 B-4
No.
Connecting to Name Pressure sensor ABS front sensor RH (ABS) Cruise control actuator Front wiper motor A/C pressure switch Transmission (AT) Starter (Magnet) ABS front sensor LH (ABS) Brake fluid level switch Vehicle speed sensor (MT) Engine wiring harness Engine wiring harness Back-up light switch (MT) Neutral position switch (MT) Lo (AWD) indicator light switch (MT) M/B Front washer motor Rear washer motor Side turn signal light LH Headlight washer motor (With OBD) M/B
T4 T3
E1 E2 E3 T1 T2 T8
WI-248
Wiring System
S6M0494
WI-249
Wiring System

S903438A1312

No. B6 B7 B8 B10 B11 B12 B14 B15 B16 B17 B18 B20 B24 B25 B29 B84 B138 B139 B143 B144 B145 B146 B147 B148 B186 #: Non-colored Connector Pole Color 2 Brown 4 Gray 6 # 2 Brown 20 Black 12 # 1 Black 2 Brown 2 Gray 3 Black 4 Gray 6 Gray 2 Gray 2 Brown 2 Gray 34 Black 2 Gray 2 Gray 3 # 6 Black 1 # 2 Green 2 # 2 # 4 Black Area B-2 B-3 B-3 B-4 B-3 B-3 B-3 C-3 B-2 C-2 B-3 B-2 C-2 C-2 C-3 B-2 C-2 C-2 C-3 B-4 C-4 C-3 C-3 B-4 B-4
No.
Connecting to Name ABS front sensor RH (ABS) Cruise control actuator Front wiper motor A/C pressure switch Transmission (AT) Starter (Magnet) ABS front sensor LH (ABS) Brake fluid level switch Vehicle speed sensor (MT) Oxygen sensor (Catalytic converter equipped vehicle) Engine wiring harness (AT) Back-up light switch (MT) Neutral position switch (MT) Lo (AWD) indicator light switch (MT) Engine control module Joint connector (E/G)
T4 T3
E1 T1 T2 T8 B139 B138
M/B Front washer motor Rear washer motor Side turn signal light LH M/B
WI-250
Wiring System
S6M0495
WI-251
Wiring System

S903438A1313
6. RHD TURBO MODEL

No. B3 B6 B7 B8 B10 B11 B12 B14 B15 B16 B17 B18 B19 B20 B21 B22 B127 B128 B143 B144 B145 B146 B147 B148 B149 B186 B279 #: Non-colored
Connector Pole Color 5 Black 2 Brown 6 Black 6 # 2 Brown 20 Black 12 # 1 Black 2 Brown 2 Gray 4 Black 4 Gray 4 # 10 # 20 # 16 Brown 2 Gray 4 Gray 3 # 6 Black 1 # 2 Green 2 # 2 # 2 Blue 4 Black 2 Gray
Area B-2 B-2 B-3 B-3 B-4 B-3 B-3 C-2 C-3 B-2 B-2 B-2 B-2 B-2 C-2 C-2 B-1 B-3 C-3 B-4 C-4 C-3 C-3 B-4 C-3 C-4 C-1
No.
Connecting to Name Mass air flow sensor ABS front sensor RH Cruise control actuator Front wiper motor A/C pressure switch Transmission (AT) Starter (Magnet) ABS front sensor LH Brake fluid level switch Vehicle speed sensor (MT) Front oxygen (A/F) sensor Oxygen sensor Engine wiring harness Engine wiring harness Engine wiring harness Wastegate control solenoid valve Transmission (MT) M/B Front washer motor Rear washer motor Side turn signal light LH Headlight washer motor (With OBD) M/B Exhaust temperature sensor
T4 T3
T5 E1 E2 E3 T9
WI-252
Wiring System
S6M0496
WI-253
Wiring System
BULKHEAD WIRING HARNESS (IN COMPARTMENT)

S903446
50. Bulkhead Wiring Harness (In Compartment)

A: LOCATION
1. LHD MODEL
Connector Pole Color
25 7 3 16 24 16 2 4 6 10 4 6 4 8 12 6 24 24 24 8 20 B62 16 B64 B65 B68 B69 B70 B71 B72 B74 B75 B76 B79 B81 B82 B83 B84 B85 B86 B87 B88 B90 B94 B97 B98 B99 B101 B104 2 4 5 4 18 17 4 2 2 2 14 12 6 6 17 2 6 2 3 8 20 10 12 20 25 4 # Black Black Black # # # Blue Black Green Green Gray # Black # # # # # # # # Blue # # # # B-1 A-2 A-2 C-2 C-2 C-2 C-2 C-2 C-2 B-1 A-2 C-3 B-2 B-2 D-4 C-4 A-3 A-3 B-3 B-4 A-4 C-1 B-4 B-4 B-4 B-4 C-1 F45 # Yellow Black # Black Black # Blue Brown # Green Brown # Blue Blue # # Gray Green # #
S903446A13 S903446A1308
No.
B30 B31 B32 B36 B37 B40 B41 B42 B43 B44 B46 B47 B50 B51 B52 B53 B54 B55 B56 B61
Area
C-1 C-1 A-2 B-3 B-2 D-2 A-1 B-1 B-4 D-3 C-1 B-1 B-1 D-2 C-1 B-2 C-2 D-2 D-2 B-1 B-1
No.
D1 AB1 i1 i2
Connecting to Name
Front door cord LH SRS (Airbag) harness Turn & hazard module Instrument panel meter harness Data link connector Power window circuit breaker Power window relay Illumination control module Seat belt timer Fuel pump relay Main relay Blower relay F/B Shield joint connector (AT) Transmission control module (AT)
No.
B107 B108 B116 B118 B119 B120 B121 B122

2 20 4 2 1 14 1 6 1 Blue # Black # # # Black # Black Green Black Green Black Blue # Gray # Gray # Gray # Black # # # # Red # Gray Black Brown # # # # # # Black # #
Area
A-2 B-1 C-3 D-3 C-3 C-3 C-3 D-4 A-2 B-4 A-2 B-4 A-2 B-2 C-4 C-3 C-4 C-3 D-4 D-3 C-4 B-4 D-2 A-2 A-3 B-1 B-1 B-1 C-1 D-1 D-1 B-2 C-2 C-3 B-3 B-3 B-3 B-4 D-1 C-3
No.
F46
Connecting to Name
Clutch switch (MT) Front wiring harness Select lever illumination light and power switch (AT) CD player illumination light Cigarette lighter (Power) Radio Audio ground Sensor ground joint connector (With OBD) Read memory connector (Without OBD) (*1) Line end connector (With OBD) (*2) Read memory connector (Without OBD) (*1) Line end connector (With OBD) (*2) Kick-down switch (AT) Rear fog light relay (With OBD) Engine control module (DOHC turbo model) Engine control module (SOHC model) Engine control module (DOHC turbo model) Engine control module (SOHC model) Engine control module (DOHC turbo model) Engine control module (SOHC model) Engine control module (DOHC turbo model) Headlight washer module (With OBD) Immobilizer control module (With OBD) (*1) Immobilizer control module (Without OBD) (*2) Immobilizer antenna F/B Ignition relay F/B F/B Front fog light switch Cruise control main switch Combination switch cord Combination switch cord Cigarette lighter (Ground) A/C switch Blower fan switch Mode control panel illumination light Mirror heater relay (With OBD) IG power supply connector Ash tray illumination light
B126
B125 1 1 B126 1 B129 B131 2 4 22 B134 35 28 B135 28 24 B136 30 B137 B140 31 6 12 B141 15 B142 B152 B157 B158 B159 B160 B161 B162 B164 B167 B168 B169 B170 B171 B173 B175 2 7 4 12 10 6 6 8 18 3 3 6 2 4 1 2
B125
F44 F45
Front wiring harness Front wiring harness (DOHC turbo model) Front wiring harness (SOHC model) Stop light switch (Without cruise control) Stop & brake switch (With cruise control) Cruise control sub switch Combination switch Ignition switch Key warning switch
B76 B75
Test mode connector Check connector Diagnosis terminal (Ground) Diagnosis connector Shield joint connector (SOHCwithOBD) Engine control module (SOHCw/oOBD model) Diode (Lighting) (With OBD) Blower motor resistor Blower motor Evaporator thermoswitch Roof cord Cruise control module Rear wiring harness Front door cord RH Seat heater/rear accessory power supply relay
B163 B165
R50 R1 R2 R3 D11
WI-254

18 2 12 12 1 1 1 1 5 4 4 6 6 2 14 4 2 24 6 2 3 6 # # # # # # # # Blue Blue # Black # # # # Black Black Black # # #
Wiring System
No.
B176 B177 B179 B180 B181 B182 B183 B184 B190 B191 B192 B193 B195 B196 B200 B203 B208 B209 B210 B224 B250 B299
Area
D-2 A-1 A-2 A-2 A-4 A-4 D-1 C-1 D-3 B-4 B-4 C-2 D-1 B-3 B-3 C-2 B-3 A-1 A-1 A-3 A-2 C-2
No.
Connecting to Name
Keyless entry control module Wiper deicer (With OBD)
B180 B179 B182 B181 B184 B183
Joint connector (E/G) (SOHC without OBD) Joint connector (E/G) (MT) (SOHC without OBD) Joint connector (Keyless entry) Speed alarm (SOHC without OBD) Wiper deicer relay (With OBD) Wiper deicer timer (With OBD) Wiper deicer switch (With OBD) Rear fog light switch (With OBD) Diode (Rear fog light) (With OBD) Panel-center harness (With OBD) Noise FILTER Glove compartment illumi. light (DOHC turbo model) Front wiring harness (DOHC turbo model) Key switch illumination light Flash memory connector (DOHC turbo model) Shield joint connector (AT)
i4
F75 F76
#: Non-colored
WI-255
Wiring System
S6M0497
WI-256

2. RHD MODEL
25 7 3 14 32 16 2 4 6 4 6 4 8 12 6 24 24 24 6 14 2 4 5 4 18 17 4 2 2 2 14 12 6 12 17 2 6 3 8 20 B94 20 B97 B98 B99 B100 B101 B104 B107 B116 10 18 20 22 25 4 2 4 # White # Blue Blue # # Blue Black C-1 C-4 C-4 C-4 B-4 C-1 C-4 C-3 C-2 R1 R2 R3 F2 D11 # Yellow Black Black # # # Blue Black Green Brown # Blue Blue # White Gray Green White # Black Black Black # # # Blue Black Green Green Gray # Black Blue # # White # # Black
S903446A1309
Wiring System
No.
B30 B31 B32 B36 B37 B40 B41 B42 B43 B46 B47 B50 B51 B52 B53 B54 B55 B56 B61 B62 B64 B65 B68 B69 B70 B71 B72 B74 B75 B76 B79 B81 B82 B83 B84 B85 B87 B88 B90
Area
D-4 D-4 B-4 A-3 B-2 D-3 A-4 C-4 B-1 C-4 C-4 B-4 C-4 C-4 B-3 B-2 B-2 C-2 B-4 B-4 A-3 A-3 C-2 C-2 C-2 C-2 C-3 D-2 A-2 A-2 C-2 A-2 A-2 D-1 C-1 A-4 B-1 B-1 B-4 C-1
No.
D1 AB1 i1 i2
Connecting to Name
Front door cord RH SRS (Airbag) harness Turn & hazard module Instrument panel meter harness Data link connector Power window circuit breaker Power window relay Illumination control module Fuel pump relay Main relay Blower relay F/B
No.
B118 B119 B120 B121 B122

2 1 14 1 6 1 # # # Black Gray Black Green Black Green Black Blue Gray # Gray # Gray # # Black # # # # Red # Gray Black Brown White # # White White White # # # # # # #
Area
C-1 D-2 C-1 D-2 D-1 A-2 C-1 A-2 C-1 B-3 A-4 D-1 D-1 D-1 D-1 D-1 D-1 C-1 B-1 C-3 C-3 D-2 B-3 B-4 C-4 C-3 D-4 D-4 D-3 D-3 C-2 B-2 B-2 B-2 C-1 D-3 D-2 B-4 A-1 A-3 A-3
No.
Connecting to Name
CD player illumination light Front accessory power supply (Power) Radio Audio ground Sensor ground joint connector (DOHC turbo model) Read memory connector (Without OBD) Line end connector (With OBD) (*1) Read memory connector (With OBD) Line end connector (With OBD) (*1) Kick-down switch (AT) Rear fog light relay (With OBD) Engine control module (Non-turbo model with OBD) Engine control module (DOHC turbo model) Engine control module (Non-turbo model with OBD) Engine control module (DOHC turbo model) Engine control module (Non-turbo model with OBD) Engine control module (DOHC turbo model) Engine control module (DOHC turbo model) Headlight washer module (With OBD) Immobilizer control module (Without OBD) Immobilizer control module (With OBD) Immobilizer antenna F/B Ignition relay F/B F/B Front fog light switch Cruise control main switch Combination switch cord Combination switch cord Cigarette lighter (Ground) A/C switch Blower fan switch Mode control panel illumination light Mirror heater relay IG power supply connector Ash tray illumination light Keyless entry control module Wiper deicer Joint connector (E/G) (SOHC model without OBD)
B126 B126 B125 B125
B125 1 1 B126 1 B129 2 4 35 B134 22 28 B135 28 30
Shield joint connector (AT) Transmission control module (AT) F44 F45 Front wiring harness Stop light switch (Without cruise control) Stop & brake switch (With cruise control) Cruise control sub switch Combination switch Ignition switch Key warning switch B76 B75 Test mode connector Check connector Diagnosis terminal (Ground) Diagnosis connector Shield joint connector (SOHC model) Engine control module (SOHCw/oOBD model) Diode (Rear fog light) (With OBD) Blower motor Evaporator thermoswitch Roof cord Cruise control module (DOHC turbo model) Cruise control module (SOHC model) Rear wiring harness Front wiring harness (With ABS model) Front door cord LH Seat heater/rear accessory power supply relay Clutch switch (MT) Select lever illumination light and power switch (AT)
B131
B136 24 B137 B140 31 6 15 B141 12 B142 B152 B157 B158 B159 B160 B161 B162 B164 B167 B168 B169 B170 B171 B173 B175 B176 B177 B179 B180 2 7 4 12 10 6 6 8 18 3 3 6 2 4 1 2 18 2 8 8
R50
B163 B165
B180 B179
WI-257
Wiring System

Connecting to Name
Joint connector (E/G) (SOHC model without OBD) Joint connector (Keyless entry) F/B Wiper deicer relay Wiper deicer timer Wiper deicer switch Rear fog light switch (With OBD) Diode (Rear fog light) (With OBD) B199 B198 i4 Joint connector (Ground) Panel-center harness (With OBD) Noise FILTER Glove compartment illumi. light (DOHC turbo model) Key switch illumination light Flash memory connector (DOHC turbo model) Shield joint connector (AT)
No.
B181 B182 B183 B184 B187 B191 B192 B193 B195 B196 B198 B199 B200 B203 B208 B224 B250 B299

1 1 1 1 9 4 4 6 6 2 1 1 14 4 2 2 3 8 # # # # Brown Blue White Black # # # # # # Black # # #
Area
B-1 B-2 D-4 D-4 C-3 B-1 C-1 D-3 D-4 A-4 B-3 A-2 C-2 D-3 B-2 D-3
No.
B182 B181 B184 B183
C-2
#: Non-colored
WI-258
Wiring System
S6M0498
WI-259
Wiring System
ENGINE WIRING HARNESS AND TRANSMISSION CORD

S903447
51. Engine Wiring Harness and Transmission Cord

A: LOCATION
S903447A13
1. NON-TURBO MODEL WITH OBD

Connector No. Pole Color E2 20 Light gray E3 16 Brown E4 2 Black E5 2 Light gray E6 2 Light gray E7 6 Black E8 3 Light gray E10 2 Light gray E11 1 # E12 4 Dark gray E13 4 Dark gray E14 2 # E15 2 Black E16 2 Light gray E17 2 Light gray E19 1 # E20 4 Black E42 2 Purple #: Non-colored Connector Pole Color 2 Gray 2 Brown 12 Black 20 Black 12 Black 2 Gray 3 Black Area A-2 A-2 A-2 B-1 A-1 A-3 B-2 B-2 B-2 A-2 A-2 A-3 B-3 B-3 B-4 B-2 A-3 A-2
S903447A1308
No. B21 B22
Connecting to Name Bulkhead wiring harness Bulkhead wiring harness Purge control solenoid valve Injector #1 Injector #3 Idle air control solenoid valve Engine coolant temperature sensor and thermometer Crankshaft position sensor Oil pressure switch Ignition coil Throttle position sensor Knock sensor Camshaft position sensor Injector #2 Injector #4 Power steering oil pressure switch Pressure sensor and intake air temperature sensor Air assist solenoid valve
No. T1 T2 T3 T4 T7 T8 T12 #: Non-colored
Area D-1 D-1 D-3 D-3 C-4 D-1 D-2
No. B24 B25 B12 B11 B29 B17
Connecting to Name Bulkhead wiring harness (MT) Bulkhead wiring harness (AT) Inhibitor switch (AT) Bulkhead wiring harness (MT) Bulkhead wiring harness (MT)
WI-260
Wiring System
S6M0500
WI-261
Wiring System

S903447A1309
2. NON-TURBO MODEL WITHOUT OBD

No. E1 E4 E5 E6 E7 E8 E10 E11 E12 E13 E14 E16 E17 E19 E20 E21 E22 #: Non-colored Connector Pole Color 6 Yellow 2 Black 2 Dark gray 2 Dark gray 3 Light gray 3 Gray 2 Gray 1 # 4 Gray 3 Black 2 # 2 Dark gray 2 Dark gray 1 # 2 Black 3 Black 26 Black Area A-3 A-2 A-2 A-2 A-3 A-3 B-3 B-3 A-3 A-3 A-3 B-4 B-4 B-3 A-3 A-3 A-3
No. B20
Connecting to Name Bulkhead wiring harness Purge control solenoid valve Injector #1 Injector #3 Idle air control solenoid valve Engine coolant temperature sensor & thermometer Crankshaft position sensor Oil pressure switch Ignition coil Throttle position sensor Knock sensor Injector #2 Injector #4 Power steering oil pressure switch Intake air temperature sensor Pressure sensor Engine control module
No. T1 T2 T3 T4 T7 T8 T12 #: Non-colored
Connector Pole Color 2 Gray 2 Brown 12 Black 20 Black 12 Black 2 Gray 3 Black
Area D-1 D-1 D-3 D-3 C-4 D-1 D-2
No. B24 B25 B12 B11 B29 B17
Connecting to Name Bulkhead wiring harness (MT) Bulkhead wiring harness (AT) Inhibitor switch (AT) Bulkhead wiring harness (MT) Bulkhead wiring harness (MT)
WI-262
Wiring System
S6M0499
WI-263
Wiring System

S903447A1310
3. TURBO MODEL
No. E1 E2 E3 E4 E5 E6 E7 E8 E10 E11 E13 E14 E15 E16 E17 E19 E21 E31 E32 E33 E34 E50 E51 E54 E55 #: Non-colored
Connector Pole Color 10 Light gray 20 16 2 2 2 3 3 2 1 3 2 2 2 2 2 3 3 3 3 3 3 2 3 2 Black Brown Black Dark gray Dark gray Black Light gray Light gray # Black Gray Light gray Dark gray Dark gray # Black # # Black Black Black Black Black Black
Area A-1 B-3 B-3 A-2 A-1 A-2 A-2 A-2 B-2 A-2 A-2 A-2 B-3 B-3 B-3 A-2 A-2 A-1 B-3 A-2 B-3 B-3 B-3 A-1 A-2
No. B20 F61 B21 F60 B22
Connecting to Name Bulkhead wiring harness Front wiring harness (LHD model) Bulkhead wiring harness (RHD model) Front wiring harness (LHD model) Bulkhead wiring harness (RHD model) Purge control solenoid valve Injector #1 Injector #3 Idle air control solenoid valve Engine coolant temperature sensor & thermometer Crankshaft position sensor Oil pressure switch Throttle position sensor Knock sensor Camshaft position sensor Injector #2 Injector #4 Power steering oil pressure switch Pressure sensor Ignition coil #1 Ignition coil #2 Ignition coil #3 Ignition coil #4 TGV angle sensor LH TGV LH TGV angle sensor RH TGV RH
No. T3 T4 T7 T9 T12 #: Non-colored
Connector Pole Color 12 Black 20 Black 12 Black 4 Gray 4 Black
Area D-3 D-3 D-4 C-1 C-1
No. B12 B11 B128 B17
Connecting to Name Bulkhead wiring harness (AT) Inhibitor switch (AT) Bulkhead wiring harness (MT) Bulkhead wiring harness (MT)
WI-264
Wiring System
S6M0501
WI-265
Wiring System
INSTRUMENT PANEL WIRING HARNESS

S903435
52. Instrument Panel Wiring Harness

A: LOCATION
1. LHD MODEL
No. i1 i2 i4 i10 i11 i12 i18 i22 i36 i38 i39 #: Non-colored
S903435A13 S903435A1302
Connector Pole Color 16 # 24 Black 14 # 18 Green 10 Green 16 Green 8 # 8 # 6 Gray 6 Black 6 #
Area B-2 B-2 C-3 B-2 B-2 B-2 B-3 B-3 C-3 C-3 C-3
No. B36 B37 B200
Connecting to Name Bulkhead wiring harness
Combination meter Rear defogger switch Hazard switch Headlight washer switch Bright switch Headlight leveling switch
WI-266
Wiring System
S6M0502
WI-267
Wiring System

S903435A1301
2. RHD MODEL
No. i1 i2 i4 i10 i11 i12 i18 i22 i36 i38 i39 #: Non-colored
Connector Pole Color 14 Black 32 # 14 # 18 Green 10 Green 16 Green 8 # 8 # 6 Gray 6 Black 6 #
Area C-3 C-3 C-2 B-3 B-3 B-3 B-2 B-2 C-2 C-2 C-2
No. B36 B37 B200
Connecting to Name Bulkhead wiring harness
Combination meter Rear defogger switch Hazard switch Headlight washer switch Bright switch Headlight leveling switch
WI-268
Wiring System
S6M0503
WI-269
Wiring System
REAR WIRING HARNESS

S903431
53. Rear Wiring Harness

A: LOCATION
1. LHD MODEL
No. R1 R2 R3 R4 R8 R9 R11 R12 R14 R15 R16 R22 R26 R28 R30 R32 R36 R37 R38 R39 R41 R42 R43 R44 R48 R50 R52 R55 R56 R57 R58 R59 R63 R70 R72 R73 R79 R80 R81 R82 R92 R97 R98
S903431A13 S903431A1306
Connector Pole Color 10 # 12 # 20 # 1 # 4 # 1 # 4 # 1 # 4 # 6 Black 1 Brown 1 Brown 6 # 6 # 2 # 2 # 8 # 2 # 6 # 4 # 4 Blue 4 # 4 Blue 4 Blue 12 # 8 # * # 1 # 2 # 8 # 6 # 2 # 4 # 3 # 2 # 2 # 10 # 3 # 3 # 4 # 2 # 2 Brown 2 #
Area C-2 C-2 C-2 C-3 C-3 C-3 C-3 B-2 B-2 B-3 B-3 B-4 B-3 B-4 B-3 B-3 B-3 B-3 B-3 B-3 C-2 C-3 C-3 C-3 C-3 B-2 A-3 B-3 B-2 B-3 B-3 C-3 B-4 C-2 B-3 C-3 B-3 B-2 C-3 B-2 C-3 B-4 B-3
No. B97 B98 B99
Connecting to Name Bulkhead wiring harness Parking brake switch Seat belt switch Front door switch LH Rear door cord LH Front door switch RH Rear door cord RH Fuel tank cord Rear door switch RH Rear door switch LH Rear combination light RH Rear combination light LH Diode (Luggage room light) Rear accessory power supply Rear wiper intermittent module Rear gate cord Seat heater RH Seat heater switch RH Seat heater switch LH Seat heater LH Front wiring harness (ABS) Bulkhead wiring harness Room light Sunroof motor Spot light Rear wiring harness Fuel gauge module & fuel pump assembly Fuel gauge sub module License plate light ABS G sensor Rear ABS sensor RH Rear ABS sensor LH Trailer connector Rear door cord RH Rear door cord LH Clock Hold mode switch (AT) Antenna amplifier Rear differential oil temp switch (Turbo model for Europe)
D21 D27 R57
D33 D34 D35
F55 B90
R15
D64 D63
WI-270
REAR WIRING HARNESS

Connector No. Pole Color #: Non-colored * With sunroof models: 2 Without sunroof models: 3 Connecting to Name
Wiring System
Area
No.
S6M0504
WI-271
Wiring System
REAR WIRING HARNESS

S903431A1301
2. RHD MODEL
No. R1 R2 R3 R4 R8 R9 R11 R12 R14 R15 R16 R22 R26 R28 R30 R32 R36 R37 R38 R39 R41 R42 R43 R44 R50 R52 R55 R56 R57 R58 R59 R63 R70 R72 R73 R79 R80 R81 R82 R92 R97 R98
Connector Pole Color 10 # 18 # 20 Blue 1 # 4 # 1 # 4 # 1 # 4 # 6 Black 1 Brown 1 Brown 6 # 6 # 2 # 2 # 8 # 2 # 6 # 4 # 4 Blue 4 # 4 Blue 4 Blue 8 # * # 1 # 2 # 8 # 6 # 2 # 4 # 3 # 2 # 2 # 10 # 3 # 3 # 4 # 2 # 2 Brown 2 #
Area B-2 B-2 B-2 C-3 C-3 C-3 C-3 B-2 B-2 B-3 B-3 B-4 B-3 B-4 B-3 B-3 B-3 A-3 B-3 B-3 B-2 C-3 C-3 C-3 B-2 A-3 B-3 B-2 B-3 B-3 B-3 B-4 C-3 B-3 C-3 B-3 B-2 C-3 B-3 C-3 B-4 B-3
No. B97 B98 B99
Connecting to Name Bulkhead wiring harness Parking brake switch Seat belt switch Front door switch LH Rear door cord LH Front door switch RH Rear door cord RH Fuel tank cord Rear door switch RH Rear door switch LH Rear combination light RH Rear combination light LH Diode (Luggage room light) Rear accessory power supply Rear wiper intermittent module Rear gate cord Seat heater RH Seat heater switch RH Seat heater switch LH Seat heater LH Bulkhead wiring harness Room light Sunroof motor Spot light Rear wiring harness Fuel gauge module & fuel pump assembly Fuel gauge sub module License plate light ABS G sensor Rear ABS sensor RH Rear ABS sensor LH Trailer connector Rear door cord RH Rear door cord LH Clock Hold mode switch (AT) Antenna amplifier Rear differential oil temp switch (Turbo model for Europe)
D21 D27 R57
D33 D34 D35
B90
R15
D64 D63
#: Non-colored * With sunroof models: 2 Without sunroof models: 3
WI-272
REAR WIRING HARNESS
Wiring System
S6M0505
WI-273
Wiring System
DOOR CORD
S903432
54. Door Cord

A: LOCATION
1. LHD MODEL
No. D1 D2 D3 D4 D5 D6 D7 D8 D11 D12 D13 D14 D15 D16 D17 D18 D21 D23 D24 D25 D26 D27 D29 D30 D31 D32 D61 D63 D64 #: Non-colored
S903432A13
S903432A1302
Connector Pole Color 25 # 2 # 2 Blue 2 Black 6 # 2 # 16 # 4 Gray 25 # 2 # 2 Blue 2 Black 6 # 2 # 8 # 4 # 4 # 2 # 2 Blue 6 # 4 # 4 # 2 # 2 Blue 6 # 4 # 10 # 3 # 3 #
Area C-2 C-3 C-3 C-3 C-3 C-3 C-3 C-3 C-2 B-2 B-2 B-2 B-2 B-2 B-2 B-2 C-3 C-4 C-4 B-4 B-4 B-2 B-3 B-2 B-3 B-3 B-3 C-3 B-2
No. B30
B101
R11
R14
R81 R80
Connecting to Name Bulkhead wiring harness Front door speaker LH Front power window motor LH Front door tweeter LH Remote control rearview mirror LH Mirror heater LH Power window main switch Front door lock actuator LH Bulkhead wiring harness Front door speaker RH Front power window motor RH Front door tweeter RH Remote control rearview mirror RH Mirror heater RH Front power window sub switch RH Front door lock actuator RH Rear wiring harness Rear door speaker LH Rear power window motor LH Rear power window sub switch LH Rear door lock actuator LH Rear wiring harness Rear door speaker RH Rear power window motor RH Rear power window sub switch RH Rear door lock actuator RH Remote control rearview mirror switch Rear wiring harness Rear wiring harness
WI-274
DOOR CORD
Wiring System
S6M0367A
WI-275
Wiring System
DOOR CORD
S903432A1301
2. RHD MODEL
No. D1 D2 D3 D4 D5 D6 D7 D8 D11 D12 D13 D14 D15 D16 D17 D18 D21 D23 D24 D25 D26 D27 D29 D30 D31 D32 D61 D63 D64 #: Non-colored
Connector Pole Color 25 # 2 # 2 Blue 2 Black 6 # 2 # 16 # 4 Gray 25 # 2 # 2 Blue 2 Black 6 # 2 # 8 # 4 # 4 # 2 # 2 Blue 6 # 4 # 4 # 2 # 2 Blue 6 # 4 # 10 # 3 # 3 #
Area C-2 C-2 B-2 B-2 B-2 B-2 B-2 B-2 C-2 C-3 C-3 C-3 C-3 C-3 C-3 C-3 C-3 C-4 C-4 C-4 B-4 B-2 B-3 B-2 B-3 B-3 B-2 C-3 B-2
No. B30
B101
R11
R14
R81 R80
Connecting to Name Bulkhead wiring harness Front door speaker RH Front power window motor RH Front door tweeter RH Remote control rearview mirror RH Mirror heater RH Power window main switch Front door lock actuator RH Bulkhead wiring harness Front door speaker LH Front power window motor LH Front door tweeter LH Remote control rearview mirror LH Mirror heater LH Front power window sub switch LH Front door lock actuator LH Rear wiring harness Rear door speaker LH Rear power window motor LH Rear power window sub switch LH Rear door lock actuator LH Rear wiring harness Rear door speaker RH Rear power window motor RH Rear power window sub switch RH Rear door lock actuator RH Remote control rearview mirror switch Rear wiring harness Rear wiring harness
WI-276
DOOR CORD
Wiring System
S6M0368A
WI-277
Wiring System
REAR GATE CORD

S903748
55. Rear Gate Cord

A: LOCATION
No. D33 D34 D35 D37 D38 D39 D40 D42 D43 D46 D47 D48 D49 #: Non-colored
S903748A13
Connector Pole Color 2 # 6 # 4 # 1 Black 1 # 2 Black 1 Black 3 # 4 # 2 Black 4 # 1 Black 3 #
Area C-4 C-4 C-4 A-3 B-3 A-3 B-4 B-4 B-3 B-3 C-4 B-3 C-3
No. R37 R38 R39
Connecting to Name Rear wiring harness Luggage room light (Power) Luggage room light High-mount stop light Rear defogger (Power) Rear finisher light RH Rear wiper motor Rear gate latch switch Rear gate lock actuator Rear defogger (Ground) Rear finisher light LH
WI-278
REAR GATE CORD
Wiring System
S6M0449A
WI-279
Wiring System
REAR GATE CORD
MEMO:
WI-280

Subaru Forester 2001 Service Manual

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Subaru Forester 2001 Service Manual

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2001 FORESTER SERVICE MANUAL GENERAL INFORMATION SECTION

QUICK REFERENCE INDEX

2001 FORESTER SERVICE MANUAL ENGINE1 SECTION

QUICK REFERENCE INDEX

2001 FORESTER SERVICE MANUAL ENGINE2 SECTION

QUICK REFERENCE INDEX

2001 FORESTER SERVICE MANUAL TRANSMISSION SECTION

QUICK REFERENCE INDEX

2001 FORESTER SERVICE MANUAL CHASSIS SECTION

QUICK REFERENCE INDEX

2001 FORESTER SERVICE MANUAL BODY SECTION

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2001 FORESTER SERVICE MANUAL BODY SECTION

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2001 FORESTER SERVICE MANUAL WIRING SYSTEM SECTION

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HOW TO USE THIS MANUALS

How to Use This Manuals

HOW TO USE THIS MANUALS

1. How to Use This Manuals

A: HOW TO USE THIS MANUALS

For each component, a composition drawing is included.

If necessary, specifications are also included

Inspections are included to be carried out before and after maintenance.

Tables showing a step-by-step process make it easy to conduct diagnosis.

mm (in) cm (cu in)

rpm kW (HP)/rpm Nm (kgf-m, ft-lb)/rpm

2.0 L TURBO NGK: PFR6B

Type and capacity (5HR)

For Europe For Australia Others

Service brake system Front Rear Parking brake

15 6J 205/70R15 Steel belted radial, Tubeless

Fuel tank Engine oil

1. EXCEPT AUSTRALIA SPEC. VEHICLE

Curb weight (CW)

Maximum permissible axle weight (MPAW) Maximum permissible weight (MPW)

Front Rear Total Front Rear Total

(lb) (lb) (lb) (lb) (lb) (lb)

Front kg (lb) Rear kg (lb) Total kg (lb)

10 (22) 1 (2) 9 (20)

2 (4) 0 (0) 2 (4)

1 (2) 2 (4) 1 (2)

3.6 (7.9) 1 (2) 2.6 (5.7)

17 (38) 3 (7) 14 (31)

9 (20) 14 (31) 23 (51)

2 (4.4) 2 (4.4) 4 (8.8)

2 (4) 1 (2) 1 (2)

2. AUSTRALIA SPEC. VEHICLE

Unladen mass (UM)

Gross vehicle mass (GVM )

Front Rear Total Front Rear Total

(lb) (lb) (lb) (lb) (lb) (lb)

10 (22) 1 (2) 9 (20)

3.6 (7.9) 1 (2) 2.6 (5.7)

9 (20) 14 (31) 23 (51)

8. AIRBAG SPECIAL TOOLS

To prevent unexpected deployment, only use special tools.

10. WINDOW ADHESIVE

2. STATIC ELECTRICITY DAMAGE

3. IGNITION OFF BATTERY

For information about training, contact a dealer or agent.

9. GENERAL SCAN TOOL

1. IDENTIFICATION NUMBER AND LABEL LOCATIONS