2004 Service Manual Subaru

2004 Model Year
PDF Service Manual
GENERAL INFORMATION SECTION (Pub.No.G2320GE1)

ENGINE SECTION 1 (Pub.No.G2320GE2)
TRANSMISSION SECTION (Pub.No.G2320GE5)
CHASSIS SECTION (Pub.No.G2320GE6)
BODY SECTION (Pub.No.G2320GE7)
WIRING SYSTEM SECTION (Pub.No.G2320GE8)
2004 LEGACY SERVICE MANUAL
QUICK REFERENCE INDEX
GENERAL INFORMATION
SECTION
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.
FOREWORD
FW
HOW TO USE THIS MANUALS
HU
SPECIFICATIONS
SPC
PRECAUTION
PC
NOTE
NT
IDENTIFICATION
ID
RECOMMENDED MATERIALS
RM
PRE-DELIVERY INSPECTION
PI
PERIODIC MAINTENANCE SERVICES
PM
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.
G2320GE1
FOREWORD
FW
1.
Page
Foreword .....................................................................................................2
Foreword
FOREWORD
1. Foreword
A: FOREWORD
These manuals are used when performing maintenance, repair, or diagnosis of Subaru LEGACY.
Applied model:
BL*****, BP***** from 2004MY
The manuals contain the latest information at the
time of publication. Changes in specifications,
methods, etc. may be made without notice.
FW-2
HU
1.
Page
How to Use This Manuals ...........................................................................2
How to Use This Manuals

1. How to Use This Manuals

A: HOW TO USE THIS MANUALS
1. STRUCTURE
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
the diagnostic information has also been added
where necessary.
2. CONTENTS
The first page has an index with tabs.
HU-2

3. COMPONENT
Illustrations are provided for each component. The information necessary for repair work (tightening torque,
grease up points, etc.) is described on these illustrations. Information is described using symbol.
To order parts, refer to parts catalogue.
Example:
(7)
(5)
(21)
T2
(5)
T6
(8)
(20)
(1)
T1
T3
(4)
(2)
T8
T2
(3) (6)
T3
T2
T10
(1)
T5
T3
T3
(2)
T4
(4)
(4)
(3)
(12) (22)
(23)
(16)
(14)
(9)
(6)
(10)
(11)
(11)
(10)
(9)
T3
(18)
T1
(13)
(15)
T2
(17)
(19)
T6
(4)
(3)
(7)
T4
(10)
(4)
(15)
T2
T11
T5
(22)
T6
(3)
(12)
(35)
T4
(8)
(10)
T3
(26)
(23)
(14)
T2
T5
(27)
T2
(34)
(24)
(25)
T7
(24)
(36)
(25)
(13)
(31)
(30)
T2
T5
(29)
(10)
(17)
(16)
(37)
(32)
(28)
(18)
T3
(33)
T4
T1
:Selective part
T1
:Replacement part
(21)
:Sealing point
:Should be lubricated with oil.
(20)
T9
:Should be lubricated with grease.
(19)
T1
T2
.... :Tightening torque

HU-00017
HU-3

4. SPECIFICATION
If necessary, specifications are also included.
5. INSPECTION
Inspections to be carried out before and after maintenance are included.
6. MAINTENANCE
Maintenance instructions for serviceable parts describe work area and detailed step with illustration. It also
describes the use of special tool, tightening torque, caution for each procedure.
If many serviceable parts are included in one service procedure, appropriate reference is provided for each
parts.
Example:
15.Main Shaft Assembly for Single-Range

A: REMOVAL
(A)
(B)
1) Remove the manual transmission assembly

from vehicie. <Ref. to MT-33, REMOVAL, Manual
Transmission Assembly.>
(C)
11) Tighten the lock nuts to the specified torque using ST1 and ST2.
NOTE:
Secure the lock nuts in two Places affer tightening.
ST2 499987003
SOCKET WRENCH
ST1 498937000
TRANSMISSION HOLDER
(E)
(D)
(F)
Tightening torque:
118 N m (12.0 kgf-m, 86.8 ft-lb)
(G)
(H)
ST2
ST1
HU-00020
(A)
(B)
(C)
Component
Process
Reference
(D)
(E)
(F)
Cautions
Tool number of special tool
Name of special tool
HU-4
(G)
(H)
Tightening torque
Illustration

7. DIAGNOSIS
Tables showing a step-by-step process make it
easy to conduct diagnosis.
8. SI UNITS
Measurements in these manuals are according to
the SI units. Metric and yard/pound measurements
are also included.
Example:
Tightening torque:
44 Nm (4.5 kgf-m, 33 ft-lb)
Item
Force
Mass (Weight)
Capacity
SI units
N (Newton)
kg, g
Torque
Rotating speed
Pressure
2, m2 or cm3
Nm
rpm
kPa (kilopascal)
Power
Calorie
Fuel consumption rate
W
Wh
g/kwh
Conventional unit
kgf
kg, g
2 or cc
kgf-m, kgf-cm
rpm
kgf/cm2
mmHg
PS
cal
g/PSh
Remarks
1 kgf = 9.80655 N
1 cc = 1 cm3 = 1 m2
1 kgf-m = 9.80655 Nm
1 kgf/cm2 = 98.0655 kPa
1 mmHg = 0.133322 kPa
1 PS = 0.735499 kW
1 kcal = 1.16279 Wh
1 g/PSh=1.3596 g/kWh
The figure used in these manuals are described in the SI units and conventional units are described in (
HU-5
).

9. EXPLANATION OF TERMINOLOGY
List
AAI
A/B
ABS
A/C
A/F
ALT
ASSY
AT
ATF
BATT
CD-R/RW
CPU
DOHC
DVD
ECM
EGR
ELR
EX
F/B
FL
Ft
FWD
GPS
H/U
IG
INT
ISC
LH
LSD
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
Air Assist Injection

Airbag
Antilock Brake System
Air Conditioner
Air Fuel Ratio
Generator
Assembly
Automatic Transmission
Automatic Transmission Fluid
Battery
CD Recordable/Rewritable
Central Processing Unit
Double Overhead Camshaft
Digital Versatile Disc
Engine Control Module (ECM)
Exhaust Gas Recirculation
Emergency Locking Retractor
Exhaust
Fuse & Joint Box
Fusible Link
Full-time AWD
Front Wheel Drive
Global Positioning System
Hydraulic Unit
Ignition
Intermittent
Idle Speed Control
LH (Left Hand)
Limited Slip Differential
M/B
MD
MPI
MP-T
MT
Non-turbo
NC
NO
OP
P/S
P/W
PCD
PCV
RH
Rr
SOHC
SRS
SSM
ST
SW
TCS
TGV
T/M
ViS-C
VSV
VTD
W/H
Pr
2ndr
HU-6
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
Main Fuse & Relay Box

Mini Disc
Multi Point Injection
Multi-Plate Transfer
Manual Transmission
Natural Aspiration
Normal Close (Relay)
Normal Open (Relay)
Option Parts
Power Steering
Power Window
Pitch Circle Diameter
Positive Crankcase Ventilation
RH (Right Hand)
Rear
Single Overhead Camshaft
Supplemental Restraint System
Subaru Select Monitor
Special Tool
Switch
Traction Control System
Tumble Generated Valve
Transmission
Viscous Coupling
Vacuum Switching Valve
Variable Torque Distribution
Wiring Harness
Primary
Secondary
SPECIFICATIONS
SPC
1.
Page
LEGACY......................................................................................................2
LEGACY
SPECIFICATIONS
1. LEGACY
A: DIMENSION
1. SEDAN MODEL
Model
Overall length
Overall width
Overall height (at C.W.)
Length
Width
Compartment
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
Height
mm (in)
Front
Rear
Minimum road clearance
mm (in)
mm (in)
mm (in)
mm (in)
Wheelbase
Tread
1:
2.0 L SOHC
2.0 L DOHC turbo

2.5 L SOHC
4,665 (183.7)
1,730 (68.1)
1,425 (56.1)
1,900 (74.8)
1,445 (56.9)
3.0 L DOHC
1,165 (45.9), 1,100 (43.3)1

2,670 (105.1)
1,495 (58.9)
1,490 (58.7)
150 (5.9)
With sunroof
2. WAGON MODEL
Model
Overall length
Overall width
Length
Width
Compartment
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
Height
mm (in)
Front
Tread
Rear
mm (in)
mm (in)
mm (in)
mm (in)
Wheelbase
1:
2.0 L SOHC
2.0 L DOHC turbo

2.5 L SOHC
4,720 (185.8)
1,730 (68.1)
1,470 (57.9)
1,840 (72.4)
1,445 (56.9)
1,190 (46.9), 1,145 (45.1)1
2,670 (105.1)
1,495 (58.9)
1,485 (58.5)
155 (6.1)
150 (5.9)
3.0 L DOHC
150 (5.9)
With sunroof
3. OUTBACK MODEL
Model
Overall length
Overall width
Length
Width
Compartment
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
4,730 (186.2)
1,770 (69.7)
1,545 (60.8)
1,840 (72.4)
1,445 (56.9)
Height
mm (in)
Front
Tread
Rear
mm (in)
mm (in)
mm (in)
mm (in)
1,190 (46.9), 1,145 (45.1)1

2,670 (105.1)
1,495 (58.9)
1,485 (58.5)
200 (7.9)
Wheelbase
1:
2.0 L SOHC
With sunroof
SPC-2
3.0 L DOHC
LEGACY
SPECIFICATIONS
B: ENGINE
Model
2.0 L SOHC
2.0 L DOHC turbo
2.5 L SOHC
Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine
Engine type
Valve arrangement
Bore Stroke
mm (in)
Displacement
cm3 (cu in)
Compression ratio
Overhead camshaft
99.5 79.0
92 75 (3.62 2.95)
(3.917 3.110)
1,994 (121.67)
10.0
9.5
Ignition order
Maximum torque
rpm
kW (PS)/rpm
Nm (kgf-m, ft-lb)/rpm
89.2 80.0
(3.512 3.150)
2,457 (149.9)
3,000 (183.06)
10.0
10.7
1632
54
1324
Idle speed at Park or Neutral

position
Maximum output
3.0 L DOHC
Horizontally
opposed, liquid
cooled, 6-cylinder, 4-stroke gasoline engine
650
650
650
650
101 (137)/5,600
187 (19.1, 137.9)/
4,400
180 (245)/6,400
310 (31.6, 228.6)/
2,400
121 (165)/5,600
226 (23.0, 166.7)/
4,400
180 (245)/6,600
297 (30.3, 219.1)/
4,200
2.0 L SOHC
13
2.0 L DOHC turbo

14
C: ELECTRICAL
Model
Ignition timing (at idling)
Spark plug
BTDC
CHAMPION:
RC10YC4
Type and manufacturer
Generator
Battery
Type and
capacity
(5HR)
EC,
EK,
K4
MT
AT
12V 48AH
(55D23L)
12V 52AH
(65D23L)
KA
KS
12V 27AH
(34B19L)
: EC, EK model
SPC-3
2.5 L SOHC
13
CHAMPION:
RC10YC4
NGK:ILFR6B
NGK:
PFR5B-111
12V 110A
12V 48AH
(55D23L)
12V 52AH
(75D23L)
12V 48AH
(55D23L)
12V 27AH
(34B19L)
3.0 L DOHC
15
NGK:ILFR6B
12V 52AH
(75D23L)
12V 48AH
(55D23L)
LEGACY
SPECIFICATIONS
D: TRANSMISSION
Model
2.0 L SOHC
Transmission type
Clutch type
Gear ratio
Auxiliary transmission gear

ratio2
1st reduction
Reduction gear
(Front)
Final
reduction
Transfer
reduction
Reduction gear
(Rear)
Final
reduction
1st
2nd
3rd
4th
4AT
TCC
2.785
1.545
1.000
0.694
5MT
DSPD
3.454
1.947
1.366
0.972
5th
0.738
2.272
Helical
1.000
Hypoid
3.333
1,000
1,447
Hypoid
4.111
4.111
Hypoid
Helical
1.000
Hypoid
4.111
4.111
Rev.
High
Low
Type of gear
Gear ratio
Type of gear
Gear ratio
Type of gear
Gear ratio
Type of gear
Gear ratio
SEDAN, WAGON
2.0 L
DOHC
2.5 L SOHC
turbo
5AT
4AT
5MT
TCC
TCC
DSPD
3.540
2.785
3.454
2.264
1.545
2.062
1.471
1.000
1.448
1.000
0.694
1.088
0.825,
0.834
0.7801
2.370
2.272
3.333
1,000
1,196
Helical
Helical
1.000
1.000
Hypoid
Hypoid
Hypoid
3.700,
3.272
4.111
4.1111
Helical
1.000
Hypoid
Hypoid
Hypoid
3.700,
3.272
4.111
4.1111
OUTBACK
Model
2.5 L SOHC
Transmission type
Clutch type
Gear ratio

ratio2
1st reduction
Reduction gear
(Front)
Final
reduction
Transfer
reduction
Reduction gear
(Rear)
Final
reduction
1st
2nd
3rd
4th
5th
Rev.
High
Low
Type of gear
Gear ratio
Type of gear
Gear ratio
Type of gear
Gear ratio
Type of gear
Gear ratio
4AT
TCC
2.785
1.545
1.000
0.694
2.272
Helical
1.000
Hypoid
4.444
Hypoid
4.444
5MT
DSPD
3.454
2.062
1.448
1.088
0.825
3.333
1,000
1,196
Hypoid
3.900,
4.1111
Helical
1.000
Hypoid
3.900,
4.1111
3.0 L
DOHC
5AT
TCC
3.540
2.264
1.471
1.000
0.834
2.370
Helical
1.000
Hypoid
3.272
Hypoid
3.272
5MT: 5-forward speeds with synchromesh and 1-reverse

4AT: Electronically controlled fully-automatic, 4-forward speeds and 1-reverse
SPC-4
3.0 L
DOHC
5AT
TCC
3.540
2.264
1.471
1.000
0.834
2.370
Helical
1.000
Hypoid
3.083
Hypoid
3.083
LEGACY
SPECIFICATIONS
5AT: Electronically controlled fully-automatic, 5-forward speeds and 1-reverse
DSPD: Dry Single Plate Diaphragm
TCC: Torque Converter Clutch
1
: KA, K4 model
2
: Dual range model only
E: STEERING
Model
2.0 L SOHC
Type
Turns, lock to lock
Minimum turning
diameter
3.2
Center of tire
width to center of
m (ft) tire width
Wall to wall
3.0 L DOHC
2.8
10.8 (35.4)
11.6 (38.1)
OUTBACK
2.5 L SOHC
3.0 L DOHC
Rack and Pinion
3.2
Model
Type
Turns, lock to lock
Minimum turning
diameter
SEDAN, WAGON
2.0 L DOHC turbo
2.5 L SOHC
Rack and Pinion
2.8
3.2
Center of tire
width to center of
m (ft) tire width
Wall to wall
10.8 (35.4)
11.6 (38.1)
F: SUSPENSION
Front
Rear
Macpherson strut type suspension

Multi-link type suspension
G: BRAKE
Model
Service brake system
Front
Rear
Parking Brake
Except for 2.0 L DOHC turbo

2.0 L DOHC turbo
Dual circuit hydraulic with vacuum suspended power unit
Ventilated disc brake
Disc brake
Ventilated disc brake
Mechanical on rear brakes
H: TIRE
Model
2.0 L SOHC
Wheel size
Tire size
Type
1:
SEDAN, WAGON
2.0 L DOHC
2.5 L SOHC
turbo
16 6 1/2JJ
17 7JJ
205/55 R16 89V
215/45 R17 87W
16 6 1/2JJ
17 7JJ
OUTBACK
3.0 L DOHC
2.5 L SOHC
3.0 L DOHC
17 7JJ
16 6 1/2JJ
17 7JJ
215/60 R16 95V

215/60 R16
95H1
215/55 R17 94V

215/55 R17
93H1
205/55 R16 89V

215/45 R17 87W
215/45 R17 87W
Steel belted radial, Tubeless
KA model
SPC-5
LEGACY
SPECIFICATIONS
I:
CAPACITY
2.0 L SOHC
Model
LHD
5MT
RHD
2 (US gal, Imp gal)
Fuel tank
Engine oil
2.0 L DOHC turbo
4AT
Capacity (at
overhaul)
Filling
amount of
engine oil
(at replace)
2 (US qt, Imp qt)
LHD
RHD
64 (16.9, 14.1)
4.5 (4.8, 4.0)
2 (US qt, Imp qt)
5.0 (5.3, 4.4)
4.0 (4.2, 3.5)

3.5 (3.7, 3.1)
4.0 (4.2, 3.5)2
0.8 (0.8, 0.7)

0.8 (0.8, 0.7)
Transmission gear oil
2 (US qt, Imp qt)
ATF
Front differential gear oil
Rear differential gear oil
Power steering fluid
2 (US qt, Imp qt)

2 (US qt, Imp qt)
2 (US qt, Imp qt)
2 (US qt, Imp qt)
8.4 (8.9, 7.4)

1.2 (1.3, 1.1)
Engine coolant
6.3
6.4
(6.7, 5.5)
(6.8, 5.6)
2 (US qt, Imp qt)
6.7
6.8
(7.1, 5.9)1 (7.2, 6.0)1
6.4
(6.8, 5.6)
6.5
(6.9, 5.7)
2.5 L SOHC
Model
4AT
LHD
Engine oil
RHD
2 (US gal, Imp gal)
Fuel tank
Capacity (at
overhaul)
Filling
amount of
engine oil
(at replace)
5AT
5MT
LHD
RHD
64 (16.9, 14.1)
9.8 (10.4, 8.6)

1.4 (1.5 1.2)
7.3 (7.7, 6.4)
3.0 L DOHC
5AT
LHD
RHD
2 (US qt, Imp qt)
4.5 (4.8, 4.0)
7.2 (7.6, 6.3)
2 (US qt, Imp qt)
4.0 (4.2, 3.5)
Approx. 5.5 (5.8, 4.8)
2 (US qt, Imp qt)
ATF
Front differential gear oil
2 (US qt, Imp qt)

2 (US qt, Imp qt)
2 (US qt, Imp qt)
2 (US qt, Imp qt)
9.3 (9.8, 8.2)

1.2 (1.3, 1.1)
Engine coolant
6.3
6.4
(6.7, 5.5)
(6.8, 5.6)
2 (US qt, Imp qt)
6.7
6.8
1
(7.1, 5.9)
(7.2, 6.0)1
: With ATF cooler (with warmer function)

Dual range model only
2:
SPC-6
3.5 (3.7, 3.1)

4.0 (4.2, 3.5)2
0.8 (0.8, 0.7)

0.8 (0.8, 0.7)
9.8 (10.4, 8.6)

1.4 (1.5, 1.2)
7.2 (7.6, 6.3)

6.4
(6.8, 5.6)
6.5
(6.9, 5.7)
7.8
7.7
1 (8.2, 6.9)1
(8.1, 6.7)
LEGACY
SPECIFICATIONS
J: WEIGHT
1. SEDAN MODEL
LHD model
Option code1
EC
Model
Curb weight
(C.W.)
Front
Rear
Total
Front
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
2.0 L SOHC
AWD
2.0 i
5MT (Single range)
740 (1,631)
755 (1,664)
760 (1,676)
760 (1,676)
765 (1,686)
775 (1,709)
590 (1,301)
590 (1,301)
590 (1,301)
590 (1,301)
605 (1,334)
615 (1,356)
1,330 (2,932) 1,345 (2,965) 1,350 (2,976) 1,350 (2,976) 1,370 (3,020) 1,390 (3,064)
1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293)
Maximum
permissible
axle weight
Rear
kgf (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
(M.P.A.W.)
Maximum
permissible
Total
kgf (lb) 1,900 (4,189) 1,900 (4,189) 1,900 (4,189) 1,900 (4,189) 1,900 (4,189) 1,900 (4,189)
weight (M.P.W.)
Vehicle Dynamics
Control
Cruise control
McIntosh audio
Leather interior
Winter pack
15 inch tire
Option
17 inch tire
A/C
Side airbag
Curtain airbag
Sunroof
Navigation system
Self levelizer
1:
For option code, refer to ID section. <Ref. to ID-5, MODEL NUMBER PLATE, IDENTIFICATION, Identification.>
SPC-7
LEGACY
SPECIFICATIONS
Option code1
EC
Model
Curb weight
(C.W.)
Front
Rear
Total
Front
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
2.0 L SOHC
AWD
2.0 i
4AT
760 (1,676)
775 (1,709)
780 (1,720)
780 (1,720)
785 (1,731)
795 (1,753)
590 (1,301)
590 (1,301)
590 (1,301)
590 (1,301)
605 (1,334)
615 (1,356)
1,350 (2,976) 1,365 (3,009) 1,370 (3,020) 1,370 (3,020) 1,390 (3,064) 1,410 (3,109)
1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293)
Maximum
permissible
axle weight
Rear
kgf (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
(M.P.A.W.)
Maximum
permissible
Total
kgf (lb) 1,900 (4,189) 1,900 (4,189) 1,900 (4,189) 1,900 (4,189) 1,900 (4,189) 1,900 (4,189)
weight (M.P.W.)
Vehicle Dynamics
Control
Cruise control
McIntosh audio
Leather interior
Winter pack
15 inch tire
Option
17 inch tire
A/C
Side airbag
Curtain airbag
Sunroof
Navigation system
Self levelizer
1:
SPC-8
LEGACY
SPECIFICATIONS
Option code1
EC
Model
Curb weight
(C.W.)
Front
Rear
Total
Front
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
2.5 L SOHC
AWD
2.5 i
5MT (Single range)
760 (1,676)
770 (1,698)
765 (1,686)
770 (1,698)
765 (1,686)
775 (1,709)
600 (1,323)
605 (1,334)
600 (1,323)
605 (1,334)
605 (1,334)
610 (1,345)
1,360 (2,998) 1,375 (3,031) 1,365 (3,009) 1,375 (3,031) 1,370 (3,020) 1,385 (3,053)
1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293)
Maximum
permissible
axle weight
Rear
kgf (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
(M.P.A.W.)
Maximum
permissible
Total
kgf (lb) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255)
weight (M.P.W.)
Vehicle Dynamics
Control
Cruise control
McIntosh audio
Leather interior
Winter pack
15 inch tire
Option
17 inch tire
A/C
Side airbag
Curtain airbag
Sunroof
Navigation system
Self levelizer
1:
SPC-9
LEGACY
SPECIFICATIONS
Option code1
EC
2.5 L SOHC
AWD
2.5 i
Model
Curb weight
(C.W.)
Front
Rear
Total
Front
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
5MT (Single range)

4AT
775 (1,709)
780 (1,720)
785 (1,731)
780 (1,720)
790 (1,742)
785 (1,731)
615 (1,356)
625 (1,378)
625 (1,378)
600 (1,323)
605 (1,334)
600 (1,323)
1,390 (3,064) 1,405 (3,097) 1,410 (3,109) 1,380 (3,042) 1,395 (3,075) 1,385 (3,053)
1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293)
Maximum
permissible
axle weight
Rear
kgf (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
(M.P.A.W.)
Maximum
permissible
Total
kgf (lb) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255)
weight (M.P.W.)
Vehicle Dynamics
Control
Cruise control
McIntosh audio
Leather interior
Winter pack
15 inch tire
Option
17 inch tire
A/C
Side airbag
Curtain airbag
Sunroof
Navigation system
Self levelizer
1:
SPC-10
LEGACY
SPECIFICATIONS
Option code1
EC
Model
Curb weight
(C.W.)
Front
Rear
Total
Front
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
2.5 L SOHC
AWD
2.5 i
4AT
790 (1,742)
785 (1,731)
795 (1,753)
800 (1,764)
805 (1,774)
805 (1,774)
605 (1,334)
605 (1,334)
610 (1,345)
615 (1,356)
625 (1,378)
625 (1,378)
1,395 (3,075) 1,390 (3,064) 1,405 (3,097) 1,415 (3,120) 1,430 (3,153) 1,430 (3,153)
1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293)
Maximum
permissible
axle weight
Rear
kgf (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
(M.P.A.W.)
Maximum
permissible
Total
kgf (lb) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255)
weight (M.P.W.)
Vehicle Dynamics
Control
Cruise control
McIntosh audio
Leather interior
Winter pack
15 inch tire
Option
17 inch tire
A/C
Side airbag
Curtain airbag
Sunroof
Navigation system
Self levelizer
1:
SPC-11
LEGACY
SPECIFICATIONS
Option code1
EC
Model
Curb weight
(C.W.)
Front
Rear
Total
Front
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
3.0 L DOHC
AWD
3.0 R, 3.0 R-A
5AT
875 (1,929)
880 (1,940)
890 (1,962)
890 (1,962)
625 (1,378)
630 (1,389)
635 (1,400)
635 (1,400)
1,495 (3,296) 1,510 (3,329) 1,525 (3,362) 1,525 (3,362)
1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293)
Maximum
permissible
axle weight
Rear
kgf (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
(M.P.A.W.)
Maximum
permissible
Total
kgf (lb) 2,030 (4,475) 2,030 (4,475) 2,030 (4,475) 2,030 (4,475)
weight (M.P.W.)
Vehicle Dynamics
Control
Cruise control
McIntosh audio
Leather interior
Winter pack
15 inch tire
Option
17 inch tire
A/C
Side airbag
Curtain airbag
Sunroof
Navigation system
Self levelizer
1:
SPC-12
LEGACY
SPECIFICATIONS
Option code1
K4
Model
Curb weight
(C.W.)
Front
Rear
Total
Front
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
KS
K4
2.0 L SOHC
AWD
2.0 i
5MT (Single range)
4AT
750 (1,653)
740 (1,631)
755 (1,664)
750 (1,653)
760 (1,676)
770 (1,698)
590 (1,301)
590 (1,301)
590 (1,301)
590 (1,301)
600 (1,323)
590 (1,301)
1,340 (2,954) 1,330 (2,932) 1,345 (2,965) 1,340 (2,954) 1,360 (2,998) 1,360 (2,998)
1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293)
Maximum
permissible
axle weight
Rear
kgf (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
(M.P.A.W.)
Maximum
permissible
Total
kgf (lb) 1,900 (4,189) 1,900 (4,189) 1,900 (4,189) 1,900 (4,189) 1,900 (4,189) 1,900 (4,189)
weight (M.P.W.)
Vehicle Dynamics
Control
Cruise control
McIntosh audio
Leather interior
Winter pack
15 inch tire
Option
17 inch tire
A/C
Side airbag
Curtain airbag
Sunroof
Navigation system
Self levelizer
1:
SPC-13
LEGACY
SPECIFICATIONS
Option code1
K4
KS
K4
2.0 L SOHC
KS
2.5 L SOHC
AWD
Model
Curb weight
(C.W.)
Front
Rear
Total
Front
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
2.0 i
2.5 i
4AT
5MT (Single range)
775 (1,709)
770 (1,698)
780 (1,720)
770 (1,698)
775 (1,709)
760 (1,676)
590 (1,301)
590 (1,301)
595 (1,312)
610 (1,345)
620 (1,367)
595 (1,312)
1,365 (3,009) 1,360 (2,998) 1,375 (3,031) 1,380 (3,042) 1,395 (3,075) 1,355 (2,987)
1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293)
Maximum
permissible
axle weight
Rear
kgf (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
(M.P.A.W.)
Maximum
permissible
Total
kgf (lb) 1,900 (4,189) 1,900 (4,189) 1,900 (4,189) 1,900 (4,189) 1,900 (4,189) 1,930 (4,255)
weight (M.P.W.)
Vehicle Dynamics
Control
Cruise control
McIntosh audio
Leather interior
Winter pack
15 inch tire
Option
17 inch tire
A/C
Side airbag
Curtain airbag
Sunroof
Navigation system
Self levelizer
1:
SPC-14
LEGACY
SPECIFICATIONS
Option code1
KS
K4
2.5 L SOHC
2.5 L SOHC
AWD
2.5 i
Model
Curb weight
(C.W.)
Front
Rear
Total
Front
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
5MT (Single range)

4AT
770 (1,698)
770 (1,698)
790 (1,742)
795 (1,753)
795 (1,753)
800 (1,764)
605 (1,334)
610 (1,345)
610 (1,345)
620 (1,367)
615 (1,356)
625 (1,378)
1,375 (3,031) 1,380 (3,042) 1,400 (3,086) 1,415 (3,120) 1,410 (3,109) 1,425 (3,142)
1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293)
Maximum
permissible
axle weight
Rear
kgf (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
(M.P.A.W.)
Maximum
permissible
Total
kgf (lb) 1,930 (4,255) 1,930 (4,255) 1,900 (4,189) 1,900 (4,189) 1,900 (4,189) 1,900 (4,189)
weight (M.P.W.)
Vehicle Dynamics
Control
Cruise control
McIntosh audio
Leather interior
Winter pack
15 inch tire
Option
17 inch tire
A/C
Side airbag
Curtain airbag
Sunroof
Navigation system
Self levelizer
1:
SPC-15
LEGACY
SPECIFICATIONS
Option code1
KS
K4
2.5 L SOHC
3.0 L DOHC
AWD
Model
Curb weight
(C.W.)
Front
Rear
Total
Front
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
2.5 i
3.0 R, 3.0 R-A
4AT
5AT
780 (1,720)
790 (1,742)
790 (1,742)
890 (1,962)
880 (1,940)
595 (1,312)
605 (1,334)
610 (1,345)
635 (1,400)
635 (1,400)
1,375 (3,031) 1,395 (3,075) 1,400 (3,086) 1,525 (3,362) 1,515 (3,340)
1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293)
Maximum
permissible
axle weight
Rear
kgf (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
(M.P.A.W.)
Maximum
permissible
Total
kgf (lb) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255) 2,030 (4,475) 2,030 (4,475)
weight (M.P.W.)
Vehicle Dynamics
Control
Cruise control
McIntosh audio
Leather interior
Winter pack
15 inch tire
Option
17 inch tire
A/C
Side airbag
Curtain airbag
Sunroof
Navigation system
Self levelizer
1:
SPC-16
LEGACY
SPECIFICATIONS
RHD model
Option code1
EK
Model
Curb weight
(C.W.)
Front
Rear
Total
Front
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
2.0 L SOHC
AWD
2.0 i
5MT (Single range)
4AT
755 (1,664)
760 (1,676)
770 (1,698)
775 (1,709)
775 (1,709)
780 (1,720)
590 (1,301)
590 (1,301)
605 (1,334)
610 (1,345)
590 (1,301)
590 (1,301)
1,345 (2,965) 1,350 (2,976) 1,375 (3,031) 1,385 (3,053) 1,365 (3,009) 1,370 (3,020)
1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293)
Maximum
permissible
axle weight
Rear
kgf (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
(M.P.A.W.)
Maximum
permissible
Total
kgf (lb) 1,900 (4,189) 1,900 (4,189) 1,900 (4,189) 1,900 (4,189) 1,900 (4,189) 1,900 (4,189)
weight (M.P.W.)
Vehicle Dynamics
Control
Cruise control
McIntosh audio
Leather interior
Winter pack
15 inch tire
Option
17 inch tire
A/C
Side airbag
Curtain airbag
Sunroof
Navigation system
Self levelizer
1:
SPC-17
LEGACY
SPECIFICATIONS
Option code1
EK
2.0 L SOHC
2.5 L SOHC
AWD
Model
Curb weight
(C.W.)
Front
Rear
Total
Front
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
2.0 i
2.5 i
4AT
5MT (Single range)
790 (1,742)
795 (1,753)
760 (1,676)
765 (1,686)
770 (1,698)
775 (1,709)
605 (1,334)
610 (1,345)
600 (1,323)
600 (1,323)
605 (1,334)
620 (1,367)
1,395 (3,075) 1,405 (3,097) 1,360 (2,998) 1,365 (3,009) 1,375 (3,031) 1,395 (3,075)
1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293)
Maximum
permissible
axle weight
Rear
kgf (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
(M.P.A.W.)
Maximum
permissible
Total
kgf (lb) 1,900 (4,189) 1,900 (4,189) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255)
weight (M.P.W.)
Vehicle Dynamics
Control
Cruise control
McIntosh audio
Leather interior
Winter pack
15 inch tire
Option
17 inch tire
A/C
Side airbag
Curtain airbag
Sunroof
Navigation system
Self levelizer
1:
SPC-18
LEGACY
SPECIFICATIONS
Option code1
EK
2.5 L SOHC
AWD
2.5 i
Model
Curb weight
(C.W.)
Front
Rear
Total
Front
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
5MT (Single range)

4AT
785 (1,731)
785 (1,731)
780 (1,720)
785 (1,731)
790 (1,742)
805 (1,774)
625 (1,378)
625 (1,378)
600 (1,323)
600 (1,323)
610 (1,345)
615 (1,356)
1,410 (3,109) 1,410 (3,109) 1,380 (3,042) 1,385 (3,053) 1,400 (3,086) 1,420 (3,131)
1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293)
Maximum
permissible
axle weight
Rear
kgf (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
(M.P.A.W.)
Maximum
permissible
Total
kgf (lb) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255)
weight (M.P.W.)
Vehicle Dynamics
Control
Cruise control
McIntosh audio
Leather interior
Winter pack
15 inch tire
Option
17 inch tire
A/C
Side airbag
Curtain airbag
Sunroof
Navigation system
Self levelizer
1:
SPC-19
LEGACY
SPECIFICATIONS
Option code1
EK
2.5 L SOHC
3.0 L DOHC
AWD
Model
Curb weight
(C.W.)
Front
Rear
Total
Front
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
2.5 i
3.0 R, 3.0 R-A
4AT
5AT
810 (1,785)
805 (1,774)
810 (1,785)
890 (1,962)
890 (1,962)
620 (1,367)
620 (1,367)
620 (1,367)
635 (1,400)
635 (1,400)
1,430 (3,153) 1,425 (3,142) 1,430 (3,153) 1,525 (3,362) 1,525 (3,362)
1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293)
Maximum
permissible
axle weight
Rear
kgf (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
(M.P.A.W.)
Maximum
permissible
Total
kgf (lb) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255) 2,030 (4,475) 2,030 (4,475)
weight (M.P.W.)
Vehicle Dynamics
Control
Cruise control
McIntosh audio
Leather interior
Winter pack
15 inch tire
Option
17 inch tire
A/C
Side airbag
Curtain airbag
Sunroof
Navigation system
Self levelizer
1:
SPC-20
LEGACY
SPECIFICATIONS
Option code1
KA
Front
Rear
Total
Front
Rear
2.0 L SOHC
AWD
2.0 i
5MT (Single range)
4AT
kgf (lb) 755 (1,664)
760 (1,676)
765 (1,687)
780 (1,720)
775 (1,709)
780 (1,720)
kgf (lb) 590 (1,301)
590 (1,301)
595 (1,312)
610 (1,345)
590 (1,301)
590 (1,301)
kgf (lb) 1,340 (2,954) 1,350 (2,976) 1,360 (2,998) 1,390 (3,064) 1,365 (3,009) 1,370 (3,020)
kgf (lb) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293)
kgf (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
Gross vehicle
mass (G.V.M.)
Total
kgf (lb) 1,900 (4,189) 1,900 (4,189) 1,900 (4,189) 1,900 (4,189) 1,900 (4,189) 1,900 (4,189)
Option
Vehicle Dynamics
Control
Cruise control
McIntosh audio
Leather interior
Winter pack
15 inch tire
17 inch tire
A/C
Side airbag
Curtain airbag
Sunroof
Navigation system
Self levelizer
Grade up
Model
Curb weight
(C.W.)
Unladen mass
(U.W.)
1:
SPC-21
LEGACY
SPECIFICATIONS
Option code1
KA
2.0 L SOHC
Model
2.0 L DOHC turbo

2.5 L SOHC
AWD
2.0 i
2.0 GT
2.5 i
4AT
5AT
5MT (Single range)
785 (1,731)
800 (1,764)
845 (1,863)
860 (1,896)
765 (1,687)
770 (1,698)
595 (1,312)
610 (1,345)
615 (1,356)
635 (1,400)
600 (1,323)
605 (1,334)
1,380 (3,042) 1,410 (3,109) 1,460 (3,219) 1,495 (3,296) 1,365 (3,009) 1,375 (3,031)
1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293)
1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
Front
Rear
Total
Front
Rear
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
Gross vehicle
mass (G.V.M.)
Total
kgf (lb) 1,900 (4,189) 1,900 (4,189) 2,000 (4,409) 2,000 (4,409) 1,930 (4,255) 1,930 (4,255)
Option
Vehicle Dynamics
Control
Cruise control
McIntosh audio
Leather interior
Winter pack
15 inch tire
17 inch tire
A/C
Side airbag
Curtain airbag
Sunroof
Navigation system
Self levelizer
Grade up
Curb weight
(C.W.)
Unladen mass
(U.W.)
1:
SPC-22
LEGACY
SPECIFICATIONS
Option code1
KA
2.5 L SOHC
AWD
2.5 i
Model
5MT (Single range)

4AT
775 (1,709)
780 (1,720)
785 (1,731)
785 (1,731)
790 (1,742)
795 (1,753)
615 (1,356)
620 (1,367)
625 (1,378)
595 (1,312)
605 (1,334)
615 (1,356)
1,390 (3,064) 1,400 (3,086) 1,410 (3,109) 1,380 (3,042) 1,395 (3,053) 1,410 (3,109)
1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293)
1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
Front
Rear
Total
Front
Rear
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
Gross vehicle
mass (G.V.M.)
Total
kgf (lb) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255)
Option
Vehicle Dynamics
Control
Cruise control
McIntosh audio
Leather interior
Winter pack
15 inch tire
17 inch tire
A/C
Side airbag
Curtain airbag
Sunroof
Navigation system
Self levelizer
Grade up
Curb weight
(C.W.)
Unladen mass
(U.W.)
1:
SPC-23
LEGACY
SPECIFICATIONS
Option code1
KA
Model
2.5 L SOHC
AWD
2.5 i
4AT
800 (1,764)
785 (1,731)
795 (1,753)
805 (1,774)
810 (1,786)
815 (1,797)
625 (1,378)
605 (1,334)
610 (1,345)
615 (1,356)
625 (1,378)
625 (1,378)
1,425 (3,142) 1,390 (3,064) 1,405 (3,097) 1,420 (3,131) 1,435 (3,164) 1,440 (3,175)
1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293)
1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
Front
Rear
Total
Front
Rear
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
Gross vehicle
mass (G.V.M.)
Total
kgf (lb) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255) 1,930 (4,255)
Option
Vehicle Dynamics
Control
Cruise control
McIntosh audio
Leather interior
Winter pack
15 inch tire
17 inch tire
A/C
Side airbag
Curtain airbag
Sunroof
Navigation system
Self levelizer
Grade up
Curb weight
(C.W.)
Unladen mass
(U.W.)
1:
SPC-24
LEGACY
SPECIFICATIONS
2. WAGON MODEL
LHD model
Option code1
EC
Model
Curb weight
(C.W.)
Front
Rear
Total
Front
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
2.0 L SOHC
AWD
2.0 i
5MT (Dual range)
750 (1,653)
765 (1,686)
770 (1,698)
770 (1,698)
775 (1,709)
785 (1,731)
610 (1,345)
610 (1,345)
610 (1,345)
610 (1,345)
635 (1,400)
645 (1,422)
1,360 (2,998) 1,375 (3,031) 1,380 (3,042) 1,380 (3,042) 1,410 (3,109) 1,430 (3,153)
1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293)
Maximum
permissible
axle weight
Rear
kgf (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
(M.P.A.W.)
Maximum
permissible
Total
kgf (lb) 1,925 (4,244) 1,925 (4,244) 1,925 (4,244) 1,925 (4,244) 1,925 (4,244) 1,925 (4,244)
weight (M.P.W.)
Vehicle Dynamics
Control
Cruise control
McIntosh audio
Leather interior
Winter pack
15 inch tire
Option
17 inch tire
A/C
Side airbag
Curtain airbag
Sunroof
Navigation system
Self levelizer
1:
SPC-25
LEGACY
SPECIFICATIONS
Option code1
EC
Model
Curb weight
(C.W.)
Front
Rear
Total
Front
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
2.0 L SOHC
AWD
2.0 i
4AT
760 (1,676)
775 (1,709)
780 (1,720)
780 (1,720)
785 (1,731)
790 (1,742)
610 (1,345)
610 (1,345)
610 (1,345)
610 (1,345)
635 (1,400)
640 (1,410)
1,370 (3,020) 1,385 (3,053) 1,390 (3,064) 1,390 (3,064) 1,420 (3,131) 1,430 (3,153)
1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293)
Maximum
permissible
axle weight
Rear
kgf (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
(M.P.A.W.)
Maximum
permissible
Total
kgf (lb) 1,925 (4,244) 1,925 (4,244) 1,925 (4,244) 1,925 (4,244) 1,925 (4,244) 1,925 (4,244)
weight (M.P.W.)
Vehicle Dynamics
Control
Cruise control
McIntosh audio
Leather interior
Winter pack
15 inch tire
Option
17 inch tire
A/C
Side airbag
Curtain airbag
Sunroof
Navigation system
Self levelizer
1:
SPC-26
LEGACY
SPECIFICATIONS
Option code1
EC
Model
Curb weight
(C.W.)
Front
Rear
Total
Front
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
2.5 L SOHC
AWD
2.5 i
5MT (Dual range)
770 (1,698)
780 (1,720)
775 (1,709)
780 (1,720)
780 (1,720)
785 (1,731)
620 (1,367)
625 (1,378)
620 (1,367)
625 (1,378)
620 (1,367)
630 (1,389)
1,390 (3,064) 1,405 (3,097) 1,395 (3,075) 1,405 (3,097) 1,400 (3,086) 1,415 (3,120)
1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293)
Maximum
permissible
axle weight
Rear
kgf (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
(M.P.A.W.)
Maximum
permissible
Total
kgf (lb) 1,935 (4,266) 1,935 (4,266) 1,935 (4,266) 1,935 (4,266) 1,935 (4,266) 1,935 (4,266)
weight (M.P.W.)
Vehicle Dynamics
Control
Cruise control
McIntosh audio
Leather interior
Winter pack
15 inch tire
Option
17 inch tire
A/C
Side airbag
Curtain airbag
Sunroof
Navigation system
Self levelizer
1:
SPC-27
LEGACY
SPECIFICATIONS
Option code1
EC
2.5 L SOHC
AWD
2.5 i
Model
Curb weight
(C.W.)
Front
Rear
Total
Front
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
5MT (Dual range)

4AT
785 (1,731)
790 (1,742)
800 (1,764)
780 (1,720)
790 (1,742)
785 (1,731)
645 (1,422)
655 (1,444)
660 (1,455)
620 (1,367)
625 (1,378)
620 (1,367)
1,430 (3,153) 1,445 (3,186) 1,460 (3,219) 1,400 (3,086) 1,415 (3,120) 1,405 (3,097)
1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293)
Maximum
permissible
axle weight
Rear
kgf (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
(M.P.A.W.)
Maximum
permissible
Total
kgf (lb) 1,935 (4,266) 1,935 (4,266) 1,935 (4,266) 1,945 (4,288) 1,945 (4,288) 1,945 (4,288)
weight (M.P.W.)
Vehicle Dynamics
Control
Cruise control
McIntosh audio
Leather interior
Winter pack
15 inch tire
Option
17 inch tire
A/C
Side airbag
Curtain airbag
Sunroof
Navigation system
Self levelizer
1:
SPC-28
LEGACY
SPECIFICATIONS
Option code1
EC
Model
Curb weight
(C.W.)
Front
Rear
Total
Front
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
2.5 L SOHC
AWD
2.5 i
4AT
790 (1,742)
785 (1,731)
795 (1,753)
800 (1,764)
805 (1,775)
815 (1,797)
625 (1,378)
625 (1,378)
630 (1,389)
645 (1,422)
655 (1,444)
660 (1,455)
1,415 (3,120) 1,410 (3,109) 1,425 (3,142) 1,445 (3,186) 1,460 (3,219) 1,475 (3,252)
1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293)
Maximum
permissible
axle weight
Rear
kgf (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
(M.P.A.W.)
Maximum
permissible
Total
kgf (lb) 1,945 (4,288) 1,945 (4,288) 1,945 (4,288) 1,945 (4,288) 1,945 (4,288) 1,945 (4,288)
weight (M.P.W.)
Vehicle Dynamics
Control
Cruise control
McIntosh audio
Leather interior
Winter pack
15 inch tire
Option
17 inch tire
A/C
Side airbag
Curtain airbag
Sunroof
Navigation system
Self levelizer
1:
SPC-29
LEGACY
SPECIFICATIONS
Option code1
EC
K4
3.0 L DOHC
2.0 L SOHC
AWD
Model
Curb weight
(C.W.)
Front
Rear
Total
Front
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
3.0 R
2.0 i
5AT
5MT (Dual range)
880 (1,940)
890 (1,962)
890 (1,962)
760 (1,676)
750 (1,653)
765 (1,686)
640 (1,410)
665 (1,466)
665 (1,466)
610 (1,345)
610 (1,345)
610 (1,345)
1,520 (3,351) 1,555 (3,428) 1,555 (3,428) 1,370 (3,020) 1,360 (2,998) 1,375 (3,031)
1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293)
Maximum
permissible
axle weight
Rear
kgf (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
(M.P.A.W.)
Maximum
permissible
Total
kgf (lb) 2,050 (4,519) 2,050 (4,519) 2,050 (4,519) 1,925 (4,244) 1,925 (4,244) 1,925 (4,244)
weight (M.P.W.)
Vehicle Dynamics
Control
Cruise control
McIntosh audio
Leather interior
Winter pack
15 inch tire
Option
17 inch tire
A/C
Side airbag
Curtain airbag
Sunroof
Navigation system
Self levelizer
1:
SPC-30
LEGACY
SPECIFICATIONS
Option code1
KS
K4
KS
2.0 L SOHC
AWD
2.0 i
Model
Curb weight
(C.W.)
Front
Rear
Total
Front
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
5MT
4AT
(Dual range)
760 (1,676)
770 (1,698)
775 (1,709)
785 (1,731)
770 (1,698)
610 (1,345)
610 (1,345)
610 (1,345)
635 (1,400)
610 (1,345)
1,370 (3,020) 1,380 (3,042) 1,385 (3,053) 1,420 (3,131) 1,380 (3,042)
1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293)
Maximum
permissible
axle weight
Rear
kgf (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
(M.P.A.W.)
Maximum
permissible
Total
kgf (lb) 1,925 (4,244) 1,925 (4,244) 1,925 (4,244) 1,925 (4,244) 1,925 (4,244)
weight (M.P.W.)
Vehicle Dynamics
Control
Cruise control
McIntosh audio
Leather interior
Winter pack
15 inch tire
Option
17 inch tire
A/C
Side airbag
Curtain airbag
Sunroof
Navigation system
Self levelizer
1:
SPC-31
LEGACY
SPECIFICATIONS
Option code1
K4
2.5 L SOHC
AWD
2.5 i
Model
Curb weight
(C.W.)
Front
Rear
Total
Front
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
5MT (Dual range)

4AT
780 (1,720)
780 (1,720)
790 (1,742)
790 (1,742)
790 (1,742)
790 (1,742)
635 (1,400)
645 (1,422)
650 (1,433)
655 (1,444)
635 (1,400)
645 (1,422)
1,415 (3,120) 1,425 (3,142) 1,440 (3,175) 1,445 (3,186) 1,425 (3,142) 1,435 (3,164)
1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293)
Maximum
permissible
axle weight
Rear
kgf (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
(M.P.A.W.)
Maximum
permissible
Total
kgf (lb) 1,935 (4,266) 1,935 (4,266) 1,935 (4,266) 1,935 (4,266) 1,945 (4,288) 1,945 (4,288)
weight (M.P.W.)
Vehicle Dynamics
Control
Cruise control
McIntosh audio
Leather interior
Winter pack
15 inch tire
Option
17 inch tire
A/C
Side airbag
Curtain airbag
Sunroof
Navigation system
Self levelizer
1:
SPC-32
LEGACY
SPECIFICATIONS
Option code1
K4
2.5 L SOHC
AWD
Model
3.0 L DOHC
3.0 R,
3.0 R-A
4AT
5AT
800 (1,764)
795 (1,753)
800 (1,764)
810 (1,785)
890 (1,962)
650 (1,433)
645 (1,422)
650 (1,433)
650 (1,433)
665 (1,466)
1,450 (3,196) 1,440 (3,175) 1,450 (3,196) 1,460 (3,219) 1,555 (3,428)
1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293)
2.5 i
Curb weight
(C.W.)
Front
Rear
Total
Front
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
Maximum
permissible
axle weight
Rear
kgf (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
(M.P.A.W.)
Maximum
permissible
Total
kgf (lb) 1,945 (4,288) 1,945 (4,288) 1,945 (4,288) 1,945 (4,288) 2,050 (4,519)
weight (M.P.W.)
Vehicle Dynamics
Control
Cruise control
McIntosh audio
Leather interior
Winter pack
15 inch tire
Option
17 inch tire
A/C
Side airbag
Curtain airbag
Sunroof
Navigation system
Self levelizer
1:
SPC-33
LEGACY
SPECIFICATIONS
Option code1
KA
2.0 L SOHC
AWD
2.0 i
Model
5MT (Dual range)

4AT
770 (1,698)
775 (1,709)
790 (1,742)
780 (1,720)
785 (1,731)
800 (1,764)
610 (1,345)
615 (1,356)
640 (1,410)
610 (1,345)
615 (1,356)
640 (1,410)
1,380 (3,042) 1,390 (3,064) 1,430 (3,153) 1,390 (3,064) 1,400 (3,086) 1,440 (3,175)
1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293)
1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
Front
Rear
Total
Front
Rear
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
Gross vehicle
mass (G.V.M.)
Total
kgf (lb) 1,925 (4,244) 1,925 (4,244) 1,925 (4,244) 1,925 (4,244) 1,925 (4,244) 1,925 (4,244)
Option
Vehicle Dynamics
Control
Cruise control
McIntosh audio
Leather interior
Winter pack
15 inch tire
17 inch tire
A/C
Side airbag
Curtain airbag
Sunroof
Navigation system
Self levelizer
Grade up
Curb weight
(C.W.)
Unladen mass
(U.W.)
1:
SPC-34
LEGACY
SPECIFICATIONS
Option code1
KA
2.0 L DOHC turbo
2.5 L SOHC
AWD
Model
Front
Rear
Total
Front
Rear
2.0 GT
2.5 i
5AT
5MT (Dual range)
kgf (lb) 845 (1,863)
850 (1,874)
860 (1,896)
775 (1,709)
780 (1,720)
785 (1,731)
kgf (lb) 635 (1,400)
645 (1,422)
665 (1,466)
620 (1,367)
625 (1,378)
645 (1,422)
kgf (lb) 1,480 (3,263) 1,495 (3,296) 1,525 (3,362) 1,395 (3,075) 1,405 (3,097) 1,430 (3,153)
kgf (lb) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293)
kgf (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
Gross vehicle
mass (G.V.M.)
Total
kgf (lb) 2,010 (4,431) 2,010 (4,431) 2,010 (4,431) 1,935 (4,266) 1,935 (4,266) 1,935 (4,266)
Option
Vehicle Dynamics
Control
Cruise control
McIntosh audio
Leather interior
Winter pack
15 inch tire
17 inch tire
A/C
Side airbag
Curtain airbag
Sunroof
Navigation system
Self levelizer
Grade up
Curb weight
(C.W.)
Unladen mass
(U.W.)
1:
SPC-35
LEGACY
SPECIFICATIONS
Option code1
KA
2.5 L SOHC
AWD
2.5 i
Model
5MT (Dual range)

4AT
795 (1,753)
805 (1,774)
780 (1,720)
790 (1,742)
795 (1,753)
800 (1,764)
650 (1,433)
660 (1,455)
620 (1,667)
625 (1,378)
640 (1,410)
650 (1,433)
1,445 (3,186) 1,465 (3,230) 1,400 (3,086) 1,415 (3,120) 1,435 (3,164) 1,450 (3,197)
1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293)
1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
Front
Rear
Total
Front
Rear
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
Gross vehicle
mass (G.V.M.)
Total
kgf (lb) 1,935 (4,266) 1,935 (4,266) 1,945 (4,288) 1,945 (4,288) 1,945 (4,288) 1,945 (4,288)
Option
Vehicle Dynamics
Control
Cruise control
McIntosh audio
Leather interior
Winter pack
15 inch tire
17 inch tire
A/C
Side airbag
Curtain airbag
Sunroof
Navigation system
Self levelizer
Grade up
Curb weight
(C.W.)
Unladen mass
(U.W.)
1:
SPC-36
LEGACY
SPECIFICATIONS
Option code1
KA
Model
2.5 L SOHC
AWD
2.5 i
4AT
785 (1,731)
790 (1,742)
800 (1,764)
810 (1,786)
815 (1,797)
620 (1,367)
630 (1,389)
645 (1,422)
650 (1,433)
660 (1,455)
1,405 (3,097) 1,420 (3,131) 1,445 (3,186) 1,460 (3,219) 1,470 (3,241)
1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293)
1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
Front
Rear
Total
Front
Rear
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
Gross vehicle
mass (G.V.M.)
Total
kgf (lb) 1,945 (4,288) 1,945 (4,288) 1,945 (4,288) 1,945 (4,288) 1,945 (4,288)
Option
Vehicle Dynamics
Control
Cruise control
McIntosh audio
Leather interior
Winter pack
15 inch tire
17 inch tire
A/C
Side airbag
Curtain airbag
Sunroof
Navigation system
Self levelizer
Grade up
Curb weight
(C.W.)
Unladen mass
(U.W.)
1:
SPC-37
LEGACY
SPECIFICATIONS
3. OUTBACK
LHD model
Option code1
EC
2.5 L SOHC
AWD
OBK 2.5 i
Model
Curb weight
(C.W.)
Front
Rear
Total
Front
5MT (Dual range)

4AT
kgf (lb) 785 (1,731)
795 (1,753)
800 (1,764)
795 (1,753)
805 (1,774)
810 (1,785)
kgf (lb) 645 (1,422)
670 (1,477)
675 (1,488)
645 (1,422)
670 (1,477)
675 (1,488)
kgf (lb) 1,430 (3,153) 1,465 (3,230) 1,475 (3,252) 1,440 (3,175) 1,475 (3,252) 1,485 (3,274)
kgf (lb) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293)
Maximum
permissible
axle weight
Rear
kgf (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
(M.P.A.W.)
Maximum
permissible
Total
kgf (lb) 1,960 (4,321) 1,960 (4,321) 1,960 (4,321) 1,970 (4,343) 1,970 (4,343) 1,970 (4,343)
weight (M.P.W.)
Vehicle Dynamics
Control
Cruise control
McIntosh audio
Leather interior
Winter pack
15 inch tire
Option
17 inch tire
A/C
Side airbag
Curtain airbag
Sunroof
Navigation system
Self levelizer
1:
SPC-38
LEGACY
SPECIFICATIONS
Option code1
EC
K4
3.0 L DOHC
2.5 L SOHC
AWD
Model
Curb weight
(C.W.)
Front
Rear
Total
Front
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
OBK 3.0 R, OBK 3.0 R-A

OBK 2.5 i
5AT
5MT (Dual range)
885 (1,951)
890 (1,962)
900 (1,984)
900 (1,984)
785 (1,731)
795 (1,753)
660 (1,455)
660 (1,455)
685 (1,510)
685 (1,510)
645 (1,422)
670 (1,477)
1,545 (3,406) 1,550 (3,417) 1,585 (3,494) 1,585 (3,494) 1,430 (3,153) 1,465 (3,230)
1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293)
Maximum
permissible
axle weight
Rear
kgf (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
(M.P.A.W.)
Maximum
permissible
Total
kgf (lb) 2,060 (4,542) 2,060 (4,542) 2,060 (4,542) 2,060 (4,542) 1,960 (4,321) 1,960 (4,321)
weight (M.P.W.)
Vehicle Dynamics
Control
Cruise control
McIntosh audio
Leather interior
Winter pack
15 inch tire
Option
17 inch tire
A/C
Side airbag
Curtain airbag
Sunroof
Navigation system
Self levelizer
1:
SPC-39
LEGACY
SPECIFICATIONS
Option code1
KS
K4
2.5 L SOHC
AWD
OBK 2.5 i
Model
Curb weight
(C.W.)
Front
Rear
Total
Front
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
5MT (Dual range)

4AT
785 (1,731)
795 (1,753)
795 (1,753)
795 (1,753)
805 (1,774)
810 (1,785)
640 (1,410)
655 (1,444)
660 (1,455)
645 (1,422)
670 (1,477)
670 (1,477)
1,425 (3,142) 1,450 (3,196) 1,455 (3,208) 1,440 (3,175) 1,475 (3,252) 1,480 (3,263)
1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293)
Maximum
permissible
axle weight
Rear
kgf (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
(M.P.A.W.)
Maximum
permissible
Total
kgf (lb) 1,960 (4,321) 1,960 (4,321) 1,960 (4,321) 1,970 (4,343) 1,970 (4,343) 1,970 (4,343)
weight (M.P.W.)
Vehicle Dynamics
Control
Cruise control
McIntosh audio
Leather interior
Winter pack
15 inch tire
Option
17 inch tire
A/C
Side airbag
Curtain airbag
Sunroof
Navigation system
Self levelizer
1:
SPC-40
LEGACY
SPECIFICATIONS
Option code1
KS
K4
2.5 L SOHC
3.0 L DOHC
AWD
Model
Curb weight
(C.W.)
Front
Rear
Total
Front
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
OBK 2.5 i
4AT
5AT
795 (1,753)
805 (1,774)
805 (1,774)
900 (1,984)
890 (1,962)
640 (1,410)
655 (1,444)
660 (1,455)
685 (1,510)
685 (1,510)
1,435 (3,164) 1,460 (3,219) 1,465 (3,230) 1,585 (3,494) 1,575 (3,472)
1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293)
Maximum
permissible
axle weight
Rear
kgf (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
(M.P.A.W.)
Maximum
permissible
Total
kgf (lb) 1,970 (4,343) 1,970 (4,343) 1,970 (4,343) 2,060 (4,542) 2,060 (4,542)
weight (M.P.W.)
Vehicle Dynamics
Control
Cruise control
McIntosh audio
Leather interior
Winter pack
15 inch tire
Option
17 inch tire
A/C
Side airbag
Curtain airbag
Sunroof
Navigation system
Self levelizer
1:
SPC-41
LEGACY
SPECIFICATIONS
RHD model
Option code1
EK
2.5 L SOHC
AWD
Model
3.0 L DOHC
OBK 3.0 R,
OBK 3.0 R-A
5MT (Dual range)
4AT
5AT
800 (1,764)
790 (1,742)
810 (1,785)
800 (1,764)
815 (1,797)
895 (1,973)
675 (1,488)
645 (1,422)
670 (1,477)
645 (1,422)
670 (1,477)
680 (1,499)
1,475 (3,252) 1,435 (3,164) 1,480 (3,263) 1,445 (3,186) 1,485 (3,274) 1,575 (3,472)
1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293)
OBK 2.5 i
Curb weight
(C.W.)
Front
Rear
Total
Front
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
Maximum
permissible
axle weight
Rear
kgf (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
(M.P.A.W.)
Maximum
permissible
Total
kgf (lb) 1,960 (4,321) 1,960 (4,321) 1,970 (4,343) 1,970 (4,343) 1,970 (4,343) 2,060 (4,542)
weight (M.P.W.)
Vehicle Dynamics
Control
Cruise control
McIntosh audio
Leather interior
Winter pack
15 inch tire
Option
17 inch tire
A/C
Side airbag
Curtain airbag
Sunroof
Navigation system
Self levelizer
1:
SPC-42
LEGACY
SPECIFICATIONS
Option code1
EK
Model
Curb weight
(C.W.)
Front
Rear
Total
Front
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
3.0 L DOHC
AWD
5AT
905 (1,995)
905 (1,995)
685 (1,510)
685 (1,510)
1,590 (1,301) 1,590 (1,301)
1,040 (2,293) 1,040 (2,293)
Maximum
permissible
axle weight
Rear
kgf (lb) 1,060 (2,336) 1,060 (2,336)
(M.P.A.W.)
Maximum
permissible
Total
kgf (lb) 2,060 (4,542) 2,060 (4,542)
weight (M.P.W.)
Vehicle Dynamics
Control
Cruise control
McIntosh audio
Leather interior
Winter pack
15 inch tire
Option
17 inch tire
A/C
Side airbag
Curtain airbag
Sunroof
Navigation system
Self levelizer
1:
SPC-43
LEGACY
SPECIFICATIONS
Option code1
KA
2.5 L SOHC
AWD
OBK 2.5 i
Model
Front
Rear
Total
Front
Rear
5MT (Dual range)

4AT
kgf (lb) 790 (1,742)
800 (1,764)
800 (1,764)
805 (1,774)
800 (1,764)
810 (1,785)
kgf (lb) 640 (1,410)
665 (1,466)
670 (1,477)
670 (1,477)
640 (1,410)
665 (1,466)
kgf (lb) 1,430 (3,153) 1,465 (3,230) 1,470(3,241) 1,475 (3,252) 1,440 (3,175) 1,475 (3,252)
kgf (lb) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293)
kgf (lb) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
Gross vehicle
mass (G.V.M.)
Total
kgf (lb) 1,960 (4,321) 1,960 (4,321) 1,960 (4,321) 1,960 (4,321) 1,970 (4,343) 1,970 (4,343)
Option
Vehicle Dynamics
Control
Cruise control
McIntosh audio
Leather interior
Winter pack
15 inch tire
17 inch tire
A/C
Side airbag
Curtain airbag
Sunroof
Navigation system
Self levelizer
Grade up
Curb weight
(C.W.)
Unladen mass
(U.W.)
1:
SPC-44
LEGACY
SPECIFICATIONS
Option code1
KA
2.5 L SOHC
3.0 L DOHC
AWD
Model
OBK 2.5 i
4AT
5AT
810 (1,785)
810 (1,785)
885 (1,951)
900 (1,984)
905 (1,995)
670 (1,477)
675 (1,488)
655 (1,444)
685 (1,510)
685 (1,510)
1,480 (3,263) 1,485 (3,274) 1,540 (3,395) 1,585 (3,494) 1,590 (1,301)
1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293) 1,040 (2,293)
1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336) 1,060 (2,336)
Front
Rear
Total
Front
Rear
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
kgf (lb)
Gross vehicle
mass (G.V.M.)
Total
kgf (lb) 1,970 (4,343) 1,970 (4,343) 2,060 (4,542) 2,060 (4,542) 2,060 (4,542)
Option
Vehicle Dynamics
Control
Cruise control
McIntosh audio
Leather interior
Winter pack
15 inch tire
17 inch tire
A/C
Side airbag
Curtain airbag
Sunroof
Navigation system
Self levelizer
Grade up
Curb weight
(C.W.)
Unladen mass
(U.W.)
1:
SPC-45
LEGACY
SPECIFICATIONS
SPC-46
PRECAUTION
PC
1.
Page
Precaution ...................................................................................................2
Precaution
PRECAUTION
1. Precaution
6. AIRBAG
A: CAUTION
To prevent bodily injury from unexpected deployment of airbags and unnecessary maintenance, follow the instructions in this manual when performing
maintenance on the airbag components or nearby,
around front of the vehicle (radiator panel, front
wheel apron, front side frame, front bumper, front
hood panel, front fender panel), around side of the
vehicle (front door panel, rear door panel, center
pillar, rear fender panel, side sill, rear wheel apron),
and the airbag wiring harnesses or nearby.
To prevent unexpected deployment, turn the ignition switch to OFF and disconnect the ground cable
from battery, then wait at least 20 seconds before
beginning work.
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
Handle the ABS as a total system. Do not disassemble or attempt to repair parts which are not instructed in this manual. Follow the instructions in
this manual during performing the maintenance of
ABSCM&H/U. To disassemble parts without instructions could prevent the ABS system from operating when needed or cause it to operate
incorrectly and result in injury.
2. VEHICLE DYNAMICS CONTROL (VDC)

Handle the VDC as a total system. Do not disassemble or attempt to repair individual parts. Doing
so could prevent the VDC system from operating
when needed or cause it to operate incorrectly and
result in injury.
3. BRAKE FLUID
7. AIRBAG MODULE AND SEAT BELT

PRETENSIONER DISPOSAL
To prevent bodily injury from unexpected airbag
deployment, do not dispose airbag modules and
seatbelt pretensioner in the same way as other
refuse. Follow the special instructions for disposal
in this manual. Follow all government regulations
concerning disposal of refuse.
8. AIRBAG MODULE
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.
4. RADIATOR FAN
The radiator 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.
5. ROAD TEST
Always conduct road tests in accordance with traffic rules and regulations to avoid bodily injury and
interrupting traffic.
Adhere to the following when handing and storing

the airbag module to prevent bodily injury from unexpected deployment:
Do not hold the 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.
9. AIRBAG SPECIAL TOOL

To prevent unexpected deployment, only use special tools.
10.WINDOW
Always wear safety glasses when working around
any glass to prevent glass fragments from damaging your eyes.
11.WINDOW ADHESIVE
Always use the recommended or equivalent adhesive when attaching glass to prevent it from coming
off and being removed, resulting in accidents and
injury.
PC-2
Precaution
PRECAUTION
12.HOSE REMOVAL/INSTALLATION
PROCEDURES
1. Hose Removal/Installation Pre-Procedures
Be careful to inspect hoses so as not to use damaged or deformed hoses. Using such hoses could
cause leakage or loss of oil, with leaked oil splashing on exhaust pipes or other hot parts, resulting in
smoke or fire.
Always remove hoses when performing work.
Not removing the hoses and moving parts out of
the way when performing procedures may damage
the inside of hoses and cause other negative affects.
Inspect the following points in continuous

use, and replace any hoses that are damaged or
defective with new parts.
Replace any hoses that are riding over the
stay or spool with new parts.
2. Hose Removal/Installation Procedures and

Inspection
Remove hoses according to the following instructions.
If using the hose remover (general tool), do not
use the sharp-pointed hose remover (hose plucker) as it may damage pipe surfaces or hoses.
(1)
PC-00067
(1) Hose riding over a stay
(1)
NG
N
G
OK
K
PC-00068
(1) Hose riding over a spool
(1)
Check the inner and outer surfaces of the

hose for damage, cracks, breakage, hardening/
softening/swelling of rubber, internal peeling,
and that there are no deformations caused by infiltration/adhesion of foreign matter, and no
twisted hoses. Replace any defective hoses
with new parts.
(1)
PC-00065
(1) Hose remover
When using pliers to make hose removal easier, always be sure to use a cloth to protect the
hose, slightly rotate the hose, and then pull
straight out by hand.
PC-3
Precaution
PRECAUTION
Install hoses according to the following instructions.

Carefully check the installation positions.
Do not use any lubricants.
Securely insert until the specified positions
(until contacting spool).
(2)
(1)
Inspect the pipes according to the following

points, and replace any parts that are damaged
or defective with new parts.
Check that the pipes do not have any damage,
rust, peeling (including peeling plating), foreign
matter adhering, twisting, crushing, bending, or
cracks.
Replace the following parts with new parts if
the hoses have been removed or their installation positions have been changed.
ATF cooler hose, engine oil cooler hose, MT oil
cooler hose, power steering suction hose, and
power steering return hose.
PC-00069
(1)
PC-00070
(1) Contacting the spool. (Do not excessively insert

the hose to prevent the hose from becoming
wrinkled up.)
(2) Apply an equal clamping force all around the
hose periphery.
Check that the position and orientation of

hose clamps, and the hose layout are correct.
(Check that the position and orientation are
matching, they are not excessively short/long,
there are no differences with before performing
the procedures, and that there is clearance between hoses and surrounding parts.)
After installing, check that there are no disconnection of hoses or leakage from hoses.
(Check that hoses are securely fixed by the
clamps.)
Inspect the hose clips and clamps according
to the following points, and replace any parts
that are damaged or defective with new parts.
Check for deformations, rust, damage, and
adhering of foreign matter.
For clips, check that the spring functions and
has clamping force.
For clamps, check that the screw can clinch,
the clamp has not become oval shaped, and the
screw is not damaged.
PC-4
NOTE
NT
1.
Page
Note.............................................................................................................2
Note
NOTE
1. Note
A: NOTE
This is the information that can improve the efficiency of maintenance and assure the sound work.
1. FASTENERS NOTICE
Fasteners are used to prevent the parts from damage, dislocation and play due to looseness. Fasteners must be tightened to the specified torque.
Do not apply paint, lubricant, rust retardant or other
substance to the surface around bolts, nuts, etc.
Doing so will make it difficult to obtain the correct
torque and result in looseness and other problem.
NOTE:
When using a lift, follow its operation manual before work.
Do not work or leave unattended while the vehicle is supported with jack, support it with rigid
racks.
Be sure to use the rigid racks with rubber attached to cradle to support the vehicle.
When using a plate lift, use a rubber attachment.
2. STATIC ELECTRICITY DAMAGE

(A)
Do not touch the control modules, connectors, logic

boards and other such parts when there is a possibility of static electricity. Always use a static electricity prevention cord or touch grounded metal for
the elimination of static electricity before conducting work.
(C)
(B)
NT-00070
(A) 80 mm (3.1 in) or more

(B) 100 150 mm (3.94 5.91 in)
(C) 120 190 mm (4.72 7.48 in)
3. BATTERY
When removing the battery terminal, always be
sure to turn the ignition switch to OFF to prevent
electrical damage of the control module from overcurrent. Be sure to remove the battery ground cable first.
4. SERVICE PARTS
Align the cushion rubber end of plate lift with the

end of rubber attachment (portion b). Also, align the
protrusion portion of the supporting locations with
the end of attachment (portion a).
Do not use the plate lift whose attachment does
not reach the supporting locations.
Use genuine parts for maximum performance and

maintenance when conducting repairs. Subaru/FHI
will not be responsible for poor performance resulting from the use of parts except for genuine parts.
5. PROTECTING VEHICLE UNDER MAINTENACE

Make sure to attach the fender cover, seat covers,
etc. before work.
6. ENSURING SECURITY DURING WORK

When working in a group of two or more, perform
the work with calling each other to ensure mutual
safety.
7. LIFTS AND JACKS

When using a lift or shop jack to raise a vehicle, or
using rigid rack to support 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 that the
vehicle is balanced before raising it. Be sure to set
the wheel stoppers when jacking-up only the front
or rear side of the vehicle.
NT-2
Note
NOTE
(1)
(2)
(3)
(6)
(4)
(6)
(5)
a
b
(6)
(6)
a
NT-00086
(1)
(2)
Supporting locations
Pantograph jack
(3)
(4)
Swing arm lift

Rigid rack
NT-3
(5)
(6)
Plate lift
Attachment
Note
NOTE
(1)
(A)
(2)
(B)
NT-00072
(A)
Front
(B)
Rear
(1)
Front crossmember
(2)
Rear differential
NT-4
Note
NOTE
8. TIE DOWNS
Tie downs are used when transporting vehicles and when using the chassis dynamo. Attach tie-down only to
the specified locations on the vehicle.
TIE-DOWN LOCATION
(1)
(1)
(1)
NT-00073
(1)
Hook for tie-down
NT-5
Note
NOTE
CHAIN DIRECTION AT TIE-DOWN CONDITION

NOTE:
The pulling directions between right and left are the
same, and those between the front and the rear are
the reverse. Pull them at the same time.
VEHICLE SINKING VOLUME AT TIE-DOWN

CONDITION
Measure the distance between the highest tire
point and highest arch point before and after tiedown. Difference of measurement value (sinking
volume) shall be within 50 mm (1.97 in) and make
sure to fix the vehicle securely.
L
L
NT-00076
NT-00117
CHAIN PULLING RANGE AT TIE-DOWN CONDITION

(2)
(2)
(2)
(2)
(2)
(2)
(3) (3)
(3) (3)
: (1)
NT-00122
(1) Chain pulling range at tie-down condition

(2) 20
(3) 45
NT-6
Note
NOTE
9. TOWING
Avoid towing vehicles except when the vehicle cannot be driven. For models with AWD, AT or VTD, use a
loader instead of towing. When towing other vehicles, pay attention to the following to prevent hook or vehicle
damage resulting from excessive weight.
Do not tow other vehicles with a front tie-down hook.
Make sure the towing vehicle is heavier than the towed vehicle.
FRONT
Remove the fog light cover (except for OUTBACK model) and hook cover, and then install the hook.
(A)
(B)
(A)
(B)
(C)
(C)
(C)
NT-00087
(A)
Fog light cover (except for OUTBACK model)
(B)
Hook cover
REAR
NT-00078
NT-7
(C)
Hook
Note
NOTE
NOTES
Towing
Lifting up four wheels (On a trailer)
Notes
Towing the vehicle after lifting up all four wheels is a
basic rule for AWD model.
MT
AT
Check if both front and rear wheels are rotated normally.

AT model driving conditions: Allow driving speed less
than 30 km/h (19 MPH).
Allow driving distance less than 30 km (19 miles).
Prohibited for full-time AWD model.
Prohibited, due to damage on bumper, front grille, etc.

Do not raise the vehicle with bumper.
NT-00023
Rope
NT-00024
Raising the front wheels
NT-00025
Lifting up the front wheels
NT-00026
Marked : OK, Marked : Prohibited, Marked : Conditionally OK.
NT-8
Note
NOTE
CAUTION:
Check ATF, gear oil and rear differential oil before driving.
Place the shift lever in N position during towing.
Do not lift up the rear wheels to avoid unsteady rotation.
Turn the ignition key to ACC, then check the steering wheel moves freely.
Release the parking brake to avoid tire dragging.
Since the power steering does not work, be careful for the heavy steering effort (When engine is
stopped)
Since the servo brake does not work, be careful that the brake is not applied effectively. (When engine is stopped)
In case of the malfunction of internal transmission or drive system, lift up four wheels (on a trailer)
for towing.
10.FRONT HOOD STAY INSTALLATION

AT THE CHECK AND GENERAL MAINTENANCE
NT-00079
WHEN WIDER HOOD OPENING IS NECESSARY

Set the stay into the hole of lower hood as shown in the figure below.
NT-00080
NT-9
Note
NOTE
11.GENERAL SCAN TOOL

Using general scan tools will greatly improve the efficiency of repairing engine electronic controls.
Subaru Select Monitor can be used to diagnose the
engine, ABS, air conditioner and other parts.
12.AWD CIRCUIT MEASURES

1) Full-time AWD MT model
Since viscous coupling (limited slip differential) is
used in the center differential, cut-off of AWD circuit
cannot be carried out.
2) Full-time AWD 5AT model
Since VTD type is used in the center differential,
cut-off of AWD circuit cannot be carried out.
3) Full-time AWD 4AT model
Insert a spare fuse into FWD fuse holder in the fuse
box located in the left side of engine room to select
the FWD. Since electronically controlled MT-P hydraulic multi-plate clutch is adapted for center differential, select FWD. When maintenance is
performed with jack-up or on the free roller, check
the illumination of AWD warning light in the combination meter.
CAUTION:
Fix the vehicle using a pulling metal (chain or
wire) to the front and rear towing hooks or tiedown hook to prevent the lateral runout of front
wheels and springing out of vehicle.
(A)
NT-00033
(A) Free roller
(3) Set the speedometer tester.

(4) Conduct the speedometer test work.
CAUTION:
Do not operate the clutch quickly and do not accelerate or decelerate suddenly during work.
2) Rear wheel jack-up system
(1) Set the vehicle on speedometer tester.
CAUTION:
Fix the vehicle using a pulling metal (chain or
wire) to the front and rear towing hooks or tiedown hook to prevent the lateral runout of front
wheels and springing out of vehicle.
(2) Jack up the rear wheels and set the rigid
racks to the specified locations of side sill.
(A)
(B)
(2) Let the vehicle ride on the tester and free

roller gently.
NT-00081
(A)
NT-00034
(A) FWD fuse holder

(B) AWD warning light
(A) Rigid rack
(3) Conduct the speedometer test work.
13.SPEEDOMETER TEST
1) Rear wheel free roller system
(1) Set the free roller on the floor of rear wheel
side securely according to the wheel base and
rear tread of the vehicle.
CAUTION:
Do not operate the clutch quickly and do not accelerate or decelerate suddenly during work.
NT-10
Note
NOTE
14.BRAKE TEST
Specifications:
1) Full-time AWD MT model

(1) Perform this test after driving the vehicle 2 to
3 km (1.24 to 1.86 miles) on road in order to stabilize the viscous torque of viscous coupling.
(2) Keep the front or rear wheels on the ground
for this test.
NOTE:
Effect of the viscous torque on braking force will be
added approx. 25 kg compared with FWD model.
Rear wheel total

Difference between
right and left
wheels
Grand total
Braking force
More than 10% of load on front or rear
wheels
Less than 8% of load on front or rear
wheels
More than 50% of vehicle weight at
the time of test
When measurement is difficult to carry out because both of front wheels are locked, check if
break force measurement in this condition conforms to grand total.
15.ON THE CAR WHEEL BALANCING
(C)
(A)
(B)
NT-00029
(A) Brake tester

(B) Position for measuring front wheel
(C) Position for measuring rear wheel
(3) When the brake dragging force is large.

Check the dragging of brake pad or brake
shoe.
Since it may be affected by the viscosity of
viscous couping, jack up either of the front or
rear two wheels to check the each wheel rotation condition with the viscous coupling affection
removed.
2) Full-time AWD AT model
(1) Keep the front or rear wheels on the ground
during measurement.
CAUTION:
Carry out this procedures after measuring
the balance of each single tire.
Set the vehicle so that the front and rear
wheels are same height.
Release the parking brake during measurement.
Rotate each wheel by hands, and make sure it
rotates without dragging.
Do not operate the clutch quickly and do not
accelerate or decelerate suddenly during work.
When an error is indicated during engine
drive, do not use the motor drive together.
1) Set the rigid rack to the specified locations of
side sill, jack up the front or rear two wheels of nonmeasuring side and set the pickup stands to two
wheels of measuring side.
(A)
(B)
(C)
(A)
NT-00031
(A) Balancer body

(B) Pickup stand
(B)
NT-00029
2) For drive wheel, drive the tires with engine for

measurement.
3) For non-drive wheel, drive the tires from the on
the car wheel balancer for measurement.
(A) Brake tester

(B) Position for measuring front wheel
(C) Position for measuring rear wheel
(2) When the brake dragging force is large.

Check the dragging of brake pad or brake
shoe.
NT-11
Note
NOTE
NT-12
IDENTIFICATION
ID
1.
Page
Identification ................................................................................................2
Identification
IDENTIFICATION
1. Identification
A: IDENTIFICATION
1. IDENTIFICATION NUMBER AND LABEL LOCATIONS
The V.I.N. (Vehicle Identification Numbers) is used to classify the vehicle.
POSITIONING OF THE PLATE LABEL FOR IDENTIFICATION
(2)
(1)
(4)
(5)
(6)
(3)
ID-00072
(1)
(2)
(3)
ID plate (EC and EK model)

ADR compliance plate (KA model)
Vehicle identification number
(VIN)
Model number plate
(4)
Tire inflation pressure label (Driver

side) (KA model)
Tire inflation pressure label (Driver
side) (Except for KA model)
ENGINE
(5)
(6)
Saudi Arabia plate (Saudi Arabia

model)
Built date plate (KA model)
Vehicle identification number
(VIN) (EK and KA model)
AUTOMATIC TRANSMISSION
(1)
(2)
(1)
(2)
ID-00059
ID-00067
(1) Engine serial number (Punch mark)

(2) Engine type (Crankcase upper side)
(1) AT type label

(2) Transmission serial number label
ID-2
Identification
IDENTIFICATION
MANUAL TRANSMISSION
VA1-TYPE
(1)
(1)
(2)
ID-00068
DI-00396
(1) Transmission serial No.

(2) MT type label
(1) Type (label)
VA2-TYPE
REAR DIFFERENTIAL
T-TYPE
(1)
(1)
DI-00397
(1) Type (label)
ID-00056
(1) Type (white paint)
MODEL NUMBER PLATE
ID-00073
ID-3
Identification
IDENTIFICATION
2. MEANING OF V.I.N.
The meaning of the V.I.N. is as follows:
EC, EK, KA AND K4 MODEL
]JF1BL5LJ34G002001[
The starting and ending brackets ( ] [ ) are stop marks.
Digits
13
JF1
Code
4
5
B
L
10
11
12 17
4
G
002001
Meaning
Details
Manufacturer body area JF1: Passenger car, FHI made (Except for KA OUTBACK
model)
JF2: Passenger car, FHI made (KA OUTBACK model)
Car line
LEGACY
Body type
L: Sedan
P: Wagon
Displacement
5: 2.0 L AWD
9: 2.5 L AWD
E: 3.0 L AWD
Steering position
L: LHD (Left-hand drive model)
K: RHD (Right-hand drive model)
Engine & transmission
J: SOHC MPI 5MT Single range
K: SOHC MPI 5MT Dual range
L: SOHC MPI 4AT-SS
U: DOHC MPI 5AT-SS
V: DOHC MPI Turbo 5AT-SS
Drive type
3: Full-time AWD Single range
4: Full-time AWD Dual range
5: AWD AT
A: AWD AT OUTBACK
B: Full-time AWD Dual range OUTBACK
Model year
4: 2004MY
Factory location
G: FHI (Gunma)
Serial number
From 002001
KS MODEL
]JF1BL54MX4G002001[
The starting and ending brackets ( ] [ ) are stop marks.
Digits
13
4
5
Code
JF1
B
L
8
9
10
11
M
X
4
G
12 17
002001
Meaning
Details
Manufacturer body area JF1: Passenger car, FHI made
Car line
LEGACY
Body type
L: Sedan
P: Wagon
Displacement
5: 2.0 L AWD
9: 2.5 L AWD
Grade
4: 2.0i
6: 2.5i
8: OUTBACK 2.5 i
Restraint
M: Manual belts, dual airbag
Check digit
09&X
Model year
4: 2004MY
Transmission type
G: Full-time AWD 5MT Single range
H: Full-time AWD 4AT
J: Full-time AWD 5MT Dual range
Serial number
From 002001
ID-4
Identification
IDENTIFICATION
3. MODEL NUMBER PLATE

The model number plate indicates the type, V.I.N. <Ref. to ID-4, MEANING OF V.I.N., IDENTIFICATION,
Identification.>, applied model, option code, trim code, engine type, transmission type and the exterior color
code. This information is helpful when placing orders for parts.
BL5ALHJ
Digits
Code
Meaning
Series
Body type
1
2
B
L
4
5
A
L
Engine displacement
Drive system
Suspension system
Model year
Destination
Grade
Transmission, fuel feed

system
Details
LEGACY
L: Sedan
P: Wagon
5: 2.0 L AWD
9: 2.5 L AWD
E: 3.0 L AWD
A: 2004MY
K: Right-hand drive model market
L: Left-hand drive model market
B: 2.0 GT
H: 2.0 i
J: 2.5 i
L: 3.0 R
M: 3.0 R-A
N: 3.0 R
P: 3.0 R-A
R: OUTBACK 2.5 i
V: OUTBACK 3.0 R
W: OUTBACK 3.0 R-A
J: SOHC MPI 5MT
K: SOHC MPI Dual range 5MT
L: SOHC MPI 4AT TIP
V: DOHC MPI Turbo 5AT TIP
U: DOHC MPI 5AT TIP
The engine and transmission type are as follows:

ENGINE
EJ202NTAHB
Digits
1 and 2
Code
EJ
Meaning
Engine type
Details
3 and 4
20
Displacement
Fuel feed system
6
7
N
T
Detailed specifications
Transmission
8 10
AHB
EJ: 4 cylinders
EZ: 6 cylinders
20: 2.0L
25: 2.5L
30: 3.0L
2: D-MPI-NA (SOHC)-B
3: MPI-NA (SOHC)
D: MPI-NA (DOHC, H6)
X: MPI Twin scroll single turbo
Used when ordering parts. See the parts catalog for details.
L: 5AT without ATF cooler (with warmer function)
P: 4AT without ATF cooler (with warmer function)
S: 5MT (Flexible type flywheel)
T: 5MT (Dual mass type flywheel)
V: 4AT with ATF cooler (with warmer function) (H4), 5AT (H6)
ID-5
Identification
IDENTIFICATION
TRANSMISSION
TY757VRAAB
1
2
Digits
T
Y
Code
Meaning
Transmission
Transmission type
3 and 4
75
Classification
5
6
7
V
Series
Transmission specification
7 10
RAAB
Details
T: Transmission
Y: Full-time AWD MT center differential
V, G: Full-time AWD AT center differential
Z: Full-time AWD AT MPT
75: 5MT
1B: 4AT
5C: 5AT
LEGACY
C: Full-time AWD VTD type 5AT
L: Full-time AWD MPT type 4AT
M: Full-time AWD VTD type 4AT
V: Full-time AWD 5MT Single range with viscous coupling center differential
X: Full-time AWD 5MT Dual range with viscous coupling center
differential
REAR DIFFERENTIAL
XJ
Code
XJ
T2
VB
EZ
XU
CF
XT
JE
Reduction gear ratio

4.111
4.111
3.700
3.900
3.272
4.444
3.083
4.111
LSD
None
None
None
Viscous
Viscous
Viscous
Viscous
Viscous
ID-6
Identification
IDENTIFICATION
OPTION
ECXV
Digits
12
EC
Code
Meaning
Destination
Option equipment
Option equipment
Details
EC: For Europe (LHD model)
EK: For Europe (RHD model)
KS: For GCC counties
K4: For Middle and South America
KA: For Australia
Nothing: For Hong Kong
A: Vehicle dynamics control, Cruise control, Power pack, 17
inch tire
B: Cruise control, Winter pack, 17 inch tire
E: Vehicle dynamics control, Cruise control, Power pack
F: Cruise control, Winter pack
G: Cruise control, 15 inch tire
I: Cruise control, Winter pack, Power pack, 17 inch tire
K: Cruise control, 17 inch tire
S: Cruise control, Winter pack, Power pack
U: Cruise control
V: 17 inch tire
X: Nothing
Y: Vehicle dynamics control, Cruise control, Power pack, Winter
pack, 17 inch tire
Z: Vehicle dynamics control, Cruise control, Power pack, Winter
pack
2: Cruise control, Power pack, 17 inch tire
3: Cruise control, Power pack
4: Cruise control, McIntosh audio, Power pack
5: Cruise control, McIntosh audio, Power pack, 17 inch tire
A: A/C
B: A/C, Side airbag, Self levelizer
F: A/C, Grade up pack
J: A/C, Sunroof
K: A/C, Side airbag, Curtain airbag, Navigation system
N: A/C, Side airbag, Curtain airbag, Navigation system, Self
levelizer, Sunroof
O: A/C, Side airbag, Navigation system
Q: A/C, Side airbag, Curtain airbag, Sunroof, Grade up pack
S: A/C, Self levelizer
U: A/C, Sunroof, Self levelizer
V: Side airbag
W: A/C, Side airbag, Curtain airbag, Sunroof
X: nothing
Y: A/C, Side airbag, Curtain airbag, Sunroof, Self levelizer
Z: A/C, Side airbag
ID-7
Identification
IDENTIFICATION
ID-8
RM
1.
Page
Recommended Materials ............................................................................2
Recommended Materials
1. Recommended Materials
A: RECOMMENDED MATERIALS
1. GENERAL
To insure the best performance, always use the
specified oil, gasoline, adhesive, sealant, etc. or a
substitute of equivalent quality.
2. FUEL
Always use gasoline of the same or higher octane
value than specified in the owners 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 for
the vehicle with catalytic converter installed to reduce air pollution. Using leaded gasoline will damage the catalytic converter.
Model
2.0 L, 2.5 L
TURBO
3.0 L
Use kind
Unleaded
gasoline
Unleaded
gasoline
Unleaded
gasoline
RON
More than 95 RON
More than 90 RON*
More than 98 RON
More than 95 RON
*: KA and KS model
RM-2
3. LUBRICANTS
Use either the lubricants in the table below or equivalent. See the table below to choose the correct SAE viscosity.
SERVICE S
PI
GY
NG
EN
SAE
0W-20
R
ACEA Spec.
A1, A2 or A3
Alternative
API Spec.
SG, SF
Engine oil
Recommended
API Spec.
CCMC Spec.
SL, SJ Grade Energy conserving, or SH
G4 or G5
VI
Lubricant
CONS E
SERVICE S
PI
L
RM-00006
GY
NG
VI
EN
SAE
5W-30
CONS E
RM-00001
TR OLEUM
ER
T I F IE
TUTE
FOR
GASOLINE
ENGINES
ST I
AM ER I CA
IN
PE
D
RM-00002
Manual transmission oil

AT front differential gear
oil
GL-5
GL-5
GL-5
RM-3
SAE viscosity No. and applicable temperature
Engine oil
SOHC model
(C)
30
20
10
10
20
30
40
(F)
22
14
32
50
68
86
104
10W-30 or 10W-40
5W-30
0W-20 Recommend
RM-00007
3.0 L and DOHC turbo model
(C)
30
20
10
10
20
30
40
(F)
22
14
32
50
68
86
104
10W-30 or 10W-40
5W-30 Recommend
RM-00003
RM-4
Manual transmission oil, rear differential gear oil and AT front differential gear oil
(F)
30
20
10
10
20
30
40
(C)
22
14
32
50
68
86
104
90
85W
80W
75W-90
RM-00004
4. FLUID
Use the fluids specified in the table below. Do not mix two different kinds or makes of fluid.
CAUTION:
Be sure to use the recommended or equivalent ATF for 5AT. Using the ATF other than recommended
or equivalent would be a trouble cause.
Fluid
Automatic transmission
fluid

Brake fluid
Clutch fluid
Recommended
Item number
Alternative
4AT
SUBARU ATF
K0410Y0700
IDEMITSU: APOLLOIL ATF HP

Castrol: Transmax J
5AT
SUBARU ATF
K0410Y0700
DEXRON III
FMVSS No. 116
DOT3
FMVSS No. 116
DOT3
Remarks
If it is impossible to
get recommended or
alternative ATF,
DEXRON III can be
used.
IDEMITSU: ATF HP
Castrol: Transmax J
5. COOLANT
Use genuine coolant to protect the engine.
Coolant
Coolant
Water for dilution
Recommended
SUBARU coolant
Distilled water
Item number
000016218
Alternative
None
Tap water (Soft water)
6. REFRIGERANT
Standard air conditioners on Subaru vehicles use HFC134a refrigerant. Do not mix it with other refrigerants.
Also, do not use any compressor oil other than DENSO OIL 8.
Air conditioner
Refrigerant
Compressor oil
Recommended
HFC134a
DENSO OIL 8
Item number
RM-5
Alternative
None
None
7. GREASE
Use the grease and supplementary lubricants shown in the table below.
Grease
Supplementary
lubricants
Grease
Application point
Oxygen sensor
Bolts, etc.
MT main shaft
Clutch master cylinder push rod
Gear shift lever
Select lever
Clutch operating cylinder
Clutch pedal
Brake pedal
Clutch bearing
Clutch release lever
Door latch
Door striker
Steering gearbox
Disc brake
(Lock pin, guide pin, piston boot)
Between brake pad and shim
Brake pad clip
Front axle PTJ
Front axle EBJ
Rear axle BJ
Rear axle EBJ
Rear axle DOJ
Recommended
Item number
Alternative
Spray type lubricant
NICHIMOLY N-130
SILICONE GREASE G-40M
004404003
KOPR-KOTE
003603001
SILICONE GREASE G-30M
004404002
VALIANT GREASE M2
003608001
NIGLUBE RX-2
K0779GA102
Molykote AS-880N
Molykote M7439
NSG301
K0777YA010
NTG2218-M
NKG205
8. ADHESIVE
Use the adhesives shown in the table below, or equivalent.
Adhesive
Adhesive
Application point
Windshield, rear window
glass, rear quarter
glass, rear gate and
body
Rearview mirror base

Soft vinyl
Momentary sealant
Recommended
Dow Automotives
Adhesive: Gurit-ESSEX
Betaseal 1502 or equivalent
Glass primer: Betawipe VP
04604, Betaprime 5001
Paint surface primer: Betaprime 5402
REPAIR KIT IN MR
65029FC000
CEMEDINE 540
CEMEDINE 3000
RM-6
Item number
Alternative
3Ms EC-776, EC-847 or EC-1022

(Spray type)
ARMSTRONGs Eastman 910
9. SEAL MATERIAL
Use the seal material shown in the table below, or equivalent.
Seal material
Seal material
Application point
MT transmission case
Cylinder block
Converter case
DOHC camshaft cap
(Turbo model)
Cylinder head plug
(Turbo model)
Oil pump (Except for
3.0 L model)
Transmission oil pan (AT
model)
Engine oil pan (Except
for 3.0 L model)
Rear differential
Engine oil pressure
switch
Connector (Oil hose)
(Turbo model)
Cylinder head (Nipple)
Camshaft bowl-shape
plug
Rear differential
PCV valve
Steering adjusting screw
SOHC camshaft cap
Cam cap (3.0 L
model)
Semicircular plug (3.0
L model)
Rocker cover (3.0 L
model)
Oil pan (Pan upper)
Block (Pan upper)
Back cover (Front
cover, block head, pan
upper)
Front sealing cover
Rear sealing cover
Recommended
Item number
Alternative
THREE BOND 1215
004403007
DOW CORNINGs No. 7038
THREE BOND 1217B
K0877YA020
THREE BOND 1207C
004403012
THREE BOND 1324
004403042
THREE BOND 1105
004403010
DOW CORNINGs No. 7038
THREE BOND 1141
004403006
THREE BOND 1280B
K0877YA018
THREE BOND 1217G
3M Butyl Rubber 8626
RM-7
RM-8
PI
1.
Page
Pre-delivery Inspection................................................................................2
Pre-delivery Inspection
1. Pre-delivery Inspection
A: GENERAL DESCRIPTION
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 to the vehicle or parts that may have taken place during transportation or storage.
Check if the vehicle after repair is in a normal state.
Make sure to provide a complete vehicle to the customer.
For the above reasons, all SUBARU dealers (dealerships) carry out the PDIs before delivering a vehicle.
Refer to this manual unless otherwise specified.
B: PRE-DELIVERY INSPECTION (PDI) PROCEDURE

STATIC CHECKS JUST AFTER VEHICLE RECEIPT
PROCEDURE
1. Appearance check
2. Tire check
3. Fuse installation
4. Air conditioner harness connection
5. Check the doors for lock/unlock and open/close
operations.
6. Double lock operation check

7. Check the operation of child safety lock system
8. Check the trunk lid for open/close operations.
9. Check the rear gate for lock/unlock and open/

close operations.
10. Operation check of fuel lid opener lock release

lever
11. Accessory check
12. Operation check of front hood lock release

system
13. Battery
14. Brake fluid
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 damage or stains in detail.
(2) Visually check the glass and light lenses for any damage, cracks or
excessive gaps to the body sheet metal.
(3) Visually check the plated parts for any damage.
(1) Check the tires for damage, abnormal conditions, and dents on the
wheels.
(2) Check the tire air pressure.
If the vehicle is about to be delivered to the customer, attach a back-up fuse.
If the vehicle is about to be delivered to the customer, connect air conditioner
harness.
(1) Using the key, check if the trunk lid can be locked or unlocked normally.
(2) Open and close all doors to see that there are no abnormal conditions.
(3) Operate the power door lock switch to check that the door (rear gate) is
locked and unlocked normally.
Check the double lock for normal operations.
Check that the child safety lock system operates normally.
(1) Operate the trunk lock release lever to check that the trunk opens normally.
(2) Operate the opener cancel lever of trunk lock to check that it operates
normally.
(3) Open and close the trunk lid to see that there are no abnormal conditions.
(1) Check if the rear gate can be unlocked normally through the emergency
hole.
(2) Open and close the rear gate to see that there are no abnormal conditions.
Operate the fuel lid opener to check that the fuel lid is unlocked normally.
Check that the following accessories are provided.
Owners manual
Warranty booklet
Maintenance note
Spare key
Jack
Tool set
Spare tire
Operate the front hood lock release lever to check that the front hood is
unlocked normally.
Check the battery terminals for any abnormal conditions such as rust and
trace of battery fluid leaks.
Check that the fluid level is normal.
PI-2
PROCEDURE
15. Engine oil
16. Transmission gear oil
17. AT front differential oil
18. Engine coolant
19. Clutch fluid
20. Window washer fluid
21. Front hood latch check
22. Keyless entry system
23. Seat
24. Seat belt
25. Wheel alignment
Check point
Check that the oil level is normal.
Check that the transmission gear oil level is normal.
Check that the AT front differential oil level is normal.
Check that the engine coolant level is normal.
Check that the clutch fluid level is normal.
Check that the window washer fluid level is normal.
Check that the hood is closed and latched securely.
Check that the keyless entry system operates normally.
(1) Check the seat surfaces for stain or dirt.
(2) Check the seat installation conditions and functionality.
Check the seat belt installation conditions and functionality.
Check that the wheel alignments are properly adjusted.
CHECKS WITH ENGINE RUNNING

PROCEDURE
26. Test mode connector
27. Immobilizer system
28. Starting condition

29. Exhaust system
30. Indicator and warning lights
31. Clock
32. Audio
33. Navigation system
34. Front accessory power supply socket

35. Lighting system
36. Wiper deicer
37. Rear fog light
38. Illumination control
39. Window washer
40. Wiper
41. Power window operation check
42. Sunroof
43. Door mirror
Check point
Test mode connectors
(1) Check that the engine starts with all keys that are equipped on vehicle.
(2) 60 seconds after turning ignition switch from ON to ACC or OFF, or immediately after removing key, check that the security indicator light blinking.
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 and warning lights are gone out.
Check that the clock operates normally.
Check the radio, CD and MD player for normal operation.
(1) Check all display functions for normal operation.
(2) Check the map disc (DVD) are provided on vehicle.
(3) Check that the navigation system operates normally.
Check that the front accessory power socket operates normally.
Check that the lighting system operates normally.
Check that the wiper deicer operates normally.
Check that the rear fog light operates normally.
Check that the illumination control operates normally.
Check that the window washer system operates normally.
Check that the wiper system operates normally.
Check the power window for normal operations.
Check that the sunroof operates normally.
Check that the remote control mirror operates normally.
DYNAMIC TEST WITH VEHICLE RUNNING

PROCEDURE
44. Brake test
45. Parking brake
46. AT shift control
47. Heater & ventilation
48. Air conditioner
49. Cruise control
Check point
Check the foot brake for normal operations.
Check the parking brake for normal operations.
Check that the AT shift patterns are correct.
Check that the heater & ventilation system operates normally.
Check that the air conditioner operates normally.
Check that the cruise control system operates normally.
PI-3
CHECKS AFTER DYNAMIC TEST

PROCEDURE
50. ATF level
51. Power steering fluid level
52. Fluid leak check
53. Water leak test
54. Appearance check 2
Check point
Check that the ATF level is correct.
Check that the power steering fluid level is normal.
Check for fluid/oil leaks.
Spray the vehicle with water and check for water leaks.
(1) Remove the protective coating (if any).
(1) Check the body paints for damage and stain.
(2) Check the plated parts for damage and rust.
1. APPEARANCE CHECK
4. CONNECTION OF AIR CONDITIONER

HARNESS
If the vehicle is covered with protective coating,

visually check the vehicle body for damage and
dents.
When the protective coating is removed, visually
check the body paints for damage or stains in detail
and repair as necessary.
Visually check the windshield glass, door glasses and light lenses for any damage, cracks or excessive gaps to the body sheet metal and repair as
necessary.
Visually check the plated parts, such as the
grilles and door knobs, for damage or loss of gloss
and replace the parts as necessary.
A vehicle just delivered has its air conditioner harness disconnected to protect the air conditioner
compressor. Connect the harness as shown in the
figure. (Except for 3.0 L model)
2. TIRE CHECK
Check the tires for damage, abnormal conditions, and dents on the wheels.
Check the tire size, spare tire and tire air pressure described on the tire air pressure label (drivers side).
PI-00159
5. CHECK DOORS FOR LOCK/UNLOCK

AND OPEN/CLOSE OPERATIONS
1) Using the key, lock and unlock the door several
times to check for normal operation. Open and
close the door several times for smooth movement.
3. FUSE INSTALLATION
Fuses for the back-up circuit have been removed to
prevent battery discharge. If the vehicle is about to
be delivered to the customer, attach a 20 A fuse (A)
as shown in the figure.
(A)
(B)
PI-00191
(A)
(A) Unlock
(B) Lock
PI-00158
2) Completely close the drivers door, and then

check the smooth movement with operating door
lock knob from lock to unlock several times.
Set the door lock knob (A) to lock position. Then
pull the inner remote (B) to ensure that doors will
not open.
PI-4
6. CHECK DOUBLE LOCK OPERATION
For other doors, place the door lock knob (A) to lock
position and then pull the inner remote (B) to ensure that doors will not open.
1) Fully open all the windows.

2) Remove the key.
3) Lock all the doors using the door key cylinder or
keyless transmitter.
4) Verify that all the doors including rear gate are
not unlocked when pressing power door lock switch
to unlock side.
5) Verify that the door is not opened when operating door lock knob to unlock position and pulling inner remote. Perform the same check for other
doors.
6) Check that all the doors are unlocked when door
is unlocked using door key cylinder or keyless
transmitter, or ignition switch is turned to ON.
(A)
(B)
PI-00192
(A) Door lock knob

(B) Inner remote
7. CHECK OPERATION OF CHILD SAFETY

LOCK SYSTEM
3) Close all the doors, and then press the lock on

power door lock switch at drivers side. Check that
all doors including rear gate are locked.
1) Set the child safety lock on both rear doors to the

lock position.
2) Close the rear doors completely.
3) Check that the lock levers of the rear doors are in
the unlock position. Then, pull inner remote of rear
doors to ensure that doors will not open.
(A)
(B)
PI-00193
4) Press the drivers side power door lock switch to

unlock side. Check that all doors including rear
gate are unlocked.
PI-00164
(A) Lock
(B) Unlock
4) Pull the outer handles to ensure that doors will

open.
8. CHECK TRUNK LID FOR OPEN/CLOSE

OPERATIONS
1) Operate the trunk lock release lever to check
that the trunk opens normally.
2) Open and close the trunk lid several times for
smooth movement.
PI-00194
5) Insert the key to ignition switch, and open the

drivers side door. Press lock on power door lock.
Check that the door is not locked.
PI-5
11.ACCESSORY CHECK
3) Put the lever (A) in the cancel lever of trunk lid to

cancel position, and close the trunk lid. Check that
the trunk lid will not open even when the trunk lock
release lever is operated. Also, check that the trunk
lid will open with keyless transmitter, then put the
lever back.
Check that the following accessories are provided.

Owners manual
Warranty booklet
Maintenance note
Spare key
Jack
Tool set
Spare tire
(A)
(B)
(A)
PI-00200
9. CHECK REAR GATE FOR LOCK/UNLOCK AND OPEN/CLOSE OPERATIONS

PI-00168
1) Open and close the rear gate several times for

smooth movement.
2) Operate the rear gate lever to check that the rear
gate is locked and unlocked normally.
(1) Remove the cover inside the rear gate.
(B)
(A)
PI-00169
(A) Jack
(B) Jack handle
PI-00165
12.OPERATION CHECK OF FRONT HOOD

LOCK RELEASE SYSTEM
(2) Operate the lever to check that the rear gate

is locked and unlocked normally.
Operate the front hood lock release lever (A) to

check that the front hood is unlocked normally.
(A)
PI-00166
10.OPERATION CHECK OF FUEL LID

OPENER LOCK RELEASE LEVER
PI-00195
Operate the fuel lid opener and verify that the fuel
lid is unlocked normally. Check that the filler cap is
securely closed.
PI-6
14.BRAKE FLUID
Operate the lever (B) and check that the front hood
is opened normally. Support the front hood with
hood stay.
Check that the brake fluid level is normal. 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.
(A)
(B)
PI-00172
(A) MAX. level

(B) MIN. level
15.ENGINE OIL
(B)
Check the engine oil amount. If the amount of oil is

insufficient, check that no leaks are found. Then,
add the necessary amount of the specified engine
oil.
Except for 3.0 L model
PI-00202
13.BATTERY
Check the battery terminals to make sure that there
are no rust or corrosions due to fluid leaks. Check
that the battery caps are securely tightened.
(A)
(B)
(C)
(A)
(E)
(D)
(B)
LU-00213
(A)
(B)
(C)
(D)
(E)
(C)
PI-00012
(A) Cap
(B) Upper level
(C) Lower level
PI-7
Oil level gauge

Engine oil filler cap
Upper level
Lower level
Approx. 1.0 2 (1.1 US qt, 0.9 Imp qt)
17.AT FRONT DIFFERENTIAL OIL
3.0 L model
Check that the AT front differential oil level is normal. If the amount of oil is insufficient, check that no
leaks are found. Then, add the necessary amount
of the specified AT front differential oil.
4AT model
(B)
(A)
(C)
(D)
(A)
(B)
(A)
(B)
(C)
(D)
(A)
(C)
LU-00111
Oil level gauge

Upper level
Lower level
PI-00183
16.TRANSMISSION GEAR OIL
(A) Oil level gauge

(B) Upper level
(C) Lower level
Check that the transmission gear oil level is normal.

If the amount of fluid is insufficient, check that no
leaks are found. Then, add the necessary amount
of the specified transmission gear oil.
5AT model
(A)
(A)
(A)
(B)
(B)
(C)
(C)
PI-00184
PM-00030
(A) Oil level gauge

(B) Upper level
(C) Lower level
(A) Oil level gauge

(B) Upper level
(C) Lower level
18.ENGINE COOLANT
Check that the engine coolant level on the reservoir
tank is normal. If the amount of engine coolant is insufficient, check that no leaks are found. Then, add
the necessary amount of coolant with the specified
concentration.
PI-8
19.CLUTCH FLUID
3) Press the trunk open button (except for EK model) or UNLOCK button (EK model) for more than
one second. Check if the trunk is unlocked and the
hazard light flashes twice.
Check that the clutch fluid level is normal. If the

amount of fluid is insufficient, check that no leaks
are found. Then, add the necessary amount of
specified fluid.
(A)
(C)
(B)
PI-00174
PI-00173
(A) Reservoir tank

(B) MIN. level
(C) MAX. level
20.WINDOW WASHER FLUID

Check that the window washer fluid level is normal.
If the amount is insufficient, check that no leaks are
found. Then, add the necessary amount of washer
fluid.
PI-00196
4) Press the LOCK button on the keyless transmitter with the trunk lock opened. Check if the all
doors are locked, hazard light blinks five times and
warning shows trunk open.
5) Press the LOCK button momentarily on the
keyless transmitter. Check that all the doors are
locked and room light goes off.
21.FRONT HOOD LATCH CHECK

Retract the hood stay and close the front hood.
Check that the front hood is securely latched.
22.KEYLESS ENTRY SYSTEM

NOTE:
The following inspections show the initial settings.
When the settings are different from the initial settings, use Subaru Select Monitor to check the details of each setting for inspections. <Ref. to
LAN(diag)-26, OPERATION, Read Current Data.>
1) Fully open all the door windows.
2) Remove the key from the ignition switch and
close all the doors including rear gate.
PI-00175
PI-00108
PI-9
6) Press the UNLOCK button momentarily on the

keyless transmitter. Check that all the doors are unlocked, hazard light blinks twice and room light illuminates for 15 seconds.
Also, when pressing the UNLOCK button of keyless transmitter momentarily drivers door is unlocked (except for EK model with setting of select
unlock). Then, check that all the doors including
rear gate are unlocked when pressing the UNLOCK button momentarily again within 5 seconds.
26.TEST MODE CONNECTOR

Turn the ignition switch to ON and check that the
malfunction indicator light starts blinking. If the light
blinks, return the ignition key to LOCK. Pull out the
test mode connector from the back of glove box
lower cover, and disconnect the test mode connector. Then, turn the ignition key to ON again. If the
malfunction indicator light blinks at that time in spite
of the disconnected test mode connector, carry out
an engine diagnosis.
(A)
PI-00176
PI-00201
(A) Test mode connector (green)
NOTE:
If it is difficult to pull out the test mode connector,
remove the glove box lower cover, and disconnect
the test mode connector.
PI-00196
7) Close all the doors including rear gate and press

the LOCK button on the keyless transmitter.
Press the OPEN button on the keyless transmitter
and wait for 25 seconds. Check if all the doors including rear gate are locked. (Except for EK model)
(B)
(A)
23.SEAT
PI-00197
1) Check the seat surfaces for stains or dirt.

2) 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 armrest.
24.SEAT BELT
1) Check installation condition of seat belt.
2) Pull out the seat belt and then release it. Check
that the belt retracts smoothly.
25.WHEEL ALIGNMENT
Check the wheel alignment. <Ref. to FS-8, Wheel
Alignment.> <Ref. to RS-8, Wheel Alignment.>
(A) Test mode connector (green)

(B) Glove box lower cover
27.IMMOBILIZER SYSTEM
1) Check that the engine starts with all keys that
are equipped on vehicle.
2) 60 seconds after turning the ignition switch from
ON to ACC or OFF, or immediately after removing
the key, check that the security indicator light blinking.
NOTE:
If malfunctions occur, refer to IMMOBILIZER (DIAGNOSIS).
PI-10
28.STARTING CONDITION
39.WINDOW WASHER
Start the engine and check that the engine starts

smoothly. If the battery voltage is low, recharge or
replace the battery. If any noises are observed, immediately stop the engine and check and repair the
abnormal components.
Check that the window washer system injects

washer fluid to the specified area of the windshield
shown in the figure.
29.EXHAUST SYSTEM
Front injection position:

A: 250 mm (9.84 in)
B: 435 mm (17.1 in)
Listen to the exhaust sound to see if no noises are

observed. Check the exhaust leaks.
30.INDICATOR AND WARNING LIGHTS

Check that all the indicator and warning lights are
off.
31.CLOCK
Check the clock for normal operations and enough
accuracy.
(1)
PI-00185
32.AUDIO
Check the radio for full functionality and normal
noise level. Also check the CD, MD unit operations.
33.NAVIGATION SYSTEM
1) Check all display function for normal operation.
(For operating procedure, refer to operating manuals.)
2) Check the map disc (DVD) are provided on vehicle.
3) Check that the navigation systems operate normally.
(1) Nozzle
Rear injection position:

Wagon model
A: 70 mm (2.8 in)
B: 70
34.FRONT ACCESSORY POWER SUPPLY

SOCKET
1) Check operation for the front accessory power

socket.
2) Check operation of the accessory power socket
in console box.
PI-00104
40.WIPER
Check the front and rear wipers for normal operations.
35.LIGHTING SYSTEM
1) Check the headlight operations.
2) Check the stop light operation.
3) Check other lights for normal operations.
41.POWER WINDOW OPERATION CHECK

Operate the power window switches one by one to
check that each of the power windows goes up and
down without noises.
36.WIPER DEICER
Check that the wiper deicer operates normally.
42.SUNROOF
37.REAR FOG LIGHT
Check the sunroof for normal operations.
Check that the rear fog light operates normally.
43.DOOR MIRROR
38.ILLUMINATION CONTROL
Check that the illumination control operates normally.
Check the remote control mirror for normal operations.
44.BRAKE TEST
Check the foot brake for normal operations.
PI-11
45.PARKING BRAKE
50.ATF LEVEL
Check the parking brake for normal operations.

When applying the parking brake with force of 200
N (20.4 kgf, 45.0 lb), check that the lever stroke of
parking brake lever is 5 to 6 notches.
Set the selector lever P range after selecting all

positions (P, R, N, D). Measure the ATF level after
the engine idles for 1 to 2 minutes. If the amount is
insufficient, check that no leaks are found. Then
add the necessary amount of the specified ATF.
4AT
1) Turn the ignition switch to ON.

2) While brake pedal is not depressed, check if the
select lever does not move from P range.
3) While brake pedal is depressed, check if the select lever moves from P range.
4) Set the select lever to other than P range.
5) When the ignition switch is turned OFF, check if
the ignition key switch cannot be removed.
6) Set the AT select lever to each gear position and
check the shifting while driving the vehicle.
(C)
(D)
L
F
HOT
(A)
(E)
COLD
L
46.AT SHIFT CONTROL
(B)
(C)
(D)
PI-00189
(A) Level gauge

(B) ATF level range [70 80C (158 176F)] at
HOT
(C) Upper level
(D) Lower level
(E) ATF level range [20 30C (68 86F)] at
COLD
P
R
N
D
5AT
PI-00199
4AT
(A)
1st
OK
OK
(C)
4th
OK
OK
5AT
Selector Position
D
SPORT shift
(E)
1st
OK
OK
Gear Position
2nd
3rd
4th
OK
OK
OK
OK
OK
OK
(B)
(D)
5th
OK
OK
COLD
L
F
D
SPORT shift
Gear Position
2nd
3rd
OK
OK
OK
OK
L
F
HOT
(A)
Selector Position
(C)
(D)
PI-00190
47.HEATER & VENTILATION

Operate the heater and ventilation system to check
for normal airflow outlet control, air inlet control, airflow capacity and heating performance.
48.AIR CONDITIONER
Operate the air conditioner. Check that the A/C
compressor operates normally and enough cooling
is provided.
49.CRUISE CONTROL
Operate the cruise control system. Check that the
system is activated and deactivated correctly.
PI-12
(A) Level gauge

(B) ATF level range [70 80C (158 176F)] at
HOT
(C) Upper level
(D) Lower level
(E) ATF level range [20 30C (68 86F)] at
COLD
51.POWER STEERING FLUID LEVEL
54.APPEARANCE CHECK 2
Check that the power steering fluid level is normal.

If the amount is insufficient, check that no leaks are
found. Then add the necessary amount of the
specified power steering fluid.
1) When vehicle body is covered with protective

film, peel it off.
HOT MAX
COLD MAX
HOT MIN
COLD MIN
PS-00463
52.FLUID LEAK CHECK

Check entire areas of the vehicle for any trace of
coolant/oil/fluid leaks.
53.WATER LEAK TEST

Spray the vehicle with water using a hose 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 the windows and doors securely. Close
the hood and trunk lid before starting the test.
Spray the vehicle with water using a hose. The
rate of water spray must be approx. 20 to 25 2 (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
spraying water on areas other than the floor 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 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
the areas that may have possibly contributed to the
leak.
NOTE:
Use of steam facilitates peeling off the warp
guard.
For the vehicle left for a long time or at low temperature, sprinkle some water heated 50 60C
(122 140F) over the vehicle to raise its surface
temperature before peeling off the wrap guard. Do
not use the water heated to over 60C (140F).
If the adhesive remains exists on the coated surface, soak a flannel rag, etc. with a small amount of
coating wax or solvent such as oil benzene and
IPA, put the soaked cloth on the remains lightly,
and then wipe them off with a flannel rag, etc.
Keep solvent from touching the resin or rubber
parts. Do not use coating wax or solvent while the
component surface temperature is high due to hot
weather, etc.
If the coated surface is swollen out due to seams
or moisture, expose the vehicle to the sunlight for a
few hours or heat the seam and swollen portions
using a dryer, etc.
Dispose of the peeled wrap guard as burnable industrial garbage.
2) Check the whole vehicle body for flaking paint,
damage by transportation, corrosion, dirt, cracks or
blisters.
NOTE:
It is better to determine an inspection pattern in
order to avoid missing an area, since the total inspection area is wide.
Do not repair the body paint unless absolutely
necessary. Also, if the vehicle is in need of repair to
remove scratches or corroded paint, the repair area
must be limited to the minimum. Re-painting and
spray painting must be avoided as possible.
3) Check each window glass for scratches carefully. Slight damage may be removed by polishing
with cerium oxide. (Fill a cup half with cerium oxide,
and add warm water to it. Then agitate the content
until it turns to wax. Apply this wax to a soft cloth,
and polish the glass with it.)
4) Check each portion of the vehicle body and underside components for the formation of rust. If rust
is discovered, remove it with sandpaper of #80 to
#180 and treat the surface with rust preventive. After this treatment is completed, flush the portion
thoroughly, and prepare the surface for repair
painting.
5) Check each portion of body and all of the plated
parts for deformation or distortion. Also, check
each lamp lens for cracks.
PI-13
6) Peel the protective tape, vinyl wrapping and

identification seal attached to the following places.
Seat
Door trim
Floor carpet
Side sill
Front hood lock release lever
Edge rear
Rear wiper
Sedan rear combination light (Trunk lid opening
portion)
Roof rail
Door mirror
PI-14
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.
Page
General Description ....................................................................................2
Schedule .....................................................................................................3
Engine Oil....................................................................................................7
Engine Oil Filter...........................................................................................9
Spark Plug.................................................................................................10
V-belt.........................................................................................................11
Timing Belt ................................................................................................14
Fuel Line ...................................................................................................17
Air Cleaner Element ..................................................................................18
Cooling System .........................................................................................20
Engine Coolant..........................................................................................22
Clutch System ...........................................................................................24
Transmission Gear Oil ..............................................................................25
Automatic Transmission Fluid ...................................................................26
Front & Rear Differential Gear Oil .............................................................28
Brake Line .................................................................................................30
Brake Fluid ................................................................................................32
Disc Brake Pad and Disc ..........................................................................33
Parking Brake............................................................................................34
Suspension ...............................................................................................35
Wheel Bearing...........................................................................................37
Axle Boots & Joints ...................................................................................38
Steering System (Power Steering)............................................................39
A/C Filter ...................................................................................................42
General Description
1. General Description
Be sure to perform periodic maintenance in order to
maintain vehicle performance and find problems
before they occur.
PM-2
Schedule
2. Schedule
A: MAINTENANCE SCHEDULE 1
1. EUROPE AREA
For periodic maintenance of less than 120,000 km (75,000 miles) or 96 months, carry out inspection by referring to the following table. For a maintenance period gone beyond these tables, apply them repeatedly as
a set of 120,000 km (75,000 miles) or 96 months.
Months
1,000 km
1,000 miles
Engine oil
Engine oil filter
Spark plug
V-belt(s)
Timing belt
Fuel line
Air cleaner element
Cooling system
Coolant
Clutch system
Transmission oil
ATF
Front & rear differential
Brake line
Brake fluid
Disc brake pads & discs
Parking brake
Suspension
Wheel bearing
Axle boots & joint
Steering system
A/C filter
3.0 L
Others
3.0 L
Others
2.0 L
Others
Maintenance interval
[Number of months or km (miles), whichever occurs first]
12
24
36
48
60
72
84
96
1.6
5
15
30
45
60
75
90 105 120
Remarks
1
3
9
19
28
38
47
56
66
75
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
For 3.0 L model,
I
I
I
I
I
I
I
I
replace every 160,000
km (100,000 miles).
R
I
I
I
I
I
R
I
R
I
R
I
R
I
I
I
I
R
R
R
R
I
I
I
I
I
R
I
R
I
R
I
R
I
R
I
R
I
I
I
I
R
R
R
R
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
(I)
I
I
I
I
I
I
I
I
I
I
I
I
Replace every 12 months or 12,000 km (7,500 miles)
NOTE (4)
Symbols used:
R: Replace
I: Inspection
(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 is physically damaged or ATF leaked.
(3) Periodic inspection and replacement of the camshaft drive chains on the 3.0 L models is not required.
(4) When the A/C filter is installed.
PM-3
Schedule
2. EXCEPT FOR EUROPE AREA

For periodic maintenance of less than 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.
Months
1,000 km
1,000 miles
Engine oil
Engine oil filter
3.0 L
Others
3.0 L
Others
5
3
R
R
12
12.5
7.5
R
R
R
R
24
36
48
25
37.5
50
Remarks
15
22.5
30
R
R
R
R
R
R
R
R
R
R
R
R
For periodic maintenance of less than 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.
Months
12
24
36
48
1,000 km
1.6
25
50
75
100
Remarks
1,000 miles
1
15
30
45
60
Spark plugs
Turbo and 3.0 L
R
2.5 L, 2.0 L non-turbo
R
R
R
R
V-belt(s)
For 3.0 L model, replace every 160,000 km
I
I
I
I
(100,000 miles).
Timing belt
R
Fuel line
I
I
Air cleaner element
I
R
I
R
Cooling system
I
I
Coolant
R
R
Clutch system
I
I
I
I
Transmission oil
R
R
ATF
R
R
Front & rear differential oil
R
R
Brake line
I
I
I
I
Brake fluid
R
R
Disc brake pads & discs
I
I
I
I
Parking brake
I
I
I
I
Suspension
I
I
Wheel bearing
(I)
Axle boots & joint
I
I
I
I
Steering system (Power steering)
I
I
I
I
A/C filter
Replace every 12 months or
NOTE (4)
12,000 km (7,500 miles)
Symbols used:
R: Replace
I: Inspection
(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 is physically damaged or ATF leaked.
(3) Periodic inspection and replacement of the camshaft drive chains on the 3.0 L models is not required.
(4) When the A/C filter is installed.
PM-4
Schedule
B: MAINTENANCE SCHEDULE 2
1. EUROPE AREA
Item
Every
Engine oil
Repeat
rough/muddy
road drive
Extremely
cold weather
area
Replace
more frequently
Replace
more frequently
Engine oil filter
Fuel line
Repeat short
distance drive
Salt or other
corrosive
used or
coastal area
High humidity or mountain area
Replace
more frequently
Replace
more frequently
12 months
15,000 km
9,000 miles
Replace
more frequently
Replace
more frequently
I
Transmission oil
Replace
more frequently
Replace
more frequently
Replace
more frequently
ATF

Brake line
Brake fluid
Brake pads
Brake linings
and drums
Parking brake
Suspension
Axle boots &

joints
Steering system
(Power steering)
Repeat towing trailer
12 months
15,000 km
9,000 miles
12 months
15,000 km
9,000 miles
12 months
15,000 km
9,000 miles
12 months
15,000 km
9,000 miles
12 months
15,000 km
9,000 miles
12 months
15,000 km
9,000 miles
12 months
15,000 km
9,000 miles
12 months
15,000 km
9,000 miles
PM-5
Schedule
2. EXCEPT FOR EUROPE AREA
Item
Every
Engine oil
Repeat
rough/muddy
road drive
Extremely
cold weather
area
Replace
more frequently
Replace
more frequently
Engine oil filter
Fuel line
Repeat short
distance drive
Salt or other
corrosive
used or
coastal area
High humidity or mountain area
Replace
more frequently
Replace
more frequently
6 months
12,500 km
7,500 miles
Replace
more frequently
Replace
more frequently
I
Transmission oil
Replace
more frequently
Replace
more frequently
Replace
more frequently
ATF

Brake line
Brake fluid
Brake pads
Brake linings
and drums
Parking brake
Suspension
Axle boots &

joints
Steering system
(Power steering)
Repeat towing trailer
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
PM-6
Engine Oil
3. Engine Oil
2.0 L non-turbo and 2.5 L model
A: REPLACEMENT
1) Open the engine oil filter cap for quick draining of
engine oil.
(A)
(B)
LU-00218
3.0 L model
PM-00161
(A) Oil level gauge

(B) Oil filler cap
3.0 L model
(B)
LU-02011
(A)
(C)
3) Tighten the engine oil drain plug after draining

engine oil.
(D)
NOTE:
Use a new drain plug gasket.
Tightening torque:
44 Nm (4.5 kgf-m, 33 ft-lb)
DOHC turbo model
LU-00111
(A)
(B)
(C)
(D)
Oil level gauge

Oil filler cap
Upper level
Lower level
2) Drain the engine oil by removing engine oil drain

plug.
DOHC turbo model
LU-00219
LU-00219
LU-00218
PM-7
Engine Oil
B: INSPECTION
3.0 L model
1) Park the vehicle on a level surface.

2) Remove the 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.
LU-02011
(B)
(A)
4) Fill engine oil through level gauge up to the center between upper level and lower level. Place the
vehicle on a level surface when checking oil level.
Use engine oil of proper quality and viscosity, selected in accordance with following.
(C)
(E)
(D)
Recommended oil:
Refer to RM section. <Ref. to RM-3, LUBRICANTS, RECOMMENDED MATERIALS, Recommended Materials.>
LU-00213
Engine oil capacity
(A)
(B)
(C)
(D)
(E)

Upper level:
Lower level:
Oil level gauge

Oil filler cap
Upper level
Lower level
Approx. 1 2 (1.1 US qt, 0.9 Imp qt)
3.0 L model
3.0 L model
Upper level:
Lower level:
The proper viscosity oil make the engine ideal temperature, and cranking speed increased by reducing viscaus friction in hot condition.
(B)
(A)
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.
(C)
(D)
LU-00111
NOTE:
If the vehicle is used in areas with very high temperatures or for other heavy duty applications, the following viscosity oils must be used: API
classification: SL, SJ or SH
SAE Viscosity No.: 30, 40, 10W-50, 20W-40, 20W50.
5) Close the engine oil filler cap.
6) Start the engine and warm it up for a time.
7) After the engine stops, recheck the oil level.
<Ref. to PM-8, INSPECTION, Engine Oil.>
(A)
(B)
(C)
(D)
Oil level gauge

Oil filler cap
Upper level
Lower level
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 engine oil.
7) To prevent overfilling the engine oil, do not add
oil above the F line when the engine is cold.
PM-8
Engine Oil Filter

4. Engine Oil Filter
6) After installing the oil filter, run the engine and

make sure that no oil is leaking around seal rubber.
A: REPLACEMENT
1) Remove the under cover.
2) Remove the oil filter using ST.
ST 18332AA000 OIL FILTER WRENCH (Outer
diameter: 68 mm (2.68 in))
NOTE:
The filter element and filter case are permanently
jointed; therefore, interior cleaning is not necessary.
7) Check the engine oil level. <Ref. to PM-8, INSPECTION, Engine Oil.>
PM-00163
Turbo model
LU-00227
ST 498547000
3.0 L model
OIL FILTER WRENCH
LU-00131
3) Obtain a new oil filter and apply a thin coat of engine oil to the seal rubber.
4) Install the oil filter by turning it by hand, being
careful not to damage seal rubber.
5) Tighten more (approx. 1 turn for oil filter 68 mm
(2.68 in) in outer diameter, approx. 3/4 turn for oil
filter 65 mm (2.56 in) in outer diameter) after the
seal rubber contacts the cylinder block. Do not
tighten excessively, or oil may leak.
PM-9
Spark Plug
5. Spark Plug
3.0 L model
A: REPLACEMENT
1. SOHC MODEL
(A)
1) Remove the intake duct and intake chamber.

2) Remove the battery.
3) Disconnect the spark plug cord.
4) Remove the spark plug with a spark plug socket.
(B)
IG-02004
(A) Bracket
(B) Connector
PM-00001
5) Tighten the new spark plug lightly with hand, and

then secure with a spark plug socket to the specified torque.
Recommended spark plug:
2.5 L EC, EK model
NGK: PFR5B-11
Except for 2.5 L EC, EK model
CHAMPION: RC10YC4
PM-00112
6) Tighten the new spark plug lightly with hand, and

then secure with a spark plug socket to the specified torque.
Tightening torque:
21 Nm (2.1 kgf-m, 15.2 ft-lb)
NOTE:
Be sure to place the gasket between the cylinder
head and spark plug.
If the torque wrench is not available, tighten the
spark plug until gasket contacts cylinder head; then
tighten further 1/4 to 1/2 turns.
Recommended spark plug:

NGK: ILFR6B
Tightening torque:
21 Nm (2.1 kgf-m, 15.2 ft-lb)
7) Tighten the ignition coil.
2. DOHC MODEL
Tightening torque:
16 Nm (1.6 kgf-m, 11.7 ft-lb)
1) Remove the battery and battery carrier.

2) Remove the air cleaner case.
3) Detach the connector from ignition coil.
4) Remove the ignition coil.
NOTE:
Be sure to place the gasket between the cylinder
head and spark plug.
If the torque wrench is not available, tighten the
spark plug until gasket contacts cylinder head; then
tighten further 1/4 to 1/2 turns.
PM-00145
PM-10
V-belt
6. V-belt
A: INSPECTION
1. EXCEPT FOR 3.0 L MODEL
1) Replace the belts if crack, fraying or wear is
found.
2) Check the V-belt tension and adjust it if necessary by changing the generator installing position
or idler pulley installing position. <Ref. to PM-12,
REPLACEMENT, V-belt.>
Belt tension (with belt tension gauge):

(A)
When installing new one: 640 785 N
(65.3 80.0 kgf, 144 176 lb)
At inspection: 490 640 N (50 65 kgf,
110 144 lb)
(B)
When installing new one: 620 760 N (63
77 kgf, 140 170 lb)
At inspection: 350 450 N (36 46 kgf, 79
101 lb)
Belt tension (without belt tension gauge):

(A)
When installing new one: 7 9 mm (0.276
0.354 in)
At inspection: 9 11 mm (0.354 0.433
in)
(B)
When installing new one: 7.5 8.5 mm
(0.295 0.335 in)
At inspection: 9.0 10.0 mm (0.354
0.394 in)
GEN
(A) (B)
A/C
I/P
C/P
PM-00002
(A)
(B)
C/P
GEN
P/S
A/C
I/P
P/S
Front side belt

Rear side belt
Crank pulley
Generator
Power steering oil pump pulley
A/C compressor pulley
Idler pulley
PM-11
A/C
GEN
(B)
I/P
C/P
PM-00154
(A)
(B)
C/P
GEN
P/S
A/C
I/P
98 N (10kg)
P/S
(A)
Front side belt

Rear side belt
Crank pulley
Generator
Idler pulley
V-belt
2. 3.0 L MODEL
Turbo model
1) Replace the belts if crack, fraying or wear is

found.
2) Check that the V-belt automatic tensioner indicator (A) is within the range (D).
(A)
(D)
ME-00807
3) Loosen the lock bolt (A).

4) Loosen the slider bolt (B).
5) Remove the front side belt (C).
6) Install a new V-belt, and tighten the slider bolt so
as to obtain the specified belt tension.
7) Tighten the lock bolt (A).
8) Tighten the slider bolt (B).
(C)
(B)
Tightening torque:
Lock bolt
25 Nm (2.5 kgf-m, 18 ft-lb)
Slider bolt
8 Nm (0.8 kgf-m, 5.8 ft-lb)
ME-00475
(A)
(B)
(C)
(D)
Indicator
Generator
Power steering oil pump
Service limit
(C)
(B)
B: REPLACEMENT
1. FRONT SIDE BELT (FOR POWER
STEERING OIL PUMP AND GENERATOR)
NOTE:
Wipe off any oil and water on the belt and pulley.
1) Remove the collector cover. (If equipped)
2) Remove the V-belt covers.
Non-turbo model
(A)
PM-00004
2. REAR SIDE BELT (FOR A/C)

NOTE:
Wipe off any oil and water on the belt and pulley.
1) Remove the front side belt.
2) Loosen the lock nut (A).
4) Remove the rear side belt.
5) Install a new V-belt, and tighten the slider bolt so
6) Tighten the lock nut (A).
PM-00003
PM-12
V-belt
Tightening torque:
23 Nm (2.3 kgf-m, 17.0 ft-lb)
(B)
(A)
PM-00005
7) Install the front side belt.

Non-turbo model <Ref. to ME(H4SO 2.0)-38,
FRONT SIDE BELT, INSTALLATION, V-belt.>
Turbo model <Ref. to ME(H4DOTC)-39, FRONT
SIDE BELT, INSTALLATION, V-belt.>
3. 3.0 L MODEL
1) Fit the tool to the belt tensioner mounting bolt.
2) Turn the tool clockwise, and loosen the V-belt to
remove.
ME-00473
3) Remove the V-belt cover.

4) Install in the reverse order of removal.
(6)
(1)
(4)
(5)
(2)
(3)
(1)
(2)
(3)
(4)
(5)
(6)
ME-00474
Power steering oil pump

Belt tension adjuster
Crankshaft pulley
A/C compressor
Belt idler
Generator
PM-13
Timing Belt
7. Timing Belt
ST
499987500
CRANKSHAFT SOCKET
A: REPLACEMENT
(B)
1. SOHC MODEL
1) Protect the radiator with cardboard and blanket.
(B)
(A)
(B)
PM-00003
3) Remove the V-belts. <Ref. to ME(H4SO 2.0)-38,

V-belt.>
4) Remove the A/C compressor V-belt tensioner.
5) Use the ST to lock the crankshaft, and remove
the pulley bolt.
ST 499977100
CRANK PULLEY WRENCH
PM-00009
(A) Notch
(B) Alignment mark
ST
11) Remove the belt idler.

12) Remove the belt idler (No. 2).
PM-00007
6) Remove the crank pulley.

7) Remove the belt cover (LH).
8) Remove the front timing belt cover.
9) Remove the timing belt guide. (MT model)
10) Turn the crankshaft and align the alignment
marks on crankshaft, and left and right cam sprockets with notches of belt cover and cylinder block.
PM-00010
13) Remove the timing belt.

14) Remove the automatic belt tension adjuster assembly.
PM-00011
15) Install in the reverse order of removal. <Ref. to

ME(H4SO 2.0)-44, INSTALLATION, Timing Belt.>
PM-14
Timing Belt
2. DOHC MODEL
1) Protect the radiator with cardboard and blanket.
2) Remove the V-belts. <Ref. to ME(H4DOTC)-39,
V-belt.>
3) Remove the A/C compressor V-belt tensioner.
4) Remove the pulley bolt. Use the ST to lock
crankshaft.
Except for turbo MT model:
ST 499977400
CRANK PULLEY WRENCH
Turbo MT model:
ST 499977100
CRANK PULLEY WRENCH
9) Remove the timing belt guide. (Except for nonturbo AT model)
PM-00008
ST
PM-00093

6) Remove the belt cover (LH).
7) Remove the belt cover (RH).
8) Remove the front belt cover.
ME-00727
ME-00728
ME-00729
10) Turn the crankshaft and align the alignment

marks on crankshaft, and left and right cam sprockets with notches of belt cover and cylinder block.
Use the ST to turn crankshaft.
PM-15
Timing Belt
ST
499987500
CRANKSHAFT SOCKET
CAUTION:
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.
B: INSPECTION
1. SOHC MODEL
1) Remove the front timing belt cover and timing
belt cover (LH).
2) While cranking engine at least four rotations,
check the timing belt back surface for cracks or
damage. Replace the faulty timing belt as needed.
3) Measure the timing belt width W. If it is less than
27 mm (1.06 in), check idlers, tensioner, water
pump pulley and cam sprocket to determine idler
alignment (squareness). Replace the worn timing
belt.
ME-00070
ME-00071
11) Remove the belt idler.
PM-00016
4) Install the front timing belt cover and timing belt

cover (LH).
2. DOHC MODEL
PM-00095

1) Remove the timing belt cover (LH).

2) While cranking engine at least four rotations,
check the timing belt back surface for cracks or
damage. Replace the faulty timing belt as needed.
3) Measure the timing belt width W. If it is less than
30 mm (1.18 in), check idlers, tensioner, water
pump pulley and cam sprocket to determine idler
alignment (squareness). Replace the worn timing
belt.
4) Install the timing belt cover (LH).
W
PM-00096
14) Install in the reverse order of removal. <Ref. to

ME(H4DOTC)-43, Timing Belt.>
PM-00097
PM-16
Fuel Line
8. Fuel Line
A: INSPECTION
The fuel line is located mostly internally, so check
pipes, areas near pipes, and engine compartment
piping for rust, hose damage, loose band, etc. If
faulty parts are found, repair or replace them.
<Ref. to FU(H4SO 2.0)-53, Fuel Delivery, Return
and Evaporation Lines.>
Turbo model
<Ref. to FU(H4DOTC)-56, Fuel Delivery, Return
and Evaporation Lines.>
3.0 L model
<Ref. to FU(H6DO)-54, Fuel Delivery, Return and
Evaporation Lines.>
PM-17
Air Cleaner Element

9. Air Cleaner Element
Non-turbo model
A: REPLACEMENT
1) Disconnect the ground cable from battery.
(B)
PM-00182
Turbo model
IN-00203
2) Disconnect the connector from mass air flow

sensor. (2.0 L turbo, 3.0 L and 2.5 L EC, EK, K4
model)
3.0 L and 2.5 L EC, EK, K4 model
(B)
(B)
(A)
(A)
PM-00183
5) Remove the air cleaner case (rear).

6) Remove the air cleaner element.
IN-00204
Turbo model
IN-00206

NOTE:
Fasten with a clip after inserting the lower tab of
the case.
PM-00181
3) Loosen the clamps (A) which connect the air

cleaner case to intake duct. (Turbo model)
4) Remove the clips (B) on air cleaner case.
IN-00207
PM-18
Air Cleaner Element

Refer to COMPONENT for tightening torque.

<Ref. to IN(H4SO 2.0)-2, COMPONENT, General Description.>
Turbo model
<Ref. to IN(H4DOTC)-2, COMPONENT, General Description.>
3.0 L model
<Ref. to IN(H6DO)-2, COMPONENT, General
Description.>
PM-19
Cooling System
10.Cooling System
A: INSPECTION
1) To check the radiator for leakage, fill it with engine coolant, and attach the radiator cap tester (A)
to the filler neck, and apply pressure. Check the following points:
Non-turbo model:
157 kPa (1.6 kg/cm2, 23 psi)
Turbo model:
122 kPa (1.2 kg/cm2, 18 psi)
Each portion of radiator for leakage
Hose joints and other connections for leakage
NOTE:
For turbo model, be sure to install the tester to filler tank side.
When attaching or detaching tester or when operating tester, use special care not to deform radiator filler neck.
Non-turbo model
(A)
NOTE:
Rust or dirt on the cap may prevent valve from functioning normally: be sure to clean the cap before
testing.
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
Non-turbo model
Standard:
93 123 kPa (0.95 1.25 kg/cm2, 14 18
psi)
Service limit:
83 kPa (0.85 kg/cm2, 12 psi)
Turbo model
Filler tank side
Standard:
93 123 kPa (0.95 1.25 kg/cm2, 14 18
psi)
Service limit:
83 kPa (0.85 kg/cm2, 12 psi)
Radiator side
Standard:
122 152 kPa (1.24 1.55 kg/cm2, 18
22 psi)
Service limit:
112 kPa (1.14 kg/cm2, 16 psi)
PM-00128
Turbo model
(A)
PM-00023
PM-00184
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.
Do not remove the radiator side cap. (Turbo
model)
2) Check the radiator cap valve open pressure using radiator cap tester.
(A)
(A)
(B)
PM-00089
(A) Check points for deformation

(B) Check points for deformation, damage, rust
PM-20
Cooling System
3) Start the engine, and then check it does not

overheat or it is cooled excessively. If it overheats
or it is cooled excessively, check the cooling system.
<Ref. to CO(H4SO 2.0)-15, Water Pump.> <Ref. to
CO(H4SO 2.0)-18, Thermostat.> <Ref. to
CO(H4SO 2.0)-20, Radiator.> <Ref. to CO(H4SO
2.0)-24, Radiator Cap.>
Turbo model
<Ref. to CO(H4DOTC)-15, Water Pump.> <Ref. to
CO(H4DOTC)-17,
Thermostat.>
<Ref.
to
CO(H4DOTC)-19,
Radiator.>
<Ref.
to
CO(H4DOTC)-23, Radiator Cap.>
3.0 L model
<Ref. to CO(H6DO)-11, Water Pump.> <Ref. to
CO(H6DO)-12, Thermostat.> <Ref. to CO(H6DO)13, Radiator.> <Ref. to CO(H6DO)-16, Radiator
Cap.>
4) Check the radiator fan operates using Subaru
Select Monitor, when the coolant temperature exceeds 95C (203F). If it does not operate, check
the radiator fan system.
<Ref. to CO(H4SO 2.0)-8, INSPECTION, Radiator
Fan System.>
Turbo model
<Ref. to CO(H4DOTC)-9, INSPECTION, Radiator
Fan System.>
3.0 L model
<Ref. to CO(H6DO)-7, INSPECTION, Radiator Fan
System.>
PM-21
Engine Coolant
11.Engine Coolant
Coolant capacity (fill up to FULL level):
A: REPLACEMENT
LHD AT model
2.0 L non-turbo and 2.5 L model (without ATF
cooler (with warmer))
2.0 L non-turbo and 2.5 L model (with ATF
3.0 L model (without ATF cooler (with warmer))
3.0 L model (with ATF cooler (with warmer))
1. REPLACEMENT OF COOLANT
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.
3) Place a container under drain pipe.
4) Remove the drain cock to drain engine coolant
into container.
CO-00248
5) For quick draining, open the radiator cap.

NOTE:
For turbo model, be sure to open the radiator cap
on the filler tank side.
Be careful not to spill coolant on the floor.
6) Drain the coolant from reservoir tank.
7) Tighten the radiator drain cock securely after
draining coolant.
8) Slowly pour the coolant into radiator. Pour the
coolant up to air bleeder hole, and then install the
cap. (Turbo model)
9) Pour the coolant from radiator filler port to neck
of filler. Then, pour the coolant into reservoir tank
up to FULL level.
Recommended engine coolant:
Refer to RM section. <Ref. to RM-5, COOLANT, RECOMMENDED MATERIALS, Recommended Materials.>
LHD MT model
RHD AT model
2.0 L non-turbo and 2.5 L model (without ATF
2.0 L non-turbo and 2.5 L model (with ATF
Turbo model
3.0 L model (without ATF cooler (with warmer))
3.0 L model (with ATF cooler (with warmer))
RHD MT model
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.
10) Securely install the radiator cap.
11) Run the 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.)
12) Stop the engine and wait until coolant temperature lowers. Then open the radiator cap to check
coolant level and add coolant up to radiator filler
neck. Next, add coolant into reservoir tank up to
FULL level.
13) After adding coolant, securely install the radiator and reservoir tank caps.
PM-22
Engine Coolant
2. RERATIONSHIP OF SUBARU COOLANT

CONCENTRATION AND FREEZING TEMPERTAURE
Safe operating temperature

Concentration
of coolant
1.100
1.090
1.080
60%
1.070
C
1.060
To adjust the concentration of 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 2 (2.2 US qt, 1.8 Imp qt). Drain 2.1
2 (2.2 US qt, 1.8 Imp qt) of coolant from the cooling system and add 2.1 2 (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.
B
50%
(1.054)
Quantity of coolant to be
drained (US qt, Imp qt)
Specific gravity
of coolant
Concentration and safe operating temperature of

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), its specific gravity is 1.054 and the concentration is 45%
(point A), the safe operating temperature is 14C
(7F) (point B), and the freezing temperature is
20C (4F) (point C).
3. PROCEDURE TO ADJUST THE CONCENTRATION OF THE COOLANT
1.050
40%
1.040
1.030
Freezing
temperature
30%
1.020
1.000
25 C
(77 F)
1.010
20%
10%
Necessary Concentration
of coolant
3
(3.2,
2.6)
0
10 20 30 40 50
-40 -30 -20 -10
(-40) (-22) (-4) (14) (32) (50) (68) (86) (104) (122)
Coolant temperature C ( F)
CO-00237
2
(2.1,
1.8)
1
(1.1,
0.9)
0
45%
A
35%
40%
30%
25%
20%
10% 15%
10
20
30
40
50
Concentration of coolant in
the vehicie cooling system %
Concentration of coolant in vehicie
and quantity to be drained
CO-00012
PM-23
Clutch System
12.Clutch System
A: INSPECTION AND ADJUSTMENT
Be careful not to allow dirt or dust to get into the

reservoir tank.
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.
(A)
(C)
(B)
(C)
(B) (A)
PM-00165
(A) Reservoir tank

(B) MIN. level
(C) MAX. level
PM-00164
(A) Release lever

(B) Push rod
(C) Operating cylinder
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-26, Clutch Pedal.>
4) Check the fluid level using the scale on the outside of the clutch reservoir tank (A). If the level is
below MIN (B), inspect the clutch master cylinder,
operating cylinder and hydraulic line for fluid leaks.
If fluid leaks are found, repair or replace. If fluid
leaks are not found, add clutch fluid to bring it up to
MAX (C) of clutch reservoir tank.
Recommended clutch fluid:
Refer to RM section. <Ref. to RM-5, FLUID,
RECOMMENDED MATERIALS, Recommended Materials.>
CAUTION:
Prevent the clutch fluid from being splashed
over vehicle body. If the clutch fluid is splashed
over vehicle body, flush it, and then wipe it up.
NOTE:
Avoid mixing different brands of brake fluid to
prevent degradation of the fluid.
PM-24
Transmission Gear Oil

13.Transmission Gear Oil

A: REPLACEMENT
1. MANUAL TRANSMISSION
1) Drain the gear oil by removing drain plug.
NOTE:
Before starting work, cool off the transmission
gear oil well.
If transmission gear oil adheres to the exhaust
pipe, wipe it off completely.
PM-00166
2) Replace the gasket with new one, and then tighten the drain plug to specified torque.
Tightening torque:
69 Nm (7.0 kgf-m, 50.6 ft-lb)
3) Fill the transmission gear oil through the oil level
gauge hole up to the upper point of level gauge.
Recommended gear oil:
NOTE:
Each oil manufacturer has its base oil and additives. Thus, do not mix two or more brands.
Gear oil capacity:
3.5 2 (3.7 US qt, 3.1 Imp qt)
(A)
(B)
(C)
PM-00030
(A) Oil level gauge

(B) Upper level
(C) Lower level
PM-25

14.Automatic Transmission Fluid
5AT model
(A)
(C)
CAUTION:
The level of ATF varies with fluid temperature.
Pay attention to the fluid temperature when
checking ATF level.
1) Raise the ATF temperature by driving a distance
of 5 to 10 km (3 to 6 miles). Otherwise, idle the engine to raise ATF temperature to 70 80C (158
176F) on Subaru Select Monitor. <Ref. to
4AT(diag)-17, READ CURRENT DATA, OPERATION, Subaru Select Monitor.>
2) Make sure the vehicle is level.
3) After selecting all positions (P, R, N, D), shift the
select lever in P range. Measure the ATF level
with engine idling for one or two minutes.
4AT model
(C)
(E)
COLD
L
(D)
L
F
HOT
(A)
(B)
(C)
(D)
PI-00189
(A) Level gauge

(B) ATF level range at HOT [70 80C (158
176F)]
(C) Upper level
(D) Lower level
(E) ATF level range at COLD [20 30C (68
86F)]
L
F
HOT
(A)
A: INSPECTION
(B)
(E)
COLD
L
F
(D)
(C)
(D)
PI-00190
(A) Level gauge

176F)]
(C) Upper level
(D) Lower level
86F)]
4) Make sure that ATF level is above the center of

upper and lower marks at HOT side.
5) If the ATF level is below the center between upper and lower marks, add the recommended ATF
until the fluid level is found above the center between upper and lower marks.
CAUTION:
Use care not to exceed the upper limit level.
Addition of ATF to the upper limit mark on
HOT side when the ATF temperature is below
70C (158F) will overfilling of ATF, causing a
transmission failure.
6) Check ATF level after raising ATF temperature
to 70 80C (158 176F) by running the vehicle
or by idling the engine again.
7) Check the ATF 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.
PM-26

B: REPLACEMENT
4AT model
1. AUTOMATIC TRANSMISSION FLUID
(A)
NOTE:
Before starting work, cool off the ATF well.
4AT model
(C)
(E)
COLD
L
(D)
L
F
HOT
1) Drain the ATF by removing drain plug.

(B)
(C)
(D)
PI-00189
(A) Level gauge

176F)]
(C) Upper level
(D) Lower level
86F)]
(B)
(A)
PM-00167
(A) Front differential gear oil drain plug

(B) ATF drain plug
5AT model
5AT model
(A)
(C)
L
F
HOT
(A)
(B)
(A)
(E)
COLD
L
F
(D)
(C)
(D)
PI-00190
(A) Level gauge

176F)]
(C) Upper level
(D) Lower level
86F)]
PM-00168
(A) ATF drain plug
Tightening torque:
4AT model
25 Nm (2.55 kgf-m, 18.4 ft-lb)
5AT model
20 Nm (2.0 kgf-m, 4.5 ft-lb)
3) Pour ATF from the ATF charge pipe.
2. ATF FILTER
Recommended ATF:
Capacity:
Fill the same amount of ATF drained.
4) Check the ATF level. <Ref. to PM-26, INSPECTION, Automatic Transmission Fluid.>
NOTE:
Basically ATF filter is maintenance free, but when it
has physically damaged or ATF leaked, the ATF filter needs replacement.
For the replacement procedure of ATF filter, refer
to ATF FILTER.
4AT model
<Ref. to 4AT-66, ATF Filter.>
5AT model
<Ref. to 5AT-61, ATF Filter.>
PM-27
Front & Rear Differential Gear Oil

15.Front & Rear Differential Gear

Oil
A: REPLACEMENT
1. FRONT DIFFERENTIAL (MT MODEL)
Front differential gear oil for MT model lubricates
the transmission and differential together. Refer to
Transmission Oil for replacement procedure.
<Ref. to PM-25, Transmission Gear Oil.>
NOTE:
Differential gear oil capacity:
4AT model
1.1 1.3 2 (1.2 1.4 US qt, 1.0 1.1 Imp
qt)
(A)
2. FRONT DIFFERENTIAL (AT MODEL)
(B)
(A)
(C)
1) Drain the differential gear oil by removing drain

plug using TORX BIT T70.
NOTE:
Before starting work, cool off the differential gear
oil well.
If front differential gear oil adheres to the exhaust
pipe, wipe it off completely.
4AT model
PI-00183
(A) Oil level gauge

(B) Upper level
(C) Lower level
5AT model
1.3 1.5 2 (1.4 1.6 US qt, 1.1 1.3 Imp
qt)
(A)
(A)
PM-00169
5AT model
(B)
(C)
PI-00184
(A) Oil level gauge

(B) Upper level
(C) Lower level
3. REAR DIFFERENTIAL
PM-00170
1) Drain the oil by removing drain plug.

2) Remove the filler plug for quick draining oil.
3) Install the drain plug after draining oil.
Tightening torque:
70 Nm (7.1 kgf-m, 16 ft-lb)
3) Fill differential gear oil through the oil level
gauge hole up to the upper point of level gauge.
NOTE:
Apply liquid gasket to the drain plug threads for
T-type.
Use a new gasket for VA-type.

Liquid gasket:
THREE BOND 1105 (Part No. 004403010)
PM-28
Front & Rear Differential Gear Oil

Tightening torque:
T-type
49.0 Nm (5.0 kgf-m, 36.2 ft-lb)
VA1-type
34 Nm (3.5 kgf-m, 25.3 ft-lb)
VA2-type
29 Nm (3.0 kgf-m, 21.4 ft-lb)
4) Pour oil to the bottom end of filler plug hole.
Liquid gasket:

Except for VA2-type
Tightening torque:
T-type
49.0 Nm (5.0 kgf-m, 36.2 ft-lb)
VA1-type
34 Nm (3.5 kgf-m, 25.3 ft-lb)
VA2-type
29 Nm (3.0 kgf-m, 21.4 ft-lb)
(A)
(B)
PM-00037
(A) Filler plug

(B) Drain plug
VA2-type
(A)
(B)
DI-00355
(A) Filler plug

(B) Drain plug
Oil capacity:
0.8 2 (0.8 US qt, 0.7 Imp qt)
NOTE:
5) Install the filler plug.
NOTE:
Apply liquid gasket to the filer plug threads for Ttype.
Use a new aluminum gasket for VA-type.
PM-29
Brake Line
16.Brake Line
2. SERVICE BRAKE
A: INSPECTION
1) Check the free play of brake pedal with pulling

up the force of less than 10 N (1 kgf, 2 lb).
1. BRAKE LINE
1) Check for scratches, swelling, corrosion, traces
of fluid leakage on the 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.
Brake pedal free play (Pulling up direction of

pedal)
0.5 2.0 mm (0.02 0.08 in)
NOTE:
When the brake fluid level in the reservoir tank is
lower than specified limit, the brake warning light
on the combination meter will come on.
Visually check the brake hose for damage. (Use
a mirror where it is difficult to see)
(2)
(1)
PM-00171
(1) Front brake hose

(2) Front brake pipe
(A)
PM-00185
(A) Pedal free play
2) If the free play is out of specifications above, adjust the brake pedal as follows:
(1) Make sure the 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. [Pulling up the brake pedal pad with a force
of less than 10 N (1 kgf, 2 lb) to a stroke of 0.5 to
2.0 mm (0.02 to 0.08 in).]
(3) 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).
(A)
(B)
(H)
(2)
(C)
(1)
(D)
(E)
(F)
(I)
(J)
(G)
PM-00186
PM-00172
(A)
(B)
(C)
(D)
(E)
(F)
(G)
(H)
(I)
(J)
(1) Rear brake pipe

(2) Rear brake hose
PM-30
Brake switch
Adjusting nut
0.3 mm (0.012 in)
Stopper
Clevis pin
Clevis
Pedal free play
Lock nut
Brake booster operating rod
Play at pin
Brake Line
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 pedal and steering wheel again.
The difference between the two measurements
must be less than specified value. If the distance is
more than specified value, there is possibility of air
inside the hydraulic unit.
Replace the both check valve and vacuum hose if

the check valve is faulty. Engine side of vacuum
hose is indicated by marking ENG as shown.
(A)
(B)
(C)
Brake pedal reserve distance A:

95 mm (3.7 in)/ 490 N (50 kgf, 110 lb) or less
PM-00046
1
=A
(A) Engine side

(B) Brake booster side
(C) ENG
(A)
5) Check the vacuum hose for cracks or other damage.
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 the vacuum hose to make sure it is tightly
secured.
(B)
PM-00045
(A) Steering wheel

(B) Toe board
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.
3. BRAKE SERVO SYSTEM

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.
4) A check valve is built into the vacuum hose. Disconnect the vacuum hose to inspect function of
check valve.
Blow compressed air into vacuum hose from its
brake booster side end. Make sure air must flow
out of engine side end of hose. Next, blow compressed air into hose from engine side. Make sure
air should not flow out of hose.
PM-31
Brake Fluid
17.Brake Fluid
A: REPLACEMENT
1) Either jack-up the vehicle and place a rigid rack
under it, or lift-up the vehicle.
2) Remove all the wheels.
3) Drain the brake fluid from master cylinder.
4) Refill the reservoir tank with recommended
brake fluid.
Recommended brake fluid:
NOTE:
Avoid mixing different brands of brake fluid to
prevent degrading the quality of fluid.
Be careful not to allow dirt or dust to get into the
reservoir tank.
Air bleeding sequence (1) (2) (3) (4)
(1)
(5)
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 the
brake pedal depressed and tighten the screw and
install bleeder cap.
(6)
(3)
(1)
(2)
(3)
(4)
(5)
(6)
(4)
NOTE:
Cover the bleeder with cloth, when loosening it,
to prevent brake fluid from being splashed over surrounding parts.
During the bleeding operation, keep the brake
reservoir tank filled with brake fluid to eliminate entry of air.
The brake pedal operation must be very slow.
For convenience and safety, two people should
do the work.
The amount of brake fluid required is approx. 500
m2 (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 the bleeder screw approximately 1/4
turn until a small amount of brake fluid drains into
the container, and then quickly tighten the screw.
8) Repeat steps 6) and 7) until there are no air bubbles in drained brake fluid and new fluid flows
through vinyl tube.
(2)
PM-00047
Front RH
Rear LH
Front LH
Rear RH
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.
Tightening torque:
8 Nm (0.8 kgf-m, 5.8 ft-lb)
10) Bleed air from each wheel cylinder by following
steps from 5) to 9).
11) Depress the brake pedal with a force of approx.
294 N (30 kgf, 66 lb) and hold it there for approx. 20
seconds. At this time check the pedal to see if it
makes any unusual movement. Visually inspect the
bleeder screws and brake pipe joints to confirm
there is no fluid leakage.
12) Install the wheels, and drive the vehicle for a
short distance between 2 to 3 km (1 to 2 miles) to
confirm brakes are operating properly.
PM-00048
PM-32
Disc Brake Pad and Disc

18.Disc Brake Pad and Disc

(A)
A: INSPECTION
(C)
1) Jack-up the vehicle and support with rigid racks.

Then remove the wheels.
2) Visually check the pad thickness through inspection hole of disc brake assembly. Replace the pad if
necessary.
(B)
NOTE:
When replacing a pad, always replace the pads for
both the left and right wheels at the same time. Also
replace the pad clips if they are twisted or worn.
PM-00140
(A) Pad thickness

(B) Back metal
(C) Lining
3) Check the disc rotor, and correct or replace if it is

damaged or worn.
Front
Disc rotor thickness
15, 16-inch
Standard
17-inch
15, 16-inch
Wear limit
17-inch
(A)
PM-00049
mm (in)
24 (0.94)
30 (1.18)
22 (0.87)
28 (1.10)
(A) Inspection hole
Rear
Front
Pad thickness
Standard
Wear limit
15-inch
16-inch
17-inch
15-inch
16-inch
17-inch
mm (in)
11 (0.43)
11 (0.43)
11 (0.43)
1.5 (0.059)
1.5 (0.059)
1.5 (0.059)
Rear
Standard
Wear limit
Pad thickness
Solid disc type
Ventilated disc type
Solid disc type
mm (in)
9 (0.35)
9 (0.35)
1.5 (0.059)
1.5 (0.059)
Disc rotor thickness

Solid disc type
Standard
Solid disc type
Wear limit
mm (in)
10 (0.39)
18 (0.71)
8.5 (0.34)
16 (0.63)
4) Remove the caliper body. <Ref. to BR-20, Front

Disc Brake Assembly.> <Ref. to BR-28, Rear Disc
Brake Assembly.>
5) Tighten the wheel nuts to secure disk rotor.
6) Set a dial gauge at a point less than 10 mm (0.39
in) from outer periphery of the rotor, and then measure the disk rotor runout.
Disc rotor runout limit:
Front: 0.05 mm (0.002 in)
Rear: 0.05 mm (0.002 in)
PM-00051
PM-33
Parking Brake
19.Parking Brake
4) When the shoe return spring tension is excessively weakened, replace it.
A: INSPECTION
Inspect the brake linings and disc rotor of both
sides of the rear brake at the same time by removing disc rotor.
1) Inspect the brake shoes for damage or deformation and check the brake linings for wear.
NOTE:
Always replace both primary and secondary brake
shoes for the left and right wheels at the same time.
B: ADJUSTMENT
For rear disc brake, adjust the parking brake after
bleeding air.
1) Remove the rear cover (rubber) installed at back
plate.
2) Turn the adjuster toward arrow mark (upward)
until it is locked slightly, by using flat-tip screwdriver
as shown in the illustration.
Thickness of brake lining (except for back metal):

Standard value: 3.2 mm (0.126 in)
Wear limit: 1.5 mm (0.059 in)
(A)
(B)
(C)
PM-00056
(A)
(B)
(A) Adjuster
(B) Cover (rubber)
(C) Back plate
(C)
PM-00054
3) Turn back (downward) the adjuster 3 to 4 notches.

4) Install the cover (rubber) in original position correctly.
(A) Forward
(B) Brake shoe (Primary side)
(C) Brake shoe (Secondary side)
2) Check the inside of disk rotor for wear, dents or

other damage. If the inside surface of dick rotor is
streaked, correct the surface with emery cloth
(#200 or more). If it is unevenly worn or tapered,
correct or replace it.
Brake drum inside diameter:
Standard value: 170 mm (6.69 in)
Wear limit: 171 mm (6.73 in)
(B)
(A)
PM-00055
(A) Inside diameter

(B) Disc
3) If the deformation or wear of back plate, shoe,

etc. is noticeable, replace them.
PM-34
Suspension
20.Suspension
NOTE:
When the front arm ball joint has been removed or
replaced, check the toe-in of front wheel. If the front
wheel toe-in is not at specified value, adjust the
toe-in. <Ref. to FS-8, Wheel Alignment.>
A: INSPECTION
1. SUSPENSION BALL JOINT
1) Jack-up the vehicle until front wheels are off
ground.
2) Grasp the bottom of tire and move it in and out.
If relative movement is observed between the
brake disc cover (A) and end of front arm (D), ball
joint (C) may be excessively worn.
(A)
PM-00059
(A) Dust seal

(A)
2. FRONT, REAR SUSPENSION BUSHING
(D)
(C)
(B)
PM-00057
3) Grasp the end of front arm and move it up and

down. Relative movement (A) between the housing
(D) and front arm (C) boss indicates ball joint (B)
may be excessively worn.
Apply pressure with tire lever etc, and inspect the

bushing for wear or crack. Replace the bushings if
there is wear or crack.
(D)
(A)
PM-00180
(C)
(B)
3. WHEEL ARCH HEIGHT

PM-00058
4) If relative movement is observed in the step 2),

3), remove and inspect the ball joint. If the free play
exceeds standard value, replace the ball joint.
<Ref. to FS-17, Front Ball Joint.>
5) Damage of dust seal
Visually inspect the ball joint dust seal. If it is damaged, remove the front arm. <Ref. to FS-19, Front
Arm.> And measure free play of ball joint. <Ref. to
FS-17, Front Ball Joint.>
(1) When looseness exceeds standard value,
replace the ball joint.
(2) If the dust seal is damaged, replace with a
new ball joint.
1) Unload the cargoes and set the vehicle in curb

weight (empty) condition.
2) Check the wheel arch height of front and rear
suspensions to ensure that they are within specified values. <Ref. to FS-8, Wheel Alignment.>
3) When the wheel arch height is out of standard,
visually inspect following components and replace
deformed parts.
Suspension components [Front strut assembly
and rear damper assembly]
Parts connecting suspension and body
4) If no components are deformed, adjust the
wheel arch height by replacing the suspension
which wheel arch height is out of standard. <Ref. to
FS-8, Wheel Alignment.> <Ref. to RS-8, Wheel
Alignment.>
PM-35
Suspension
4. WHEEL ALIGNMENT OF FRONT SUSPENSION
Rear suspension
<Ref. to RS-2, General Description.>
1) Check the alignment of front suspension to ensure that following items conform to standard values.
Toe-in
Camber
Caster
Steering angle
<Ref. to FS-8, Wheel Alignment.>
2) When the caster angle does not conform to reference obviously, visually inspect the following
components and replace deformed parts.
Suspension components [Strut assembly, crossmember, front arm, etc.]
3) When the toe-in and camber are out of standard
value, adjust them so that they conform to standard
value.
4) When the right-and-left turning angles of tire are
out of standard, adjust to standard value.
8. DAMAGE TO SUSPENSION PARTS
5. WHEEL ALIGNMENT OF REAR SUSPENSION

1) Check the alignment of rear suspension to ensure that following items are within standard values.
Toe-in
Camber
Thrust angle
<Ref. to RS-8, Wheel Alignment.>
2) When the camber angle does not conform to
standard value, visually inspect the following components. If the deformation is observed, replace the
damaged parts.
Suspension components [Shock absorber, front
link, rear link, upper link, rear arm, sub frame, etc]
3) When the toe-in and thrust angle are out of standard value, adjust them so that they conform to
standard value.
Check the following parts and the fastening portion

of the vehicle body for deformation or excessive
rusting which impairs the suspension. If necessary,
replace the damaged parts with new ones. If minor
rust formation, pitting, etc. are noted, remove the
rust and take rust prevention measure.
Front suspension
Front arm
Crossmember
Strut
Rear suspension
Sub frame
Front link
Rear link
Upper link
Rear arm
Shock absorber
In the area 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 AND SHOCK

ABSORBER
Visually inspect the front strut and rear shock absorber for oil leakage. Replace the front strut and
rear shock absorber if oil leaks excessively.
7. TIGHTNESS OF BOLTS AND NUTS

Check the bolts and nuts for looseness. Retighten
the bolts and nuts to specified torque. If the selflocking nuts and bolts are removed, replace them
with new ones.
Front suspension
<Ref. to FS-2, General Description.>
PM-36
Wheel Bearing
21.Wheel Bearing
6) While supporting rear drive shaft horizontally

with one hand, turn the hub with the other hand to
check for noise or binding.
If the hub is noisy or binds, replace the rear axle.
A: INSPECTION
1. FRONT WHEEL BEARING
NOTE:
Inspect the condition of front wheel bearing grease.
1) Jack-up the front side of vehicle.
2) While holding the front wheel by hand, swing it in
and out to check bearing free play.
3) Loosen the wheel nuts, and remove the front
wheel.
4) If the bearing free play exists in step 2) above,
attach a dial gauge to the hub and measure axial
play in axial direction.
Service limit:
Straight-ahead position within 0.05 mm
(0.0020 in)
5) Remove the bolts and self-locking nuts, and extract the front arm from front crossmember.
6) Remove the PTJ of front drive shaft from transmission. <Ref. to DS-13, Front Axle.>
7) While supporting the front drive shaft horizontally with one hand, turn the hub with the other hand to
check for noise or binding.
If the hub is noisy or binds, replace the front axle.
PM-00173
2. REAR WHEEL BEARING

1) Jack-up the rear side of vehicle.
2) While holding the rear wheel by hand, swing it in
and out to check bearing free play.
3) Loosen the wheel nuts, and remove the rear
wheel.
4) If the bearing free play exists in step 2) above,
attach a dial gauge to the hub and measure axial
play 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-26, Rear Drive Shaft.>
PM-37
PM-00173
Axle Boots & Joints

22.Axle Boots & Joints

A: INSPECTION
1. FRONT AND REAR AXLE BOOTS
Inspect the front axle boots (A) and rear axle boots
(B) for deformation, damage or failure. If faulty, replace them with new ones. <Ref. to DS-22, Front
Drive Shaft.> <Ref. to DS-26, Rear Drive Shaft.>
Front
(A)
PM-00174
Rear
(B)
PM-00175
2. PROPELLER SHAFT
Inspect the propeller shaft for damage or failure. If
faulty, replace them with new ones. <Ref. to DS-10,
Propeller Shaft.>
PM-38
Steering System (Power Steering)

23.Steering System (Power

Steering)
2. STEERING SHAFT JOINT
A: INSPECTION
1. STEERING WHEEL
1) Set the steering wheel in a straight-ahead position, and check the wheel spokes to make sure
they are correctly set in their specified positions.
2) Lightly turn the 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.
When the steering wheel free play is excessive,

disconnect the 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)
Steering wheel free play:

0 17 mm (0 0.67 in)
(1)
PS-00450
(1) Steering wheel free play
Move the 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 the 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) Pulled 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.
PM-00176
3. GEARBOX
1) With the vehicle placed on a level surface, turn
the steering wheel 90 in both the left and right directions.
While the wheel is being rotated, reach under the
vehicle and check for looseness in gearbox.
Tightening torque:
59 Nm (6.0 kgf-m, 43.4 ft-lb)
PM-00177
2) Check the boot for damage, cracks or deterioration.
PM-39

3) With the vehicle placed on a level surface, quickly turn the steering wheel to the left and right.
While steering wheel is being rotated, check the
gear backlash. If any noise is noticed, adjust the
gear backlash.
4) Adjustment for LHD model
(1) Apply liquid gasket to at least 1/3 of entire
perimeter of adjusting screw thread.
(2) Tighten adjusting screw to 25 Nm (2.5 kgfm, 18.0 ft-lb) and then loosen.
(3) Tighten adjusting screw to 3.9 Nm (0.40
kgf-m, 2.9 ft-lb) and then loosen 20.
5) Adjustment for RHD model
perimeter of adjusting screw thread.
(2) Tighten adjusting screw to 9.8 Nm (1.0 kgfm, 7.2 ft-lb) and then loosen.
kgf-m, 3.6 ft-lb) and then loosen.
kgf-m, 3.6 ft-lb) and then loosen 37.
4. TIE-ROD
1) Check the tie-rod and tie-rod ends for bends,
scratches or other damage.
(A)
(B)
PM-00069
(A) Tie-rod end

(B) Knuckle arm
2) Check the 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)
3) Check the lock nut on the tie-rod for tightness. If
it is loose, retighten it to the specified torque.
(A)
Tightening torque:
83 Nm (8.5 kgf-m, 61.5 ft-lb)
5. POWER STEERING FLUID LEVEL
PM-00068
(A) Apply liquid gasket to at least 1/3 of entire

perimeter
6) Install the lock nut. While holding adjusting

screw with a wrench, tighten the lock nut using ST.
ST 926230000
SPANNER
Tightening torque (lock nut):
LHD model
25 Nm (2.5 kgf-m, 18.0 ft-lb)
RHD model
39 Nm (4.0 kgf-m, 28.9 ft-lb)
Hold the adjusting screw with a wrench to prevent it
from turning while tightening the lock nut.
NOTE:
At power steering fluid temperature 20C (68F);
read the fluid level on the COLD side.
At power steering fluid temperature 80C
(176F); read the fluid level on the HOT side.
1) Place the vehicle with engine OFF on a level
surface.
2) Remove the cover. (3.0 L and turbo model)
3) Check the fluid level using the scale on the outside of the reservoir tank (A). If the level is below
MIN (B), add fluid to bring it up to MAX (C).
(C)
(A)
(B)
PM-00178
PM-40

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.
Recommended fluid:
Fluid capacity:
0.8 2 (0.8 US qt, 0.7 Imp qt)
6. POWER STEERING FLUID FOR LEAKS

Inspect the underside of oil pump and gearbox of
power steering system, hoses, pipes and their couplings for fluid leaks.
If the fluid leaks are found, retighten their fitting
bolts (or nuts) and/or replace their parts.
9. GEARBOX BOOTS
Inspect both sides of the gearbox boot as follows,
and correct the defects if necessary.
1) Positions (A) and (B) of the gearbox boot are fitted correspondingly in grooves (A) and (B) of the
gearbox and rod (C).
2) Clips are fitted outside of positions (A) and (B) of
boot.
3) Boot does not have crack and hole.
NOTE:
Rotate the position (B) of gearbox boot against the
twist of it produced by adjustment of toe-in, etc. Apply grease to the groove (C).
(C)
NOTE:
Wipe the leaked fluid off after correcting fluid
leaks.
Also pay attention to clearances between hoses
(or pipes) and other parts when inspecting fluid
leaks.
(B)
(A)
PM-00090
7. HOSES OF OIL PUMP FOR DAMAGES
10.FITTING BOLTS AND NUTS
Check the pressure hose and return hose of oil

pump for crack, swell or damage. Replace the hose
with a new one if necessary.
Inspect the 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.
NOTE:
Prevent hoses from turning and/or bending when
installing hoses.
PM-00179
8. POWER STEERING PIPES FOR DAMAGES

Check the power steering pipes for corrosion and
damage.
Replace the pipes with new ones if necessary.
PM-41
A/C Filter
24.A/C Filter
A: REPLACEMENT
1) Remove the instrument panel side cover.
PM-00273
2) Remove the clips and damper.
(1)
(2)
(1)
PM-00274
(1) Clip
(2) Damper
3) Remove the tray.
PM-00275
4) Remove the A/C filter.
PM-00276
PM-42
ENGINE SECTION 1

of SUBARU vehicles.

approval.
FUEL INJECTION (FUEL SYSTEMS)
FU(H4SO 2.0)
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICES)
EC(H4SO 2.0)
INTAKE (INDUCTION)
IN(H4SO 2.0)
MECHANICAL
ME(H4SO 2.0)
EXHAUST
EX(H4SO 2.0)
COOLING
CO(H4SO 2.0)
LUBRICATION
LU(H4SO 2.0)
SPEED CONTROL SYSTEMS
SP(H4SO 2.0)
IGNITION
IG(H4SO 2.0)
STARTING/CHARGING SYSTEMS
SC(H4SO 2.0)
ENGINE (DIAGNOSTICS)
EN(H4SO 2.0)
(diag)
FU(H4SO 2.5)
EMISSION CONTROL
EC(H4SO 2.5)
INTAKE (INDUCTION)
IN(H4SO 2.5)
MECHANICAL
ME(H4SO 2.5)
EXHAUST
EX(H4SO 2.5)
COOLING
CO(H4SO 2.5)
G2320GE2
ENGINE SECTION 1
LUBRICATION
LU(H4SO 2.5)
SP(H4SO 2.5)
IGNITION
IG(H4SO 2.5)
SC(H4SO 2.5)
EN(H4SO 2.5)
(diag)
G2320GE2
FUEL INJECTION
(FUEL SYSTEMS)
FU(H4SO 2.0)
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
Throttle Body.............................................................................................10
Intake Manifold..........................................................................................11
Engine Coolant Temperature Sensor........................................................20
Crankshaft Position Sensor.......................................................................21
Camshaft Position Sensor.........................................................................22
Knock Sensor............................................................................................23
Throttle Position Sensor............................................................................25
Manifold Absolute Pressure Sensor..........................................................26
Intake Air Temperature Sensor .................................................................27
EGR Valve ................................................................................................28
Fuel Injector ..............................................................................................29
Front Oxygen (A/F) Sensor .......................................................................32
Rear Oxygen Sensor.................................................................................33
Engine Control Module (ECM) ..................................................................34
Main Relay ................................................................................................35
Fuel Pump Relay.......................................................................................36
Electronic Throttle Control Relay ..............................................................37
Fuel ...........................................................................................................38
Fuel Tank ..................................................................................................39
Fuel Filler Pipe ..........................................................................................45
Fuel Pump.................................................................................................47
Fuel Level Sensor .....................................................................................49
Fuel Sub Level Sensor..............................................................................50
Fuel Filter ..................................................................................................51
Fuel Damper Valve ...................................................................................52
Fuel Delivery, Return and Evaporation Lines............................................53
Fuel System Trouble in General ...............................................................56
General Description
A: SPECIFICATION
Fuel tank
Fuel pump
Capacity
Location
Type
Shutoff discharge pressure
Discharge
Fuel filter
64 2(16.9 US gal, 14.1 Imp gal)

Under rear seat
Impeller
441 686 kPa (4.50 7.00 kg/cm2, 64.0 99.5 psi)
75 2 (19.8 US gal, 16.5 Imp gal)/h or more
[12 V at 300 kPa (3.06 kg/cm2, 43.5 psi)]
In-tank type
FU(H4SO 2.0)-2
General Description
B: COMPONENT
1. INTAKE MANIFOLD
T4
T2
(7)
(17)
T2
(9)
T4
(8)
T6
T4
(19)
(10)
(11)
(7)
T5
T3
T2
T4
T4
(17)
(14)
(12)
(4)
T4
T2
(12)
T5
(9)
(8)
T5
(10)
T5
(13)
(5)
(2)
(3)
T3
(1)
T5
T4
T4
(12)
T1
T1
T1
(16)
T2
(16)
(18)
(3)
(2)
(6)
T1
(18)
(15)
T1
(16)
T1
T4
T2
(18)
FU-02056
FU(H4SO 2.0)-3
General Description
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Intake manifold
Gasket
Guide pin
EGR valve (EC, EK, K4 model)
Fuel pipe protector RH
Fuel pipe protector LH
Fuel injector pipe
Fuel injector
O-ring
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
O-ring
Purge control solenoid valve
Plug cord holder
Nipple (LHD model)
Nipple (RHD model)
Fuel pipe ASSY
Fuel hose
Clip
Clamp
(19)
PCV valve
Tightening torque: Nm (kgf-m, ft-lb)

T1: 1.5 (0.15, 1.1)
T2: 6.4 (0.65, 4.7)
T3: 17 (1.7, 12.5)
T4: 19 (1.9, 13.7)
T5: 25 (2.5, 18.1)
T6: 23 (2.3, 17.0)
2. AIR INTAKE SYSTEM
T1
(3)
T2
(4)
(2)
(1)
FU-02057
(1)
(2)
(3)
Gasket
Throttle body
Manifold absolute pressure sensor
(4)
O-ring
FU(H4SO 2.0)-4

T1: 2.0 (0.20, 1.5)
T2: 8 (0.8, 5.8)
General Description
3. CRANKSHAFT POSITION, CAMSHAFT POSITION AND KNOCK SENSORS
T1
T2
(1)
(2)
T1
(4)
(3)
T1
FU-00414
(1)
(2)
(3)
Crankshaft position sensor

Knock sensor
Camshaft position sensor
(4)
Camshaft position sensor support
FU(H4SO 2.0)-5

T1: 6.4 (0.65, 4.7)
T2: 24 (2.4, 17.4)
General Description
4. FUEL TANK
T1
(19)
(17)
(18)
(15)
(16)
(8)
T1
(17)
(14)
(7)
(15)
(10)
(12)
(9)
(11)
(1)
(13)
(22)
T4
(6)
(22)
(5)
(20)
(3)
(2)
T4
(21)
T4
(4)
T3
T3
T3
T3
(23)
(24)
(25)
T3
T2
T2
T3
FU-01080
FU(H4SO 2.0)-6
General Description
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
Fuel tank
Fuel tank band RH
Fuel tank band LH
Delivery tube
Return tube
Jet pump tube
Fuel pump assembly
Fuel pump upper plate
Fuel pump gasket
Fuel level sensor
Fuel sub level sensor
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
Fuel sub level sensor upper plate

Fuel sub level sensor gasket
Fuel filler hose
Clamp
Vent hose
Clip
Fuel tank protector RH (Rear)
Fuel tank protector LH (Rear)
Stopper RH
Stopper LH
FU(H4SO 2.0)-7
(22)
(23)
(24)
(25)
Retainer
Heat shield cover
Fuel tank protector RH (Front)
Fuel tank protector LH (Front)

T1: 4.4 (0.45, 3.3)
T2: 9.0 (0.92, 6.6)
T3: 17.5 (1.78, 12.9)
T4: 33 (3.4, 25)
General Description
5. FUEL LINE
T1
(1)
(28)
(18)
(26)
(23)
(25)
(27)
(15)
(17)
(19)
(1)
(20)
(22)
(14)
(13)
(24)
(21)
T2
(1)
(16)
(1)
(1) (22)
(34)
(11)
(29)
(10)
T2
(12)
T3
T2
(1)
(4)
(5)
A
T2
(1)
(3)
(1)
(2)
(33)
(9)
(1)
(32)
(6)
(1)
(7)
(30)
(31)
(8)
FU-01081
FU(H4SO 2.0)-8
General Description
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
Clip
Fuel return hose
Evaporation hose A
Fuel delivery hose A
Fuel delivery hose B
Fuel damper
Fuel damper holder
Fuel damper bracket
Fuel pipe ASSY
Clamp
Canister
Canister protector (Sedan model)
Canister drain hose A
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
Two-way valve hose A

Purge hose A
Purge hose B
Two-way valve hose B
Canister drain hose B
Two-way valve drain hose
Two-way valve
Two-way valve hose C
Connector
Evaporation hose holder
Fuel filler pipe ASSY
Filler pipe packing
Filler ring
C: CAUTION
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.
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
Filler cap
Tether
Clip
Fuel hose
Purge hose C
Connector
Purge pipe
Two-way valve bracket

T1: 4.4 (0.45, 3.2)
T2: 7.5 (0.76, 5.53)
T3: 8.3 (0.85, 6.1)
Be careful not to burn yourself, 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 rigid racks at the specified
points.
Before disconnecting electrical connectors of
sensors or units, be sure to disconnect the ground
cable from battery.
Place NO FIRE signs near the working area.
Be careful not to spill fuel on the floor.
D: PREPARATION TOOL
ILLUSTRATION
TOOL NUMBER
24082AA230
DESCRIPTION
CARTRIDGE
REMARKS
Troubleshooting for electrical system.
22771AA030
SUBARU SELECT
MONITOR KIT

English: 22771AA030 (Without printer)
German: 22771AA070 (Without printer)
French: 22771AA080 (Without printer)
Spanish: 22771AA090 (Without printer)
ST24082AA230
ST22771AA030
FU(H4SO 2.0)-9
Throttle Body
2. Throttle Body
A: REMOVAL
IN-00203
2) Remove the air intake chamber. <Ref. to

IN(H4SO 2.0)-8, REMOVAL, Air Intake Chamber.>
3) Disconnect the connectors from the throttle position sensor and manifold absolute pressure sensor.
(B)
(A)
FU-02058
(A) Throttle position sensor

(B) Manifold absolute pressure sensor
4) Disconnect the engine coolant hoses from throttle body.

5) Remove the bolts which secure throttle body to
intake manifold.
FU-02059
B: INSTALLATION
Install in the reverse order of removal.
NOTE:
Use a new gasket.
Tightening torque:
8 Nm (0.8 kgf-m, 5.8 ft-lb)
FU(H4SO 2.0)-10
Intake Manifold
3. Intake Manifold
9) Disconnect the engine harness connectors from

bulkhead harness connectors.
A: REMOVAL
1) Release the fuel pressure.
<Ref. to FU(H4SO 2.0)-38, RELEASING OF FUEL
PRESSURE, PROCEDURE, Fuel.>
2) Open the fuel filler flap lid, and remove the fuel
filler cap.
FU-02061
10) Disconnect the connectors from engine coolant

temperature sensor.
IN-00203
4) Remove the air cleaner case and air intake

chamber. <Ref. to IN(H4SO 2.0)-6, REMOVAL, Air
Cleaner Case.> <Ref. to IN(H4SO 2.0)-8, REMOVAL, Air Intake Chamber.>
5) Disconnect the spark plug cords from spark
plugs.
FU-00055
11) Disconnect the knock sensor connector.
FU-01334
FU-02060
7) Disconnect the PCV hose from intake manifold.

8) Disconnect the brake booster hose.
12) Disconnect the connector from crankshaft position sensor.
FU-00056
FU-02089
13) Disconnect the connector from power steering

pump switch (A).
FU(H4SO 2.0)-11
Intake Manifold
14) Disconnect the connector from oil pressure

switch (B).
Catch the fuel from hoses using a container

or cloth.
(A)
(A)
(B)
(C)
FU-01087
15) Disconnect the connector from camshaft position sensor.
(B)
FU-02062
(A) Fuel delivery hose

(B) Return hose
(C) Evaporation hose
18) Remove the bolts which secure intake manifold

to cylinder head.
FU-01335
16) Remove the EGR pipe from intake manifold.

(EC, EK, K4 model)
FU-00260
19) Remove the intake manifold.
B: INSTALLATION
1) Install the intake manifold onto cylinder heads.
NOTE:
Use a new gasket.
FU-00148
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
17) Disconnect the fuel hoses from fuel pipes.

WARNING:
Be careful not to spill fuel.
FU-00260
2) Connect the fuel hoses.
FU(H4SO 2.0)-12
Intake Manifold
NOTE:
If fuel hoses or clamps are damaged, replace them
with new ones.
6) Connect the connector to oil pressure switch (B).
Tightening torque (Hose clamp screw):

1.25 Nm (0.13 kgf-m, 0.94 ft-lb)
(A)
(B)
(A)
FU-01087
(C)
7) Connect the connector to crankshaft position

sensor.
(B)
FU-02062

(B) Return hose
3) Install the EGR pipe to intake manifold. (EC, EK,

K4 model)
Tightening torque:
34 Nm (3.4 kgf-m, 24.6 ft-lb)
FU-00056
8) Connect the knock sensor connector.
FU-00148
4) Connect the connector to camshaft position sensor.
FU-01334
9) Connect the connectors to engine coolant temperature sensor.
FU-01335
5) Connect the connector to power steering pump

switch (A).
FU-00055
10) Connect the PCV hose to intake manifold.
FU(H4SO 2.0)-13
Intake Manifold
C: DISASSEMBLY
11) Connect the brake booster hose.
1) Disconnect the engine ground terminal from intake manifold.
FU-02089
12) Connect the engine harness connectors to

FU-02061
FU-02063
2) Remove the ignition coil & ignitor ASSY. <Ref. to

IG(H4SO 2.0)-8, REMOVAL, Ignition Coil and Ignitor Assembly.>
3) Remove the throttle body. <Ref. to FU(H4SO
2.0)-10, REMOVAL, Throttle Body.>
4) Remove the EGR valve. (EC, EK, K4 model)
<Ref. to FU(H4SO 2.0)-28, REMOVAL, EGR
Valve.>
5) Disconnect the pressure regulator vacuum hose
from intake manifold.
13) Connect the engine coolant hoses to throttle

body.
FU-02064
6) Remove the fuel pipe protector LH.

FU-02060
14) Connect the spark plug cords to spark plugs.

15) Install the air cleaner case and air intake chamber. <Ref. to IN(H4SO 2.0)-7, INSTALLATION, Air
Cleaner Case.> <Ref. to IN(H4SO 2.0)-8, INSTALLATION, Air Intake Chamber.>
16) Install the fuse of fuel pump to main fuse box.
17) Connect the battery ground cable to battery.
FU-02065
IN-00203
FU(H4SO 2.0)-14
Intake Manifold
7) Remove the fuel pipe protector RH.
RH side
FU-02066
FU-02070
8) Disconnect the connectors from fuel injector.
FU-02071
FU-02067
LH side
9) Remove the purge control solenoid valve. <Ref.

to EC(H4SO 2.0)-7, REMOVAL, Purge Control Solenoid Valve.>
10) Remove the harness band (A) and bolts (B),
(C) which secure engine harness to intake manifold.
(B)
(A)
FU-02072
(A)
(A)
FU-02068
(C)
FU-02073
13) Remove the fuel injector.
FU-02069
11) Remove the engine harness from intake manifold.

12) Remove the bolts which install injector pipe on
the intake manifold as shown in the figure.
FU(H4SO 2.0)-15
Intake Manifold
(1) Remove the clip which secures fuel injector

from injector pipe.
17) Remove the bolt which installs fuel pipes on intake manifold.
FU-02077
FU-02074
(2) Remove the fuel injector with lifting up the

fuel injector pipe.
14) Loosen the clamp which holds fuel injector pipe
LH to fuel hose, and then disconnect the pipe from
fuel hose.
18) Remove the fuel pipe assembly and pressure

regulator, from intake manifold.
D: ASSEMBLY
1) Install the fuel pipe assembly and pressure regulator to intake manifold.
NOTE:
Use a new gasket.
When assembling the nipple, apply liquid gasket.
Liquid gasket:
2) Tighten the bolt which installs fuel pipes on intake manifold.
FU-02075
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)

RH to fuel hose, and then disconnect the pipe from
fuel hose.
FU-02077
FU-02076
3) Connect the fuel injector pipe RH to fuel hose,

and tighten the clamp screw.
16) Remove the fuel injector pipe.
FU-02076
FU(H4SO 2.0)-16
Intake Manifold
4) Connect the fuel injector pipe LH to fuel hose,

LH side
Tightening torque:
19 Nm (1.9 kgf-m, 13.7 ft-lb)
FU-02075
5) Install the fuel injectors.

6) Install the clip which secures fuel injector.
FU-02078
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
FU-02074
7) Tighten the bolts which install injector pipe on intake manifold.

RH side
FU-02073
8) Install the engine harness onto intake manifold.
Tightening torque:
19 Nm (1.9 kgf-m, 13.7 ft-lb)
FU-02070
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
FU-02071
FU(H4SO 2.0)-17
Intake Manifold
9) Secure the engine harness with harness band

(A) and bolts (B), (C).
Tightening torque:
(B): 16 Nm (1.6 kgf-m, 11.8 ft-lb)
(C): 6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
(B)
12) Install the fuel pipe protector RH.

Tightening torque:
19 Nm (1.9 kgf-m, 13.7 ft-lb)
(A)
(A)
FU-02066
(A)
13) Install the fuel pipe protector LH.

FU-02068
Tightening torque:
19 Nm (1.9 kgf-m, 13.7 ft-lb)
(C)
FU-02069
10) Install the purge control solenoid valve. <Ref.

to EC(H4SO 2.0)-7, INSTALLATION, Purge Control Solenoid Valve.>
11) Connect the connectors to fuel injector.
FU-02065
14) Connect the pressure regulator vacuum hose

to intake manifold.
FU-02064
FU-02067
15) Install the EGR valve. (EC, EK, K4 model)

<Ref. to FU(H4SO 2.0)-28, INSTALLATION, EGR
Valve.>
16) Install the throttle body to intake manifold.
<Ref. to FU(H4SO 2.0)-10, INSTALLATION, Throttle Body.>
17) Install the ignition coil & ignitor ASSY. <Ref. to
IG(H4SO 2.0)-8, INSTALLATION, Ignition Coil and
Ignitor Assembly.>
18) Install the engine ground terminal to intake
manifold.
FU(H4SO 2.0)-18
Intake Manifold
Tightening torque:
19 Nm (1.9 kgf-m, 13.7 ft-lb)
FU-02063
E: INSPECTION
Make sure the fuel pipe and fuel hoses are not
damaged and the connections are tightened firmly.
FU(H4SO 2.0)-19
Engine Coolant Temperature Sensor

4. Engine Coolant Temperature

Sensor
A: REMOVAL
IN-00203
2) Remove the generator. <Ref. to SC(H4SO 2.0)14, REMOVAL, Generator.>

temperature sensor.
FU-00055
4) Remove the engine coolant temperature sensor.
B: INSTALLATION
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
FU(H4SO 2.0)-20
Crankshaft Position Sensor

5. Crankshaft Position Sensor
B: INSTALLATION
A: REMOVAL
Tightening torque:
T: 6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
IN-00203
2) Remove the bolt which installs crankshaft position sensor to cylinder block.
FU-00056
3) Remove the crankshaft position sensor, and disconnect the connector from it.
FU-00057
FU(H4SO 2.0)-21
FU-00058
Camshaft Position Sensor

6. Camshaft Position Sensor
6) Remove the camshaft position sensor itself.
A: REMOVAL
FU-00179
B: INSTALLATION
IN-00203

Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
FU-01335
3) Remove the bolt which installs camshaft position

sensor to the support.
FU-00177

sensor support to camshaft cap LH.
FU-00178
5) Remove the camshaft position sensor and the

support as a unit.
FU(H4SO 2.0)-22
Knock Sensor
7. Knock Sensor
B: INSTALLATION
A: REMOVAL
1) Install the knock sensor to cylinder block.
NOTE:
Extraction area of knock sensor cord must be positioned at a 60 angle relative to the engine rear.
Tightening torque:
24 Nm (2.4 kgf-m, 17.4 ft-lb)
(A)
IN-00203
2) Remove the air cleaner case. <Ref. to IN(H4SO

2.0)-6, REMOVAL, Air Cleaner Case.>
3) Remove the harness bracket from intake manifold.
60
FU-00413
(A) Front side
FU-02078

FU-01334
3) Install the harness bracket to intake manifold.

Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
FU-01334
5) Remove the knock sensor from cylinder block.
FU-02078
4) Install the air cleaner case.

<Ref. to IN(H4SO 2.0)-7, INSTALLATION, Air
Cleaner Case.>
FU-00519
FU(H4SO 2.0)-23
Knock Sensor
IN-00203
FU(H4SO 2.0)-24
Throttle Position Sensor

8. Throttle Position Sensor

A: SPECIFICATION
Throttle body is a non-disassembled part, so do not
remove the throttle position sensor from throttle
body.
Refer to Throttle Body for removal and installation
procedure. <Ref. to FU(H4SO 2.0)-10, REMOVAL,
Throttle Body.> <Ref. to FU(H4SO 2.0)-10, INSTALLATION, Throttle Body.>
FU(H4SO 2.0)-25
Manifold Absolute Pressure Sensor

9. Manifold Absolute Pressure

Sensor
A: REMOVAL
IN-00203
2) Disconnect the connector from manifold absolute pressure sensor.
FU-02079
3) Remove the manifold absolute pressure sensor

from throttle body.
B: INSTALLATION
NOTE:
Use new O-rings.
Tightening torque:
2.0 Nm (0.20 kgf-m, 1.5 ft-lb)
FU(H4SO 2.0)-26
Intake Air Temperature Sensor

10.Intake Air Temperature Sensor

A: REMOVAL
IN-00203
2) Disconnect the connector from intake air temperature sensor.

3) Remove the intake air temperature sensor.
FU-02080
B: INSTALLATION
FU(H4SO 2.0)-27
EGR Valve
11.EGR Valve
A: REMOVAL
NOTE:
EGR valve is equipped to EC, EK and K4 model.
IN-00203
2) Disconnect the connector from EGR valve.

3) Remove the EGR valve from intake manifold.
FU-02082
B: INSTALLATION
NOTE:
Use a new gasket.
Tightening torque:
19 Nm (1.9 kgf-m, 13.7 ft-lb)
FU(H4SO 2.0)-28
Fuel Injector
12.Fuel Injector
8) Remove the clip which secure fuel injector.
A: REMOVAL
1. RH SIDE
filler cap.
FU-02074
9) Remove the bolts which hold fuel injector pipe

onto intake manifold.
IN-00203

5) Remove the spark plug cords from spark plugs
(#1 and #3 cylinders).
FU-02070
FU-02071
FU-02066
7) Disconnect the connector from fuel injector.
10) Remove the fuel injector while lifting up the fuel

injector pipe.
2. LH SIDE
filler cap.
FU-02067
FU(H4SO 2.0)-29
Fuel Injector

FU-02065
FU-02072
FU-02067
FU-02073
7) Remove the clips which secure fuel injector.

injector pipe.
B: INSTALLATION
1. RH SIDE
NOTE:
Use new O-rings.
FU-02074
Tightening torque:
19 Nm (1.9 kgf-m, 13.7 ft-lb)
FU-02070
FU(H4SO 2.0)-30
Fuel Injector
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
Tightening torque:
19 Nm (1.9 kgf-m, 13.7 ft-lb)
FU-02071
Tightening torque:
19 Nm (1.9 kgf-m, 13.7 ft-lb)
FU-02072
Tightening torque:
19 Nm (1.9 kgf-m, 13.7 ft-lb)
FU-02066
2. LH SIDE
NOTE:
Use new O-rings.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
FU-02073
FU(H4SO 2.0)-31
FU-02065
Front Oxygen (A/F) Sensor

13.Front Oxygen (A/F) Sensor
B: INSTALLATION
A: REMOVAL
1) Before installing front oxygen (A/F) sensor, apply anti-seize compound only to the threaded portion of front oxygen (A/F) sensor to make the next
removal easier.
Anti-seize compound:
SS-30 JET LUBE
CAUTION:
Never apply anti-seize compound to the protector of front oxygen (A/F) sensor.
2) Install the front oxygen (A/F) sensor.
IN-00203
Tightening torque:
21 Nm (2.1 kgf-m, 15.2 ft-lb)
2) Remove the air intake duct. <Ref. to IN(H4SO

2.0)-9, REMOVAL, Air Intake Duct.>
3) Remove the connector of front oxygen (A/F)
sensor.
FU-01114
ME-00859
4) Remove the clip holding harness.

7) Apply spray-type lubricant to the threaded portion of front oxygen (A/F) sensor, and leave it for
one minute or more.
8) Remove the front oxygen (A/F) sensor.
3) Install the under cover.

4) Lower the vehicle.
5) Hold the harness with clip.
6) Connect the connector of front oxygen (A/F)
sensor.
CAUTION:
When removing the front oxygen (A/F) sensor,
wait until exhaust pipe cools, otherwise it will
damage the exhaust pipe.
ME-00859
7) Install the air intake duct. <Ref. to IN(H4SO 2.0)9, INSTALLATION, Air Intake Duct.>
FU-01114
IN-00203
FU(H4SO 2.0)-32
Rear Oxygen Sensor

14.Rear Oxygen Sensor
B: INSTALLATION
A: REMOVAL
1) Before installing rear oxygen sensor, apply antiseize compound only to the threaded portion of
rear oxygen sensor to make the next removal easier.
SS-30 JET LUBE
CAUTION:
Never apply anti-seize compound to the protector of rear oxygen sensor.
2) Install the rear oxygen sensor.
IN-00203
Tightening torque:
21 Nm (2.1 kgf-m, 15.2 ft-lb)

3) Disconnect the connector from rear oxygen sensor.
FU-01117

4) Connect the connector to rear oxygen sensor.
FU-01116

5) Apply spray-type lubricant to the threaded portion of rear oxygen sensor, and leave it for one
minute or more.
6) Remove the rear oxygen sensor.
CAUTION:
When removing the rear oxygen sensor, wait
until exhaust pipe cools, otherwise it will damage the exhaust pipe.
FU-01116

FU-01117
IN-00203
FU(H4SO 2.0)-33

15.Engine Control Module (ECM)
B: INSTALLATION
A: REMOVAL
CAUTION:
When replacing the ECM, be careful not to
use the wrong spec. ECM to avoid any damage
to fuel injection system.
damage the harnesses and connectors.
Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
IN-00203
2) Remove the lower inner trim of passengers

side. <Ref. to EI-60, REMOVAL, Lower Inner
Trim.>
3) Detach the floor mat of front passenger seat.
4) Remove the protect cover.
FU-02090
5) Remove the nuts (A) which hold ECM to bracket.

6) Remove the clip (B) from bracket.
(B)
(A)
(A)
FU-02091
7) Disconnect the ECM connectors and take out

the ECM.
FU(H4SO 2.0)-34
Main Relay
16.Main Relay
A: REMOVAL
IN-00203
2) Remove the glove box. <Ref. to EI-51, REMOVAL, Glove Box.>

3) Remove the harness cover (A).
(A)
FU-02092
4) Disconnect the connector from main relay.
FU-02093
B: INSTALLATION
FU(H4SO 2.0)-35
Fuel Pump Relay

17.Fuel Pump Relay

A: REMOVAL
IN-00203

(A)
FU-02092
4) Disconnect the connector from fuel pump relay.
FU-02094
B: INSTALLATION
FU(H4SO 2.0)-36
Electronic Throttle Control Relay

18.Electronic Throttle Control

Relay
A: REMOVAL
IN-00203

(A)
FU-02092
4) Disconnect the connector from electric control

throttle relay.
FU-02095
B: INSTALLATION
FU(H4SO 2.0)-37
Fuel
19.Fuel
6) Set a container under the vehicle and remove

the drain plug from fuel tank to drain fuel from the
fuel tank.
A: PROCEDURE
1. RELEASING OF FUEL PRESSURE
WARNING:
1) Remove the fuse of fuel pump from main fuse
box.
FU-01123
7) Tighten the fuel drain plug.

NOTE:
Use a new gasket.
FU-01122
2) Start the engine and run until it stalls.

3) After the engine stalls, crank it for five more seconds.
4) Turn the ignition switch to OFF.
2. DRAINING FUEL
WARNING:
1) Set the vehicle on a lift.
Tightening torque:
26 Nm (2.65 kgf-m, 19.2 ft-lb)
8) Install the fuel tank protector.
NOTE:
Use a new nut.
Tightening torque:
Nut
9.0 Nm (0.92 kgf-m, 6.6 ft-lb)
Bolt
17.5 Nm (1.78 kgf-m, 12.9 ft-lb)
IN-00203
filler cap.
5) Remove the fuel tank protector.
FU(H4SO 2.0)-38
Fuel Tank
20.Fuel Tank
(2) Push the grommet (B) down under the body

and remove the service hole cover.
A: REMOVAL
WARNING:
3) Drain fuel from the fuel tank.
<Ref. to FU(H4SO 2.0)-38, DRAINING FUEL,
PROCEDURE, Fuel.>
4) Remove the rear seat.
5) Remove the service hole cover from fuel pump.
(1) Remove the bolts (A).
(A)
(A)
(B)
FU-01126
8) Disconnect the connector (A) from fuel sub level

sensor.
9) Disconnect the quick connector from the fuel delivery (B) and return hose (C). <Ref. to FU(H4SO
2.0)-53, REMOVAL, Fuel Delivery, Return and
Evaporation Lines.>
(A)
(A)
(A)
(B)
(C)
(B)
FU-01124
6) Disconnect the connector from fuel pump.
FU-01127
10) Remove the rear wheels.

11) Remove the bolts which secure rear brake
hose installation bracket.
FU-01125
7) Remove the service hole cover from fuel sub level sensor.
FU(H4SO 2.0)-39
FU-01128
Fuel Tank
12) Remove the rear brake caliper and tie it to the

side of vehicle body.
19) Remove the bolts which install parking brake

cable clamp.
FU-00462
13) Remove the parking brake cable from parking

brake assembly. <Ref. to PB-7, REMOVAL, Parking Brake Assembly (Rear Disc Brake).>
15) Remove the rear exhaust pipe.
<Ref. to EX(H4SO 2.0)-11, REMOVAL, Rear Exhaust Pipe.>
16) Remove the propeller shaft. <Ref. to DS-10,
REMOVAL, Propeller Shaft.>
17) Remove the heat shield cover.
18) Disconnect the connector from rear ABS wheel
speed sensor.
FU-01130
FU-01131
20) Remove the rear suspension assembly.

CAUTION:
A helper is required to perform this work.
(1) Support the rear differential with transmission jack.
(2) Remove the bolt which installs rear shock
absorber to rear suspension arm.
FU-01129
FU-01132
FU(H4SO 2.0)-40
Fuel Tank
(3) Remove the bolts which secure rear suspension assembly to body.
23) Support the fuel tank with transmission jack, remove the bolts from fuel tank bands and dismount
the fuel tank from vehicle.
WARNING:
FU-01133
FU-01137
B: INSTALLATION
1) Support the fuel tank with transmission jack, set
the fuel tank, and then temporarily tighten the bolts
of fuel tank band.
WARNING:
FU-01134
(4) Remove the rear suspension assembly.

21) Disconnect the two-way valve hose (A) from
two-way valve, and then remove the two-way valve
from bracket.
FU-01137
(A)
FU-01135
22) Loosen the clamp and disconnect the fuel filler

hose (A) and vent hose (B) from fuel filler pipe.
(A)
(B)
FU-01136
FU(H4SO 2.0)-41
Fuel Tank
2) Correctly insert the fuel filler hose (A) and vent

hose (B) to specified position, and then tighten the
clamp.
Tightening torque:
T1: 125 Nm (12.7 kgf-m, 92.2 ft-lb)
T2: 65 Nm (6.2 kgf-m, 48 ft-lb)
T3: 175 Nm (17.8 kgf-m, 129 ft-lb)
(A)
T1
T1
(B)
T1
T1
FU-01136
FU-01150
(2)
(1)
(3)
L/2
T3
T2
T2
T3
FU-00104
FU-01138
(1) Hose
(2) Clip or clamp
(3) Pipe
(3) Tighten the bolts which install rear shock absorber to rear suspension arm. <Ref. to RS-11,
INSTALLATION, Rear Arm.>
3) Install the two-way valve to bracket, and connect

the two-way valve hose (A) to two-way valve.
Tightening torque:
62 Nm (6.3 kgf-m, 46 ft-lb)
(A)
FU-01135
FU-01132
4) Tighten the bolts of fuel tank band.
6) Tighten the bolts which install parking brake cable clamp.
Tightening torque:
33 Nm (3.4 kgf-m, 25 ft-lb)
5) Install the rear suspension assembly.
CAUTION:
(2) Support the rear suspension assembly, and
then tighten the bolts which secure rear suspension assembly to body.
FU(H4SO 2.0)-42
Fuel Tank
Tightening torque:
33 Nm (3.4 kgf-m, 25 ft-lb)
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
FU-01130
Tightening torque:
32 Nm (3.3 kgf-m, 23.9 ft-lb)
FU-01128
15) Install the rear wheels.

17) Connect the connector (A) to fuel sub level sensor.
18) Connect the quick connector to the fuel delivery
(B) and return hose (C).
<Ref. to FU(H4SO 2.0)-54, INSTALLATION, Fuel
Delivery, Return and Evaporation Lines.>
NOTE:
Be careful not to misconnect the delivery side and
return side.
FU-01131
7) Connect the connector to ABS wheel speed sensor.

(A)
(C)
(B)
FU-01127
19) Install the service hole cover of fuel sub level

sensor.
FU-01129
8) Install the heat shield cover.

9) Install the propeller shaft. <Ref. to DS-11, INSTALLATION, Propeller Shaft.>
10) Install the rear exhaust pipe.
<Ref. to EX(H4SO 2.0)-11, INSTALLATION, Rear
Exhaust Pipe.>
12) Connect the parking brake cable to parking
brake assembly. <Ref. to PB-8, INSTALLATION,
Parking Brake Assembly (Rear Disc Brake).>
13) Install the rear brake caliper.
14) Tighten the bolt which secures rear brake hose
installation bracket.
(A)
(A)
(B)
(A) Bolt
(B) Grommet
FU(H4SO 2.0)-43
FU-01126
Fuel Tank
20) Connect the connector to fuel pump.
FU-01125
21) Install the service hole cover of fuel pump.
(A)
(A)
(B)
FU-01124
(A) Bolt
(B) Grommet
22) Install the rear seat.

C: INSPECTION
1) Check that the fuel tank is not holed, cracked, or
otherwise damaged.
2) Make sure that the fuel hoses and fuel pipes are
not cracked and those connections are tight.
FU(H4SO 2.0)-44
Fuel Filler Pipe

21.Fuel Filler Pipe

fuel tank.
A: REMOVAL
WARNING:
FU-01123

NOTE:
Use a new gasket.
IN-00203
2) Open the fuel filler flap lid, and remove the filler
cap.
3) Remove the screws which secure the packing.
Tightening torque:
26 Nm (2.65 kgf-m, 19.2 ft-lb)
8) Remove the mud guard. <Ref. to EI-29, REMOVAL, Mud Guard.>
9) Remove the rear sub frame. <Ref. to RS-23, REMOVAL, Rear Sub Frame.>
10) Remove the bolts which hold fuel filler pipe
bracket on the body.
FU-00095

5) Remove the rear wheel RH.
FU-01139

(A)
(B)
FU-00096
FU-01136
12) Remove the fuel filler pipe to under side of the

vehicle.
FU(H4SO 2.0)-45
Fuel Filler Pipe

B: INSTALLATION
1) Open the fuel filler flap lid.
2) Set the fuel saucer (A) with rubber packing (C)
and insert the fuel filler pipe into hole from the inner
side of apron.
3) Align the holes in fuel filler pipe neck and set the
cup (B), and tighten the screws.
5) Tighten the bolts which hold fuel filler pipe bracket on the body.
Tightening torque:
7.5 Nm (0.75 kgf-m, 5.4 ft-lb)
NOTE:
If the edges of rubber packing are folded toward the
inside, straighten it with a flat tip screwdriver.
(A)
FU-01139
6) Install the rear sub frame. <Ref. to RS-23, INSTALLATION, Rear Sub Frame.>
7) Install the mud guard. <Ref. to EI-29, INSTALLATION, Mud Guard.>
8) Install the rear wheel RH.
(B)
(C)
FU-00103

clamp.
(A)
(B)
FU-00096

FU-01136
(2)
(1)
(3)
L/2
IN-00203
FU-00104
(1) Hose
(2) Clip or clamp
(3) Pipe
FU(H4SO 2.0)-46
Fuel Pump
22.Fuel Pump
7) Remove the nuts which install fuel pump assembly onto fuel tank.
A: REMOVAL
WARNING:
Reduce the fuel in the fuel tank to less than
3/4 beforehand. Be careful that fuel may spill
when the fuel is more than 3/4.
NOTE:
Fuel pump assembly consists of fuel pump and fuel
level sensor.
2) Drain fuel. <Ref. to FU(H4SO 2.0)-38, DRAINING FUEL, PROCEDURE, Fuel.>
4) Remove the service hole cover.
(A)
(B)
(C)
(A)
FU-01140
(A) Delivery hose

(B) Return hose
(C) Jet pump hose
8) Take off the fuel pump assembly from fuel tank.
B: INSTALLATION
NOTE:
Use a new gasket.
(1) Ensure the sealing portion is free from fuel or
foreign particles before installation.
(2) Tighten the nuts to specified torque in the order
Tightening torque:
4.4 Nm (0.45 kgf-m, 3.3 ft-lb)
(A)
1
(B)
FU-01124

5
7
2
FU-01141
C: INSPECTION
FU-01125
6) Disconnect the quick connector and then disconnect the fuel delivery hose, return hose and jet
pump hose. <Ref. to FU(H4SO 2.0)-53, REMOVAL, Fuel Delivery, Return and Evaporation Lines.>
Connect the lead harness to the connector terminal

of fuel pump and apply the battery power supply to
check whether the pump operates.
WARNING:
Wipe off the fuel completely.
Keep battery as far apart from fuel pump as
possible.
Be sure to turn the battery supply to ON and
OFF on the battery side.
FU(H4SO 2.0)-47
Fuel Pump
Do not run fuel pump for a long time under

non-load condition.
2 1
4 3
6 5
FU-01330
FU(H4SO 2.0)-48
Fuel Level Sensor

23.Fuel Level Sensor

A: REMOVAL
WARNING:
NOTE:
Fuel level sensor is built in fuel pump assembly.
1) Remove the fuel pump assembly. <Ref. to
FU(H4SO 2.0)-47, REMOVAL, Fuel Pump.>
2) Disconnect the connector from fuel pump bracket.
FU-01142
3) Remove the fuel level sensor.
B: INSTALLATION
FU(H4SO 2.0)-49
Fuel Sub Level Sensor

24.Fuel Sub Level Sensor
6) Remove the bolts which install the fuel sub level

sensor on fuel tank.
A: REMOVAL
WARNING:
(C)
(A)
(B)
FU-01144
(A) Jet pump hose

(B) Delivery hose
(C) Return hose
7) Remove the fuel sub level sensor.
B: INSTALLATION
(A)

(A)
(B)
FU-01126
4) Disconnect the connector from fuel sub level

sensor.
NOTE:
Use a new gasket.
(2) Tighten the nuts and bolts to specified torque in
the order as shown in the figure.
Tightening torque:
4.4 Nm (0.45 kgf-m, 3.3 ft-lb)
3
1
5
6
2
4
FU-01143
FU-01145
FU-01146
FU(H4SO 2.0)-50
Fuel Filter
25.Fuel Filter
A: SPECIFICATION
Fuel filter forms a unit with fuel pump.
Refer to Fuel Pump for removal and installation.
<Ref. to FU(H4SO 2.0)-47, REMOVAL, Fuel
Pump.>
Pump.>
FU(H4SO 2.0)-51
Fuel Damper Valve

26.Fuel Damper Valve

A: REMOVAL
1. DELIVERY SIDE
2) Remove the fuel damper valve from fuel delivery
line.
FU-01147
2. RETURN SIDE
Fuel damper valve forms a unit with fuel injector
pipe RH.
Refer to Intake Manifold for removal. <Ref. to
FU(H4SO 2.0)-14, DISASSEMBLY, Intake Manifold.>
B: INSTALLATION
1. DELIVERY SIDE
Tightening torque:
1.25 Nm (0.13 kgf-m, 0.94 ft-lb)
2. RETURN SIDE
pipe RH.
Refer to Intake Manifold for installation. <Ref. to
FU(H4SO 2.0)-16, ASSEMBLY, Intake Manifold.>
FU(H4SO 2.0)-52
Fuel Delivery, Return and Evaporation Lines

27.Fuel Delivery, Return and Evaporation Lines

A: REMOVAL
2) Release the fuel pressure. <Ref. to FU(H4SO 2.0)-38, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.>
3) Open the fuel filler flap lid, and remove the fuel filler cap.
4) Remove the floor mat. <Ref. to EI-73, REMOVAL, Floor Mat.>
5) Disconnect the fuel delivery pipes and hoses, and then disconnect the fuel return pipes and hoses, evaporation pipes and hoses.
FU-01148
6) In the engine compartment, disconnect the fuel

delivery hoses, return hoses and evaporation hose.
(A)
9) Separate the quick connector on fuel line.

(1) Clean the pipe and connector, if they are
covered with dust.
(2) To prevent from damaging or entering foreign matter, wrap the pipes and connectors with
plastic bag, etc.
(C)
(B)
FU-02062

(B) Return hose
FU-01333

8) Remove the fuel tank. <Ref. to FU(H4SO 2.0)39, REMOVAL, Fuel Tank.>
(3) Hold the connector (A) and push retainer (B)

down.
(4) Pull out the connector (A) from retainer (B).
FU(H4SO 2.0)-53

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 the hoses and their connections for fuel leakage.
CAUTION:
Always use a new retainer.
(B)
(C)
(A)
FU-00124
(A)
(A) Connector
(B) Retainer
(C) Pipe
(B)
(C)
FU-00127
B: INSTALLATION
1) Connect the quick connector on fuel line.
CAUTION:
Make sure that the connected portion is not
damaged or has dust. If necessary, clean the
seal surface of pipe.
(A) Connector
(B) Retainer
(C) Pipe
2) Connect the fuel delivery hose to the pipe with

an overlap of 20 to 25 mm (0.79 to 0.98 in).
Type A: When the amount of inserting is specified.
Type B: When the amount of inserting is not specified.
2: 2.51.5 mm (0.0980.059 in)
(A)
L: 22.52.5 mm (0.8860.098 in)

(B)
(1)
(2)
(3)
Type A
FU-00125
L
(A) Seal surface

(B) Pipe
Type B
(1) Set the new retainer (B) to connector (A).

(2) Push the pipe into the connector completely.
FU-00128
(1) Pipe
(2) Clamp
(3) Hose
(A)
(B)
(C)
FU-00126
3) Connect the return hose and evaporation hose

to pipe by approx. 15 mm (0.59 in) from the hose
end.
Fuel return hose:
L = 22.52.5 mm (0.8850.098 in)
Fuel evaporation hose:
L = 17.52.5 mm (0.6890.098 in)
(A) Connector
(B) Retainer
(C) Pipe
FU(H4SO 2.0)-54

CAUTION:
(2)
(1)
(3)
L/2
L
FU-00129
(1) Hose
(2) Clip
(3) Pipe
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 tightened firmly.
FU(H4SO 2.0)-55
Fuel System Trouble in General

28.Fuel System Trouble in General

A: INSPECTION
Trouble and possible cause
1. Insufficient fuel supply to injector
1)
Fuel pump does not operate.
Corrective action
Defective terminal contact.
Trouble in electromagnetic or electronic circuit parts.

2)
Decline 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 air breather tube or pipe.
7)
Damaged diaphragm of pressure regulator.
2. Leakage or blow out of 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.
3. Gasoline smell inside of compartment

Loose joints at air breather tube, air vent tube and fuel filler
1)
pipe.
2)
Defective packing air tightness on the fuel saucer.
3)
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.
Inspect contact, especially ground, and tighten it

securely.
Replace the faulty parts.
Replace the fuel pump.
Replace fuel filter, clean or replace fuel tank.
Clean, correct or replace the 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.
Retightening.
Correct or replace the packing.
Replace.
Replace.
Replace.
Replace.
NOTE:
When the vehicle is left unattended for an extended period of time, water may accumulate in the fuel tank.
Fill fuel fully to prevent those problem. And also drain the water condensation from fuel filter.
In snow-covered areas, mountainous areas, skiing areas, etc. where ambient temperatures drop below
0C (32F) throughout the winter season, use water removing agent in the fuel system to prevent freezing
fuel system and accumulating water. Fill the water removing agent at the time when the fuel reduced at half
to maintain the advantage.
When water condensation is noticed in the fuel filter, drain the water from both the fuel filter and fuel tank
or use water removing agent in the fuel tank.
Before using water removing agent, follow the cautions noted on the bottle.
FU(H4SO 2.0)-56
EMISSION CONTROL
EC(H4SO 2.0)
1.
2.
3.
4.
5.
6.
7.
8.
Page
Front Catalytic Converter ............................................................................3
Rear Catalytic Converter.............................................................................4
EGR Valve ..................................................................................................5
Canister.......................................................................................................6
Purge Control Solenoid Valve .....................................................................7
Two-way Valve............................................................................................9
PCV Valve.................................................................................................10
General Description
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)
A: CAUTION
points.
cable from battery.
EC(H4SO 2.0)-2
Front Catalytic Converter

2. Front Catalytic Converter

A: REMOVAL
The front and rear catalytic converters are integrated into center exhaust pipe as a unit; therefore, refer to Center Exhaust Pipe for removal procedure.
<Ref. to EX(H4SO 2.0)-10, REMOVAL, Center Exhaust Pipe.>
B: INSTALLATION
The front and rear catalytic converters are integrated into center exhaust pipe as a unit; therefore, refer to Center Exhaust Pipe for installation
procedure. <Ref. to EX(H4SO 2.0)-10, INSTALLATION, Center Exhaust Pipe.>
C: INSPECTION
1) Make sure there are no exhaust leaks from connections and welds.
2) Make sure there are no holes or rusting.
EC(H4SO 2.0)-3
Rear Catalytic Converter

3. Rear Catalytic Converter

A: REMOVAL
The front and rear catalytic converters are integrated into center exhaust pipe as a unit; therefore, refer to Center Exhaust Pipe for removal procedure.
<Ref. to EX(H4SO 2.0)-10, REMOVAL, Center Exhaust Pipe.>
B: INSTALLATION
The front and rear catalytic converters are integrated into center exhaust pipe as a unit; therefore, refer to Center Exhaust Pipe for installation
procedure. <Ref. to EX(H4SO 2.0)-10, INSTALLATION, Center Exhaust Pipe.>
C: INSPECTION
EC(H4SO 2.0)-4
EGR Valve
4. EGR Valve
A: SPECIFICATION
Refer to EGR Valve for removal and installation.
<Ref. to FU(H4SO 2.0)-28, EGR Valve.> or <Ref.
to FU(H4SO 2.5)-30, EGR Valve.>
EC(H4SO 2.0)-5
Canister
5. Canister
Tightening torque:
8.3 Nm (0.85 kgf-m, 6.1 ft-lb)
A: REMOVAL
2) Remove the rear wheel LH.
3) Remove the mud guard LH.
4) Remove the protector. (Sedan model)
5) Disconnect the quick connector (A).
6) Remove the canister (B) from body.
(B)
(B)
(A)
(A)
(B)
(B)
EC-02027
C: INSPECTION
Make sure the canister and canister hoses are not
cracked or loose.
EC-02027
B: INSTALLATION
NOTE:
Make sure there are no damage or dust on the connection of quick connector. If necessary, clean the
EC(H4SO 2.0)-6
Purge Control Solenoid Valve

6. Purge Control Solenoid Valve
B: INSTALLATION
A: REMOVAL
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
2.0 L model
IN-00203
2) Disconnect the connector and hoses of purge

control solenoid valve, and then remove the purge
control solenoid valve.
2.0 L model
EC-02015
2.5 L model
EC-00223
EC-02015
2.5 L model
NOTE:
Connect the evaporation hose as shown in the figure.
2.0 L model
(B)
EC-00223
(A)
EC-02016
EC(H4SO 2.0)-7

2.5 L model
(B)
(A)
EC-00224
(A) To fuel pipe (Evaporation line)

(B) To intake manifold
C: INSPECTION
Make sure the hoses are not cracked or loose.
EC(H4SO 2.0)-8
Two-way Valve
7. Two-way Valve
A: REMOVAL
2) Disconnect the evaporation hoses from two-way
valve.
3) Remove the two-way valve as a unit with bracket
from body.
EC-00221
4) Remove the two-way valve from bracket.
B: INSTALLATION
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
C: INSPECTION
EC(H4SO 2.0)-9
PCV Valve
8. PCV Valve
A: REMOVAL
Disconnect the PCV hose and remove the PCV
valve.
2.0 L model
EC-02029
2.5 L model
EC-00225
B: INSTALLATION
NOTE:
Apply liquid gasket to the bolt threads of PCV
valve. (2.0 L model)
Liquid gasket:
Tightening torque:
23 Nm (2.3 kgf-m, 17 ft-lb)
EC(H4SO 2.0)-10
INTAKE (INDUCTION)
IN(H4SO 2.0)
1.
2.
3.
4.
5.
6.
Page
Air Cleaner Element ....................................................................................5
Air Cleaner Case.........................................................................................6
Air Intake Chamber .....................................................................................8
Air Intake Duct.............................................................................................9
Resonator Chamber..................................................................................10
General Description
INTAKE (INDUCTION)
A: COMPONENT
T2
(15)
(14)
(14)
(13)
(11)
T2
(13)
(12)
(10)
T4
(22)
T4
(16)
(23)
(19)
T3
(18)
T3
T4
T3
(17)
T6
(9)
(9)
(21)
(8)
(7)
T5
(4)
(20)
(3)
T1
(2)
(6)
(6)
(1)
(5)
(5)
IN-02004
IN(H4SO 2.0)-2
General Description
INTAKE (INDUCTION)
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
Air intake duct

Clip
Resonator chamber
Air cleaner case (front)
Spacer
Cushion
Air cleaner element
Air cleaner case (rear)
Clip
Clamp
Intake duct
Clamp
Cushion
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
Spacer
Air intake chamber
Stay LH (MT model)
Stay LH (AT model)
Clamp
Stay RH
Cushion
Mass air flow and intake air temperature sensor (2.5 L EC, EK, K4
model)
(22)
Bushing (Except for 2.5 L EC, EK,

K4 model)
IN(H4SO 2.0)-3
(23)
Intake air temperature sensor

(Except for 2.5 L EC, EK, K4
model)

T1: 6.0 (0.6, 4.4)
T2: 6.5 (0.66, 4.8)
T3: 16 (1.6, 11.6)
T4: 3.0 (0.3, 2.2)
T5: 7.5 (0.76, 5.5)
T6: 1.0 (0.10, 0.7)
General Description
INTAKE (INDUCTION)
B: CAUTION
goggles, and protective shoes during operation.
points.
cable from battery.
IN(H4SO 2.0)-4
Air Cleaner Element

INTAKE (INDUCTION)
B: INSTALLATION
A: REMOVAL
NOTE:
Fasten the air cleaner case (rear) with a clip after
inserting the lower tab of the case.
IN-00203
2) Disconnect the connector from mass air flow and

intake air temperature sensor. (2.5 L EC, EK, K4
model)
IN-00207
C: INSPECTION
Replace if excessively damaged or dirty.
IN-00204
3) Remove the clip (A) from upper side of air cleaner case.
(A)
IN-00254
4) Pull the air cleaner case (rear) to rearward of the

vehicle, and then remove the air cleaner element.
NOTE:
Be careful that the power steering hose is secured
to the under side of air cleaner case (rear).
IN(H4SO 2.0)-5
Air Cleaner Case

INTAKE (INDUCTION)
3. Air Cleaner Case
6) Remove the air cleaner case (rear) and air

cleaner element.
A: REMOVAL
IN-00206
IN-00203
7) Remove the bolt (A) and nut (B) which hold the
air cleaner case on body.

intake air temperature sensor. (2.5 L EC, EK, K4
model)
(B)
(A)
IN-00208
8) Remove the air cleaner case (front).
IN-00204
4) Loosen the clamp (A) which connects the air

cleaner case to intake duct.
5) Remove the clip (B) from upper side of air cleaner case.
(B)
(A)
IN-00205
IN(H4SO 2.0)-6
Air Cleaner Case

INTAKE (INDUCTION)
B: INSTALLATION
Tightening torque:
Bolt (A): 6.0 Nm (0.6 kgf-m, 4.4 ft-lb)
Nut (B): 7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
(B)
(A)
IN-00208
NOTE:
Fasten with a clip after inserting the lower tab of the
case.
IN-00207
C: INSPECTION
Check for cracks or loose connection.
IN(H4SO 2.0)-7
Air Intake Chamber

INTAKE (INDUCTION)
4. Air Intake Chamber
B: INSTALLATION
A: REMOVAL

(Except for EC, EK, K4 model)
Tightening torque:
Clamp (A), (B)
3.0 Nm (0.3 kgf-m, 2.2 ft-lb)
Bolt (C)
6.5 Nm (0.66 kgf-m, 4.8 ft-lb)
(C)
(B)
(C)
(A)
IN-00203
2) Disconnect the connector from intake air temperature sensor. (Except for EC, EK, K4 model)
IN-02005
C: INSPECTION
1) Check for cracks or loose connections.
2) Inspect that no foreign objects in the air intake
chamber.
FU-02080
3) Loosen the clamp (A) which connects the air intake chamber to throttle body.
4) Loosen the clamp (B) which connects the intake
duct to air intake chamber.
5) Remove the bolt (C) which secures the air intake
chamber to the stay.
(C)
(B)
(C)
(A)
IN-02005
6) Disconnect the three parts of blow-by hose, and

remove the air intake chamber.
IN(H4SO 2.0)-8
Air Intake Duct

INTAKE (INDUCTION)
5. Air Intake Duct

A: REMOVAL
1) Remove the clips which install the air intake duct
on the front side of body.
2) Remove the air intake duct.
IN-00210
B: INSTALLATION
C: INSPECTION
duct.
IN(H4SO 2.0)-9
Resonator Chamber
INTAKE (INDUCTION)
6. Resonator Chamber
A: REMOVAL
Refer to Air Cleaner Case for removal procedure
because the resonator chamber forms a single unit
with air cleaner case. <Ref. to IN(H4SO 2.0)-6, REMOVAL, Air Cleaner Case.>
B: INSTALLATION
Refer to Air Cleaner Case for installation procedure because the resonator chamber forms a single unit with air cleaner case. <Ref. to IN(H4SO
2.0)-7, INSTALLATION, Air Cleaner Case.>
C: INSPECTION
Check for cracks or loose connections.
IN(H4SO 2.0)-10
MECHANICAL
ME(H4SO 2.0)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
Page
Compression .............................................................................................22
Idle Speed .................................................................................................23
Ignition Timing...........................................................................................24
Intake Manifold Vacuum............................................................................25
Engine Oil Pressure ..................................................................................26
Fuel Pressure............................................................................................27
Valve Clearance........................................................................................28
Engine Assembly ......................................................................................30
Engine Mounting .......................................................................................36
Preparation for Overhaul...........................................................................37
V-belt.........................................................................................................38
Crank Pulley..............................................................................................40
Timing Belt Cover......................................................................................42
Timing Belt ................................................................................................43
Cam Sprocket ...........................................................................................48
Crank Sprocket .........................................................................................50
Valve Rocker Assembly ............................................................................51
Camshaft...................................................................................................53
Cylinder Head ...........................................................................................57
Cylinder Block ...........................................................................................63
Engine Trouble in General ........................................................................83
Engine Noise.............................................................................................88
General Description
MECHANICAL
A: SPECIFICATION
Model
Cylinder arrangement
Valve system mechanism
Bore Stroke
mm (in)
Displacement
cm3 (cu in)
Compression ratio
Compression pressure (at 350 rpm)
Engine
2.0 L
2.5 L
Horizontally opposed, liquid cooled, 4-cylinder,
4-stroke gasoline engine
Belt driven, single over-head camshaft, 4-valve/
cylinder
99.5 79.0
92 75 (3.62 2.95)
(3.917 3.110)
1,994 (121.67)
2,457 (150)
10.0
kPa (kg/cm2,
psi)
Number of piston rings

Open
Intake valve timing
Close
Open
Exhaust valve timing
Close
Intake
Valve clearance
mm (in)
Exhaust
Idle speed [at neutral position on MT, or P or
rpm
N range on AT]
Ignition order
Ignition timing
BTDC/rpm
1,020 1,275 (10.4 13.0, 148 185)

Pressure ring: 2, Oil ring: 1
BTDC 2
BTDC 2
ABDC 54
ABDC 56
BBDC 39
BBDC 50
ATDC 5
ATDC 8
0.200.04 (0.00790.0016)
0.250.04 (0.00980.0016)
650100 (No load)
800100 (A/C ON)
1324
1310/650
NOTE:
US: undersize OS: oversize
Belt tension
adjuster
Belt tensioner
Valve rocker
arm
Camshaft
Cylinder
Head
Protrusion of adjuster rod
mm (in)
5.2 6.2 (0.205 0.244)
Spacer O.D.
Tensioner bushing I.D.
Clearance between spacer
and bushing
Side clearance of spacer
Clearance between shaft and
arm
Bend limit
Side clearance
mm (in)
mm (in)
17.955 17.975 (0.7069 0.7077)

18.00 18.08 (0.7087 0.7118)
mm (in) Standard
0.025 0.125 (0.0010 0.0049)
mm (in) Standard
0.20 0.55 (0.0079 0.0217)
mm (in) Standard
0.020 0.054 (0.0008 0.0021)
mm (in)
mm (in) Standard
Intake
Standard
2.0 L
Exhaust
Standard
Cam lobe height
mm (in)
Intake
Standard
2.5 L
Exhaust
Standard
Camshaft journal O.D.
mm (in)
Camshaft journal hole I.D.
mm (in)
Oil clearance
mm (in) Standard
Surface warpage limit (mating with cylinder
mm (in)
block)
Grinding limit
mm (in)
Standard height
mm (in)
ME(H4SO 2.0)-2
0.020 (0.00079)
0.030 0.090 (0.0012 0.0035)
39.646 39.746 (1.5609 1.5648)
39.351 39.451 (1.5493 1.5532)
39.485 39.585 (1.5545 1.5585)
39.904 40.004 (1.5710 1.5750)
31.928 31.945 (1.2570 1.2577)
32.000 32.018 (1.2598 1.2605)
0.055 0.090 (0.0022 0.0035)
0.03 (0.001)
0.1 (0.004)
97.5 (3.84)
General Description
MECHANICAL
Refacing angle
Valve seat
Valve guide
Valve
Valve
springs
Cylinder
block
Piston
Piston pin
Piston Ring
90
Standard
0.8 1.4 (0.03 0.055)
Contacting width
Standard
1.2 1.8 (0.047 0.071)
Inside diameter
mm (in)
6.000 6.012 (0.2362 0.2367)
Intake
20.0 21.0 (0.787 0.827)
Protrusion above head
mm (in)
Exhaust
16.5 17.5 (0.650 0.689)
Intake
Standard
0.8 1.2 (0.03 0.047)
Head edge thickmm (in)
ness
Exhaust
Standard
1.0 1.4 (0.039 0.055)
Intake
5.950 5.965 (0.2343 0.2348)
Stem outer diameters
mm (in)
Exhaust
5.945 5.960 (0.2341 0.2346)
Intake
0.035 0.062 (0.0014 0.0024)
Valve stem gap
mm (in) Standard
Exhaust
0.040 0.067 (0.0016 0.0026)
Intake
120.6 (4.75)
Overall length
mm (in)
Exhaust
121.7 (4.79)
Free length
mm (in)
54.30 (2.1378)
Squareness
2.5, 2.4 mm (0.094 in)
Set
214 246 (22 25, 48 55)/ 45.0 (1.772)
Tension/spring
N (kgf, lb)/mm (in)
height
Lift
526 582 (54 59, 119 130)/ 34.7 (1.366)
Surface warpage limit (mating with cylinder
mm (in)
0.025 (0.00098)
head)
Grinding limit
mm (in)
0.1 (0.004)
Standard height
mm (in)
201.0 (7.91)
A
92.005 92.015 (3.6222 3.6226)
2.0 L
Standard
B
91.995 92.005 (3.6218 3.6222)
Cylinder inner
diameter
mm (in)
A
99.505 99.515 (3.9175 3.9179)
2.5 L
Standard
B
99.495 99.505 (3.9171 3.9175)
Taper
mm (in) Standard
0.015 (0.0006)
Out-of-roundness
mm (in) Standard
0.010 (0.0004)
Piston clearance
mm (in) Standard
0.010 0.010 (0.00039 0.00039)
Boring limit
mm (in)
0.5 (0.020)
A
92.005 92.015 (3.6222 3.6226)
Standard
B
91.995 92.005 (3.6219 3.6222)
2.0 L
0.25 (0.0098) OS
92.245 92.265 (3.6317 3.6325)
0.50 (0.0197) OS
92.495 92.515 (3.6415 3.6423)
Outer diameter
mm (in)
A
99.505 99.515 (3.9175 3.9179)
Standard
B
99.495 99.505 (3.9171 3.9175)
2.5 L
0.25 (0.0098) OS
99.745 99.765 (3.9270 3.9278)
0.50 (0.0197) OS
99.995 100.015 (3.9368 3.9376)
Piston pin standard diameter
mm (in)
23.000 23.006 (0.9055 0.9057)
Outer diameter
mm (in)
22.994 23.000 (0.9053 0.9055)
Standard clearance between piston and piston
mm (in)
0.004 0.008 (0.0002 0.0003)
pin
Piston pin must be fitted into position with thumb
Degree of fit
at 20C (68F).
Top ring
Standard
0.20 0.35 (0.0079 0.0138)
0.40 0.50 (0.0157 0.0197)
Second 2.0 L Standard
Ring closed gap
mm (in)
ring
2.5 L Standard
0.35 0.50 (0.0138 0.0197)
Oil ring
Standard
0.20 0.50 (0.0079 0.0197)
Top ring
Standard
0.040 0.080 (0.0016 0.0031)
Ring groove gap
mm (in)
Second ring
Standard
0.030 0.070 (0.0012 0.0028)
Intake
mm (in)
Exhaust
ME(H4SO 2.0)-3
General Description
MECHANICAL
Connecting
Rod
Bearing of
large end
Bush of
small end
Crankshaft
Main bearing
Bend twist per 100

mm (3.94 in) in
length
Side clearance of
large end
Oil clearance
Bearing size
(Thickness at center)
Clearance between
piston pin and
bushing
Bend limit
mm (in) Limit
0.10 (0.0039)
mm (in) Standard
0.070 0.330 (0.0028 0.0130)
mm (in) Standard
Standard
0.03 (0.0012) US
mm (in)
0.05 (0.0020) US
0.25 (0.0098) US
0.016 0.044 (0.00063 0.0017)

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)
mm (in) Standard
0 0.022 (0 0.0009)
mm (in)
Out-of-roundness 2.0 L
mm (in) 2.5 L
Crank pin
2.0 L
Cylindricality
mm (in) 2.5 L
Grinding limit (dia.)
Out-of-roundness
Crank journal
Cylindricality
Standard
0.03 (0.0012) US
Crank pin outer
mm (in)
diameter
0.05 (0.0020) US
0.25 (0.0098) US
Standard
0.03 (0.0012) US
Crank journal outer
mm (in)
diameter
0.05 (0.0020) US
0.25 (0.0098) US
Side clearance
mm (in) Standard
Oil clearance
mm (in) Standard
Standard
0.03 (0.0012) US
#1, #3
0.05 (0.0020) US
0.25 (0.0098) US
Main bearing
mm (in)
Standard
#2, #4, 0.03 (0.0012) US
#5
0.05 (0.0020) US
0.25 (0.0098) US
mm (in)
mm (in)
mm (in)
mm (in)
ME(H4SO 2.0)-4
0.035 (0.0014)
0.005 (0.0002)
0.003 (0.0001)
0.006 (0.0002)
0.004 (0.0002)
To 51.750 (2.0374)
0.005 (0.0002)
0.006 (0.0002)
To 59.750 (2.3524)
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)
59.992 60.008 (2.3619 2.3625)
59.962 59.978 (2.3607 2.3613)
59.942 59.958 (2.3599 2.3605)
59.742 59.758 (2.3520 2.3527)
0.030 0.115 (0.0012 0.0045)
0.010 0.030 (0.0001 0.0012)
1.998 2.011 (0.0787 0.0792)
2.017 2.020 (0.0794 0.0795)
2.027 2.030 (0.0798 0.0799)
2.127 2.130 (0.0837 0.0839)
2.000 2.013 (0.0787 0.0793)
2.019 2.022 (0.0795 0.0796)
2.029 2.032 (0.0799 0.0800)
2.129 2.132 (0.0838 0.0839)
General Description
MECHANICAL
B: COMPONENT
1. TIMING BELT
(5)
T1
(1)
(2)
T2
(3)
T5
(6)
(4)
T4
(7)
(8)
(12)
T3
T1
(9)
T4
T1
T4
(10)
(13)
(11)
(15)
T5
(14)
T6
(16)
T1
T6
ME-00376
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Timing belt cover No. 2 (RH)

Timing belt guide (MT model)
Crankshaft sprocket
Timing belt cover No. 2 (LH)
Camshaft sprocket No. 1
Belt idler (No. 1)
Tensioner bracket
Belt idler (No. 2)
Automatic belt tension adjuster
ASSY
(10)
(11)
(12)
(13)
(14)
(15)
(16)
Belt idler No. 2

Camshaft sprocket No. 2
Timing belt
Front timing belt cover
Timing belt cover (LH)
Crank pulley (2.0 L model)
Crank pulley (2.5 L model)
ME(H4SO 2.0)-5

T1: 5 (0.5, 3.6)
T2: 10 (1.0, 7.2)
T3: 25 (2.5, 18.1)
T4: 39 (4.0, 28.9)
T5: 78 (8.0, 57.9)
T6: <Ref. to ME(H4SO 2.0)-40,
INSTALLATION, Crank Pulley.>
General Description
MECHANICAL
2. CYLINDER HEAD AND CAMSHAFT

(1)
(2)
T3
T2
(4)
T4
(6)
(7)
T5
(8)
(3)
(9)
T3
(10)
T1
(8)
(5)
(19)
(8)
(14)
(15)
T1
(7)
(16)
(13)
T6
T4
(2)
(10)
(11)
(17)
(18)
(19)
(12)
T3
(5)
T5
T3
T4
T2
(3)
T5
(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 duct
O-ring
Rocker cover (LH)
Stud bolt
ME(H4SO 2.0)-6
ME-00186

T1: <Ref. to ME(H4SO 2.0)-57,
INSTALLATION, Cylinder
Head.>
T2:
T3:
T4:
T5:
T6:
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)
General Description
MECHANICAL
3. VALVE ROCKER ASSEMBLY
(2)
(1)
(4)
(3)
(5)
(4)
(2)
T2
(1)
T1
(6)
(1)
(3)
(2)
(4)
T3
(5)
(4)
(2)
(3)
(8)
(1)
(2)
T1
(3)
(2)
T2
(7)
T2
T2
(3)
(3)
T3
ME-00187
(1)
(2)
(3)
(4)
Intake valve rocker arm

Valve rocker nut
Valve rocker adjust screw
Spring
(5)
(6)
(7)
(8)
Rocker shaft support

Intake rocker shaft
Exhaust rocker shaft
Exhaust valve rocker arm
ME(H4SO 2.0)-7

T1: 5 (0.5, 3.6)
T2: 10 (1.0, 7.2)
T3: 25 (2.5, 18.1)
General Description
MECHANICAL
4. CYLINDER HEAD AND VALVE ASSEMBLY
(1)
(1)
(3)
(4)
(5)
(6)
(7)
(8)
(2)
(2)
(3)
(4)
(9)
(6)
(7)
(8)
ME-00760
(1)
(2)
(3)
Exhaust valve
Intake valve
Valve guide
(4)
(5)
(6)
Valve spring seat

Intake valve oil seal
Valve spring
ME(H4SO 2.0)-8
(7)
(8)
(9)
Retainer
Retainer key
Exhaust valve oil seal
General Description
MECHANICAL
5. CYLINDER BLOCK
T2
T2
T8
T4
(7)
(1)
(5)
T5
(2)
(6)
(3)
(4)
T2
T4
T6
(10)
(8)
(11)
(9)
T2
(10)
(4)
T2
(3)
T4
(14)
(15)
T6
(10)
T10
(10)
(26)
(4)
T6
(17)
(16)
(23)
(3)
(12)
(22)
T2
(18)
T3
T5
T2
T4
(24)
(21)
T7
(13)
(20)
(25)
T1
T9
(19)
ME-00810
(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)
(26)
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
Seal
ME(H4SO 2.0)-9

T1: 5 (0.5, 3.6)
T2: 6.4 (0.65, 4.7)
T3: 10 (1.0, 7.2)
T4: 25 (2.5, 18.1)
T5: <Ref. to ME(H4SO 2.0)-67,
Block.>
T6: 70 (7.1, 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: 45 (4.6, 33.3)
General Description
MECHANICAL
6. CRANKSHAFT AND PISTON
(1)
T2
(4)
(5)
(6)
(9)
(8)
(10)
(11)
(3)
T2
(12)
(9)
(7)
(14)
T1
(12)
(2)
(13)
T1
(9)
(12)
(7)
(11)
(15)
(18)
(10)
(9) (8)
(6)
(4)
(5)
(17)
(16)
(16)
(17)
ME-00190
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Flywheel (MT model)

Reinforcement (AT model)
Drive plate (AT model)
Top ring
Second ring
Oil ring
Piston
(8)
(9)
(10)
(11)
(12)
(13)
(14)
Piston pin
Snap ring
Connecting rod bolt
Connecting rod
Connecting rod bearing
Connecting rod cap
Crankshaft
ME(H4SO 2.0)-10
(15) Woodruff key

(16) Crankshaft bearing #1, #3
(17) Crankshaft bearing #2, #4
(18) Crankshaft bearing #5
T1: 45 (4.6, 33.3)
T2: 72 (7.3, 52.8)
General Description
MECHANICAL
7. ENGINE MOUNTING
2.0 L model
T2
T2
(2)
(2)
T1
(1)
(1)
T1
T3
T3
ME-00413
(1)
Front cushion rubber
(2)
Front engine mounting bracket
ME(H4SO 2.0)-11

T1: 35 (3.6, 25.8)
T2: 42 (4.3, 31.0)
T3: 85 (8.7, 63)
General Description
MECHANICAL
2.5 L model
(1)
T1
T2
T1
T2
ME-02090
(1)

T1: 35 (3.6, 25.8)
T2: 85 (8.7, 62.7)
ME(H4SO 2.0)-12
General Description
MECHANICAL
C: CAUTION
points.
cable 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 the 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 not to 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 TOOL
ILLUSTRATION
TOOL NUMBER
18231AA010
DESCRIPTION
CAM
SPROCKET
WRENCH
REMARKS
Used for removing and installing cam sprocket.
(LH side)
CAM SPROCKET WRENCH (499207100) can
also be used.
CARTRIDGE
ST18231AA010
24082AA230
ST24082AA230
ME(H4SO 2.0)-13
General Description
MECHANICAL
ILLUSTRATION
TOOL NUMBER
22771AA030
DESCRIPTION
SUBARU
SELECT MONITOR KIT
REMARKS
498267800
CYLINDER
HEAD TABLE
Used for replacing valve guides.

Used for removing and installing valve spring.
498277200
STOPPER SET
Used for installing automatic transmission assembly to engine.
498457000
ENGINE STAND
ADAPTER RH
Used with ENGINE STAND (499817100).
ST22771AA030
ST-498267800
ST-498277200
ST-498457000
ME(H4SO 2.0)-14
General Description
MECHANICAL
ILLUSTRATION
TOOL NUMBER
498457100
DESCRIPTION
ENGINE STAND
ADAPTER LH
REMARKS
498497100
CRANKSHAFT
STOPPER
Used for stopping rotation of flywheel when loosening/tightening crank pulley bolt.
398744300
PISTON GUIDE
Used for installing piston in cylinder. (2.0 L model)
498747300
PISTON GUIDE
Used for installing piston in cylinder. (2.5 L model)
ST-498457100
ST-498497100
ST-398744300
ST-498747300
ME(H4SO 2.0)-15
General Description
MECHANICAL
ILLUSTRATION
TOOL NUMBER
498857100
DESCRIPTION
VALVE OIL SEAL
GUIDE
REMARKS
Used for press-fitting of intake and exhaust valve
guide oil seals.
499017100
PISTON PIN
GUIDE
Used for installing piston pin, piston and connecting rod.
499037100
CONNECTING
ROD BUSHING
REMOVER AND
INSTALLER
Used for removing and installing connecting rod

bushing.
499587200
CRANKSHAFT
OIL SEAL
INSTALLER
Used for installing crankshaft oil seal.

Used with CRANKSHAFT OIL SEAL GUIDE
(499597100).
ST-498857100
ST-499017100
ST-499037100
ST-499587200
ME(H4SO 2.0)-16
General Description
MECHANICAL
ILLUSTRATION
TOOL NUMBER
499587500
DESCRIPTION
OIL SEAL
INSTALLER
REMARKS
Used for installing camshaft oil seal.
Used with OIL SEAL GUIDE (499597000).
499587700
CAMSHAFT OIL
SEAL
INSTALLER
Used for installing cylinder head plug.
499097700
PISTON PIN
REMOVER
ASSY
Used for removing piston pin.
499207400
CAM
SPROCKET
WRENCH
Used for removing and installing cam sprocket.

(RH side)
ST-499587500
ST-499587700
ST-499097700
ST-499207400
ME(H4SO 2.0)-17
General Description
MECHANICAL
ILLUSTRATION
TOOL NUMBER
499497000
DESCRIPTION
TORX PLUS
REMARKS
Used for removing and installing camshaft cap.
ST-499497000
499587100
OIL SEAL
INSTALLER
Used for installing oil pump oil seal.
499597000
OIL SEAL GUIDE Used for installing camshaft oil seal.

Used with CAMSHAFT OIL SEAL INSTALLER
(499587500).
499597100
CRANKSHAFT
OIL SEAL GUIDE Used with CRANKSHAFT OIL SEAL
INSTALLER (499587200).
ST-499587100
ST-499597000
ST-499597100
ME(H4SO 2.0)-18
General Description
MECHANICAL
ILLUSTRATION
TOOL NUMBER
499718000
DESCRIPTION
VALVE SPRING
REMOVER
REMARKS
499767200
VALVE GUIDE
REMOVER
Used for removing valve guides.
499767400
VALVE GUIDE
REAMER
Used for reaming valve guides.
499767700
VALVE GUIDE
ADJUSTER
Used for installing valve guides. (Intake side)
ST-499718000
ST-499767200
ST-499767400
ST-499767700
ME(H4SO 2.0)-19
General Description
MECHANICAL
ILLUSTRATION
TOOL NUMBER
499767800
DESCRIPTION
VALVE GUIDE
ADJUSTER
REMARKS
Used for installing valve guides. (Exhaust side)
499817100
ENGINE STAND
Stand used for engine disassembly and assembly.

Used with ENGINE STAND ADAPTER RH
(498457000) & LH (498457100).
499977400
CRANK PULLEY
WRENCH
Used for stopping rotation of crank pulley when

loosening/tightening crank pulley bolt. (2.0 L
model)
499977100
CRANK PULLEY
WRENCH

loosening/tightening crank pulley bolt. (2.5 L
model)
ST-499767800
ST-499817100
ST-499977400
ST-499977100
ME(H4SO 2.0)-20
General Description
MECHANICAL
ILLUSTRATION
TOOL NUMBER
18332AA000
DESCRIPTION
OIL FILTER
WRENCH
REMARKS
Used for removing and installing oil filter. (Outer
OIL FILTER
WRENCH

CRANKSHAFT
SOCKET
Used for rotating crankshaft.
ST18332AA000
18332AA010
ST18332AA010
499987500
ST-499987500
2. GENERAL TOOL
TOOL NAME
Compression gauge
Tachometer (Secondary pick-up type)
Timing light
REMARKS
Used for measuring compression.
Used for measuring idle speed.
Used for measuring ignition timing.
E: PROCEDURE
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(H4SO 2.0)-21
Compression
MECHANICAL
2. Compression
A: INSPECTION
CAUTION:
After warming-up, engine becomes very hot. Be
careful not to burn yourself during measurement.
1) After warming-up the engine, turn the ignition
switch to OFF.
2) Make sure that the battery is fully charged.
4) Remove all the spark plugs. <Ref. to IG(H4SO
2.0)-5, REMOVAL, Spark Plug.>
5) Fully open the throttle valve.
6) Check the starter motor for satisfactory performance and operation.
7) Hold the compression gauge tight against the
spark plug hole.
NOTE:
When using a screw-in type compression gauge,
the screw (put into cylinder head spark plug hole)
should be less than 18 mm (0.71 in) long.
8) Crank the engine by means of the starter motor,
and read the maximum value on the gauge when
the pointer is steady.
ME-00192
9) Perform at least two measurements per cylinder,

and make sure that the values are correct.
Compression (350 rpm and fully open throttle):
Standard:
1,020 1,275 kPa (10.4 13.0 kgf/cm2,
148 185 psi)
Difference between cylinders:
49 kPa (0.5 kgf/cm2, 7 psi) or less
ME(H4SO 2.0)-22
Idle Speed
MECHANICAL
3. Idle Speed
(2) Start the engine, and read engine idle

speed.
A: INSPECTION
1) Before checking the idle speed, check the following:
(1) Ensure the air cleaner element is free from
clogging, ignition timing is correct, spark plugs
are in good condition, and hoses are connected
properly.
(2) Ensure the malfunction indicator light does
not illuminate.
2) Idle the engine.
3) Stop the engine, and turn the ignition switch to
OFF.
4) When using Subaru Select Monitor, refer to the
following. <Ref. to ME(H4SO 2.0)-13, SPECIAL
TOOL, PREPARATION TOOL, General Description.>
(1) Insert the cartridge to the Subaru Select
Monitor.
(2) Connect the Subaru Select Monitor to data
link connector.
(1)
ME-00811
NOTE:
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 the idle speed when unloaded. (With
headlights, heater fan, rear defroster, radiator fan,
A/C, etc. OFF)
Idle speed [No load and gears in N or P
range]:
650100 rpm
7) Check the idle speed when loaded. (Turn the A/
C switch to ON and operate the compressor for at
least one minute before measurement.)
Idle speed [A/C ON and gears in N or P
range]:
800100 rpm
AT-01712
(1) Data link connector
(3) Turn the ignition switch to ON, and Subaru

select monitor switch to ON.
(4) Select {Each System Check} in the Main
Menu.
(5) Select {Engine} in the Selection Menu.
(6) Select {Current Data Display & Save} in the
Engine Control System Diagnosis.
(7) Select {Data Display} in the Data Display
Menu.
(8) Start the engine, and read engine idle
speed.
5) When using the tachometer (Secondary pick-up
type):
(1) Attach the pick-up clip to No. 1 cylinder
spark plug cord.
NOTE:
Idle speed cannot be adjusted manually, because
the idle speed is automatically adjusted. If the idle
speed is out of specifications, refer to General Diagnosis Table under Engine Control System.
<Ref. to EN(H4SO 2.0)(diag)-2, Basic Diagnostic
Procedure.>
ME(H4SO 2.0)-23
Ignition Timing
MECHANICAL
4. Ignition Timing
A: INSPECTION
CAUTION:
careful not to burn yourself at measurement.
1) Idle 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 and check the ignition timing at
the following idle speed.
Ignition timing [BTDC/rpm]:
1310/650
20
10
ME-00812
If the timing is not correct, check the ignition control

system. <Ref. to EN(H4SO 2.0)(diag)-2, Basic Diagnostic Procedure.>
ME(H4SO 2.0)-24
Intake Manifold Vacuum

MECHANICAL
5. Intake Manifold Vacuum

A: INSPECTION
1) Idle the engine.
2) Disconnect the brake vacuum hose from the intake manifold, and then install the vacuum gauge.
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.
ME-00813
Vacuum pressure (at idling, A/C OFF):

Less than 60.0 kPa (450 mmHg, 17.72 inHg)
Diagnosis of engine condition by measurement of intake manifold vacuum
Vacuum gauge indication
Possible engine condition
1. Needle is steady but lower than normal position. This tenAir leakage around intake manifold gasket, disconnection or
dency becomes more evident as engine temperature rises.
damage of vacuum hose
2. Needle intermittently drops to position lower than normal
Leakage around cylinder
position.
3. Needle drops suddenly and intermittently from normal posiValve anchoring
tion.
4. 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.
5. Needle vibrates above and below normal position in narrow
Defective ignition system
range.
ME(H4SO 2.0)-25
Engine Oil Pressure

MECHANICAL
6. Engine Oil Pressure

A: INSPECTION
IN-00203
2) Remove the generator from bracket. <Ref. to

SC(H4SO 2.0)-14, REMOVAL, Generator.>
switch.
4) Remove the pressure switch from cylinder block.
<Ref. to LU(H4SO 2.0)-17, REMOVAL, Oil Pressure Switch.>
5) Connect the oil pressure gauge hose to cylinder
block.
CAUTION:
If the oil pressure is out of specification,
check oil pump, oil filter and lubrication line.
<Ref. to LU(H4SO 2.0)-19, INSPECTION, General Diagnostic Table.>
If the oil pressure warning light is turned to
ON but oil pressure is within specification, replace the oil pressure switch. <Ref. to LU(H4SO
2.0)-19, INSPECTION, General Diagnostic Table.>
NOTE:
The specified value is based on an engine oil temperature of 80C (176F).
8) After measuring the oil pressure, install the oil
pressure switch. <Ref. to LU(H4SO 2.0)-17, INSTALLATION, Oil Pressure Switch.>
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
IN-00203
7) Start the engine, and measure oil pressure.
ME-00196
Oil pressure:
Standard
88 kPa (0.9 kg/cm2, 13 psi) or more at 800 rpm
294 kPa (3.0 kg/cm2, 43 psi) or more at 5,000
rpm
ME(H4SO 2.0)-26
Fuel Pressure
MECHANICAL
7. Fuel Pressure
A: INSPECTION
WARNING:
Before removing the fuel pressure gauge, release fuel pressure.
NOTE:
When the fuel pressure is out of specification,
check or replace the pressure regulator and pressure regulator vacuum hose.
filler cap.
3) Disconnect the fuel delivery hose from fuel
damper, and connect a fuel pressure gauge.
ME-00814

5) Start the engine.
6) Measure the 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)
7) After connecting the pressure regulator vacuum
hose, measure the fuel pressure.
Fuel pressure:
Standard: 206 235 kPa (2.1 2.4 kg/cm2,
30 34 psi)
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.
ME(H4SO 2.0)-27
Valve Clearance
MECHANICAL
8. Valve Clearance
A: INSPECTION
NOTE:
Inspection and adjustment of valve clearance
should be performed while engine is cold.
NOTE:
When the arrow mark (A) on cam sprocket (LH)
comes exactly to the top, #1 cylinder piston is
brought to the top dead center of compression
stroke.
(A)
ME-00200
10) Measure #1 cylinder valve clearance using

thickness gauge.
IN-00203
CAUTION:
Insert the thickness gauge (A) in as horizontally as possible with respect to the valve stem
end face.
Measure the exhaust valve clearances while
lifting-up the vehicle.
Valve clearance (Standard):
Intake:
0.200.04 mm (0.00790.0016 in)
Exhaust:
0.250.04 mm (0.00980.0016 in)
(A)
ME-00199
7) When inspecting #1 and #3 cylinders:

(1) Disconnect the spark plug cords from spark
plugs RH side. <Ref. to IG(H4SO 2.0)-5, RH
SIDE, REMOVAL, Spark Plug.>
(2) Disconnect the PCV hose from rocker cover
(RH).
(3) Remove the bolts, then remove the rocker
cover (RH).
(1) Disconnect the spark plug cords from spark
plugs (LH Side). <Ref. to IG(H4SO 2.0)-5, LH
SIDE, REMOVAL, Spark Plug.>
(LH).
cover (LH).
9) Set #1 cylinder piston to top dead center of compression stroke by rotating the crank pulley clockwise using the socket wrench.
ME-00201
11) If necessary, adjust the valve clearance. <Ref.

to ME(H4SO 2.0)-29, ADJUSTMENT, Valve Clearance.>
12) Measure the valve clearance in #3, #2 and #4
cylinder in the same measurement procedure as #1
cylinder.
ME(H4SO 2.0)-28
Valve Clearance
MECHANICAL
NOTE:
Be sure to set the cylinder pistons to their respective top dead centers on compression stroke
before measuring valve clearances.
By rotating the crank pulley clockwise every 180
from the state that #1 cylinder piston is on the top
dead center of compression stroke, #3, #2 and #4
cylinder pistons come to the top dead center of
compression stroke in this order.
13) After inspection, install the related parts in the
reverse order of removal.
Valve clearance
Intake:
0.200.04 mm (0.00790.0016 in)
Exhaust:
0.250.04 mm (0.00980.0016 in)
B: ADJUSTMENT
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 the crank pulley clockwise using the socket wrench.
NOTE:
When the arrow mark (A) on cam sprocket (LH)
comes exactly to the top, #1 cylinder piston is
brought to the top dead center of compression
stroke.
(A)
ME-00203
3) Adjust the valve clearance in #3, #2 and #4 cylinder in the same adjustment procedure as #1 cylinder.
NOTE:
Be sure to set the cylinder pistons to their respective top dead centers on compression stroke
before adjusting valve clearances.
By rotating the crank pulley clockwise every 180
from the state that #1 cylinder piston is on the top
dead center of compression stroke, #3, #2 and #4
cylinder pistons come to the top dead center of
compression stroke in this order.
4) Ensure the valve clearances of each cylinder are
within specifications. If necessary, readjust the
valve clearances.
ME-00200
2) Adjust the #1 cylinder valve clearance.

(1) Loosen the valve rocker nut and screw.
(2) Place a suitable thickness gauge.
(3) While noting the valve clearance, tighten the
valve rocker adjusting screw.
(4) When the specified valve clearance is obtained, tighten the valve rocker nut.
Tightening torque:
10 Nm (1.0 kgf-m, 7.2 ft-lb)
CAUTION:
Insert the thickness gauge in as horizontally
as possible with respect to the valve stem end
face.
Adjust the exhaust valve clearances while
lifting-up the vehicle.
ME(H4SO 2.0)-29
Engine Assembly
MECHANICAL
9. Engine Assembly
(1) Front oxygen (A/F) sensor connector
A: REMOVAL
2) Open the front hood fully and support with the
front food stay.
3) Collect the refrigerant from A/C system. <Ref. to
AC-20, PROCEDURE, Refrigerant Recovery Procedure.>
PRESSURE, PROCEDURE, Fuel.> or <Ref. to
FU(H4SO 2.5)-40, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.>
5) Remove the fuel filler cap.
ME-00859
(2) Rear oxygen sensor connector
FU-01116
(3) Engine ground cable

IN-00203
7) Remove the air intake duct, air cleaner case and

air intake chamber.
<Ref. to IN(H4SO 2.0)-9, REMOVAL, Air Intake
Duct.> <Ref. to IN(H4SO 2.0)-6, REMOVAL, Air
9) Remove the radiator from vehicle. <Ref. to
CO(H4SO 2.0)-20, REMOVAL, Radiator.>
10) Disconnect the A/C pressure hoses from A/C
compressor.
11) Remove the air intake chamber stay.
ME-00206
(4) Engine harness connectors
ME-00817
ME-00816
12) Disconnect the following connectors and cables.
ME(H4SO 2.0)-30
Engine Assembly
MECHANICAL
(5) Generator connector and terminal
14) Remove the power steering pump from bracket.

(1) Loosen the lock bolt and slider bolt, and remove the front side belt. <Ref. to ME(H4SO
2.0)-38, FRONT SIDE BELT, REMOVAL, Vbelt.>
(2) Remove the power steering pump bracket.
(A)
(B)
ME-00818
(A) Terminal
(B) Generator connector
(6) A/C compressor connectors

FU-00139
(3) Place the power steering pump on the right

side wheel apron.
15) Remove the front and center exhaust pipe.
<Ref. to EX(H4SO 2.0)-7, REMOVAL, Front Exhaust Pipe.>
16) Remove the nuts which hold lower side of
transmission to engine.
ME-00819
(7) Power steering switch connector
ME-00210
17) Remove the nuts which install front cushion

rubber onto front crossmember.
FU-00878
13) Disconnect the following hoses.

(1) Brake booster vacuum hose
LU-00223
ME-00820
(2) Heater inlet and outlet hoses
18) Separate the torque converter clutch from drive

plate. (AT model)
(1) Lower the vehicle.
(2) Remove the service hole plug.
(3) Remove the bolts which hold torque converter clutch to drive plate.
ME(H4SO 2.0)-31
Engine Assembly
MECHANICAL
(4) Remove other bolts while rotating the engine using a socket wrench.
22) Support the transmission with a garage jack.

CAUTION:
Doing this is very important because the
transmission lowers for its own weight. This
work is also of great importance for facilitating
reinstallation.
(A)
(B)
ME-00212
19) Remove the pitching stopper.
ME-00215
(A) Transmission
(B) Garage jack
ME-00213
20) Disconnect the fuel delivery hose (A), return

hose (B) and evaporation hose (C).
CAUTION:
Catch fuel from the hose into container.
Disconnect the hose with its end wrapped
with cloth to prevent fuel from splashing.
Before removing the engine away from transmission, check to be sure no work has been
overlooked.
23) Separation of engine and transmission.
(1) Remove the starter. <Ref. to SC(H4SO 2.0)6, REMOVAL, Starter.>
(2) Remove the bolts which hold upper side of
(A)
(C)
(B)
ME-00216
FU-01088
24) Set the ST to converter case. (AT model)

ST 498277200
STOPPER SET
21) Support the engine with a lifting device and

wire ropes.
ST
ME-00217
LU-00222
25) Remove the engine from vehicle.

(1) Slightly raise the engine.
(2) Raise the transmission with garage jack.
ME(H4SO 2.0)-32
Engine Assembly
MECHANICAL
(3) Move the engine horizontally until main

shaft is withdrawn from clutch cover.
(4) Slowly move the engine away from engine
compartment.
Tightening torque:
T1: 50 Nm (5.1 kgf-m, 36.9 ft-lb)
T2: 58 Nm (5.9 kgf-m, 42.8 ft-lb)
NOTE:
Be careful not to damage adjacent parts or body
panels with crank pulley, oil level gauge, etc.
26) Remove the front cushion rubbers.
B: INSTALLATION
1) Install the front cushion rubbers.
Tightening torque:
35 Nm (3.6 kgf-m, 25.8 ft-lb)
2) Position the engine in engine compartment and
align it with transmission.
NOTE:
LU-00222
3) Apply a small amount of grease to splines of

main shaft. (MT model)
4) Tighten the bolts which hold upper side of transmission to engine.
T2
T1
ME-00218
8) Remove the ST from converter case. (AT model)

NOTE:
Be careful not to drop the ST into the converter
case when removing the ST.
ST 498277200
STOPPER SET
9) Install the starter. <Ref. to SC(H4SO 2.0)-6, INSTALLATION, Starter.>
10) Install the torque converter clutch to drive plate.
(AT model)
(1) Tighten the bolts which hold torque converter clutch to drive plate.
(2) Tighten other bolts while rotating the engine
using a socket wrench.
CAUTION:
Be careful not to drop bolts into the torque converter clutch housing.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
ME-00212
ME-00216
5) Remove the lifting device and wire ropes.

6) Remove the garage jack.
7) Install the pitching stopper.
(3) Clog the service hole plug and prevent foreign matters from being mixed.
11) Install the power steering pump on bracket.
(1) Install the power steering pump on bracket,
and tighten the bolts.
ME(H4SO 2.0)-33
Engine Assembly
MECHANICAL
Tightening torque:
22 Nm (2.2 kgf-m, 16 ft-lb)
NOTE:
Make sure the front cushion rubber mounting bolts
are securely installed.
FU-00139
(2) Connect the power steering switch connector.
FU-00878
(3) Install the front side belt and adjust it. <Ref.
to ME(H4SO 2.0)-38, FRONT SIDE BELT, INSTALLATION, V-belt.>
13) Tighten the nuts which hold lower side of transmission to engine.
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
ME-00219
14) Tighten the nuts which install the front cushion

rubber onto crossmember.
Tightening torque:
85 Nm (8.7 kgf-m, 63 ft-lb)
LU-00223
15) Install the front and center exhaust pipe.

<Ref. to EX(H4SO 2.0)-8, INSTALLATION, Front
Exhaust Pipe.>
17) Connect the following hoses:
(1) Fuel delivery hose, return hose and evaporation hose
18) Connect the following connectors:
(1) Front oxygen (A/F) sensor connector
(2) Rear oxygen sensor connector
(3) Engine ground cable
Tightening torque:
14 Nm (1.4 kgf-m, 10.1 ft-lb)
(6) A/C compressor connector
19) Install the air intake chamber stay.
Tightening torque:
16 Nm (1.6 kgf-m, 11.6 ft-lb)
20) Install the A/C pressure hoses.
<Ref. to AC-38, INSTALLATION, Hose and Tube.>
21) Install the radiator to vehicle. <Ref. to
CO(H4SO 2.0)-21, INSTALLATION, Radiator.>
22) Install the air intake duct, air cleaner case and
air intake chamber. <Ref. to IN(H4SO 2.0)-9, INSTALLATION, Air Intake Duct.> <Ref. to IN(H4SO
2.0)-7, INSTALLATION, Air Cleaner Case.> <Ref.
to IN(H4SO 2.0)-8, INSTALLATION, Air Intake
Chamber.>
24) Install the battery in the vehicle, and connect
cables.
25) Fill engine coolant.
<Ref. to CO(H4SO 2.0)-13, FILLING OF ENGINE
COOLANT, REPLACEMENT, Engine Coolant.>
ME(H4SO 2.0)-34
Engine Assembly
MECHANICAL
26) Check the ATF level and replenish it if necessary.

<Ref. to 4AT-31, INSPECTION, Automatic Transmission Fluid.>
27) Charge the A/C system with refrigerant. <Ref.
to AC-21, PROCEDURE, Refrigerant Charging
Procedure.>
28) Remove the front hood stay, and close the front
hood.
29) Take off the vehicle from a lift.
C: INSPECTION
1) Check pipes and hoses are installed firmly.
2) Check that the engine coolant and ATF are at
specified levels.
ME(H4SO 2.0)-35
Engine Mounting
MECHANICAL
10.Engine Mounting
A: REMOVAL
1) Remove the engine assembly. <Ref. to
ME(H4SO 2.0)-30, REMOVAL, Engine Assembly.>
2) Remove the engine mounting from engine assembly.
B: INSTALLATION
Tightening torque:
Engine mounting;
35 Nm (3.6 kgf-m, 25.8 ft-lb)
C: INSPECTION
Make sure that no crack or other damages do not
exist.
ME(H4SO 2.0)-36
Preparation for Overhaul

MECHANICAL
11.Preparation for Overhaul

A: PROCEDURE
1) After removing the engine from the body, secure
it in the ST shown below.
ST1 498457000 ENGINE STAND ADAPTER
RH
LH
ST3 499817100 ENGINE STAND
ST3
ST2
ST1
ME-00221
2) In this section the procedures described under

each index are all connected and stated in order.
The procedure for overhauling of the engine will be
completed when you go 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(H4SO 2.0)-37
V-belt
MECHANICAL
12.V-belt
4) Remove the belt tensioner.
A: REMOVAL
NOTE:
Perform the following procedures with the engine
installed to the body.
1. FRONT SIDE BELT

ME-00225
B: INSTALLATION
NOTE:
Wipe off any oil or water on the belt and pulley.
1. FRONT SIDE BELT

ME-00222

(C)
1) Install a V belt (C), and tighten the slider bolt so

as to obtain the specified belt tension. <Ref. to
ME(H4SO 2.0)-39, INSPECTION, V-belt.>
Tightening torque:
Lock bolt (A):
25 Nm (2.5 kgf-m, 18.1 ft-lb)
(B)
(C)
(A)
(B)
ME-00223
2. REAR SIDE BELT

(A)

ME-00223
2. REAR SIDE BELT

1) Install the belt tensioner.
2) Install a V belt, and tighten the slider bolt (B) so
<Ref. to ME(H4SO 2.0)-39, INSPECTION, V-belt.>
(B)
(A)
ME-00224
3) Remove the rear side belt.
ME(H4SO 2.0)-38
V-belt
MECHANICAL
Belt tension (without belt tension gauge)
Tightening torque:
Lock nut (A);
23 Nm (2.3 kgf-m, 17.0 ft-lb)
(A)
When installing new parts:
7 9 mm (0.276 0.354 in)
At inspection:
9 11 mm (0.354 0.433 in)
(B)
(B)
7.5 8.5 mm (0.295 0.335 in)
At inspection:
9.0 10.0 mm (0.354 0.394 in)
(A)
98 N (10 kg, 22 Ib)
ME-00224
C: INSPECTION
P/S
1) Replace the belts, if cracks, fraying or wear is

found.
2) Remove the V-belt cover and reservoir tank.
(with belt tension gauge)
or idler pulley installing position.
GEN
(A) (B)
A/C
I/P
C/P
ME-00226
Belt tension (with belt tension gauge)

(A)
618 755 N (63 77 kgf, 139 170 lb)
At inspection:
490 640 N (50.0 65.3 kgf, 110.2 143.9
lb)
(A)
(B)
C/P
GEN
P/S
A/C
I/P
(B)
740 880 N (75.5 89.7 kgf, 166 198 lb)
At inspection:
350 450 N (35.7 45.9 kgf, 78.7 101.2
lb)
(A)
P/S
A/C
GEN
(B)
I/P
C/P
PM-00154
(A)
(B)
C/P
GEN
P/S
A/C
I/P
Front side belt

Rear side belt
Crank pulley
Generator
Air conditioning compressor pulley
Idler pulley
ME(H4SO 2.0)-39
Front side belt

Rear side belt
Crank pulley
Generator
Air conditioning compressor pulley
Idler pulley
Crank Pulley
MECHANICAL
13.Crank Pulley
A: REMOVAL
REMOVAL, V-belt.>
2) Remove the crank pulley bolt. To lock the crankshaft, use ST.
ST 499977400
CRANK PULLEY WRENCH
(2.0 L model)
ST 499977100
CRANK PULLEY WRENCH
(2.5 L model)
ST
ME-00227
CAUTION:
If the tightening angle of crank pulley bolt is
less than 45, the bolt should be damaged. In
this case, the bolt must be replaced.
(1) Replace and clean the crank pulley bolts.
Crank pulley bolt:
Part No. 12369AA011
(2) Clean the crankshaft thread using compressed air.
(3) Apply engine oil to the crank pulley bolt seat
and thread.
(4) Tighten the bolts temporarily with tightening
torque of 44 Nm (4.5 kgf-m, 33 ft-lb).
(5) Tighten the crank pulley bolts keeping them
in an angle 45 60.
NOTE:
Conduct the tightening procedures by confirming
the turning angle of the crank pulley bolt referring to
the gauge indicated on the timing belt cover.
4) Install the belt tensioner.
B: INSTALLATION
1. 2.0 L MODEL
1) Install the crank pulley.
2) Install the pulley bolt.
To lock the crankshaft, use ST.
ST 499977400
CRANK PULLEY WRENCH
and thread.
(4) Tighten the crank pulley bolts.
Tightening torque:
130 Nm (13.3 kgf-m, 95.9 ft-lb)
ST
ME-00225
5) Install the V-belts. <Ref. to ME(H4SO 2.0)-38,

INSTALLATION, V-belt.>
2. 2.5 L MODEL
ST 499977100
CRANK PULLEY WRENCH
and thread.
ME-00227
3) Confirm that the tightening angle of the crank

pulley bolt is 45 or more. Perform the following
procedures when less than 45.
ME(H4SO 2.0)-40
Crank Pulley
MECHANICAL
Tightening torque:
180 Nm (18.4 kgf-m, 132.8 ft-lb)
ST
ME-00227
3) Confirm that the tightening angle of crank pulley

bolt is 65 degrees or more. If the tightening angle of
crank pulley bolt is less than 65 degrees, conduct
the following procedures.
(1) Replace the crank pulley bolts and clean
them.
crank pulley bolt:
12369AA011
(3) Apply engine oil to the crank pulley bolt seal
and thread.
in an angle between 65 degrees and 75 degrees.
NOTE:
the turning angle of crank pulley bolt referring to the
gauge indicated on timing belt cover.
4) Install the A/C belt tensioner.
ME-00225
5) Install the V-belt. <Ref. to ME(H4SO 2.0)-38, INSTALLATION, V-belt.>
C: INSPECTION
1) Make sure the V-belt is not worn or otherwise
damaged.
2) Check the tension of the belt. <Ref. to ME(H4SO
2.0)-39, INSPECTION, V-belt.>
ME(H4SO 2.0)-41
Timing Belt Cover

MECHANICAL
14.Timing Belt Cover

A: REMOVAL
REMOVAL, V-belt.>
2) Remove the crank pulley. <Ref. to ME(H4SO
2.0)-40, REMOVAL, Crank Pulley.>
4) Remove the front timing belt cover.
(B)
(A)
ME-00821
(A) Timing belt cover (LH)

(B) Front timing belt cover
B: INSTALLATION
1) Install the front timing belt cover.
Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
2) Install the timing belt cover (LH).
Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
(B)
(A)
ME-00821
(A) Timing belt cover (LH)

(B) Front timing belt cover
3) Install the crank pulley. <Ref. to ME(H4SO 2.0)40, INSTALLATION, Crank Pulley.>
C: INSPECTION
Check the cover for damage.
ME(H4SO 2.0)-42
Timing Belt
MECHANICAL
15.Timing Belt
A: REMOVAL
(d)
1. TIMING BELT
(c)

REMOVAL, V-belt.>
3) Remove the timing belt cover. <Ref. to
ME(H4SO 2.0)-42, REMOVAL, Timing Belt Cover.>
(b)
(a)
(f)
(e)
ME-00232
ME-00065
5) If the alignment mark (a) or arrow mark (which

indicates rotation direction) on timing belt fade
away, put new marks before removing the timing
belt as shown in procedures below.
(1) To turn crankshaft, use the ST: Align the
mark (a) of sprocket to the cylinder block notch
(b), and then ensure the right side cam sprocket
mark (c), cam cap and cylinder head matching
surface (d) or left side cam sprocket mark (e),
timing belt cover notch (f) are properly adjusted.
ST 499987500
CRANKSHAFT SOCKET
(2) Using white paint, put alignment marks or

arrow marks on the timing belts in relation to the
crank sprocket and cam sprockets.
ME-00233
Specified data:
Z1: Length of 46.8 teeth
Z2: Length of 43.7 teeth
Z1
Z2
ST
ME-00231
ME-000234
ME(H4SO 2.0)-43
Timing Belt
MECHANICAL
B: INSTALLATION
7) Remove the belt idler No. 2.
1. AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER

1) Preparation for installation of automatic belt tension adjuster assembly.
ME-00235
ME-00236
2. BELT IDLER AND 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 the 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 cylinder. Doing so may damage the cylinder.
Do not release the press pressure until stopper pin is completely inserted.
(1) Attach the automatic belt tension adjuster
assembly to the vertical pressing tool.
(2) Slowly move the adjuster rod down with a
pressure of 165 N (16.8 kgf, 37.1 lb) or more until the adjuster rod is aligned with the stopper pin
hole in the cylinder.
ME-00239
ME-00237
(3) With a 2 mm (0.08 in) dia. stopper pin or a 2

mm (0.08 in) (nominal) dia. hex wrench inserted
into the stopper pin hole in cylinder, secure the
adjuster rod.
ME-00238
ME-00350
ME(H4SO 2.0)-44
Timing Belt
MECHANICAL
2) Install the automatic belt tension adjuster assembly.
ST2
499207400 CAM SPROCKET WRENCH

(A)
Tightening torque:
39 Nm (4.0 kgf-m, 28.9 ft-lb)
ME-00243
ME-00241
(2) While aligning the alignment mark (B) on

timing belt with the mark (A) on sprockets, position the timing belt properly.
3) Install the belt idler (No. 1).

Tightening torque:
39 Nm (4.0 kgf-m, 28.9 ft-lb)
ME-00244
3) Install the belt idler No. 2.
ME-00242
2. TIMING BELT
1) Prepare for installation of automatic belt tension
adjuster assembly. <Ref. to ME(H4SO 2.0)-44, AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER, INSTALLATION, Timing
Belt.>
2) Installation of timing belt:
(1) Turn the cam sprocket No. 2 using ST1, and
turn the cam sprocket No. 1 using ST2 so that
their alignment marks (A) come to top positions.
ST1 18231AA010 CAM SPROCKET WRENCH
Tightening torque:
39 Nm (4.0 kgf-m, 28.9 ft-lb)
4) Install the belt idler (No. 2).
Tightening torque:
39 Nm (4.0 kgf-m, 28.9 ft-lb)
NOTE:
also be used.
ME(H4SO 2.0)-45
ME-00235
Timing Belt
MECHANICAL
5) After ensuring the marks on timing belt and cam

sprockets are aligned, remove the stopper pin from
belt tension adjuster.
Tightening torque:
10 Nm (1.0 kgf-m, 7.2 ft-lb)
ME-00247
ME-00245
6) Install the timing belt guide. (MT model)

(1) Temporarily tighten the timing belt guide
mounting bolts.
7) Install the timing belt cover.

<Ref. to ME(H4SO 2.0)-42, INSTALLATION, Timing Belt Cover.>
C: INSPECTION
1. TIMING BELT
ME-00230
(2) Check and adjust the clearance between

timing belt and timing belt guide by using thickness gauge.
Clearance:
1.00.5 mm (0.0390.020 in)
1) Check the timing belt teeth for breaks, cracks

and wear. If any fault is found, replace the belt.
2) Check the condition of the backside of belt. If
cracks are found, replace the 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 timing belt sharply.
In radial diameter h:
60 mm (2.36 in) or more
ME-00246
(3) Tighten the timing belt guide mounting bolts.
ME(H4SO 2.0)-46
ME-00248
Timing Belt
MECHANICAL
2. AUTOMATIC BELT TENSION ADJUSTER

1) Visually check the oil seals for leaks, and rod
ends for abnormal wear or scratches. If necessary,
replace the faulty parts.
2) Check that the adjuster rod does not move when
a pressure of 165 N (16.8 kgf, 37.1 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 165 N (16.8 kgf, 37.1 lb), check it using the following procedures:
(1) Slowly press the adjuster rod down to the
end surface of the cylinder. Repeat this operation two to three times.
(2) With the adjuster rod moved all the way up,
apply a pressure of 165 N (16.8 kgf, 37.1 lb) to it.
Check the 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.
3. BELT TENSION PULLEY

1) Check the mating surfaces of timing belt and
contact point of adjuster rod for abnormal wear or
scratches. Replace the automatic belt tension adjuster assembly if faulty.
2) Check the belt tension pulley for smooth rotation. Replace if noise or excessive play occurs.
3) Check the belt tension pulley for grease leakage.
4. BELT IDLER
1) Check the belt idler for smooth rotation. Replace
if noise or excessive play occurs.
2) Check the outer contacting surfaces of idler pulley for abnormal wear and scratches.
3) Check the belt idler for grease leakage.
CAUTION:
Press the 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 cylinder. Do not press the adjuster rod
into cylinder. Doing so may damage the cylinder.
4) Measure the amount of rod protrusion beyond
the body. If it is not within specifications, replace
with a new one.
Amount of rod protrusion H:
5.70.5 mm (0.2240.020 in)
ME-00249
ME(H4SO 2.0)-47
Cam Sprocket
MECHANICAL
16.Cam Sprocket
B: INSTALLATION
A: REMOVAL
1) Install the cam sprocket No. 1. To lock the camshaft, use ST.
ST 499207400
CAM SPROCKET WRENCH

REMOVAL, V-belt.>
4) Remove the timing belt. <Ref. to ME(H4SO 2.0)43, REMOVAL, Timing Belt.>
5) Remove the camshaft position sensor. <Ref. to
FU(H4SO 2.0)-22, REMOVAL, Camshaft Position
Sensor.>
6) Remove the cam sprocket No. 2. To lock the
camshaft, use ST.
ST 18231AA010 CAM SPROCKET WRENCH
Tightening torque:
78 Nm (8.0 kgf-m, 57.9 ft-lb)
NOTE:
Do not confuse left and right side cam sprockets
during installation. Cam sprocket No. 2 is identified
by a protrusion used to monitor the camshaft position sensor.
ST
NOTE:
also be used.
ME-00251
2) Install the cam sprocket No. 2. To lock the camshaft, use ST.
NOTE:
also be used.
ST
ME-00250
Tightening torque:
78 Nm (8.0 kgf-m, 57.9 ft-lb)
7) Remove the cam sprocket No. 1. To lock the

camshaft, use ST.
ST 499207400
CAM SPROCKET WRENCH
ST
ST
ME-00250
ME-00251
3) Install the camshaft position sensor. <Ref. to

FU(H4SO 2.0)-22, INSTALLATION, Camshaft Position Sensor.>
4) Install the timing belt. <Ref. to ME(H4SO 2.0)44, INSTALLATION, Timing Belt.>
ME(H4SO 2.0)-48
Cam Sprocket
MECHANICAL
C: INSPECTION
1) Check the cam sprocket teeth for abnormal wear
and scratches.
2) Make sure there is no free play between cam
sprocket and key.
3) Check the cam sprocket protrusion used for sensor for damage and contamination of foreign matter.
ME(H4SO 2.0)-49
Crank Sprocket
MECHANICAL
17.Crank Sprocket
C: INSPECTION
A: REMOVAL
1) Check the crank sprocket teeth for abnormal

wear and scratches.
2) Make sure there is no free play between crank
sprocket and key.
3) Check the crank sprocket protrusion used for
sensor for damage and contamination of foreign
matter.

REMOVAL, V-belt.>
5) Remove the cam sprocket. <Ref. to ME(H4SO
2.0)-48, REMOVAL, Cam Sprocket.>
6) Remove the crank sprocket.
ME-00252
B: INSTALLATION
1) Install the crank sprocket.
ME-00252
2) Install the cam sprocket. <Ref. to ME(H4SO

2.0)-48, INSTALLATION, Cam Sprocket.>
ME(H4SO 2.0)-50
Valve Rocker Assembly

MECHANICAL
18.Valve Rocker Assembly
(3) Tighten the bolts (a) through (d) to specified

torque.
A: REMOVAL
REMOVAL, V-belt.>
6) Disconnect the PCV hose and remove the rocker cover.
7) Removal of valve rocker assembly
(1) Remove the bolts (a) through (h) in alphabetical sequence.
NOTE:
Leave two or three threads of bolts (g) and (h) engaged in order to retain the valve rocker assembly.
(b)
(h)
(f)
(d)
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
(g)
(f)
(a)
(d)
(e)
(c)
(b)
(h)
ME-00255
2) Adjust the valve clearance. <Ref. to ME(H4SO

2.0)-29, ADJUSTMENT, Valve Clearance.>
3) Install the rocker cover and connect PCV hose.
C: DISASSEMBLY
(c)
(e)
(g)
(a)
ME-00253
(2) Remove the valve rocker assembly.
1) Remove the bolts which secure the rocker shaft.

2) Extract the rocker shaft. Remove the valve rocker arms, springs and shaft supports from rocker
shaft.
NOTE:
Keep all the removed parts in order for re-installing
in their original positions.
3) Remove the nut and adjusting screw from valve
rocker.
D: ASSEMBLY
ME-00254
B: INSTALLATION
1) Install the valve rocker assembly.
(1) Temporarily tighten the bolts (a) through (d)
equally in order as shown in the figure.
NOTE:
Do not allow the valve rocker assembly to damage
knock pins.
(2) Tighten the bolts (e) through (h) to specified
torque.
1) Install the adjusting screw and nut to valve rocker.

2) Arrange the valve rocker arms, springs and shaft
supports in assembly order, and then insert the
valve rocker shaft.
Tightening torque (Shaft supports installing
bolts):
5 Nm (0.5 kgf-m, 3.6 ft-lb)
NOTE:
Valve rocker arms, rocker shaft and shaft supports
have identification marks. Ensure the parts with
same markings are properly assembled.
3) Install the valve rocker shaft securing bolts.
ME(H4SO 2.0)-51
Valve Rocker Assembly

MECHANICAL
E: INSPECTION
1. VALVE ROCKER ARM AND ROCKER
SHAFT
1) Measure the inner diameter of valve rocker arm
and outer diameter of valve rocker shaft, and determine the difference (oil clearance) between the two
values.
Clearance between arm and shaft:
Standard:
0.020 0.054 mm (0.0008 0.0021 in)
ME-00256
ME-00257
2) If the oil clearance exceeds the standard value,

replace the 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) If the cam or valve contact surface of valve rocker arm is worn or dented excessively, replace the
valve rocker arm.
4) Check that the valve rocker arm roller rotates
smoothly. If not, replace the valve rocker arm.
ME(H4SO 2.0)-52
Camshaft
MECHANICAL
19.Camshaft
(1) Remove the bolts (a) and (b) in alphabetical

sequence.
A: REMOVAL
REMOVAL, V-belt.>
6) Remove the crank sprocket. <Ref. to ME(H4SO
2.0)-50, REMOVAL, Crank Sprocket.>
7) Remove the timing belt cover No. 2 (LH).
8) Remove the timing belt cover No. 2 (RH).
(a)
(b)
ME-00260
(2) Equally loosen the bolts (c) through (j) all the
way in alphabetical sequence.
(e)
(c)
(i)
NOTE:
Do not damage or lose the seal rubber when removing the timing belt covers.
(g)
(h)
(j)
(f)
(d)
ME-00261
(3) Remove the bolts (k) through (p) in alphabetical sequence using ST.
ST 499497000
TORX PLUS
(m)
(k)
(p)
(l)
(o)
ME-00258
9) Remove the tensioner bracket.
( n ) ME-00262
(4) Remove the camshaft cap.
ME-00259
10) Remove the camshaft position sensor support.

(LH side only)
11) Remove the oil level gauge guide. (LH side
only)
12) Remove the valve rocker assembly. <Ref. to
ME(H4SO 2.0)-51, REMOVAL, Valve Rocker Assembly.>
13) Remove the camshaft cap.
ME-00263
14) Remove the camshaft.

15) Remove the oil seal.
16) Remove the plug from the rear side of camshaft.
ME(H4SO 2.0)-53
Camshaft
MECHANICAL
CAUTION:
Do not remove the oil seal unless necessary.
Do not scratch the journal surface when removing the oil seal.
(3) Install the valve rocker assembly.
B: INSTALLATION
1) Apply a coat of engine oil to camshaft journals
and install the camshaft.
2) Install the camshaft cap.
(1) Apply liquid gasket to the mating surfaces of
camshaft cap.
Liquid gasket:
THREE BOND 1280B (Part No. K0877YA018)
ME-00267
(4) Tighten the bolts (a) through (h) in alphabetical sequence.

Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
(g)
(c)
(a)
(e)
(f)
(h)
ME-00264
NOTE:
Apply a coat of liquid gasket of 3 mm (0.12 in) in
diameter (A) along the edge (B) of camshaft cap
(C) mating surface.
Assemble them within 20 min. after applying liquid gasket.
(d)
(b)
ME-00268
bolts (i) through (n) in al-
(5) Tighten the TORX

phabetical sequence using ST.
ST 499497000
TORX PLUS
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
(A)
(i)
(k)
(m)
(B)
(C)
ME-00265
(2) Temporarily tighten the bolts (g) through (j)

in alphabetical sequence.
(l)
(n)
(j)
ME-00269
(6) Tighten the bolts (o) through (v) in alphabetical sequence.
(i)
(g)
(h)
(j)
ME-00266
ME(H4SO 2.0)-54
Camshaft
MECHANICAL
9) Install the tensioner bracket.
Tightening torque:
10 Nm (1.0 kgf-m, 7.2 ft-lb)
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
(q)
(o)
(u)
(s)
(t)
(v)
(p)
(r)
ME-00270
(7) Tighten the bolts (w) and (x) in alphabetical

sequence.
Tightening torque:
10 Nm (1.0 kgf-m, 7.2 ft-lb)
ME-00273
10) Install the timing belt cover No. 2 (RH).

Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
11) Install the timing belt cover No. 2 (LH).
Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
(w)
(x)
ME-00271
3) Apply a coat of grease to oil seal lips and install

the oil seal (A) on camshaft using ST1 and ST2.
NOTE:
Use a new oil seal.
ST1 499597000 OIL SEAL GUIDE
ST2 499587500 OIL SEAL INSTALLER
S T1
S T2
(A)
ME-00272
4) Install the plug using ST.

ST 499587700
CAMSHAFT OIL SEAL INSTALLER
5) Adjust the valve clearance. <Ref. to ME(H4SO
2.0)-29, ADJUSTMENT, Valve Clearance.>
6) Install the rocker cover and connect PCV hose.
7) Install the oil level gauge guide. (LH side only)
8) Install the camshaft position sensor support. (LH
side only)
ME-00274

<Ref. to ME(H4SO 2.0)-50, INSTALLATION,
Crank Sprocket.>
16) Install the crank pulley. <Ref. to ME(H4SO
2.0)-40, INSTALLATION, Crank Pulley.>
ME(H4SO 2.0)-55
Camshaft
MECHANICAL
C: INSPECTION
Cam base circle diameter A:

Intake: 34.00 mm (1.3386 in)
Exhaust: 34.00 mm (1.3386 in)
1. CAMSHAFT
1) Measure the bend, and repair or replace if necessary.
Service limit:
0.020 mm (0.00079 in)
ME-00276
2. CAMSHAFT SUPPORT
ME-00275
2) Check the journal for damage and wear. Replace if faulty.

3) Measure the outer diameter of camshaft journal
and inner diameter of cylinder head journal, and
determine the difference (oil clearance) between
the two values. If the oil clearance exceeds standard value, replace the camshaft or cylinder head
as necessary.
Measure the side clearance of camshaft with setting the dial gauge at end of camshaft. If side clearance exceeds the limit, replace the camshaft
support.
Standard:
0.030 0.090 mm (0.0012 0.0035 in)
Unit: mm (in)
Clearance at
journal
0.055 0.090
(0.0022 0.0035)
Standard
31.928 31.945
(1.2570 1.2577)
32.000 32.018
(1.2598 1.2605)
Camshaft journal O.D.

Journal hole I.D.
4) Check the cam face condition, and remove the

minor faults by grinding with oil stone. Measure the
cam height H. If it exceeds the limit, replace it.
Cam height: H:
Model
Parts
Intake
2.0 L
Exhaust
Intake
2.5 L
Exhaust
Standard
Standard
Standard
Standard
Unit: mm (in)
39.646 39.746
(1.5609 1.5648)
39.351 39.451
(1.5493 1.5532)
39.485 39.585
(1.5545 1.5585)
39.904 40.004
(1.5710 1.5750)
ME(H4SO 2.0)-56
Cylinder Head
MECHANICAL
20.Cylinder Head
A: REMOVAL
REMOVAL, V-belt.>
6) Remove the intake manifold. <Ref. to FU(H4SO
2.0)-11, REMOVAL, Intake Manifold.>
7) Remove the bolt which installs the A/C compressor bracket on cylinder head.
8) Remove the valve rocker assembly. <Ref. to
ME(H4SO 2.0)-51, REMOVAL, Valve Rocker Assembly.>
9) Remove the camshaft. <Ref. to ME(H4SO 2.0)53, REMOVAL, Camshaft.>
10) Remove the cylinder head bolts in alphabetical
sequence as shown in the figure.
NOTE:
Leave bolts (a) and (c) engaged by three or four
threads to prevent the cylinder head from falling.
(c)
(e)
(a)
CAUTION:
Be careful not to scratch the mating surface of
cylinder head and cylinder block.
14) Similarly, remove the right side cylinder head.
B: INSTALLATION
1) Install the 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 the 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 ftlb) in alphabetical sequence.
Then tighten all bolts to 69 Nm (7.0 kgf-m, 51 ftlb) in alphabetical sequence.
(3) Back off all bolts by 180 in reverse order of
installation, and back them off again by 180.
(5) Tighten all bolts by 80 90 in alphabetical sequence.
(6) Tighten all bolts by 40 45 in alphabetical sequence.
CAUTION:
Tightening angle of the bolt must not exceed
45.
(7) Further tighten bolts (a) and (b) by 40
45.
CAUTION:
Total re-tightening angle of the step (6) and
(7) must not exceed 90.
(b)
(f)
(d)
11) While tapping the cylinder head with a plastic

hammer, separate it from cylinder block.
12) Remove the bolts (a) and (c) to remove the cylinder head.
(f)
(a)
ME-00278
(c)
(d)
(c)
(e)
(b)
(e)
(a)
(b)
(f)
(d)
ME-00278
ME-00279
3) Install the camshaft. <Ref. to ME(H4SO 2.0)-54,

INSTALLATION, Camshaft.>
4) Install the valve rocker assembly. <Ref. to
ME(H4SO 2.0)-51, INSTALLATION, Valve Rocker
Assembly.>
5) Install the A/C compressor bracket on cylinder
head.
13) Remove the cylinder head gasket.
ME(H4SO 2.0)-57
Cylinder Head
MECHANICAL
ST
6) Install the intake manifold.

<Ref. to FU(H4SO 2.0)-12, INSTALLATION, Intake
Manifold.>
499718000
VALVE SPRING REMOVER
NOTE:
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.
ST
C: DISASSEMBLY
1) Place the cylinder head on the ST.
ST 498267800
CYLINDER HEAD TABLE
2) Set the ST on valve spring. Compress the valve
spring and remove the valve spring retainer key.
Remove each valve and valve spring.
ME-00280
D: ASSEMBLY
(8)
(1)
(3)
(5)
(7)
(11)
(12)
(2)
(4)
(6)
(9)
(10)
(13)
ME-00281
(1)
(2)
(3)
(4)
(5)
Valve
Valve guide
Valve spring seat
Oil seal
Valve springs
(6)
(7)
(8)
(9)
(10)
Retainer
Retainer key
Spark plug gasket
Camshaft
Oil seal
ME(H4SO 2.0)-58
(11)
(12)
(13)
Plug
Camshaft cap
Valve rocker ASSY
Cylinder Head
MECHANICAL
1) Installation of valve spring and valve:

(1) Place the cylinder head on the ST.
ST 498267800
CYLINDER HEAD TABLE
(2) Coat the stem of each valve with engine oil
and insert the valve into valve guide.
CAUTION:
Use extreme care not to damage the oil lips
when inserting the valve into valve guide.
(3) Install the valve spring and retainer.
NOTE:
Be sure to install the valve springs with their closecoiled end facing the seat on the cylinder head.
(4) Set the ST on valve spring.
ST 499718000
E: INSPECTION
1. VALVE SPRING
1) Check the valve springs for damage, free length,
and tension. Replace the valve spring if it is not
within the standard value 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 of spring using a try square.
Free length
mm (in)
Tension/spring
height
N (kgf, lb)/mm
(in)
Squareness
54.30 (2.1378)
Set
Lift
214 246
(22 25, 48 55)/45.0 (1.772)
526 582
(54 59, 119 130)/34.7
(1.366)
2.5, 2.4 mm (0.094 in)
ST
ME-00280
(5) Compress the valve spring and fit the valve

spring retainer key.
ME-00283
2. INTAKE AND EXHAUST VALVE OIL

SEAL
(B)
(B)
(A)
ME-00282
(A) Retainer key

(B) Valve springs
(6) After installing, tap the valve spring retainers

lightly with a plastic hammer for better seating.
In the following case, pinch and remove the oil seal

from valve using pliers, and then replace it with a
new one.
When the lip is damaged.
When the spring is out of the specified position.
When readjusting the surfaces of intake valve
and valve sheet.
When replacing the intake valve guide.
1) Place the cylinder head on ST1.
2) Using ST2, press-fit the oil seal.
CAUTION:
Apply engine oil to oil seal before press-fitting.
When press-fitting the oil seal, do not use a
hammer or strike in.
Differentiate between the intake valve oil seal
and exhaust valve oil seal by noting their difference in color.
ST1 498267800 CYLINDER HEAD TABLE
ST2 498857100 VALVE OIL SEAL GUIDE
ME(H4SO 2.0)-59
Cylinder Head
MECHANICAL
2. VALVE SEAT
Color of rubber part:

Intake [Gray]
Exhaust [Green]
Inspect the intake and exhaust valve seats, and

correct the contact surfaces with a valve seat cutter
if they are defective or when valve guides are replaced.
ST2
Valve seat width W:

Standard
Intake (A)
0.8 1.4 mm (0.03 0.055 in)
Exhaust (B)
1.2 1.8 mm (0.047 0.071 in)
ST1
ME-00284
F: ADJUSTMENT
(A)
(B)
1. CYLINDER HEAD
1) Make sure that no crack or other damage do not
exist. In addition to visual inspection, inspect important areas using liquid penetrant tester.
Also make sure the gasket installing surface shows
no trace of gas and water leaks.
2) Place the cylinder head on the 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 the limit, regrind the surface
with a surface grinder.
ME-00397
Warping limit:
0.03 mm (0.0012 in)
Grinding limit:
0.1 mm (0.004 in)
ME-00287
3. VALVE GUIDE
Standard height of cylinder head:

97.5 mm (3.839 in)
NOTE:
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
respectively the outer diameter of valve stem and
inner diameter of valve guide with a micrometer.
(A)
(B)
ST
ME-00285
(A) Straight edge

(B) Thickness gauge
ME(H4SO 2.0)-60
Cylinder Head
MECHANICAL
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)
ST1
ST2
498267800 CYLINDER HEAD TABLE

499767200 VALVE GUIDE REMOVER
ST2
ST1
ME-00290
(A)
ME-00763
(A) Valve guide
(3) Turn the cylinder head upside down and

place the ST as shown in the figure.
Intake side:
ST 499767700
VALVE GUIDE ADJUSTER
Exhaust side:
ST 499767800
Y
X
ST
(A)
ME-00291
ME-00289
2) If the clearance between valve guide and stem

exceeds the standard value, replace the valve
guide or valve itself whichever shows greater
amount of wear. See the 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 the cylinder head on ST1 with the
combustion chamber upward so that valve
guides enter the holes in ST1.
(2) Insert ST2 into the valve guide and press it
down to remove the valve guide.
(A) Valve guide
(4) Before installing a 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 a new valve guide, coated with sufficient
oil, in cylinder, and insert the 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
ST1
ST2
ME-00292
ME(H4SO 2.0)-61
Cylinder Head
MECHANICAL
4. INTAKE AND EXHAUST VALVE
(6) Check the valve guide protrusion.

Valve guide protrusion L:
Intake
20.0 21.0 mm (0.787 0.827 in)
Exhaust
16.5 17.5 mm (0.650 0.689 in)
1) Inspect the flange and stem of valve, and replace if damaged, worn or deformed, or if H exceed the standard value.
H:
Intake
Standard: 0.8 1.2 mm (0.03 0.047 in)
Exhaust
Standard: 1.0 1.4 mm (0.039 0.055 in)
Valve overall length:
Intake
120.6 mm (4.75 in)
Exhaust
121.7 mm (4.79 in)
(A)
ME-00293
(A) Valve guide
(7) Ream the inside of valve guide using ST.

Put the reamer in valve guide, and rotate the
reamer slowly clockwise while pushing it lightly.
Bring the reamer back while rotating it clockwise. After reaming, clean the 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 chip,
use a new reamer or remedy the reamer.
ST 499767400
VALVE GUIDE REAMER
ME-00295
2) Put a small amount of grinding compound on the

seat surface and lap the valve and seat surface.
<Ref. to ME(H4SO 2.0)-60, VALVE SEAT, ADJUSTMENT, Cylinder Head.> Install a new intake
valve oil seal after lapping.
ME-00294
(8) Recheck the contact condition between

valve and valve seat after replacing the valve
guide.
ME(H4SO 2.0)-62
Cylinder Block
MECHANICAL
21.Cylinder Block
12) Remove the bolts (a) and (c) to remove the cylinder head.
A: REMOVAL
NOTE:
Before conducting this procedure, drain the engine
oil completely.
1) Remove the intake manifold. <Ref. to FU(H4SO
2.0)-11, REMOVAL, Intake Manifold.>
REMOVAL, V-belt.>
7) Remove the crank sprocket. <Ref. to ME(H4SO
8) Remove the generator and A/C compressor with
their brackets.
9) Remove the rocker cover.
sequence as shown in the figure.
(a)
(e)
(c)
(A)
(d)
(f)
(b)
ME-00296
(A) Front side

NOTE:
Do not scratch the mating surface of cylinder head
and cylinder block.
14) Similarly, remove the right side cylinder head.
15) Remove the clutch housing cover. (MT model)
16) Remove the flywheel (MT model) or drive plate
(AT model).
Lock the crankshaft using ST.
ST 498497100
CRANKSHAFT STOPPER
MT model
NOTE:
Leave bolts (a) and (c) engaged by three or four
(a)
(e)
(c)
(A)
ST
ME-00297
AT model
(d)
(f)
(b)
ME-00296
(A) Front side

ME-00298
17) Remove the oil separator cover.

18) Remove the water by-pass pipe for heater.
ME(H4SO 2.0)-63
Cylinder Block
MECHANICAL
19) Remove the water pump after loosening the

bolts in alphabetical sequence as shown in the figure.
25) Remove the oil filter.
(F)
(E)
(A)
(D)
(C)
(B)
ME-00299
26) Remove the water pipe.

ME-00847
20) Remove the oil pump from cylinder block.

Use a flat tip screwdriver as shown in the figure
when removing the oil pump.
CAUTION:
cylinder block and oil pump.
ME-00300
ME-00138
21) Remove the oil pan.

(1) Place the cylinder block to face the #2 and
#4 piston side upward.
(2) Remove the bolts which secure oil pan to
cylinder block.
(3) Insert a oil pan cutter blade between cylinder block-to-oil pan clearance and remove the
oil pan.
NOTE:
Do not use a screwdriver or similar tools in place of
oil pan cutter.
22) Remove the oil strainer stay.
23) Remove the oil strainer.
24) Remove the baffle plate.
ME(H4SO 2.0)-64
Cylinder Block
MECHANICAL
(2)
(1)
(3)
(4)
(6)
(4)
(3)
(5)
(4)
(2)
(3)
(1)
(4)
(3)
(1)
(2)
ME-00139
(1)
(2)
Service hole plug

Gasket
(3)
(4)
Snap ring
Piston pin
27) Remove the service hole cover and service

hole plugs using a hexagon wrench (14 mm).
(5)
(6)
Service hole cover

O-ring
28) Rotate the crankshaft to bring #1 and #2 pistons to bottom dead center position, then remove
the piston snap ring through service hole of #1 and
#2 cylinders.
ME-00140
ME-00141
29) Draw out the piston pin from #1 and #2 pistons

using ST.
ST 499097700
PISTON PIN REMOVER
ME(H4SO 2.0)-65
Cylinder Block
MECHANICAL
NOTE:
Be careful not to confuse the original combination
of piston, piston pin and cylinder.
ST
ME-00142
30) Similarly remove the piston pins from #3 and #4

pistons.
31) Remove the bolts which connect cylinder block
on the side of #2 and #4 cylinders.
32) Back off the bolts which connect cylinder block
on the side of #1 and #3 cylinders two or three
turns.
33) Set up the cylinder block so that #1 and #3 cylinders are on the upper side, then remove the cylinder block connecting bolts.
34) Separate the cylinder block (RH) and (LH).
NOTE:
When separating the cylinder block, do not allow
the connecting rod to fall or damage the cylinder
block.
(5)
(1)
(4)
(2)
(4)
(3)
(1)
(5)
ME-00143
(1)
(2)
Cylinder block
Rear oil seal
(3)
(4)
Crankshaft
Crankshaft bearing
35) Remove the rear oil seal.

36) Remove the crankshaft together with connecting rod.
37) Remove the crankshaft bearings from cylinder
block using a hammer handle.
(5)
Piston
38) Draw out each piston from cylinder block using

a wooden bar or hammer handle.
NOTE:
of piston and cylinder.
NOTE:
Be careful not to confuse the crankshaft bearing
combination. Press the bearing at the end opposite
to locking lip.
ME(H4SO 2.0)-66
Cylinder Block
MECHANICAL
B: INSTALLATION
(4)
(1)
(3)
(2)
(3)
ME-00144
(1)
(2)
Crankshaft bearing
Crankshaft
(3)
Cylinder block
NOTE:
Remove oil on the mating surface of bearing and
cylinder block before installation. Apply a coat of
engine oil to crankshaft pins.
1) Position the crankshaft on the #2 and #4 cylinder
block.
2) Apply liquid gasket to the mating surface of #1
and #3 cylinder block, and position it on #2 and #4
cylinder block.
(4)
Rear oil seal
NOTE:
Do not allow liquid gasket to flow into O-ring
grooves, oil passages, bearing grooves, etc.
Liquid gasket:
THREE BOND 1215 (Part No. 004403007) or
equivalent
ME-00145
3) Tighten the 10 mm cylinder block connecting

bolts on LH side (A D) in alphabetical sequence.
ME(H4SO 2.0)-67
Cylinder Block
MECHANICAL
Tightening torque:
(E), (F), (G), (I): 20 Nm (2.0 kgf-m, 14.8 ft-lb)
(H), (J): 18 Nm (1.8 kgf-m, 13.3 ft-lb)
Tightening torque:
10 Nm (1.0 kgf-m, 7.4 ft-lb)
(A)
(G)
(D)
(E)
(J)
(B)
(C)
(H)
(I)
ME-00398

bolts on RH side (E J) in alphabetical sequence.
Tightening torque:
10 Nm (1.0 kgf-m, 7.4 ft-lb)
(F)
ME-00399
7) Further tighten the LH side bolts (A D) to 90

(A)
(G)
(D)
(E)
(J)
(B)
(C)
(H)
(I)
ME-00398
(F)
ME-00399
5) Further tighten the LH side bolts (A D) in alphabetical sequence.
8) Further tighten the RH side bolts (E J) to 90

Tightening torque:
(A), (C): 20 Nm (2.0 kgf-m, 14.8 ft-lb)
(B), (D): 15 Nm (1.5 kgf-m, 10.8 ft-lb)
(G)
(E)
(J)
(H)
(I)
(A)
(D)
(F)
ME-00399
9) Tighten the 8 mm and 6 mm cylinder block connecting bolts on LH side (A H) in alphabetical sequence.
(B)
(C)
ME-00398
6) Further tighten the RH side bolts (E J) in alphabetical sequence.
ME(H4SO 2.0)-68
Cylinder Block
MECHANICAL
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)
13) Position the upper rail gap at (C) in the figure.
(G)
(C)
(E)
(A)
(B)
25
(C)
ME-02087
(D)
(F)
(H)
ME-00147
14) Align the upper rail spin stopper (E) to the side
hole (D) on the piston.
10) Install the rear oil seal using ST1 and ST2.
(B)
(D)
(E)
(A)
(F)
ST2
(G)
ME-00843
15) Position the expander gap at 180 on the reverse side of (C) that shown (F) in the figure.
ST1
ME-00148
(A) Rear oil seal

(B) Flywheel attaching bolt
(F)
11) Position the top ring gap at (A) or (B) in the figure.
12) Position the second ring gap at 180 on the reverse side of the top ring gap.
ME-02088
16) Position the lower rail gap at 120 on counterclockwise of (C) that shown (G) in the figure.
(A)
(B)
ME-00718
(G)
(C)
120
ME-02089
CAUTION:
Ensure ring gaps do not face the same direction.
Ensure ring gaps are not within the piston
skirt area.
ME(H4SO 2.0)-69
Cylinder Block
MECHANICAL
17) Install the snap ring.

Install snap rings in the piston holes located opposite to the service holes in cylinder block, when positioning all pistons in the corresponding cylinders.
CAUTION:
Piston front mark faces towards the front of engine.
NOTE:
Use new snap rings.
#3
#1
(A)
#4
ME-00742
(A) Front mark

(A)
#2
ME-00306
(A) Front side

(5)
(4)
(1)
(5)
(3)
(4)
(3)
(2)
(2)
(1)
ME-00155
(1)
(2)
(3)
Piston
Piston pin
Snap ring
(4)
(5)

T: 70 (7.1, 50.6)
Gasket
Service hole plug
18) Install the piston.

#2 cylinder side upward.
(2) Using ST1, turn the 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 the pistons and
cylinders and insert pistons in their cylinders using ST2.
ST 2
ST 2
398744300 PISTON GUIDE (2.0 L model)

498747300 PISTON GUIDE (2.5 L model)
ST1
ST2
ME-00157
ME(H4SO 2.0)-70
Cylinder Block
MECHANICAL
19) Install the piston pin.

(1) Apply a coat of engine oil to ST3.
(2) Insert ST3 into the service hole to align piston pin hole with connecting rod small end.
ST3 499017100 PISTON PIN GUIDE
ST1
(6) Install the service hole plug and gasket.

NOTE:
Use a new gasket.
ST3
ME-00140
ME-00158
(3) Apply a coat of engine oil to piston pin, and

insert the piston pin into piston and connecting
rod through service hole.
(4) Install the snap ring.
NOTE:
Use new snap rings.
ME-00159
(5) Apply liquid gasket around the service hole

plug.
Liquid gasket:
equivalent
ME-00160
ME(H4SO 2.0)-71
Cylinder Block
MECHANICAL
T2
(5)
T1
(6)
(3)
(4)
(7)
(2)
(1)
(3)
(2)
(1)
ME-00161
(1)
(2)
(3)
(4)
Piston
Piston pin
Snap ring
Gasket
(5)
(6)
(7)
Service hole plug

Service hole cover
O-ring

#4 cylinder side upward. Following the same
procedures as used for #1 and #2 cylinders, install the pistons and piston pins.
20) Install the water pipe.

T1: 6.4 (0.65, 4.7)
T2: 70 (7.1, 50.6)
24) Apply liquid gasket to mating surfaces and install the oil pan.
Liquid gasket:
THREE BOND 1207C (Part No. 004403012) or
equivalent
ME-00300
ME-00162
21) Install the baffle plate.

Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
22) Install the oil strainer and O-ring.
Tightening torque:
10 Nm (1.0 kgf-m, 7.2 ft-lb)
23) Install the oil strainer stay.
ME(H4SO 2.0)-72
Cylinder Block
MECHANICAL
25) Apply liquid gasket to mating surfaces and install the oil separator cover.
ST
499587100
OIL SEAL INSTALLER
Liquid gasket:
equivalent
ME-00164
(2) Apply liquid gasket to the matching surface

of oil pump.
ME-00163
26) Install the flywheel. (MT model)

<Ref. to CL-16, INSTALLATION, Flywheel.>
To lock the crankshaft, use the ST.
ST 498497100
CRANKSHAFT STOPPER
Liquid gasket:
equivalent
Tightening torque:
72 Nm (7.3 kgf-m, 52.8 ft-lb)
(A)
ME-00165
(A) O-ring
(3) Apply a coat of engine oil to the inside of oil

seal.
ST
ME-00297
27) Install the drive plate.

To lock the crankshaft, use the ST.
ST 498497100
CRANKSHAFT STOPPER
Tightening torque:
72 Nm (7.3 kgf-m, 52.8 ft-lb)
ME-00312
(4) Install the oil pump on cylinder block. Be

careful not to damage the oil seal during installation.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
ME-00298
28) Install the housing cover.

29) Installation of oil pump:
(1) Discard the front oil seal after removal. Replace with a new one using ST.
CAUTION:
Do not forget to install the O-ring and seal
when installing the oil pump.
Align the flat surface of oil pumps inner rotor
with crankshaft before installation.
30) Install the water pump and gasket.
ME(H4SO 2.0)-73
Cylinder Block
MECHANICAL
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:
Total re-tightening angle of the step (6) and
(7) must not exceed 90.
CAUTION:
Be sure to use a new gasket.
When installing the water pump, tighten bolts
in two stages in alphabetical sequence as
(c)
(f)
(a)
(A)
(F)
(E)
(A)
(D)
(e)
(C)
(b)
(d)
ME-00309
(B)
(A) Front side
ME-00847
31) Install the water by-pass pipe for heater.

32) Install the oil filter.
bolt threads.
(2) Tighten all bolts to 29 Nm (3.0 kgf-m, 22 ftlb) in alphabetical sequence. Then tighten all
bolts to 69 Nm (7.0 kgf-m, 51 ft-lb) in alphabetical sequence.
installation and back them off again by 180.
(4) Tighten all bolts to 42 Nm (4.3 kgf-m, 31 ftlb).
(5) Tighten all bolts by 80 90 in alphabetical
sequence.
sequence.
CAUTION:
Tightening angle of the bolt must not exceed
45.
(7) Further tighten the bolts (A) and (B) by 40
45.
34) Install the oil level gauge guide and tighten the
bolt (left side only).
35) Install the rocker cover.
<Ref. to ME(H4SO 2.0)-50, INSTALLATION,
Crank Sprocket.>
41) Install the generator and A/C compressor
brackets on cylinder head.
<Ref. to FU(H4SO 2.0)-12, INSTALLATION, Intake
Manifold.>
ME(H4SO 2.0)-74
Cylinder Block
MECHANICAL
C: DISASSEMBLY
(1)
(2)
(2)
(5)
(4)
(3)
(6)
ME-00168
(1)
(2)
Connecting rod cap

(3)
(4)
Top ring
Second ring
1) Remove the connecting rod cap.

2) Remove the connecting rod bearing.
NOTE:
Arrange the removed connecting rod, connecting
rod cap and bearing in order, to prevent confusion.
3) Remove the piston rings using the piston ring expander.
4) Remove the oil ring by hand.
NOTE:
Arrange the removed piston rings in proper order,
to prevent confusion.
5) Remove the snap ring.
ME(H4SO 2.0)-75
(5)
(6)
Oil ring
Snap ring
Cylinder Block
MECHANICAL
D: ASSEMBLY
(3)
T
(1)
(1)
(2)
(4)
(5)
(6)
(8)
(7)
ME-00392
(1)
(2)
(3)
(4)

Connecting rod
Connecting rod cap
Oil ring
(5)
(6)
(7)
(8)

T: 45 (4.6, 33.3)
Second ring
Top ring
Snap ring
Side mark
1) Apply oil to the surfaces of the connecting rod

bearings.
2) Install the connecting rod bearings on connecting rods and connecting rod caps.
3) Position each connecting rod with the marked
side facing forward, and install it.
4) Install the connecting rod cap with connecting
rod nut.
Ensure the arrow on connecting rod cap faces toward front during installation.
E: INSPECTION
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.
5) Install the expander, lower rail and upper rail in
this order by hand. Install the second ring and top
ring with a piston ring expander.
Warping limit:
0.025 mm (0.00098 in)
1. CYLINDER BLOCK
1) Visually check for cracks and damage. Especially, inspect the important parts using liquid penetrant tester.
2) Check the oil passages for clogging.
3) Inspect the cylinder block surface that mates
with cylinder head for warping by using a straight
edge, and correct by grinding if necessary.
Grinding limit:
0.1 mm (0.004 in)
Standard height of cylinder block:
201.0 mm (7.91 in)
2. CYLINDER AND PISTON

1) The cylinder bore size is stamped on the cylinder
blocks front upper surface.
NOTE:
Measurement should be performed at a temperature of 20C (68F).
Standard sized pistons are classified into two
grades, A and B. These grades should be used
as guide lines in selecting a standard piston.
ME(H4SO 2.0)-76
Cylinder Block
MECHANICAL
Standard diameter:
2.0 L model
A: 92.005 92.015 mm (3.6222 3.6226
in)
B: 91.995 92.005 mm (3.6218 3.6222
in)
2.5 L model
A: 99.505 99.515 mm (3.9175 3.9179
in)
B: 99.495 99.505 mm (3.9171 3.9175
in)
Out-of-roundness:
Standard
0.010 mm (0.0004 in)
(A)
(B)
H1
H2
H3
H4
#5
#4
(B)
(A)
ME-00171
#1
#2
(F)
#3
(D)
(A)
(B)
H1
H2
H3
H4
(E) (C)
Piston pin direction

Thrust direction
10 mm (0.39 in)
45 mm (1.77 in)
80 mm (3.15 in)
115 mm (4.53 in)
ME-00170
(A)
(B)
(C)
(D)
(E)
(F)
Main journal size mark

Cylinder block (RH)-(LH) combination mark
#1 cylinder bore size mark
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 as
shown in the figure, using a cylinder bore gauge.
NOTE:
3) When the piston is to be replaced due to general

or cylinder wear, determine a suitable sized piston
by measuring the piston clearance.
4) How to measure the outer diameter of each piston:
Measure the outer diameter of each piston at the
height as shown in the figure. (Thrust direction)
NOTE:
Piston grade point H:
2.0 L model
40.0 mm (1.575 in)
2.5 L model
37.0 mm (1.457 in)
Taper:
Standard
0.015 mm (0.0006 in)
ME(H4SO 2.0)-77
Cylinder Block
MECHANICAL
Standard
2.0 L model
A: 92.005 92.015 mm (3.6222 3.6226
in)
B: 91.995 92.005 mm (3.6219 3.6222
in)
2.5 L model
A: 99.505 99.515 mm (3.9175 3.9179
in)
B: 99.495 99.505 mm (3.9171 3.9175
in)
0.25 mm (0.0098 in) oversize
2.0 L model
92.245 92.265 mm (3.6317 3.6325 in)
2.5 L model
99.745 99.765 mm (3.9270 3.9278 in)
2.0 L model
92.495 92.515 mm (3.6415 3.6423 in)
2.5 L model
99.995 100.015 mm (3.9368 3.9376 in)
H
ME-00172
(2) If the cylinder inner diameter exceeds limit*

after boring and honing, replace the cylinder
block.
*: 2.0 L model
92.515 mm (3.6423 in)
2.5 L model
100.015 mm (3.9376 in)
NOTE:
Immediately after reboring, the cylinder diameter
may differ from its real diameter due to temperature
rise. Thus, pay attention when measuring the cylinder diameter.
Limit of cylinder boring:
0.5 mm (0.020 in)
3. PISTON AND PISTON PIN

1) Check the 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(H4SO 2.0)-76, CYLINDER AND PISTON, INSPECTION, Cylinder
Block.> If any of the clearances is not within the
standard value, replace the piston. Or bore the cylinder to use an oversize piston.
3) Make sure that the piston pin can be inserted
into the piston pin hole with a thumb at 20C (68F).
Replace if defective.
Clearance between piston hole and piston pin:
Standard
0.004 0.008 mm (0.0002 0.0003 in)
5) Calculate the clearance between cylinder and

piston.
NOTE:
Cylinder to piston clearance at 20C (68F):
Standard
0.010 0.010 mm (0.00039 0.00039 in)
6) Boring and honing
(1) If the value of taper, out-of-roundness, or
cylinder-to-piston clearance measured exceeds
the standard value 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.
ME(H4SO 2.0)-78
ME-00173
ME-00174
Cylinder Block
MECHANICAL
4) Check the snap ring installation groove (A) on

the piston for burr. If necessary, remove burr from
the groove so that the piston pin can lightly move.
2) Clean the piston ring groove and piston ring.

3) Squarely place the piston ring and oil ring in cylinder, and measure the piston ring gap with a thickness gauge.
Top ring
(A)
Piston ring
gap
Second
ring
2.0 L
2.5 L
Oil ring rail

ME-00175
Standard mm (in)
0.20 0.35
(0.0079 0.0138)
0.40 0.50
(0.0157 0.0197)
0.35 0.50
(0.0138 0.0197)
0.20 0.50
(0.0079 0.0197)
5) Check the piston pin snap ring for distortion,

cracks and wear.
4. PISTON RING
1) If the piston ring is broken, damaged or worn, or
if its tension is insufficient, or when the piston is replaced, replace the piston ring with a new one of
the same size as the piston.
CAUTION:
Mark is displayed on the end of top and second rings. When installing the rings to the piston, face these marks upward.
Oil ring consists of the upper rail, expander
and lower rail. Be careful about the direction of
rail when installing the oil ring to piston.
(A)
ME-00177
4) Measure the clearance between piston ring and

piston ring groove with a thickness gauge.
Clearance
between piston ring and
piston ring
groove
Top ring
Second ring
Standard mm (in)
0.040 0.080
(0.0016 0.0031)
0.030 0.070
(0.0012 0.0028)
(B)
(C)
(A)
(B)
ME-00178
5. CONNECTING ROD
(C)
ME-00789
1) Replace the connecting rod, if the large or small

end thrust surface is damaged.
2) Check for bend or twist using a connecting rod
aligner. Replace the connecting rod if the bend or
twist exceeds the limit.
(A) Upper rail

(B) Expander
(C) Lower rail
ME(H4SO 2.0)-79
Cylinder Block
MECHANICAL
Limit of bend or twist per 100 mm (3.94 in) in

length:
0.10 mm (0.0039 in)
Connecting rod oil clearance:

Standard
0.016 0.044 mm (0.00063 0.0017 in)
Unit: mm (in)
(A)
Bearings
Standard
(B)
0.03
(0.0012)
undersize
0.05
(0.0020)
undersize
0.25
(0.0098)
undersize
Bearing size
1.492 1.501
(0.0587 0.0591)
51.984 52.000
(2.0466 2.0472)
1.510 1.513
(0.0594 0.0596)
51.954 51.970
(2.0454 2.0461)
1.520 1.523
(0.0598 0.0600)
51.934 51.950
(2.0446 2.0453)
1.620 1.623
(0.0638 0.0639)
51.734 51.750
(2.0368 2.0374)
Outer diameter of
crank pin
(A)
6) Inspect the bushing at connecting rod small end,

and replace if worn or damaged. Also measure the
piston pin clearance at the connecting rod small
end.
(B)
ME-00179
Clearance between piston pin and bushing:

Standard
0 0.022 mm (0 0.0009 in)
(A) Thickness gauge

(B) Connecting rod
3) Install the connecting rod fitted with bearing to

crankshaft and measure the side clearance (thrust
clearance). If side clearance exceeds the limit, replace the connecting rod.
Connecting rod side clearance:
Standard
0.070 0.330 mm (0.0028 0.0130 in)
ME-00181
ME-00180
4) Inspect the 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 the specification, replace the
defective bearing with a new one of standard size
or undersize as necessary. (See the table below.)
ME-00174
7) Replacement procedure is as follows.

(1) Remove the bushing from connecting rod
with ST and press.
(2) Press the bushing with ST after applying oil
on the periphery of bushing.
ME(H4SO 2.0)-80
Cylinder Block
MECHANICAL
ST
499037100
CONNECTING ROD BUSHING REMOVER AND INSTALLER
ST
ME-00182
(3) Make two 3 mm (0.12 in)-holes in bushing.

Ream the inside of bushing.
(4) After completion of reaming, clean the bushing to remove chips.
6. CRANKSHAFT AND CRANKSHAFT

BEARING
1) Clean the crankshaft completely, and check it for
cracks using liquid penetrant tester. Replace if
faulty.
2) Measure the bend of crankshaft. If it exceeds the
limit, repair or replace it.
Crank pin:
2.0 L model
Out-of-roundness
0.005 mm (0.0002 in)
Cylindricality
0.006 mm (0.0002 in)
Grinding limit
To 51.750 mm (2.0374 in) dia.
2.5 L model
Out-of-roundness
0.003 mm (0.0001 in)
Cylindricality
0.004 mm (0.0002 in)
Grinding limit
To 51.750 mm (2.0374 in) dia.
Crank journal:
Out-of-roundness
0.005 mm (0.0002 in)
Cylindricality
0.006 mm (0.0002 in)
Grinding limit
To 59.750 mm (2.3524 in) dia.
NOTE:
If a suitable V-block is not available, install #1 and
#5 crankshaft bearing on cylinder block, position
the crankshaft on these bearings, and then measure the crankshaft bend using a dial gauge.
Crankshaft bend limit:
0.035 mm (0.0014 in)
ME-00184
ME-00183
3) Inspect the crank journal and crank pin for wear.

If they are not within the specifications, replace the
bearing with a suitable (undersize) one, and replace or recondition crankshaft as necessary.
When grinding the crank journal or crank pin, finish
them to the specified dimensions according to the
undersize bearing to be used.
ME(H4SO 2.0)-81
Cylinder Block
MECHANICAL
Unit: mm (in)
Journal O.D.
Standard
0.03 (0.0012)
undersize
0.05 (0.0020)
undersize
0.25 (0.0098)
undersize
Bearing size
Journal O.D.
Bearing size
Journal O.D.
Bearing size
Journal O.D.
Bearing size
Crank journal outer 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
2.000 2.013
(0.0787 0.0792)
(0.0787 0.0793)
59.962 59.978
59.962 59.978
(2.3607 2.3613)
(2.3607 2.3613)
2.017 2.020
2.019 2.022
(0.0794 0.0795)
(0.0795 0.0796)
59.942 59.958
59.942 59.958
(2.3599 2.3605)
(2.3599 2.3605)
2.027 2.030
2.029 2.032
(0.0798 0.0799)
(0.0799 0.0800)
59.742 59.758
59.742 59.758
(2.3520 2.3527)
(2.3520 2.3527)
2.127 2.130
2.129 2.132
(0.0837 0.0839)
(0.0838 0.0839)
4) Measure the side clearance of crankshaft at center bearing. If clearance exceeds the limit, replace
the bearing.
Crankshaft side clearance:
Standard
0.030 0.115 mm (0.0012 0.0045 in)
ME-00322
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 the defective bearing with an undersize one, and replace
or recondition the crankshaft as necessary.
Crankshaft oil clearance:
Standard
0.010 0.030 mm (0.0004 0.0012 in)
ME(H4SO 2.0)-82
Crank pin outer 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)
Engine Trouble in General

MECHANICAL
22.Engine Trouble in General

A: INSPECTION
NOTE:
RANK shown in the chart refers to the possibility of reason for the trouble in order (Very often to Rarely)
A Very often
B Sometimes
C Rarely
Symptom
1. Engine does not start.
1) Starter does not turn.
2) Initial combustion does

not occur.
3) Initial combustion occurs.
Problem parts, etc.

Starter
Possible cause
Defective battery-to-starter harness

Defective starter switch
Defective inhibitor 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(H4SO 2.0)(diag)-2, Basic Diagnostic Procedure.>
Fuel line
Defective fuel pump and relay
Lack of or insufficient fuel
Belt
Trouble
Defective timing
Compression
Incorrect valve clearance
Loosened spark plug or defective gasket
Loosened cylinder head bolt or defective gasket
Improper valve sealing
Defective valve stem
Worn or broken valve spring
Worn or stuck piston rings, cylinder and piston
Incorrect valve timing
Improper engine oil (low viscosity)
Intake system
Defective intake manifold gasket
Defective throttle body gasket
Fuel line
Clogged fuel line
Belt
Trouble
Defective timing
Compression
ME(H4SO 2.0)-83
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
A
B
B
C
C
B
B
B
C
C
C
C
C
B
C
B
B

MECHANICAL
Symptom
4) Engine stalls after initial
combustion.
2. Rough idle and engine

stall
Problem parts, etc.

Possible cause
Intake system
Loosened or cracked intake duct
Loosened or cracked PCV hose
Loosened or cracked vacuum hose
Dirty air cleaner element
Fuel line
Clogged fuel line
Belt
Trouble
Defective timing
Compression
Intake system
Defective PCV valve
Loosened oil filler cap
Fuel line
Clogged fuel line
Belt
Defective timing
Compression
Lubrication system
Incorrect oil pressure
Defective rocker cover gasket
Cooling system
Over-heating
Other
Evaporative emission control system malfunction
Stuck or damaged throttle valve
ME(H4SO 2.0)-84
RANK
A
B
C
C
B
B
C
C
B
B
B
C
C
C
C
C
B
C
B
B
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

MECHANICAL
Symptom
3. Low output, hesitation and
poor acceleration
4. Surging
Problem parts, etc.

Possible cause
Intake system
Defective PCV valve
Fuel line
Clogged fuel line
Belt
Defective timing
Compression
Lubrication system
Cooling system
Over-heating
Over-cooling
Other
Intake system
Defective PCV valve
Fuel line
Clogged fuel line
Belt
Defective timing
Compression
Cooling system
Over-heating
Other
ME(H4SO 2.0)-85
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

MECHANICAL
Symptom
5. Engine does not return to
idle.
6. Dieseling (Run-on)
7. After burning in exhaust

system
8. Knocking
9. Excessive engine oil consumption
Problem parts, etc.

Possible cause
Intake system
Other
Cooling system
Over-heating
Other
Intake system
Defective PCV valve
Belt
Defective timing
Compression
Lubrication system
Cooling system
Over-cooling
Other
Intake system
Belt
Defective timing
Compression
Cooling system
Over-heating
Intake system
Defective PCV valve
Compression
Lubrication system
Loosened oil pump attaching bolts and defective gasket
Defective oil filter seal
Defective crankshaft oil seal
Loosened oil drain plug or defective gasket
Loosened oil pan fitting bolts or defective oil pan
ME(H4SO 2.0)-86
RANK
A
A
A
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

MECHANICAL
Symptom
Problem parts, etc.
Possible cause
10. Excessive fuel consump- Engine control system <Ref. to EN(H4SO 2.0)(diag)-2, Basic Diagnostic Procedure.>
tion
Intake system
Belt
Defective timing
Compression
Lubrication system
Cooling system
Over-cooling
ME(H4SO 2.0)-87
RANK
A
A
B
B
C
C
B
C
C
B
B
C
C
Engine Noise
MECHANICAL
23.Engine Noise
A: INSPECTION
Type of sound
Regular clicking sound
Heavy and dull clank
High-pitched clank (Spark

knock)
Clank when engine speed is

1,000 to 2,000 rpm
Knocking sound when engine

is operating under idling speed
and engine is warm
Squeaky sound
Rubbing sound
Gear scream when starting
engine
Sound like polishing glass with
a dry cloth
Hissing sound
Timing belt noise
Valve tappet noise
Condition
Possible cause
Valve mechanism is defective.
Sound increases as engine
Worn valve rocker
speed increases.
Worn camshaft
Broken valve spring
Worn camshaft main bearing
Oil pressure is low.
Worn connecting rod bearing (big end)
Oil pressure is normal.
Damaged engine mounting
Ignition timing advanced
Sound is noticeable when
Accumulation of carbon inside combustion chamber
accelerating with an overload. Wrong spark plug
Improper gasoline
Sound is reduced when fuel
injector connector of noisy cyl- Worn bearing at crankshaft end of connecting rod
inder is disconnected.
(NOTE*)
Worn cylinder liner and piston ring
injector connector of noisy cyl- Broken or stuck piston ring
Worn piston pin and hole at piston end of connecting rod
(NOTE*)
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
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 with case/adjacent part
NOTE*)
When disconnecting the fuel injector connector, the malfunction indicator light illuminates and DTC is stored in ECM memory.
Therefore, carry out the clear memory mode <Ref. to EN(H4SO 2.0)(diag)-38, OPERATION, Clear Memory Mode.> and inspection mode <Ref. to EN(H4SO 2.0)(diag)-32, OPERATION, Inspection Mode.> after connecting the fuel injector connector.
ME(H4SO 2.0)-88
EXHAUST
EX(H4SO 2.0)
1.
2.
3.
4.
5.
Page
Front Exhaust Pipe......................................................................................7
Center Exhaust Pipe .................................................................................10
Rear Exhaust Pipe ....................................................................................11
Muffler .......................................................................................................13
General Description
EXHAUST
A: COMPONENT
2.0 L model
(19)
T7
(20)
(22)
(21)
(19)
(16)
(19)
(15)
(18)
(17)
(5)
(1)
(23)
(4)
(6)
(3)
T6
(2)
T2
(7)
T5
T3
(24)
(11)
(12)
T1
(14)
(10)
T3
(8)
T1
(8)
(13)
T4
T1
T1
T1
T4
(9)
EX-02020
EX(H4SO 2.0)-2
General Description
EXHAUST
(1)
Front catalytic converter upper

cover
(2)
(3)
(4)
(5)
Front catalytic converter

Center exhaust pipe
Center exhaust pipe upper cover
Rear catalytic converter upper
cover
(6)
(7)
(8)
(9)
(10)
Rear catalytic converter

Rear oxygen sensor
Gasket
Front exhaust pipe
Rear catalytic converter lower
cover
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
Center exhaust pipe lower cover

Gasket
Front catalytic converter lower
cover
Front oxygen (A/F) sensor
Gasket
Spring
Chamber
Rear exhaust pipe
Cushion rubber
Self-locking nut
Gasket
Muffler
EX(H4SO 2.0)-3
(23)
(24)
Rear exhaust pipe upper cover

Rear exhaust pipe lower cover

T1: 13 (1.3, 9.4)
T2: 18 (1.8, 13.0)
T3: 21 (2.1, 15.2)
T4: 30 (3.1, 22.4)
T5: 35 (3.6, 26.0)
T6: 40.8 (4.2, 30.1)
T7: 48 (4.9, 35.4)
General Description
EXHAUST
2.5 L model
(22)
(19)
(19)
(23)
(21)
(19)
(21)
T7
(20)
(19)
(16)
(19)
(20)
(15)
(18)
T7
(17)
(5)
(1)
(24)
(4)
(6)
(3)
T6
(2)
T2
(7)
T5
T3
(25)
(11)
(12)
T1
(14)
(10)
T3
T1
(8)
(8)
(13)
T4
T1
T1
T1
T4
(9)
EX-02012
EX(H4SO 2.0)-4
General Description
EXHAUST
(1)

cover
(2)
(3)
(4)
(5)

Center exhaust pipe
Center exhaust pipe upper cover
Rear catalytic converter upper
cover
(6)
(7)
(8)
(9)
(10)

Rear oxygen sensor
Gasket
Front exhaust pipe
cover
(11)
(12)
(13)
Center exhaust pipe lower cover

Gasket
cover
(23)
(24)
(25)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)

Gasket
Spring
Chamber
Rear exhaust pipe
Cushion rubber
Self-locking nut
Gasket
Muffler (RH)

T1: 13 (1.3, 9.4)
T2: 18 (1.8, 13.0)
T3: 21 (2.1, 15.2)
T4: 30 (3.1, 22.4)
T5: 35 (3.6, 26.0)
T6: 40.8 (4.2, 30.1)
T7: 48 (4.9, 35.4)
EX(H4SO 2.0)-5
Muffler (LH)
Rear exhaust pipe upper cover
Rear exhaust pipe lower cover
General Description
EXHAUST
B: CAUTION
points.
cable from battery.
EX(H4SO 2.0)-6
Front Exhaust Pipe

EXHAUST
2. Front Exhaust Pipe
7) Remove the nuts which hold front exhaust pipe

onto cylinder heads.
A: REMOVAL
CAUTION:
Be careful not to pull down the front and center
exhaust pipe assembly.
IN-00203
2) Disconnect the front oxygen (A/F) sensor connector.
EX-00215
8) Remove the bolt which holds center exhaust

pipe to hanger bracket.
ME-00859

4) Disconnect the rear oxygen sensor connector.
FU-01116
EX-00216
9) Remove the front and center exhaust pipe assembly from the vehicle.
CAUTION:
Be careful not to let the front and center exhaust pipe assembly fall off when removing as
it is quite heavy.
After removing the front and center exhaust
pipe assembly, do not apply excessive pulling
force on the rear exhaust pipe.
10) Separate the front exhaust pipe from center exhaust pipe.
5) Separate the center exhaust pipe from rear exhaust pipe.
EX-00217
EX-00214
EX(H4SO 2.0)-7
Front Exhaust Pipe

EXHAUST
11) Remove the front oxygen (A/F) sensor and rear

oxygen sensor. <Ref. to FU(H4SO 2.0)-32, REMOVAL, Front Oxygen (A/F) Sensor.> <Ref. to
FU(H4SO 2.0)-33, REMOVAL, Rear Oxygen Sensor.> or <Ref. to FU(H4SO 2.5)-34, REMOVAL,
Front Oxygen (A/F) Sensor.> <Ref. to FU(H4SO
2.5)-35, REMOVAL, Rear Oxygen Sensor.>
5) Install the nuts to cylinder head which hold front

exhaust pipe.
Tightening torque:
30 Nm (3.1 kgf-m, 22.4 ft-lb)
B: INSTALLATION
1) Install the front oxygen (A/F) sensor and rear oxygen sensor. <Ref. to FU(H4SO 2.0)-32, INSTALLATION, Front Oxygen (A/F) Sensor.> <Ref. to
FU(H4SO 2.0)-33, INSTALLATION, Rear Oxygen
Sensor.> or <Ref. to FU(H4SO 2.5)-34, INSTALLATION, Front Oxygen (A/F) Sensor.> <Ref. to
FU(H4SO 2.5)-35, INSTALLATION, Rear Oxygen
Sensor.>
2) Install the front exhaust pipe to center exhaust
pipe.
NOTE:
Use a new gasket.
EX-00215

7) Tighten the bolts which install the center exhaust
pipe to rear exhaust pipe.
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
Tightening torque:
40.8 Nm (4.2 kgf-m, 30.1 ft-lb)
EX-00214
EX-00217
3) Install the front and center exhaust pipe assembly to the vehicle.
4) Temporarily tighten the bolt which holds the center exhaust pipe to hanger bracket.
8) Tighten the bolt which holds the center exhaust

Tightening torque:
35 Nm (3.6 kgf-m, 26.0 ft-lb)
EX-00216
EX-00216
EX(H4SO 2.0)-8
Front Exhaust Pipe

EXHAUST
9) Connect the rear oxygen sensor connector.
FU-01116

11) Connect the front oxygen (A/F) sensor connector.
ME-00859
IN-00203
C: INSPECTION
EX(H4SO 2.0)-9
Center Exhaust Pipe

EXHAUST
3. Center Exhaust Pipe

A: REMOVAL
After removing the center and front exhaust pipes
as one unit, separate them. Refer to Front Exhaust
Pipe for removal procedure. <Ref. to EX(H4SO
2.0)-7, REMOVAL, Front Exhaust Pipe.>
B: INSTALLATION
Install the center exhaust pipe and front exhaust
pipe as one unit. Refer to Front Exhaust Pipe for
installation procedure. <Ref. to EX(H4SO 2.0)-8,
INSTALLATION, Front Exhaust Pipe.>
C: INSPECTION
EX(H4SO 2.0)-10
Rear Exhaust Pipe

EXHAUST
4. Rear Exhaust Pipe
4) Remove the rear exhaust pipe bracket from

cushion rubber.
A: REMOVAL
1) Separate the rear exhaust pipe from center exhaust pipe.
EX-00219
B: INSTALLATION
EX-00214
2) Separate the rear exhaust pipe from muffler.

CAUTION:
Be careful not to pull down the rear exhaust
pipe.
LH side
1) Apply a coat of spray type lubricant to mating

area of cushion rubber.
2) Install the rear exhaust pipe bracket to cushion
rubber.
EX-00219
3) Install the rear exhaust pipe to muffler.

EX-00222
RH side (2.5 L model)
NOTE:
Use a new gasket and self-locking nut.
Tightening torque:
48 Nm (4.9 kgf-m, 35.4 ft-lb)
LH side
EX-00218

EX(H4SO 2.0)-11
EX-00222
Rear Exhaust Pipe

EXHAUST
EX-00218
4) Install the rear exhaust pipe to center exhaust

pipe.
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
EX-00214
C: INSPECTION
3) Make sure the cushion rubber is not worn or
cracked.
EX(H4SO 2.0)-12
Muffler
EXHAUST
5. Muffler
B: INSTALLATION
A: REMOVAL
1) Separate the muffler from rear exhaust pipe.

LH side
NOTE:
Tightening torque:
48 Nm (4.9 kgf-m, 35.4 ft-lb)
LH side
EX-00222

EX-00222
EX-00218

LH side
EX-00218
C: INSPECTION
cracked.
EX-00220
EX-00221
3) Remove the front and rear cushion rubber, and

then remove the muffler.
EX(H4SO 2.0)-13
Muffler
EXHAUST
EX(H4SO 2.0)-14
COOLING
CO(H4SO 2.0)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Page
Radiator Fan System ..................................................................................7
Engine Coolant..........................................................................................13
Water Pump ..............................................................................................15
Thermostat ................................................................................................18
Radiator.....................................................................................................20
Radiator Cap .............................................................................................24
Radiator Main Fan and Fan Motor ............................................................25
Radiator Sub Fan and Fan Motor..............................................................27
Reservoir Tank..........................................................................................29
Engine Cooling System Trouble in General ..............................................30
General Description
COOLING
A: SPECIFICATION
Cooling system
Electric fan + Forced engine coolant circulation system

MT: approx. 6.5 (6.9, 5.7)
Total engine coolant capacity
2 (US qt, Imp qt) AT: approx. 6.4 (6.8, 5.6) (Model without ATF warmer)
AT: approx. 6.8 (7.1, 6.0) (Model with ATF warmer)
Type
Centrifugal impeller type
Discharge 2 (US gal, Imp gal) /min
20 (5.3, 4.4)
Discharge perfor- Pump speed Discharge pres760 rpm 2.9 kPa (0.3 mAq)
mance I
sure
Engine coolant temperature
85C (185F)
100 (26.4, 22.0)
Discharge perfor- Pump speed Discharge pres3,000 rpm 49.0 kPa (5.0 mAq)
sure
mance II
85C (185F)
Water pump
200 (52.8, 44.0)
Discharge perfor- Pump speed Discharge pres6,000 rpm 225.4 kPa (23.0 mAq)
sure
mance III
85C (185F)
Impeller diameter
mm (in)
76 (2.99)
Number of impeller vanes
8
Pump pulley diameter
mm (in)
60 (2.36)
Clearance between impeller
Standard
mm (in)
0.5 1.5 (0.020 0.06)
and case
Type
Wax pellet type
Starting temperature to open
80 84C (176 183F)
Thermostat
Fully opens
95C (203F)
Valve lift
mm (in)
9.0 (0.354) or more
Valve bore
mm (in)
35 (1.38)
Main fan
90 W
Motor input
Sub fan
90 W
Radiator fan
Main fan
300 mm (11.81 in) /4
Fan diameter /
Blades
Sub fan
300 mm (11.81 in) /5
Type
Down flow, pressure type
Width Height
687.4 340 16
Core dimensions
mm (in)
Thickness
(27.06 13.39 0.63)
Above: 10815, or more
Radiator
Pressure range in which cap
(1.10.15, 162)
2
kPa (kg/cm , psi)
valve is open
Below: 1.0 4.9, or less
(0.01 0.05, 0.1 0.7)
Fins
Corrugated fin type
Reservoir
Capacity
2 (US qt, Imp qt)
0.45 (0.48, 0.40)
tank
CO(H4SO 2.0)-2
General Description
COOLING
Vehicle speed
19 km/h (12 MPH) or less
20 69 km/h
(12 43 MPH)
70 105 km/h
(43 65 MPH)
106 km/h (66 MPH) or more
A/C compressor load
OFF
Low
High
OFF
Low
High
OFF
Low
High
OFF
Low
High

96 99C
95C (203F) or less
100C (212F) or more
(203 210F)
Operation of radiator
fan
fan
fan
OFF
Low-Speed
High-Speed
Low-Speed
Low-Speed
High-Speed
High-Speed
High-Speed
High-Speed
OFF
Low-Speed
High-Speed
High-Speed
High-Speed
High-Speed
High-Speed
High-Speed
High-Speed
OFF
Low-Speed
High-Speed
OFF
Low-Speed
High-Speed
Low-Speed
High-Speed
High-Speed
OFF
OFF
High-Speed
OFF
Low-Speed
High-Speed
OFF
Low-Speed
High-Speed
CO(H4SO 2.0)-3
General Description
COOLING
B: COMPONENT
1. WATER PUMP
(2)
(1)
T1
T1
(5)
(3)
(4)
(6)
T2
(7)
CO-02031
(1)
(2)
(3)
(4)
Water pump ASSY

Gasket
Heater by-pass hose
ATF warmer by-pass hose (Model
with ATF warmer)
(5)
(6)
(7)
Thermostat
Gasket
Thermostat cover

T1: First 12 (1.2, 8.7)
Second 12 (1.2, 8.7)
T2: 12 (1.2, 8.7)
CO(H4SO 2.0)-4
General Description
COOLING
2. RADIATOR AND RADIATOR FAN

T2
T1
(5)
(6)
(8)
T3
(5)
(4)
T2
(7)
(10)
T1
T4
(14)
(27)
(3)
(11)
(26)
(24)
T2
T4
(12)
(9)
(14)
T2
(2)
(28)
(13)
B
(14)
A
(22)
(15)
(20)
(5)
(14)
T2
(14)
(21)
(5)
(16)
(1)
(14)
(25)
T2
T2
(23)
(14)
(17)
(18)
(14)
(19)
CO-02010
(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
Radiator sub fan shroud
Radiator sub fan, radiator sub fan
motor assembly
(12)
(13)
Radiator main fan shroud

Radiator main fan, radiator main
fan motor assembly
(14)
(15)
ATF hose clamp (AT model)

ATF inlet hose A (Model without
ATF warmer)
(24)
(25)
Radiator cap
Heat shield cover (Model without
ATF warmer)
(16)
ATF outlet hose A (Model without

ATF warmer)
(26)
ATF inlet hose A (Model with ATF

warmer)
(17)
ATF pipe (Model without ATF

warmer)
(27)
ATF outlet hose A (Model without

ATF warmer)
(18)
ATF outlet hose B (Model without

ATF warmer)
(28)
ATF pipe (Model with ATF warmer)
(19)
ATF inlet hose B (Model without

ATF warmer)
(20)
(21)
(22)
(23)
Radiator outlet hose

Radiator drain plug
O-ring
Radiator lower bracket

T1: 4.4 (0.45, 3.3)
T2: 7.5 (0.76, 5.5)
T3: 12 (1.2, 8.9)
T4: 3.4 (0.35, 2.5)
CO(H4SO 2.0)-5
General Description
COOLING
C: CAUTION

points.
cable from battery.
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
499977400
DESCRIPTION
CRANK PULLEY
WRENCH
REMARKS
Used for stopping rotation of crank pulley
when loosening/tightening crank pulley bolt.
(2.0 L model)
499977100
CRANK PULLEY
WRENCH
Used for stopping rotation of crank pulley

when loosening/tightening crank pulley bolt.
(2.5 L model)
18231AA010
CAM SPROCKET
WRENCH
Used for removing and installing cam

sprocket.
CAM SPROCKET WRENCH (499207100)
can also be used.
ST-499977400
ST-499977100
ST18231AA010
CO(H4SO 2.0)-6
Radiator Fan System

COOLING
2. Radiator Fan System

A: WIRING DIAGRAM
SBF-1
SBF-7
No.3
IGNITION
SWITCH
No.2
No.26
No.22
MAIN FUSE BOX (M/B)
C:
F35
E:
F36
E3
B7
C11
B: B143
C10
E5
E6
MAIN
FAN
RELAY 1
THROUGH JOINT
CONNECTOR
MAIN
FAN
RELAY 2
SUB
FAN
RELAY
B360
A/C RELAY HOLDER

F27
THROUGH JOINT
CONNECTOR
22
21
F108
F16
16
B361
*1
*1
2.5 L EC, EK, K4 MODEL: A31
SUB FAN
MOTOR
*2
F17
MAIN FAN
MOTOR
3
F109
23
20
10
EXCEPT FOR 2.5 L EC, EK, K4 MODEL: A10
A: B134
*2
2.5 L EC, EK, K4 MODEL: B34
ECM
B: B135
EXCEPT FOR 2.5 L EC, EK, K4 MODEL: A9
F16
B361
F17
1 2 3
4 5 6
7 8 9 10 11 12 13 14
F27
B360
F108
F109
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
1 2 3 4
5 6 7 8
9 10 11 12 13 14 15 16 17 18
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
1
2 4 5
3
2 1
C:
A: B134
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
F35
E:
1 2
3 4 5
6 7 8 9 10 11 12
F36
1 2
4 5
B: B143
B: B135
3
7
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
10
8 9 11
12
18 19
20 21
22
23
24 25
26
27
28 29
13
14 16 17
15
6
7
30
31
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
CO-02011
CO(H4SO 2.0)-7
Radiator Fan System

COOLING
B: INSPECTION
DETECTING CONDITION:
Engine coolant temperature is more than 96C (205F).
Vehicle speed is below 19 km/h (12 MPH).
TROUBLE SYMPTOMS:
Radiator main and sub fan do not rotate under the above conditions.
Step
Check
CHECK OPERATION OF RADIATOR FAN.
Do the radiator main fan and
1) Connect the test mode connector.
sub fan rotate at low speed?
3) Perform the compulsory operation check for
the radiator fan relay using Subaru Select
Monitor.
NOTE:
When performing the compulsory operation
check for the radiator fan relay using Subaru
Select Monitor, the radiator main fan and sub
fan will repeat such a operation as low speed
revolution high speed revolution OFF in
this order.
Refer to Compulsory Valve Operation Check
Mode for more operation procedure. <Ref. to
EN(H4SO 2.0)(diag)-39, Compulsory Valve
Operation Check Mode.> <Ref. to EN(H4SO
2.5)(diag)-42, Compulsory Valve Operation
Check Mode.>
sub fan rotate at high speed?
Monitor.
Yes
Go to step 2.
No
Go to step 3.
Radiator fan system is normal.
Go to step 27.
NOTE:
this order.
EN(H4SO 2.0)(diag)-39, Compulsory Valve
Operation Check Mode.> <Ref. to EN(H4SO
Check Mode.>
CHECK POWER SUPPLY TO SUB FAN RE- Is the voltage more than 10 V? Go to step 4.
LAY.
2) Remove the sub fan relay from A/C relay
holder.
3) Measure the voltage between sub fan relay
terminal and chassis ground.
Connector & terminal
(F27) No. 20 (+) Chassis ground ():
CO(H4SO 2.0)-8
Go to step 5.
Radiator Fan System

COOLING
10
11
12
13
Step
CHECK POWER SUPPLY TO SUB FAN RELAY.
CHECK FUSE.
2) Remove the fuse No. 3.
3) Check the condition of fuse.
CHECK FUSE.
CHECK SUB FAN RELAY.
2) Measure the resistance between sub fan
relay terminals.
Terminals
No. 20 No. 21:
1) Connect the battery to terminals No. 22 and
No. 23 of sub fan relay.
relay terminals.
Terminals
No. 20 No. 21:
CHECK HARNESS BETWEEN SUB FAN RELAY TERMINAL AND SUB FAN MOTOR
CONNECTOR.
1) Disconnect the connector from sub fan
motor.
2) Measure the resistance of harness
between sub fan relay terminal and sub fan
motor connector.
(F16) No. 2 (F27) No. 21:
CHECK HARNESS BETWEEN SUB FAN MOTOR CONNECTOR AND MAIN FAN RELAY 2
CONNECTOR.
1) Remove the main fan relay 2 from A/C relay
holder.
between sub fan motor connector and main fan
relay 2 connector.
(F16) No. 1 (F27) No. 5:
CHECK POOR CONTACT.
Check the poor contact in sub fan motor connector.
CHECK SUB FAN MOTOR.
Connect the battery positive (+) terminal to terminal No. 2 of sub fan motor, and the ground (
) terminal to terminal No. 1.
CHECK MAIN FAN RELAY 2.
Measure the resistance of main fan relay 2.
Terminals
No. 2 No. 5:
Check
Yes
Is the voltage more than 10 V? Go to step 7.
No
Go to step 6.
Is the fuse blown out?
Replace the fuse.
Repair the power

supply line.
Replace the fuse.
Repair the power

supply line.
Is the resistance more than 1

M?
Go to step 8.
Replace the sub

fan relay.
Is the resistance less than 1

?
Go to step 9.
Replace the sub

fan relay.

?
Go to step 10.
Measure the open

circuit of harness
between sub fan
relay terminal and
sub fan motor connector.

?
Go to step 11.
Repair the open

harness between
sub fan motor connector and main
fan relay 2 connector.
Is there poor contact in sub fan Repair the poor

motor connector?
contact in sub fan
motor connector.
Does the sub fan rotate?
Go to step 13.
Go to step 12.

?
Replace the main

fan relay 2.
CO(H4SO 2.0)-9
Go to step 14.
Replace the sub

fan motor.
Radiator Fan System

COOLING
14
15
16
17
18
19
20
21
Step
CHECK HARNESS BETWEEN MAIN FAN
RELAY 2 TERMINAL AND MAIN FAN MOTOR CONNECTOR.
1) Disconnect the connector from main fan
motor.
between main fan relay 2 terminal and main
fan motor connector.
(F17) No. 2 (F27) No. 2:
CHECK MAIN FAN MOTOR AND GROUND
CIRCUIT.
Measure the resistance between main fan
motor connector and chassis ground.
(F17) No. 1 Chassis ground:
CHECK POOR CONTACT.
Check poor contact in main fan motor connector.
CHECK MAIN FAN MOTOR.
Connect the battery positive (+) terminal to terminal No. 2 of main fan motor, and the ground
() terminal to terminal No. 1.
CHECK HARNESS BETWEEN SUB FAN RELAY AND ECM.
1) Disconnect the connector from ECM.
relay terminal and ECM connector.
2.5 L EC, EK, K4 model
(B134) No. 31 (F27) No. 22:
Except for 2.5 L EC, EK, K4 model
(B134) No. 10 (F27) No. 22:
CHECK POOR CONTACT.
Check poor contact in ECM connector.

holder.
3) Measure the resistance of terminal in main
fan relay 1 switch.
1) Connect the battery to terminal of main fan
relay 1 coil.
2) Measure the resistance between terminals
of main fan relay 1 switch.
Check
?
Yes
Go to step 15.
No
Repair the open
circuit of harness
between main fan
relay 2 terminal
and main fan
motor connector.

?
Go to step 16.
Is there poor contact in main

fan motor connector?
Repair the open

circuit in harness
between main fan
motor connector
and chassis
ground.
Go to step 17.
Repair the poor

contact in main fan
motor connector.
Go to step 18.
Replace the main
fan motor.
Does the main fan rotate?

?
Go to step 19.
Repair the open

circuit in harness
between sub fan
relay terminal and
ECM.
Is there poor contact in ECM

connector?
Repair the poor

contact in ECM
connector.

M?
Go to step 21.
Check the DTC.

Repair the trouble
cause. <Ref. to
EN(H4SO
2.0)(diag)-31,
Read Diagnostic
Trouble Code
(DTC).> <Ref. to
EN(H4SO
2.5)(diag)-33,
Read Diagnostic
Trouble Code
(DTC).>
Replace the main
fan relay 1.

?
Go to step 22.
CO(H4SO 2.0)-10
Replace the main

fan relay 1.
Radiator Fan System

COOLING
22
23
24
25
26
27
28
29
Step
motor.
(F17) No. 2 (F36) No. 6:
RELAY 1 AND ECM.
2) Measure the resistance between main fan
relay 1 terminal and ECM connector.
(B135) No. 34 (B143) No. 7:
(B134) No. 9 (B143) No. 7:
RELAY 2 AND ECM.
(B135) No. 34 (F27) No. 3:
(B134) No. 9 (F27) No. 3:
CHECK FUSE.
2) Remove the fuse No. 2 and No. 26.
CHECK POOR CONTACT.
Check
?
Yes
Go to step 23.
No
Repair the open
circuit of harness
between main fan
relay 1 terminal
and main fan
motor connector.

?
Go to step 24.
Repair the open

circuit of harness
between main fan
relay 1 terminal
and ECM.

?
Go to step 25.
Repair the open

circuit of harness
between main fan
relay 2 terminal
and ECM.
Replace the fuse.
Go to step 26.
Is there a poor contact in ECM Repair the poor

connector?
contact in ECM
connector.
Go to step 20.

Check if the sub fan rotates when both fans do
not rotate at high speed under the step 2.
CHECK GROUND CIRCUIT OF MAIN FAN
Go to step 29.
RELAY 2.
?
holder.
relay 2 terminal and chassis ground.
CHECK POWER SUPPLY TO MAIN FAN RE- Is the voltage more than 10 V? Go to step 30.
LAY 2.
2) Measure the voltage between main fan
CO(H4SO 2.0)-11
Repair the power

supply circuit for
main fuse box.
Go to step 28.
Repair the open

circuit in harness
between main fan
relay 2 and chassis ground.
Repair the power

supply line.
Radiator Fan System

COOLING
30
31
Step
2) Remove the main fan relay 2.
3) Measure the resistance of main fan relay 2.
Terminals
(F27) No. 2 (F27) No. 4:
No. 3 of main fan relay 2.
Terminals
(F27) No. 4 (F27) No. 5:
Check
M?
Yes
Go to step 31.
No
Replace the main
fan relay 2.

?
Go to step 23.
Replace the main

fan relay 2.
CO(H4SO 2.0)-12
Engine Coolant
COOLING
3. Engine Coolant
2) Fill engine coolant into the reservoir tank up to

FULL level.
A: REPLACEMENT
1. DRAINING OF ENGINE COOLANT
3) Remove the drain plug to drain engine coolant
into container.
FULL
FULL
LOW
LOW
NOTE:
Remove the radiator cap so that engine coolant will
drain faster.
(B)
(A)
CO-00269
3) Warm-up the engine completely for more than

five minutes at 2,000 to 3,000 rpm.
4) If the engine coolant level drops in radiator, add
engine coolant to filler neck position.
5) If the engine coolant level drops from FULL level of reservoir tank, add engine coolant to FULL
level.
6) Attach the radiator cap and reservoir tank cap
properly.
CO-00268
(A) Drain plug

(B) Heat shield cover
4) Install the drain plug.
2. FILLING OF ENGINE COOLANT

1) Fill engine coolant into the radiator up to the filler
neck position.
MT model:
6.5 2(6.9 US qt, 5.7 Imp qt)
AT model (model without ATF warmer):
6.4 2(6.8 US qt, 5.6 Imp qt)
AT model (model with ATF warmer):
6.8 2(7.2 US qt, 6.0 Imp qt)
NOTE:
CO(H4SO 2.0)-13
Engine Coolant
COOLING
B: INSPECTION
1. RELATIONSHIP OF SUBARU COOLANT
Specific gravity
of coolant
The concentration and safe operating temperature

of 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 45%
20C (4F) (point C).
Concentration
of coolant
1.100
1.090

[Example]
only.
60%
1.070
C
1.060
B
50%
(1.054)
1.050
40%
1.040
1.030
Freezing
temperature
30%
1.020
1.000
20%
25 C
(77 F)
1.010
10%
0
10 20 30 40 50
-40 -30 -20 -10
(-40) (-22) (-4) (14) (32) (50) (68) (86) (104) (122)
CO-00237
1.080
of coolant
3
(3.2,
2.6)
2
(2.1,
1.8)
1
(1.1,
0.9)
0
45%
A
35%
40%
30%
25%
20%
10% 15%
10
20
30
40
50
CO-00012
CO(H4SO 2.0)-14
Water Pump
COOLING
4. Water Pump
7) Remove the belt cover No. 2 (LH).
A: REMOVAL
1) Remove the radiator. <Ref. to CO(H4SO 2.0)20, REMOVAL, Radiator.>
REMOVAL, V-belt.>
3) Remove the timing belt. <Ref. to ME(H4SO 2.0)43, TIMING BELT, REMOVAL, Timing Belt.>
4) Remove the automatic belt tension adjuster.
CO-00019
CO-00016

CO-00020
9) Disconnect the hose from water pump.

10) Remove the water pump.
CO-00017
6) Remove the cam sprocket (LH) using ST.

NOTE:
also be used.
CO-00021
B: INSTALLATION
1) Install the water pump onto cylinder block (LH).
NOTE:
Use a new gasket.
When installing the water pump, tighten the bolts
in two stages in alphabetical sequence as shown in
figure.
ST
CO-00018
CO(H4SO 2.0)-15
Water Pump
COOLING
Tightening torque:
First:
12 Nm (1.2 kgf-m, 8.7 ft-lb)
Second:
12 Nm (1.2 kgf-m, 8.7 ft-lb)
Tightening torque:
78 Nm (8.0 kgf-m, 57.9 ft-lb)
ST
(F)
(E)
(A)
(D)
(C)
(B)
CO-00018

ME-00847
2) Connect the hose to the water pump.

Tightening torque:
39 Nm (4.0 kgf-m, 28.9 ft-lb)
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
CO-00017
CO-00020
4) Install the belt cover No. 2 (LH).

Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
7) Install the automatic belt tension adjuster to

which tension rod is held with pin. <Ref. to
ME(H4SO 2.0)-44, AUTOMATIC BELT TENSION
ADJUSTER ASSEMBLY AND BELT IDLER, INSTALLATION, Timing Belt.>
8) Install the timing belt. <Ref. to ME(H4SO 2.0)45, TIMING BELT, INSTALLATION, Timing Belt.>
10) Install the radiator. <Ref. to CO(H4SO 2.0)-21,
INSTALLATION, Radiator.>
C: INSPECTION
CO-00019
5) Install the cam sprocket (LH) using ST.

1) Check the water pump bearing for smooth rotation.

2) Check the water pump pulley for abnormalities.
3) Make sure the impeller is not deformed or damaged.
4) Inspect the clearance between impeller and
pump case.
NOTE:
also be used.
CO(H4SO 2.0)-16
Water Pump
COOLING
Clearance between impeller and pump case:

Standard value
0.5 1.5 mm (0.020 0.060 in)
CO-00293
5) After water pump installation, check the pulley

shaft for engine coolant leaks and noise. If leaks or
noise are noted, replace the water pump assembly.
CO(H4SO 2.0)-17
Thermostat
COOLING
5. Thermostat
6) Remove the thermostat cover and gasket, and

then remove the thermostat.
A: REMOVAL
4) Drain engine coolant completely.
<Ref. to CO(H4SO 2.0)-13, DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>
(B)
(C)
(A)
(B)
CO-00268
(A)
(A) Drain plug

(B) Heat shield cover
CO-00154
5) Disconnect the radiator outlet hose from thermostat cover.
(A) Thermostat cover

(B) Gasket
(C) Thermostat
B: INSTALLATION
1) Install a gasket to thermostat, and install the
thermostat and gasket to water pump as a unit.
Then, install the thermostat cover.
CO-00270
NOTE:
When reinstalling the thermostat, use a new gasket.
The thermostat must be installed with the jiggle
pin facing to the up side.
CO(H4SO 2.0)-18
Thermostat
COOLING
Tightening torque:
12 Nm (1.2 kgf-m, 8.7 ft-lb)
Valve lift:
9.0 mm (0.354 in) or more
(A)
(B)
CO-00033
(D)
(A) Thermometer
(B) Thermostat
T
(C)
(B)
(A)
CO-00155
(A)
(B)
(C)
(D)
Thermostat cover
Gasket
Thermostat
Jiggle pin
2) Connect the radiator outlet hose to thermostat

cover.
5) Fill with engine coolant. <Ref. to CO(H4SO 2.0)13, FILLING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>
C: INSPECTION
Replace the thermostat if the valve does not close
completely at an ambient temperature or if the following test shows unsatisfactory results.
Inspection method
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.
Starting temperature to open:
80 84C (176 183F)
Fully opens:
95C (203F)
CO(H4SO 2.0)-19
Radiator
COOLING
6. Radiator
7) Disconnect the connector (A) of radiator main

fan motor and connector (B) of sub fan motor.
A: REMOVAL
(A)
CO-00274
IN-00203

5) Remove the heat shield cover from radiator.
(Model without ATF warmer)
(B)
CO-00275
CO-00273

<Ref. to CO(H4SO 2.0)-13, DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>
CO-00270
9) Disconnect the ATF cooler hoses from ATF

pipes. (Model without ATF warmer)
Plug the ATF pipe to prevent ATF leaks.
CO-00253

11) Disconnect the over flow hose.
12) Remove the reservoir tank. <Ref. to CO(H4SO
2.0)-29, REMOVAL, Reservoir Tank.>
CO(H4SO 2.0)-20
Radiator
COOLING
13) Remove the hood stay holder.
NOTE:
Make pins on the lower side of radiator be fitted into
the radiator lower cushions on body side.
3) Install the radiator upper brackets and tighten
the bolts.
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
CO-00276

15) Disconnect the radiator inlet hose from engine.
CO-00278
4) Connect the radiator inlet hose.
CO-00277
16) Remove the radiator upper brackets.
CO-00277
6) Install the hood stay holder.
CO-00278
17) Lift the radiator up and away from vehicle.
B: INSTALLATION
1) Attach the radiator lower cushions to holes on
the radiator lower bracket.
CO-00276
7) Install the reservoir tank. <Ref. to CO(H4SO

2.0)-29, INSTALLATION, Reservoir Tank.>
8) Connect the over flow hose.
CO-00041
2) Install the radiator to vehicle.
CO(H4SO 2.0)-21
Radiator
COOLING
10) Connect the ATF cooler hoses. (Model without

ATF warmer)
13) Install the heat shield cover. (Model without

ATF warmer)
CO-00253
CO-00273

11) Connect the radiator outlet hose.
CO-00270
12) Connect the connector (A) to radiator main fan

motor and connector (B) to sub fan motor.
IN-00203
17) Fill with engine coolant. <Ref. to CO(H4SO

2.0)-13, FILLING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>
18) Check the ATF level. <Ref. to 4AT-31, INSPECTION, Automatic Transmission Fluid.>
C: INSPECTION
1) Remove the radiator cap, top off the radiator with
coolant, and then attach the tester in place of cap.
(A)
CO-00274
CO-00094
(B)
CO-00275
2) Apply a pressure of 157 kPa (1.6 kg/cm2, 23 psi)

to the radiator to check if:
Engine coolant leaks at/around radiator.
Engine coolant leaks at/around hoses or connections.
CAUTION:
Engine should be turned off.
Wipe engine coolant from check points in advance.
CO(H4SO 2.0)-22
Radiator
COOLING
Be careful to prevent engine coolant from

spurting out when removing tester.
Be careful not to deform the filler neck of radiator when installing or removing the tester.
CO(H4SO 2.0)-23
Radiator Cap
COOLING
7. Radiator Cap
A: INSPECTION
1) Attach the radiator cap to tester.
CO-00044
2) Increase pressure until the 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(H4SO 2.0)-24
Radiator Main Fan and Fan Motor

COOLING
8. Radiator Main Fan and Fan

Motor
11) Remove the bolts which hold the radiator main

fan shroud to radiator.
A: REMOVAL
CO-00096
12) Remove the radiator main fan motor assembly.
B: INSTALLATION
IN-00203

5) Disconnect the connector (A) of main fan motor.

NOTE:
When the radiator main fan motor assembly cannot
be installed, loosen the bolts which secure radiator
sub fan motor assembly.
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
(A)
CO-00274
6) Remove the heat shield cover. (Model without

ATF warmer)
CO-00096
C: DISASSEMBLY
1) Remove the clip which holds motor connector
onto the shroud.
2) Remove the nut which holds the fan onto fan
motor and shroud.
CO-00273
7) Remove the ATF hose from the clip of radiator

main fan motor assembly. (Model without ATF
warmer)
10) Remove the reservoir tank. <Ref. to CO(H4SO
2.0)-29, REMOVAL, Reservoir Tank.>
CO(H4SO 2.0)-25
CO-00102

COOLING
3) Remove the bolts which install fan motor onto

the shroud.
CO-00098
D: ASSEMBLY
Assemble in the reverse order of disassembly.
Tightening torque:
4.4 Nm (0.45 kgf-m, 3.3 ft-lb)
CO-00098
Tightening torque:
3.4 Nm (0.35 kgf-m, 2.5 ft-lb)
CO-00102
CO(H4SO 2.0)-26
Radiator Sub Fan and Fan Motor

COOLING
9. Radiator Sub Fan and Fan

Motor
10) Remove the bolts which hold the radiator sub

fan shroud to radiator.
A: REMOVAL
CO-00101
11) Remove the radiator sub fan motor assembly

from the lower side of vehicle.
IN-00203

5) Disconnect the connector (B) of sub fan motor.
B: INSTALLATION
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
(B)
CO-00101
CO-00275
6) Remove the heat shield cover. (Model without

ATF warmer)
C: DISASSEMBLY
1) Remove the clip which holds the fan motor connector onto shroud.
2) Remove the nut which holds fan onto the fan
motor and shroud assembly.
CO-00273

sub fan motor assembly. (Model without ATF
warmer)
CO(H4SO 2.0)-27
CO-00097

COOLING
3) Remove the bolts which install fan motor onto

the shroud.
CO-00098
D: ASSEMBLY
Tightening torque:
4.4 Nm (0.45 kgf-m, 3.3 ft-lb)
CO-00098
Tightening torque:
3.4 Nm (0.35 kgf-m, 2.5 ft-lb)
CO-00097
CO(H4SO 2.0)-28
Reservoir Tank
COOLING
10.Reservoir Tank
A: REMOVAL
2) Pull out the reservoir tank to the direction of arrow while pushing the pawl (A).
(A)
CO-00279
B: INSTALLATION
C: INSPECTION
Make sure the engine coolant level is between
FULL and LOW.
CO(H4SO 2.0)-29
Engine Cooling System Trouble in General

COOLING
11.Engine Cooling System Trouble in General

A: INSPECTION
Trouble
Over-heating
Over-cooling
Engine coolant
leaks
Strange noise
Possible cause
Corrective action
Replenish engine coolant, inspect for leakage, and
a. Insufficient engine coolant
repair it if necessary.
b. Loose timing belt
Repair or replace timing belt tensioner.
c. Oil on timing belt
Replace.
d. Malfunction of thermostat
Replace.
e. Malfunction of water pump
Replace.
f. Clogged engine coolant passage
Clean.
Inspect and repair ignition control system.
g. Improper ignition timing
<Ref. to EN(H4SO 2.0)(diag)-2, Basic Diagnostic Procedure.>
h. Clogged or leaking radiator
Clean, repair or replace.
i. Improper engine oil in engine coolant
Replace engine coolant.
Inspect and repair the fuel injection system. <Ref. to
j. Air/fuel mixture ratio too lean
EN(H4SO 2.0)(diag)-2, Basic Diagnostic Procedure.>
k. Excessive back pressure in exhaust system
Clean or replace.
l. Insufficient clearance between piston and cylinder Adjust or replace.
m. Slipping clutch
Correct or replace.
n. Dragging brake
Adjustment.
Inspect radiator fan relay, engine coolant temperature
o. Defective radiator fan
sensor or radiator motor and replace them.
a. Ambient temperature extremely low
Partly cover radiator front area.
b. Defective thermostat
Replace.
a. Loosened or damaged connecting units on hoses Correct or replace.
b. Leakage from water pump
Replace.
c. Leakage from water pipe
Correct or replace.
d. Leakage around cylinder head gasket
Retighten cylinder head bolts or replace gasket.
e. Damaged or cracked cylinder head and crankcase Correct or replace.
f. Damaged or cracked thermostat case
Correct or replace.
g. Leakage from radiator
Correct or replace.
a. Defective timing belt
Replace.
b. Defective radiator fan
Replace.
c. Defective water pump bearing
Replace water pump.
d. Defective water pump mechanical seal
Replace water pump.
CO(H4SO 2.0)-30
LUBRICATION
LU(H4SO 2.0)
1.
2.
3.
4.
5.
6.
7.
8.
Page
Oil Pressure System ...................................................................................6
Engine Oil....................................................................................................8
Oil Pump ...................................................................................................10
Oil Pan and Strainer..................................................................................14
Oil Pressure Switch...................................................................................17
Engine Oil Filter.........................................................................................18
General Diagnostic Table..........................................................................19
General Description
LUBRICATION
A: SPECIFICATION
Lubrication method
Pump type
Inner rotor
Outer rotor
Outer rotor diameter thickness
Tip clearance between inner and
Standard value
outer rotors
Side clearance between inner rotor
Standard value
and pump case
Case clearance between outer
Standard value
rotor and pump case
Discharge
pressure
600 rpm
Discharge rate
Performance at
80C (176F)
Discharge
5,000 rpm pressure
Discharge rate
mm (in)
Forced lubrication
Trochoid type
9
10
78 7 (3.07 0.28)
mm (in)
0.04 0.14 (0.0016 0.0055)
mm (in)
0.02 0.07 (0.0008 0.0028)
mm (in)
0.10 0.175 (0.0039 0.0069)
Number of teeth
OIL PUMP
kPa (kg/cm2, psi)
98 (1.0, 14)
2 (US qt, Imp qt)/min.
3.2 (3.4, 2.8)
kPa (kg/cm2, psi)
294 (3.0, 43)
Relief valve working pressure
kPa
(kg/cm2,
32.6 (34.4, 28.7)

490 (5.0, 71)
psi)
Filter type
Filtration area
Oil filter
Oil pressure
switch
kPa (kg/cm2, psi)
By-pass valve opening pressure

Outer diameter width
Full-flow filter type

800 (124)
470 (73)
Outer diameter 68 mm
cm2 (sq in)
mm (in)
157 (1.60, 22.8)

68 65 (2.68 2.56)
65 74.4 (2.56 2.93)
M 20 1.5
Immersed contact point type
12 V 3.4 W or less
Installation screw specifications

Type
Working voltage wattage
kPa (kg/cm2, psi)
Warning light activation pressure
14.7 (0.15, 2.1)
2,
Proof pressure
981 (10, 142) or more
kPa (kg/cm psi)

2 (US qt, Imp qt)
Oil capacity (at replacement)
Recommended oil:
API classification SL, SJ with the Energy
Conserving logo is printed, or SH (if you
cannot obtain the oil with SL, SJ or SH
grades, you may use SG, SF grades ENERGY CONSERVING oil.)
ACEA specification, A1, A2 or A3
CCMC specification, G4 or G5
New API certification mark (Star burst mark)
label is on the container.
SAE (1)
( C) -30 -20 -15
( F) -22 -4 5
4.0 (4.2, 3.5)
0
32
15
59
30 40
86 104
10W-30,10W-40
5W-30,0W-20
(2)
LU-00071
(1) SAE viscosity No. and applicable temperature

(2) Recommend
CAUTION:
When replacing oil, use only SUBARU genuine
engine oil.
LU(H4SO 2.0)-2
General Description
LUBRICATION
B: COMPONENT
(13)
(16)
(15)
T5
(14)
T3
(12)
T1
(17)
(11)
T3
T3
(18)
T1
(10)
(19)
(9)
(8)
T2
T3
(23)
(20)
(26)
(7)
(6)
(21)
T4
(22)
(5)
T6
(4)
(3)
T1
T1
(2) (1)
(25)
T6
(24)
LU-00228
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
Plug
Gasket
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)
Oil pressure switch

Oil filler duct
O-ring
Oil filler cap
O-ring
Baffle plate
O-ring
Oil strainer
Oil pan
Oil level gauge
LU(H4SO 2.0)-3
(24)
(25)
(26)
Drain plug
Metal gasket
Gasket

T1: 5 (0.5, 3.6)
T2: 5.4 (0.55, 4.0)
T3: 6.4 (0.65, 4.7)
T4: 10 (1.0, 7.2)
T5: 25 (2.5, 18.1)
T6: 44 (4.5, 32.5)
General Description
LUBRICATION
C: CAUTION

points.
cable from battery.
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
499977400
DESCRIPTION
CRANK PULLEY
WRENCH
REMARKS
removing and tightening crank pulley bolt. (2.0 L
model)
499977100
CRANK PULLEY
WRENCH

removing and tightening crank pulley bolt. (2.5 L
model)
OIL FILTER
WRENCH

ST-499977400
ST-499977100
18332AA000
ST18332AA000
LU(H4SO 2.0)-4
General Description
LUBRICATION
ILLUSTRATION
TOOL NUMBER
18332AA010
DESCRIPTION
OIL FILTER
WRENCH
REMARKS
OIL SEAL
INSTALLER
Used for installing oil seal into oil pump.
ST18332AA010
499587100
ST-499587100
LU(H4SO 2.0)-5
Oil Pressure System

LUBRICATION
2. Oil Pressure System

A: WIRING DIAGRAM
BATTERY
No.5
SBF-7
6
3
IGNITION
SWITCH
OIL PRESSURE
WARNING LIGHT
3
4
B72
SBF-1
COMBINATION
METER
15
i10
17
i3
31
B38
B21
E2
E11
OIL PRESSURE
SWITCH
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
B72
B38
i10
1 2 3
4 5 6
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
LU-00229
LU(H4SO 2.0)-6
Oil Pressure System

LUBRICATION
B: INSPECTION
1
Step
Check
CHECK COMBINATION METER.
Does the warning light illumi1)Turn the ignition switch to ON (engine OFF). nate?
2)Check the warning light of combination
meter.
Yes
Go to step 2.
CHECK HARNESS CONNECTOR BETWEEN Is the voltage more than 10 V?

COMBINATION METER AND OIL PRESSURE SWITCH.
1)Turn the ignition switch to OFF.
2)Disconnect the connector from oil pressure
switch.
3)Turn the ignition switch to ON.
4)Measure the voltage of harness between oil
pressure switch connector and chassis ground.
(E11) No. 1 (+) Chassis ground ():
?
2)Remove the combination meter.
3)Measure the resistance of the combination
meter.
(i10) No. 3 (i10) No. 15:
(i10) No. 4 (i10) No. 15:
Replace the oil

pressure switch.
LU(H4SO 2.0)-7
Replace the harness connector

between combination meter and oil
pressure switch.
No
Repair or replace
the combination
meter. <Ref. to IDI3, INSPECTION,
Combination
Meter System.>
Go to step 3.
Repair or replace
the combination
Combination
Meter System.>
Engine Oil
LUBRICATION
3. Engine Oil
B: REPLACEMENT
A: INSPECTION
1) Open the engine oil filler cap for quick draining of

the engine oil.
3) Drain engine oil by loosening the engine oil drain
plug.

the level gauge is correctly inserted and properly
orientated.
4) Remove it again and check the engine oil level. If
the engine oil level is below L line, add oil to bring
the level up to F line.
for the oil to return to the oil pan before checking
the level.
6) Just after driving or while the engine is warm, engine oil level show in the range between F line
and the notch mark. This is caused by thermal expansion of the engine oil.
NOTE:
To prevent overfilling the engine oil, do not add oil
above F line when the engine is cold.
(A)
LU-00230

the engine oil.
NOTE:
(B)
(C)
(E)
(D)
LU-00213
(A)
(B)
(C)
(D)
(E)
NOTE:
Prepare a container for draining of engine oil.
Oil level gauge

Upper level
Lower level
Tightening torque:
44 Nm (4.5 kgf-m, 32.5 ft-lb)
5) Use the engine oil of proper quality and viscosity, fill engine oil through the oil filler duct to upper
level on level gauge. Make sure that the vehicle is
parked on a level surface when checking oil level.
Recommended oil:
Refer to SPECIFICATION for the recommended oil. <Ref. to LU(H4SO 2.0)-2, SPECIFICATION, General Description.>
Engine oil capacity:
Upper level
4.0 2 (4.2 US qt, 3.5 Imp qt)
Lower level
3.0 2 (3.2 US qt, 2.6 Imp qt)
LU(H4SO 2.0)-8
Engine Oil
LUBRICATION
8) After the engine stops, recheck the oil level. If

necessary, add engine oil up to the upper level on
level gauge.
(A)
(B)
(C)
(E)
(D)
LU-00213
(A)
(B)
(C)
(D)
(E)
Oil level gauge

Upper level
Lower level
LU(H4SO 2.0)-9
Oil Pump
LUBRICATION
4. Oil Pump
A: REMOVAL
9) Remove the crank pulley using ST.

ST 499977400
CRANK PULLEY WRENCH
(2.0 L model)
ST 499977100
CRANK PULLEY WRENCH
(2.5 L model)
IN-00203

5) Remove the radiator. <Ref. to CO(H4SO 2.0)20, REMOVAL, Radiator.>
6) Remove the crankshaft position sensor.
LU-00012
10) Remove the water pump. <Ref. to CO(H4SO

2.0)-15, REMOVAL, Water Pump.>
LU-00013

LU-00046

REMOVAL, V-belt.>
8) Remove the belt tensioner.
LU-00014
LU-00011
LU(H4SO 2.0)-10
Oil Pump
LUBRICATION
13) Remove the bolts which install oil pump onto

cylinder block.
3) Apply a coat of engine oil to the inside of oil seal.
NOTE:
When disassembling and checking the oil pump,
loosen the relief valve plug before removing the oil
pump.
ME-00312
4) Position the oil pump, aligning the notched area

with the crankshaft, and push the oil pump straight.
LU-00015
14) Remove the oil pump by using flat tip screwdriver.

CAUTION:
Be careful not to scratch mating surfaces of
CAUTION:
Make sure the oil seal lip is not folded.
Be careful not to scratch oil seal when installing oil pump on cylinder block.
5) Install the oil pump.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
T
LU-00016
B: INSTALLATION
Perform the following.
1) Apply liquid gasket to the matching surfaces of
oil pump.
Liquid gasket:
equivalent
2) Replace the O-ring (A) with a new one.
(A)
LU-00017
LU(H4SO 2.0)-11
LU-00019
Oil Pump
LUBRICATION
C: DISASSEMBLY
D: ASSEMBLY
Remove the screws which secure oil pump cover

and then disassemble oil pump. Inscribe alignment
marks on the inner and outer rotors so that they can
be replaced in their original positions during reassembly.
1) Install the front oil seal using ST.

ST 499587100
OIL SEAL INSTALLER
NOTE:
Use a new oil seal.
CAUTION:
Before disassembling the oil pump, remove the
relief valve.
ST
(E)
(D)
(B)
LU-00021
(C)
2) Apply a coat of engine oil to the inner and outer

rotors.
3) Install the inner and outer rotors in their original
positions.
4) Install the oil relief valve and relief valve spring
and plug.
(A)
(I)
(F)
NOTE:
Use a new gasket.
5) Install the oil pump cover.
(G)
Tightening torque:
T1: 5.4 Nm (0.55 kgf-m, 4.0 ft-lb)
T2: 44 Nm (4.5 kgf-m, 32.5 ft-lb)
(H)
LU-00020
(A)
(B)
(C)
(D)
(E)
(F)
(G)
(H)
(I)
T1
Oil seal
Oil pump case
Inner rotor
Outer rotor
Oil pump cover
Relief valve
Relief valve spring
Plug
Gasket
T2
LU-00022
LU(H4SO 2.0)-12
Oil Pump
LUBRICATION
E: INSPECTION
3. SIDE CLEARANCE
1. TIP CLEARANCE
Measure the clearance between oil pump inner rotor and pump cover. If the clearance is out of the
standard value, replace the rotor or oil pump case.
Measure the tip clearance of rotors. If the clearance

is out of the standard value, replace the rotors as a
matched set.
Tip clearance:
Standard value
0.04 0.14 mm (0.0016 0.0055 in)
Side clearance:
Standard value
0.02 0.07 mm (0.0008 0.0028 in)
LU-00025
LU-00023
2. CASE CLEARANCE
Measure the clearance between the outer rotor and
oil pump rotor housing. If the clearance is out of the
standard value, replace the oil pump case.
Case clearance:
Standard value
0.10 0.175 mm (0.0039 0.0069 in)
4. OIL RELIEF VALVE

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
72.8 mm (2.866 in)
Installed length
54.7 mm (2.154 in)
Load when installed
81.3 N (8.29 kgf, 18.24 lb)
5. OIL PUMP CASE

Check the worn shaft hole, clogged oil passage,
worn rotor chamber, cracks and other faults.
6. OIL SEAL
LU-00024
Check the oil seal lips for deformation, hardening,

wear, etc, and replace if defective.
LU(H4SO 2.0)-13
Oil Pan and Strainer

LUBRICATION
5. Oil Pan and Strainer
8) Support the engine with a lifting device and wire

ropes.
A: REMOVAL
2) Remove the front wheels.
LU-00222

IN-00203
4) Remove the air intake duct and air cleaner case.

Duct.> <Ref. to IN(H4SO 2.0)-6, REMOVAL, Air
Cleaner Case.>
CAUTION:
When lifting up the vehicle, raise up wire ropes
at the same time.
11) Drain engine oil. <Ref. to LU(H4SO 2.0)-8, REPLACEMENT, Engine Oil.>
<Ref. to EX(H4SO 2.0)-7, REMOVAL, Front Exhaust Pipe.> <Ref. to EX(H4SO 2.0)-10, REMOVAL, Center Exhaust Pipe.>
LU-00231
7) Remove the hood stay holder (A) and radiator

upper brackets (B).
LU-00223
14) Remove the bolts which install oil pan on cylinder block with engine raised up.
15) Insert the oil pan cutter blade into the clearance
between cylinder block and oil pan.
(B)
(A)
CAUTION:
Do not use a screwdriver or similar tool in place
of oil pan cutter.
(B)
LU-00232
LU(H4SO 2.0)-14

LUBRICATION
3) Apply liquid gasket to the mating surfaces and

install the oil pan.
Liquid gasket:
equivalent
(D)
(C)
(B)
LU-00034
4) Tighten the bolts which install oil pan onto cylinder block.
(A)
Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
LU-00189
(D)
(A)
(B)
(C)
(D)
Oil pan
Oil strainer
Baffle plate
Cylinder block
B: INSTALLATION
CAUTION:
Before installing the oil pan, clean the mating
surface of oil pan and cylinder block.
(C)
(B)
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
2) Install the oil strainer onto baffle plate.
(A)
NOTE:
Replace O-ring with new one.
Tightening torque:
10 Nm (1.0 kgf-m, 7.2 ft-lb)
LU-00189
(A)
(B)
(C)
(D)
Oil pan
Oil strainer
Baffle plate
Cylinder block
5) Lower the engine onto front crossmember.
LU(H4SO 2.0)-15

LUBRICATION
6) Tighten the nuts which install front cushion rubber onto front crossmember.
12) Install the hood stay holder (A) and radiator upper brackets (B).
Tightening torque:
69 Nm (7.0 kgf-m, 50.9 ft-lb)
(B)
(A)
(B)
LU-00232
LU-00223

Exhaust Pipe.> <Ref. to EX(H4SO 2.0)-10, INSTALLATION, Center Exhaust Pipe.>
13) Install the air intake chamber.

<Ref. to IN(H4SO 2.0)-8, INSTALLATION, Air Intake Chamber.>
14) Install the air intake duct and air cleaner case.
<Ref. to IN(H4SO 2.0)-9, INSTALLATION, Air Intake Duct.> <Ref. to IN(H4SO 2.0)-7, INSTALLATION, Air Cleaner Case.>
15) Install the front wheels.
CAUTION:
When lowing the vehicle, lower the lift-up device and wire ropes at the same time.
IN-00203
17) Fill engine oil. <Ref. to LU(H4SO 2.0)-8, INSPECTION, Engine Oil.>
LU-00222
C: INSPECTION
Visually check that the oil pan, oil strainer, oil
strainer stay and baffle plate are not damaged.
Tightening torque:
T1: 50 Nm (5.1 kgf-m, 36.9 ft-lb)
T2: 58 Nm (5.9 kgf-m, 42.8 ft-lb)
T2
T1
LU-00233
LU(H4SO 2.0)-16
Oil Pressure Switch

LUBRICATION
6. Oil Pressure Switch
2) Install the oil pressure switch onto engine block.
A: REMOVAL
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
1) Remove the generator from bracket.

<Ref. to SC(H4SO 2.0)-14, REMOVAL, Generator.>
2) Disconnect the terminal from oil pressure switch.
LU-00037
3) Connect the terminal to oil pressure switch.

LU-00036
3) Remove the oil pressure switch.
LU-00036
LU-00037
4) Install the generator to bracket.

<Ref. to SC(H4SO 2.0)-14, INSTALLATION, Generator.>
B: INSTALLATION
C: INSPECTION
1) Apply liquid gasket to the oil pressure switch

threads.
Check the oil pressure switch installation portion for

oil leakage and oil seepage.
Liquid gasket:
equivalent
LU-00038
LU(H4SO 2.0)-17
Engine Oil Filter

LUBRICATION

A: REMOVAL
LU-00234
B: INSTALLATION
1) Clean the oil filter installing surface on cylinder
block.
3) Install the oil filter turning it by hand, being careful not to damage the seal rubber.
4) Tighten more after the seal rubber contacts the
cylinder block.
NOTE:
In case of oil filter in outer diameter 68 mm (2.68
in), tighten by approx. one turn.
In case of oil filter in outer diameter 65 mm (2.56
in), tighten by approx. 2/3 to 3/4 turn.
Over-tightening may cause oil leak.
C: INSPECTION
1) After installing the oil filter, run engine and make
sure that no oil is leaking around the seal rubber.
NOTE:
2) Check the engine oil level. <Ref. to LU(H4SO
2.0)-8, INSPECTION, Engine Oil.>
LU(H4SO 2.0)-18
General Diagnostic Table

LUBRICATION
8. General Diagnostic Table

A: INSPECTION
Before performing diagnosis, make sure that the engine oil level is correct and no oil leakage exists.
Symptom
1. Warning light remains

on.
2. Warning light does

not come on.
3. Warning light flickers

momentarily.
Possible cause
Cracked
diaphragm or oil leakage within switch
1) Oil pressure switch
failure
Broken spring or seized contacts
Clogging of oil filter
Malfunction of oil by-pass valve in oil filter
Malfunction of oil relief valve in oil pump
2) Low oil pressure
Clogged oil passage
Excessive tip clearance and side clearance of oil
pump rotor and gear
Clogged oil strainer or broken pipe
Insufficient engine oil
3) No oil pressure
Broken pipe of oil strainer
Stuck oil pump rotor
1) Malfunction of combination meter
2) Poor contact of switch contact points
3) Disconnection of wiring
1) Poor contact at terminals
2) Defective wiring harness
3) Low oil pressure
LU(H4SO 2.0)-19
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).

LUBRICATION
LU(H4SO 2.0)-20
SP(H4SO 2.0)
1.
2.
Page
Accelerator Pedal........................................................................................4
General Description
A: SPECIFICATION
Accelerator pedal
Stroke
LHD model
RHD model
At pedal pad
50 63 mm (1.97 2.48 in)

53 65 mm (2.09 2.56 in)
B: COMPONENT
LHD model
(1)
(3)
T
(4)
(2)
SP-02002
(1)
(2)
Accelerator pedal ASSY

Accelerator plate
(3)
(4)
Clip
Stopper
SP(H4SO 2.0)-2

T: 18 (1.8, 13.0)
General Description
RHD model
(1)
(2)
SP-02003
(1)
(2)

T: 18 (1.8, 13.0)
Accelerator pedal ASSY

Stopper
C: CAUTION
points.
cable from battery.
SP(H4SO 2.0)-3
Accelerator Pedal
2. Accelerator Pedal
A: REMOVAL
2) Disconnect the connector.
3) Remove the nut securing accelerator pedal assembly.
LHD model
T
T
SP-02001
RHD model
SP-00052
B: INSTALLATION
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
C: DISASSEMBLY
NOTE:
Accelerator pedal cannot be disassembled.
SP(H4SO 2.0)-4
IGNITION
IG(H4SO 2.0)
1.
2.
3.
4.
Page
Spark Plug...................................................................................................5
Ignition Coil and Ignitor Assembly...............................................................8
Spark Plug Cord........................................................................................10
General Description
IGNITION
A: SPECIFICATION
1. 2.0 L MODEL
Ignition coil & ignitor

ASSY
Spark plug
Item
Model
Manufacturer
Secondary coil resistance
Manufacturer and Type
Thread size (diameter, pitch, length)
Spark plug gap
Electrode
mm
mm (in)
Designation
CM12-100C
HITACHI
18.0 k 20%
CHAMPION: RC10YC4
14, 1.25, 19
1.0 1.1 (0.039 0.043)
Nickel
2. 2.5 L MODEL
Item
ASSY
Model
Manufacturer
Manufacturer and Type
Spark plug

Spark plug gap
Electrode
EC, EK, K4 model

Except for EC, EK,
K4 model
mm
mm (in)
EC, EK, K4 model
Except for EC, EK,
K4 model
IG(H4SO 2.0)-2
Designation
FH 0286
DIAMOND
11.2 k15%
NGK: PFR5B-11
CHAMPION: RC10YC4
14, 1.25, 19
1.0 1.1 (0.039 0.043)
Platinum
Nickel
General Description
IGNITION
B: COMPONENT
2.0 L model
T1
(3)
(2)
(2)
(1)
T2
(4)
(4)
T2
IG-00016
(1)
(2)
(3)
Spark plug
Spark plug cord (#1, #3)
Ignition coil & ignitor ASSY
(4)
IG(H4SO 2.0)-3

T1: 6.4 (0.65, 4.7)
T2: 21 (2.1, 15.2)
General Description
IGNITION
2.5 L model
(4)
(4)
(1)
T2
(3)
T1
(2)
(2)
(1)
T2
IG-00094
(1)
(2)
(3)
Spark plug
(4)
C: CAUTION

T1: 6.4 (0.65, 4.7)
T2: 21 (2.1, 15.2)

points.
cable from battery.
IG(H4SO 2.0)-4
Spark Plug
IGNITION
2. Spark Plug
2. LH SIDE
A: REMOVAL

2) Remove the spark plug cords by pulling the boot.
(Do not pull the cord itself.)
CAUTION:
All spark plugs installed on an engine must be
of the same heat range.
Spark plug:
<Ref. to IG(H4SO 2.0)-2, SPECIFICATION,
General Description.>
1. RH SIDE
IG-00021
IN-00203

3) Remove the spark plug cords by pulling the boot.
(Do not pull the cord itself.)
IG-00022
B: INSTALLATION
1. RH SIDE
Tightening torque:
21 Nm (2.1 kgf-m, 15.2 ft-lb)
IG-00017
NOTE:
The above torque should be only applied to new
spark plugs without oil on their threads.
In case their threads are lubricated, the torque
should be reduced by approx. 1/3 of the specified
torque in order to avoid over-stressing.
2. LH SIDE
Tightening torque:
21 Nm (2.1 kgf-m, 15.2 ft-lb)
IG-00018
NOTE:
IG(H4SO 2.0)-5
Spark Plug
IGNITION
C: INSPECTION
Check the electrodes and inner and outer ceramic
insulator 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.
(A)
(B)
(C)
(D)
(E)
IG-00010
IG-00013
(A)
(B)
(C)
(D)
(E)
Spark plug gap

Carbon accumulation or wear
Crack
Damage
Damaged gasket
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 brown
spots and bluish burnt electrodes indicate engine
overheating. Moreover, the appearance results
from incorrect ignition timing, loose spark plugs,
wrong selection of fuel, etc.
IG-00014
IG-00011
2) Carbon fouled:
Dry fluffy carbon deposits on insulator and electrode are mostly caused by slow speed driving in
the city, weak ignition, too rich fuel mixture, dirty air
cleaner, etc.
CAUTION:
Avoid using a plug cleaner because of the
spark plug with a platinum tip. (2.5 L model)
D: ADJUSTMENT
Adjust the spark plug gap, if necessary, by measuring with a gap gauge. (2.0 L model)
Spark plug gap: L
1.0 1.1 mm (0.039 0.043 in)
L
(A)
IG-00012
IG-00015
IG(H4SO 2.0)-6
Spark Plug
IGNITION
NOTE:
Replace with a new spark plug if the area (A) is
worn to spherical shape.
IG(H4SO 2.0)-7
Ignition Coil and Ignitor Assembly

IGNITION
3. Ignition Coil and Ignitor Assembly
4) Remove the bolt (B) which secures the ignition

coil & ignitor ASSY to intake manifold.
2.0 L model
A: REMOVAL
(B)
(A)
(B)
IG-02002
2.5 L model
IN-00203
(B)
2) Disconnect the spark plug cords from ignition

coil & ignitor ASSY.
2.0 L model
(A)
(B)
IG-00096
B: INSTALLATION
IG-02001
2.5 L model
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
CAUTION:
Connect the spark plug cords to correct positions. Failure to do so will damage the unit.
C: INSPECTION
Check the following using a tester. Replace if defective.
IG-00095
3) Disconnect the connector (A) from ignition coil &

ignitor ASSY.
CAUTION:
If the resistance is extremely low, it indicates
the presence of a short-circuit.
Ignitor is integrated with the coil. Therefore
the resistance of primary side coil cannot be
measured.
IG(H4SO 2.0)-8

IGNITION
Specified resistance (2.0 L model):

[Secondary side]
Between (A) and (B)
18.0 k20%
Between (C) and (D)
18.0 k20%
(C)
(D)
(A)
(B)
IG-02003
Specified resistance (2.5 L model):

[Secondary side]
Between (A) and (B)
11.2 k15%
Between (C) and (D)
11.2 k15%
(C)
(D)
(A)
(B)
IG-00097
IG(H4SO 2.0)-9
Spark Plug Cord

IGNITION
4. Spark Plug Cord

A: INSPECTION
Check the following items:
Damage to cords, deformation, burning or rust
formation of terminals
Resistance values of cords
Resistance value (2.0 L model):
#1 cord: 5.9 11.1 k
#2 cord: 8.8 14.8 k
#3 cord: 6.8 11.7 k
#4 cord: 8.8 14.8 k
Resistance value (2.5 L model):
#1 cord: 7.1 12.1 k
#2 cord: 12.1 19.9 k
#3 cord: 7.7 13.0 k
#4 cord: 12.3 20.2 k
IG-00102
IG(H4SO 2.0)-10
SC(H4SO 2.0)
1.
2.
3.
4.
Page
Starter .........................................................................................................6
Generator ..................................................................................................14
Battery.......................................................................................................20
General Description
A: SPECIFICATION
Item
Specification
Vehicle model
Starter
MT
Type
Model
Manufacturer
Voltage and output
Revolving direction
Number of pinion teeth
Voltage
No-load characCurrent
teristics
Rotating speed
Voltage
Current
Load characteristics
Torque
Lock characteristics
Rotating speed
Voltage
Current
Torque
Model
Generator
Model
Manufacturer
Voltage and output
Polarity on ground side
Revolving direction
Armature connection
Output current
Regulated voltage
Battery
EC, EK, K4
Type and capac- model
ity
KS, KA model
AT
Reduction type
M000T30471
M000T20171
Mitsubishi Electric
12 V 1.0 kW
12 V 1.4 kW
Counterclockwise (when observed from pinion)
8
9
11 V
95 A or less
90 A or less
2,500 rpm or more
2,000 rpm or more
7.5 V
7.7 V
300 A
400 A
8.84 Nm (0.90 kgf-m, 6.5 ft-lb) or
16.7 Nm (1.70 kgf-m, 12.3 ft-lb) or
more
more
870 rpm or more
710 rpm or more
4V
3.5 V
680 A or less
960 A or less
17 Nm (1.73 kgf-m, 12.5 ft-lb) or
31 Nm (3.16 kgf-m, 22.9 ft-lb) or
more
more
Rotating-field three-phase type, voltage regulator built-in type, with load
response control system
A3TG0491
Mitsubishi Electric
12 V 110 A
Negative
Clockwise (when observed from pulley side)
3-phase Y-type
1,500 rpm 50 A or more
14.1 14.8 V [20C (68F)]
12 V 52 AH (65D23L)
12 V 48 AH (55D23L)
12 V 52 AH (75D23L)
12 V 27 AH (34B19L)
12 V 48 AH (55D23L)
SC(H4SO 2.0)-2
General Description
B: COMPONENT
1. STARTER
(1)
(4)
(10)
(9)
(3)
(2)
(8)
(7)
(6)
(5)
(16)
(12)
(11)
(14)
(15)
(13)
SC-02005
(1)
(2)
(3)
(4)
(5)
(6)
Front bracket
Sleeve bearing
Lever set
Magnet switch ASSY
Stopper set
Overrunning clutch
(7)
(8)
(9)
(10)
(11)
(12)
Internal gear ASSY

Shaft ASSY
Gear ASSY
Packing
Yoke ASSY
Armature
SC(H4SO 2.0)-3
(13)
(14)
(15)
(16)
Brush holder ASSY

Sleeve bearing
Rear cover
Rear cover set
General Description
2. GENERATOR
(7)
(6)
(5)
(4)
(3)
T1
(2)
(1)
T1
T2
(13)
(12)
(11)
(10)
(9)
(8)
SC-00163
(1)
(2)
(3)
(4)
(5)
(6)
Pulley nut
Pulley
Front cover
Ball bearing
Bearing retainer
Rotor
(7)
(8)
(9)
(10)
(11)
(12)
Bearing
Stator coil
IC regulator with brush
Brush
Rectifier
Rear cover
SC(H4SO 2.0)-4
(13)
Terminal

T1: 4.7 (0.48, 3.5)
T2: 108 (11.0, 80)
General Description
C: CAUTION
points.
cable from battery.
SC(H4SO 2.0)-5
Starter
2. Starter
5) Disconnect the connector and terminal from

starter.
A: REMOVAL
SC-00006
IN-00203
2) Remove the air intake chamber. (Non-turbo

model) <Ref. to IN(H4SO 2.0)-8, REMOVAL, Air Intake Chamber.>
3) Remove the intercooler. (Turbo model)
<Ref. to IN(H4DOTC)-12, REMOVAL, Intercooler.>
4) Remove the air intake chamber stay LH. (Nonturbo model).
MT model
(A) Terminals
(B) Connector
6) Remove the starter from transmission.

NOTE:
In case of MT model, the bolt is used in place of nut
(A) shown in the figure.
(A)
SC-00184
B: INSTALLATION
SC-00176
AT model
NOTE:
In case of MT model, the bolt is used in place of nut
(A) shown in the figure.
Tightening torque:
50 Nm (5.1 kgf-m, 37 ft-lb)
(A)
SC-00177
SC-00184
SC(H4SO 2.0)-6
Starter
C: DISASSEMBLY
4) Remove the through-bolts and brush holder

screws of both sides, and then detach the rear cover and brush holder assembly.
1. STARTER ASSEMBLY
1) Loosen the nut which holds terminal M of switch
assembly, and then disconnect the connector.
(A)
(A)
(B)
SC-00062
SC-00059
(A) Terminal M
2) Remove the bolts which hold switch assembly,

and then remove the switch assembly, plunger and
plunger spring from starter as a unit.
(A) Brush holder ASSY

(B) Rear cover
5) Remove the armature and yoke assembly from

front bracket.
(B)
(A)
(A)
(C)
SC-00063
SC-00060
(A) Switch ASSY
3) Remove the nuts of both sides, and then remove

rear cover set.
(A) Armature
(B) Yoke ASSY
(C) Front bracket
6) Remove the packing A, planetary gear and

packing B.
(C)
(A)
(A)
(B)
SC-00064
SC-00061
(A) Rear cover set
(A) Packing A
(B) Planetary gear
(C) Packing B
SC(H4SO 2.0)-7
Starter
7) Remove the plate.
(2) Remove the ring, stopper and clutch from

shaft.
(A)
(A)
(B)
(D)
(C)
SC-00065
(A) Plate
8) Remove the shaft assembly and overrunning

clutch from front bracket as a unit.
NOTE:
Check the following points before removal.
Lever direction
Position of internal gear assembly
(A)
SC-00014
(A)
(B)
(C)
(D)
Socket wrench
Ring
Shaft
Stopper
(B)
(C)
(A)
(B)
(C)
(D)
(D)
SC-00066
Lever
Shaft ASSY
Overrunning clutch
Internal gear ASSY
9) Remove the overrunning clutch from shaft assembly as follows:

(1) Remove the stopper from ring by lightly tapping the stopper with an appropriate tool (such
as a fit socket wrench).
D: ASSEMBLY
NOTE:
Apply grease to the following parts before assembly.
Sleeve bearing
Pinion shaft rotating part
Shaft spline portion
Inside of reduction system
Lever fulcrum/Clutch rotating part
1) Install the overrunning clutch to shaft assembly.
2) Install the stopper to shaft assembly as follows.
SC(H4SO 2.0)-8
Starter
(1) Insert the ring into the shaft groove by lightly

tapping it with an appropriate tool (such as a fit
socket wrench).
(2) Internal gear position
(A)
(B)
SC-00070
SC-00067
4) Install the plate.
(A) Ring
(B) Stopper
(A)
(2) Install the stopper to ring using a press.

(A)
(B)
SC-00065
(A) Plate
SC-00068
5) Install the planetary gear.

6) Install the packing A and B while taking care of
installing positions.
(A) Ring
(B) Stopper
(B)
3) Install the shaft assembly to front bracket while

taking care of the following points.
(1) Lever direction
(A)
SC-00071
(A) Packing A
(B) Packing B
7) Install the armature to yoke assembly.

SC-00069
SC(H4SO 2.0)-9
Starter
8) Install the yoke to front bracket matching front

bracket to the groove of yoke assembly.
10) Install the rear cover matching its groove to

brush holder assembly.
(A)
(B)
SC-00072
9) Install the brush holder to yoke assembly as follows.

(1) Press the brush down into brush holder, and
then fix the brush in that position using an appropriate tool (such as a fit socket wrench).
SC-00062

(B) Rear cover
11) Install rear cover set.
(A)
SC-00061
SC-00073
(2) Match the brush holder to groove of yoke,

and then slide the brush holder into yoke assembly to install.
(A) Rear cover set
12) Install the switch assembly to front bracket as

follows.
(1) Insert the plunger and plunger spring into
switch assembly.
(2) Hook the plunger protrusion on lever edge
to install plunger to front bracket.
(A)
SC-00074
SC-00060
(A) Switch ASSY
SC(H4SO 2.0)-10
Starter
13) Connect the connector to terminal M of switch

assembly.
Depth of segment mold:

0.5 mm (0.020 in)
(A)
(B)
(C)
(A)
SC-00059
(A) Terminal M
SC-00022
(A) Depth of mold

(B) Segment
(C) Mold
E: INSPECTION
1. ARMATURE
1) Check the 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 for run-out, and then 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)
4) Armature short-circuit test

Check the armature for short-circuit by placing it on
growler tester. Hold an iron sheet against the armature core while slowly rotating the armature. A
short-circuited armature will cause the iron sheet to
vibrate and to be attracted to core. If the iron sheet
is attracted or vibrates, the armature, which is
short-circuited, must be replaced or repaired.
(A)
(B)
(A)
SC-00023
(A) Iron sheet

(B) Growler tester
(B)
(A) Dial gauge

(B) V-block
3) Depth of segment mold

Check the depth of segment mold.
SC-00021
5) Armature ground test

Using a circuit tester, touch one probe to the commutator segment and the other to shaft. There
should be no continuity. If there is continuity, the armature is grounded.
Replace the armature if it is grounded.
SC-00024
SC(H4SO 2.0)-11
Starter
2. YOKE
5. SWITCH ASSEMBLY
Make sure the pole is set in position.
Be sure there is continuity between the 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.
3. OVERRUNNING CLUTCH
Inspect the teeth of pinion for wear and damage.
Replace if it is damaged. Rotate the pinion in the
right direction of rotation (counterclockwise). It
should rotate smoothly. But in the opposite direction, it should be locked.
CAUTION:
Do not clean the overrunning clutch with oil to
prevent grease from flowing out.
Terminal / Specified resistance:

S M / Less than 1
S Ground / Less than 1
M B / More than 1 M
4. BRUSH AND BRUSH HOLDER

B
1) Brush length
Measure the brush length, and then 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)
S
M
SC-00075
6. SWITCH ASSEMBLY OPERATION

1) Using a lead wire, connect the terminal S of
switch assembly to positive terminal of battery, and
starter body to ground terminal of battery. The pinion should be forced endwise on shaft.
(A)
(B)
SC-00102
(A) Service limit line

(B) Brush
2) Brush movement
Be sure the brush moves smoothly inside brush
holder.
3) Brush spring force
Measure the brush spring force with a spring scale.
If it is less than the service limit, replace the brush
holder.
Brush spring force:
Standard
15.9 19.5 N (1.62 1.99 kgf, 3.57 4.38
lb) (when new)
Service limit
2.5 N (0.25 kgf, 0.56 lb)
CAUTION:
With the 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 the connector from terminal M. Then
using a lead wire, connect the positive terminal of
battery and terminal M and ground terminal to starter body.
In this test set up, the pinion should return to its
original position even when it is pulled out with a
screwdriver.
(A)
(B)
SC-00076
(A) Terminal S
(B) Terminal M
SC(H4SO 2.0)-12
Starter
7. PERFORMANCE TEST
The starter should be submitted to performance
tests whenever it has been overhauled, to assure
its satisfactory performance when installed on the
engine.
Three performance tests, no-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 the figure.
(B)
(A)
M
+
(C)
12V
V
A
SC-00077
Current / Speed
MT model
300 A / 870 rpm or more
AT model
400 A / 710 rpm or more
3) Lock test
With the 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 model
4 V / 680 A or less
AT model
3.5 V / 960 A or less
Torque
MT model
17 Nm (1.73 kgf-m, 12.5 ft-lb)
AT model
31 Nm (3.16 kgf-m, 22.9 ft-lb)
(A) Variable resistance

(B) Starter body
(C) Magnetic switch
1) No-load test
With switch on, adjust the variable resistance for
the voltage to obtain 11 V, read the ammeter and
measure the starter speed. Compare these values
with the specifications.
No-load test (Standard):
Voltage / Current
MT model
11 V / 95 A or less
AT model
11 V / 90 A or less
Rotating speed
MT model
2,500 rpm or more
AT model
2,000 rpm or more
2) Load test
Apply the specified braking torque to starter. The
condition is satisfactory if the current draw and
starter speed are within specifications.
Load test (Standard):
Voltage / Load
MT model
7.5 V / 8.84 Nm (0.90 kgf-m, 6.5 ft-lb)
AT model
7.7 V / 16.7 Nm (1.70 kgf-m, 12.3 ft-lb)
SC(H4SO 2.0)-13
Generator
3. Generator
5) Remove the bolts which install the generator

onto bracket.
A: REMOVAL
SC-00179
IN-00203

generator.
Non-turbo model
B: INSTALLATION
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
CAUTION:
Check and adjust the V-belt tension.
<Ref. to ME(H4SO 2.0)-39, INSPECTION, Vbelt.> or <Ref. to ME(H4DOTC)-40, INSPECTION, V-belt.>
SC-00178
Turbo model
SC-00179
C: DISASSEMBLY
1) Remove the four through-bolts.
ME-00830

4) Remove the front side belts.
<Ref. to ME(H4SO 2.0)-38, FRONT SIDE BELT,
REMOVAL, V-belt.> or <Ref. to ME(H4DOTC)-39,
FRONT SIDE BELT, REMOVAL, V-belt.>
SC-00078
SC(H4SO 2.0)-14
Generator
2) Heat portion (A) of rear cover to 50C (122F)

with a heater drier.
(A)
CAUTION:
When holding the rotor with a vise, place aluminum plates or wooden pieces on the vise jaws
to prevent rotor from damage.
(A)
(B)
SC-00079
(C)
3) Then insert the tip of a flat tip screwdriver into the

gap between stator core and front cover. Pry them
apart to disassemble.
(D)
(A)
(B)
(C)
(D)
SC-00036
Front cover
Pulley
Nut
Rotor
5) Remove the ball bearing as follows.

(1) Remove the bolt, and then remove the bearing retainer.
(A)
(A)
SC-00080
(A) Screwdriver
4) Hold the rotor with a vise and remove pulley nut.
SC-00081
(2) Firmly install an appropriate tool (such as a

fit socket wrench) to bearing inner race.
SC-00035
SC-00082
(3) Push the ball bearing off the front cover using a press.
SC(H4SO 2.0)-15
Generator
6) Remove the bearing from rotor using a bearing

puller.
(2) Unsolder the connection between IC regulator and rectifier to remove the IC regulator.
SC-00046
7) Unsolder connection between rectifier and stator

coil to remove the stator coil.
SC-00085
9) Remove the brush as follows.

(1) Remove cover A.
CAUTION:
Do not allow a 180 270 W soldering iron to
contact the terminals for more than 5 seconds
at once because the rectifier cannot withstand
so much heat.
(A)
SC-00086
(A) Cover A
(2) Remove cover B.

(A)
SC-00083
8) Remove the IC regulator as follows.

(1) Remove the screws which secure IC regulator to rear cover.
SC-00087
(A) Cover B
(3) Separate the brush from connection to remove.

SC-00084
SC-00088
SC(H4SO 2.0)-16
Generator
10) Remove the rectifier as follows.

(1) Remove the bolt which secures the rectifier.
CAUTION:
Be sure to remove the wire after reassembly.
(A)
SC-00089
SC-00092
(2) Remove the cover of terminal B.

(A) Wire
SC-00090
(3) Remove the nut of terminal B, and then remove the rectifier.
2) Install the ball bearing.

(1) Set the ball bearing on the front cover, and
then securely install an appropriate tool (such as
a fit socket wrench) to the bearing outer race.
(2) Press the ball bearing into the specified position using a press.
(3) Install the bearing retainer.
3) Press the bearing (rear side) into the rotor shaft
using a press to install.
4) Heat the bearing box in rear cover [50 to 60C
(122 to 140F)], and then press the rear bearing
into rear cover.
CAUTION:
Grease should not be applied to rear bearing.
Remove the oil completely if it is found on bearing box.
5) After reassembly, turn the pulley by hand to
check that rotor turns smoothly.
SC-00091
D: ASSEMBLY
1) Pulling up brush
Before assembling, press the brush down into
brush holder, and then fix them in that position by
passing a [1 mm (0.08 in) dia. 40 to 50 mm (1.6 to
2.0 in) long] wire through the hole as shown in the
figure.
SC(H4SO 2.0)-17
Generator
E: INSPECTION
1. DIODE
CAUTION:
Never use a mega tester (designed for reading
high voltage) or any other similar instrument
for this test; otherwise, the diodes may be damaged.
1) Checking positive diode
Check for continuity between the diode lead and
positive side heat sink. The positive diode is in
good condition if resistance is 1 or less only in the
direction from the diode lead to heat sink.
(A)
Slip ring outer diameter:

Standard
22.7 mm (0.894 in)
Limit
22.1 mm (0.870 in)
3) Continuity test
Check the resistance between slip rings using circuit tester.
If the resistance is not within the specified range,
replace the rotor assembly.
Specified resistance:
Approx. 1.8 2.2
(B)
SC-00044
SC-00042
(A) Diode lead

(B) 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
direction from the heat sink to diode lead.
4) Insulation test
Check the continuity between slip ring and rotor
core or shaft. If resistance is 1 or less, the rotor
coil is grounded, and so replace the rotor assembly.
(A)
(B)
SC-00045
SC-00043
5) Ball bearing (rear side)

Check the rear ball bearing. Replace if it is noisy or
if the rotor does not turn smoothly.
(A) Diode lead

(B) Heat sink (negative side)
2. ROTOR
1) Slip ring surface
Inspect the slip rings for contamination or any
roughness on the sliding surface. Repair the slip
ring surface using a lathe or sand paper.
2) Slip ring outer diameter
Measure the slip ring outer diameter. If the slip ring
is worn, replace the rotor assembly.
SC(H4SO 2.0)-18
Generator
3. STATOR
1) Continuity test
Inspect the stator coil for continuity between each
end of the lead wires. If resistance is 1 M or more,
the lead wire is broken, and so replace the stator
assembly.
Brush length:
Service limit (1)
5.0 mm (0.197 in)
Standard (2)
18.5 mm (0.728 in)
(A)
(1)
(A)
(2)
SC-00162
SC-00047
(A) Stator
2) Insulation test
Inspect the stator coil for continuity between stator
core and each end of lead wire. If resistance is 1
or less, the stator coil is grounded, and so replace
the stator assembly.
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 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 20.810 oz).
SC-00093
SC-00048
4. BRUSH
5. BEARING (FRONT SIDE)
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.
Check the front ball bearing. If the resistance is felt

while rotating, or if abnormal noise is heard, replace the ball bearing.
SC(H4SO 2.0)-19
Battery
4. Battery
A: REMOVAL
1) Disconnect the positive (+) terminal after disconnecting the negative () terminal of battery.
2) Remove the flange nuts from battery rods and
take off battery holder.
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. This
may cause short circuit.
1. EXTERNAL PARTS
Check the battery case, top cover, vent plugs, and
terminal posts for dirt or cracks. 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
SC-00180
B: INSTALLATION
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
Tightening torque:
3.4 Nm (0.35 kgf-m, 2.5 ft-lb)
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:
Battery with standard specific gravity 1,280 (20 C)

1.28
Good
WARNING:
Electrolyte has toxicity; be careful handling
the fluid.
Avoid contact with skin, eyes or clothing. Especially at contact with eyes, flush with water
for 15 minutes and get prompt medical attention.
Batteries produce explosive gases. 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.
1.24
1.22
SC(H4SO 2.0)-20
1.20
Need to charge
C: INSPECTION
S20 = St + 0.0007 (t 20)

S20: Specific gravity corrected at electrolyte
temperature of 20C (68F)
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
[20C (68F)]
2) Measuring the specific gravity of the electrolyte
in the battery will disclose the state of charge of the
battery. The relation between specific gravity and
state of charge is as shown in the figure.
Specific gravity ( C)
NOTE:
Clean the battery cable terminals and apply
grease to retard the formation of corrosion.
Connect the positive (+) terminal, and then connect the negative () terminal of battery.
Initial diagnosis of electronic control throttle is
performed after battery installation. For this reason,
start the engine after 10 seconds or more have
elapsed since the ignition switch was turned to ON.
1.16
1.12
1.08
1.04
10
20
30
40
50
60
Amount of discharge (%)
70
80
90
100
SC-00054
Battery
D: MEASUREMENT
4. QUICK CHARGING
WARNING:
Do not bring an open flame close to the battery
at this time.
Quick charging is a method that 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).
Also 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:
Prior to charging, corroded terminals should
be cleaned with a brush and common caustic
soda solution.
Be careful since battery electrolyte overflows
while charging the battery.
Observe instructions when handling the battery charger.
Before charging the battery on vehicle, disconnect the battery ground terminal to prevent
damage of generator diodes or other electrical
modules.
1. JUDGMENT OF BATTERY IN CHARGED

CONDITION
CAUTION:
Observe the items in 3. NORMAL CHARGING.
Never use more than 10 A when charging the
battery because it will shorten the battery life.
1) Specific gravity of electrolyte should be held

within the specific range from 1.250 to 1.290 for
more than one hour.
2) Voltage per battery cell should be held at a specific value in a range from 2.5 to 2.8 V for more than
one hour.
2. CHECK HYDROMETER FOR STATE OF

CHARGE
Hydrometer
indicator
Green
Dark
Charge batCorrective action

tery
Above 65%
Load test
Below 65%
Charge battery
Low electroReplace battery*
Clear
lyte
(If cranking is difficult)
* Check electrical system before replacement.
3. NORMAL CHARGING
Charge the battery at current value specified by
manufacturer or at approx. 1/10 of batterys ampere-hour rating.
SC(H4SO 2.0)-21
Battery
SC(H4SO 2.0)-22
EN(H4SO 2.0)(diag)
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...............................................................................3
Electrical Component Location ...................................................................8
Engine Control Module (ECM) I/O Signal .................................................17
Engine Condition Data ..............................................................................21
Data Link Connector .................................................................................22
General Scan Tool ....................................................................................23
Subaru Select Monitor...............................................................................25
Read Diagnostic Trouble Code (DTC) ......................................................31
Inspection Mode........................................................................................32
Drive Cycle................................................................................................36
Clear Memory Mode..................................................................................38
Compulsory Valve Operation Check Mode ...............................................39
Malfunction Indicator Light ........................................................................41
Diagnostics for Engine Starting Failure.....................................................51
List of Diagnostic Trouble Code (DTC) .....................................................66
Diagnostic Procedure with Diagnostic Trouble Code (DTC) .....................71
General Diagnostic Table........................................................................224
Basic Diagnostic Procedure

1. Basic Diagnostic Procedure

A: PROCEDURE
1. ENGINE
Step
CHECK ENGINE START FAILURE.
1) Ask the customer when and how the trouble occurred using the interview check list.
<Ref. to EN(H4SO 2.0)(diag)-3, CHECK,
Check List for Interview.>
CHECK ILLUMINATION OF MALFUNCTION

INDICATOR LIGHT.
CHECK INDICATION OF DTC ON DISPLAY.

2) Connect the Subaru Select Monitor to data
link connector.
3) Turn the ignition switch to ON, and the Subaru Select Monitor switch to ON.
4) Read DTC on Subaru Select Monitor.
PERFORM DIAGNOSIS.
1) Perform the clear memory mode. <Ref. to
EN(H4SO 2.0)(diag)-38, Clear Memory
Mode.>
2) Perform the inspection mode. <Ref. to
EN(H4SO 2.0)(diag)-32, Inspection Mode.>
Check
Does the engine start?
No
Inspection using
Diagnostics for
Engine Starting
Failure. <Ref. to
EN(H4SO
2.0)(diag)-51,
Diagnostics for
Engine Starting
Failure.>
Does the malfunction indicator Go to step 3.
Inspection using
light illuminate?
General Diagnostic Table. <Ref. to
EN(H4SO
2.0)(diag)-224,
INSPECTION,
General Diagnostic Table.>
Is DTC displayed on the Sub- Record the DTC. Repair the related
aru Select Monitor?
Repair the trouble parts.
cause. <Ref. to
NOTE:
EN(H4SO
If DTC is not
2.0)(diag)-66, List shown on display
of Diagnostic Trou- although the enble Code (DTC).> gine warning light
Go to step 4.
illuminates,
perform the diagnostics of malfunction
indicator light circuit or combination
meter. <Ref. to
EN(H4SO 2.0)(diag)-41, Malfunction
Indicator
Light.>
Is DTC displayed on the Sub- Check on DiagFinish the diagnoaru Select Monitor?
nostic Chart with sis.
Diagnostic Trouble Code (DTC)
<Ref. to EN(H4SO
2.0)(diag)-71,
Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
EN(H4SO 2.0)(diag)-2
Yes
Go to step 2.
Check List for Interview

2. Check List for Interview

A: CHECK
1. CHECK LIST No. 1
Check the following items when problem has occurred.
NOTE:
Use copies of this page for interviewing customers.
Customers name
Date of sale
Date of repair
V.I.N.
Weather
Engine No.
Fuel brand
Fine
Cloudy
Rainy
Snowy
Various/Others:
C (F)
Ambient air temperature
Place
Engine temperature
Engine speed
Vehicle speed
Driving conditions
Headlight
Blower
A/C compressor
Radiator fan
Front wiper
Rear wiper
km
miles
Odometer reading
Hot
Warm
Cool
Cold
Highway
Suburbs
Inner city
Uphill
Downhill
Rough road
Others:
Cold
Warming-up
After warming-up
Any temperature
Others:
rpm
km/h (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
Rear defogger
Audio
Car phone
ON / OFF
ON / OFF
ON / OFF

2. CHECK LIST No. 2

Check the following items about the vehicles state when malfunction indicator light turns on.
NOTE:
a) Other warning lights or indicators turn on. Yes / No
Low fuel warning light
Charge indicator light
AT diagnostic indicator light
ABS warning light
Oil pressure indicator light
b) Fuel level
Lack of gasoline: Yes / No
Indicator position of fuel gauge:
Experienced running out of fuel: Yes / No
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 other parts except 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
Does not shift.
Excessive shift shock
General Description
8) Use ECM mounting stud bolts as the grounding

point to body when measuring voltage and resistance inside the passenger compartment.
A: CAUTION
1) Airbag system wiring harness is routed near the
ECM, main relay and fuel pump relay.
CAUTION:
All airbag system wiring harnesses and connectors are colored yellow. Do not use electrical test equipment on these circuits.
Be careful not to damage the airbag system
wiring harness when servicing the ECM, 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 parts will be damaged.
3) Do not disconnect the battery terminals while the
engine is running.
A large counter electromotive force will be generated in the generator, and this voltage may damage
electronic parts such as ECM, etc.
4) Before disconnecting the connectors of each
sensor and ECM, be sure to turn the ignition switch
to OFF. Perform the inspection mode after connecting the connectors.
5) Poor contact has been identified as a primary
cause of this problem. Measure the voltage or resistance of individual sensor or all electrical control
modules using 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) Remove the ECM from the located position after
disconnecting two cables on battery.
Otherwise, the ECM may be damaged.
CAUTION:
When replacing the ECM, be careful not to use
the wrong spec. ECM to avoid any damage on
the fuel injection system.
7) Connectors of 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.
(A)
EN-00001
(A) Stud bolt
9) Use engine grounding terminal or engine as the

grounding point to body when measuring voltage
and resistance in the engine compartment.
FU-02063
10) Use TCM mounting stud bolts as the grounding

point to body when measuring voltage and resistance inside the passenger compartment.
(A)
EN-00154
(A) Stud bolt
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 instrument
panel lower trim panel.)
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 mentioned
above.
Incorrect installation of the radio may affect
the operation of 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 customers complaint, and distinguish between the
three causes.
16) For AT models, do not hold the stall for more
than five seconds. (from closed throttle, fully open
throttle to stall engine speed.)
17) On the model with ABS, 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 clear procedure of selfdiagnosis function.
B: INSPECTION
Before performing diagnostics, check the following
items which might affect engine problems.
1. BATTERY
1) Measure battery voltage and specific gravity of
electrolyte.
Standard voltage: 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.
2. ENGINE GROUND
Make sure the engine grounding terminal is properly connected to engine.
FU-02063
C: NOTE
1. GENERAL DESCRIPTION
The on-board diagnostics (OBD) system detects
and indicates a fault in various inputs and outputs
of the complex electronic control. Malfunction indicator light 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 E-OBD Regulations. 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, malfunction indicator light illuminates. At the
same time of the malfunction indicator light illumination or blinking, a 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, malfunction indicator light is turned off, but DTC remains at onboard computer.
When troubleshooting the vehicle which complies with E-OBD Regulations, connect the Subaru
Select Monitor or general scan tool to the vehicle.
General Description
2. ENGINE AND EMISSION CONTROL SYSTEM

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.
D: PREPARATION TOOL
ILLUSTRATION
TOOL NUMBER
24082AA230
DESCRIPTION
CARTRIDGE
REMARKS
22771AA030
SUBARU SELECT
MONITOR KIT

ST24082AA230
ST22771AA030
Electrical Component Location

4. Electrical Component Location

A: LOCATION
1. ENGINE
Control module
(3)
(1)
(4)
(2)
EN-02413
(4)
(2)
(3)
(1)
EN-02451
(1)
(2)
Engine control module (ECM)

Malfunction indicator light
(3)
Test mode connector
(4)
Data link connector

(1)
(2)
EN-01147
EN-01966
(4)
(3)
EN-02414
AT-01877

Sensor
(3)
(4)
(1)
(2)
(5)
(7)
(6)
EN-02415
(1)
(2)
(3)

Engine coolant temperature sensor
(4)
(5)
Electronic throttle control

Knock sensor
(6)
(7)


(1)
(2)
EN-02416
EN-02417
(3)
EN-02179
(4)
EN-02418
(5)
(6)
EN-00010
(7)
EN-00012
EN-00011

(1)
(3)
(4)
(2)
EN-01973
(1)
(2)

Rear oxygen sensor
(3)
(1)
(4)
(2)
(4)
(3)
EN-02091
EN-02092

Solenoid valve, actuator, emission control system parts and ignition system parts
(1)
(3)
(2)
EN-02419
(1)
(2)
EGR Valve (EC, EK, K4 model)
(3)

(1)
(2)
EN-02420
(3)
EN-02422
EN-02421

(1)
(8) (7)
(6) (9)
(5) (4) (3)
(2)
(3)
EN-02423
(2)
(1)
(8) (7) (6) (9) (5) (4) (3)

EN-01979
(1)
(2)
(3)
Inhibitor switch
Fuel pump
Main relay
(4)
(5)
(6)
Fuel pump relay

Electronic throttle control relay
Radiator main fan relay 1
(7)
(8)
(9)
Radiator sub fan relay

Starter

(2)
EN-02093
EN-00178
(3)
(6)
(8)
(4)
(7)
(5)
EN-02094
(9)
EN-02096
EN-02095
Engine Control Module (ECM) I/O Signal

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

A: ELECTRICAL SPECIFICATION
B134
1
8 9
18 19
28 29
2
10
20
30
B135
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
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
32 33
34 35
28 29 30 31
B136
B137
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
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
EN-01982
Crankshaft
position sensor (Model
with immobilizer)
Crankshaft
without immobilizer)
Camshaft
with immobilizer)
Camshaft
Signal (V)
Ignition SW ON
Engine ON
(engine OFF)
(idling)
Connector
No.
Terminal
No.
Signal (+)
B136
27
7 +7
Signal ()
B136
24
Sensor output waveform
Shield
B136
32
Signal (+)
B136
26
7 +7
Signal ()
B136
24
Shield
B136
32
Signal (+)
B136
26
7 +7
Signal ()
B136
25
Shield
B136
32
Signal (+)
B136
27
7 +7
Signal ()
B136
25
Shield
B136
32
Main
B137
23
0.4 1.1
Fully opens: 3.7 4.3
Sub
B137
24
3.9 4.8
Fully opens:
0.65 1.5
0.3 0.9
(After engine is
warmed-up.)
4.05 4.95
(After engine is
warmed-up.)
B137
Duty waveform
Duty waveform
Drive frequency: 1 kHz
B137
Duty waveform
Duty waveform
B137
Duty waveform
Duty waveform
DESCRIPTION
Electronic
throttle control

motor 1 (+)
motor 2 (+)
motor 1 ()
NOTE

Signal (V)
Ignition SW ON
Engine ON
(engine OFF)
(idling)
Connector
No.
Terminal
No.
B137
Duty waveform
Duty waveform
B137
10 13
13 14
B137
10 13
13 14
B137
B137
29
B137
25
B137
31
Sub
B137
30
Signal
Shield
Signal 1
B136
B136
B135
19
30
2
B135
0 1.0
13 14
B134
0 1.0
13 14
B136
22
1.0 1.6
1.0 1.6
After engine is
warmed-up.
Starter switch
B135
23
A/C switch
B135
20
Ignition switch
Neutral position switch
(AT model)
(MT model)
Test mode connector
Signal
Knock sensor
Shield
B135
13
OFF: 0
ON: 10 13
ON: 10 13
OFF: 0
10 13
OFF: 0
ON: 13 14
ON: 13 14
OFF: 0
13 14
DESCRIPTION
motor 2 ()
motor 1 power supply
motor 2 power supply
motor relay
Main
Accelerator
position sensor
Rear oxygen
sensor
Power
supply
Ground
Front oxygen
(A/F) sensor
Signal 2
heater
Rear oxygen sensor heater
signal
sensor
ON: 0
ON: 0
OFF: 10 13
OFF: 13 14
Fully closed: 0.5 1.5 Fully closed: 0.5 1.5
Fully opens: 3 5
Fully opens: 3 5
5
0
0
Fully closed: 0.5 1.5 Fully closed: 0.5 1.5
Fully opens: 3 5
Fully opens: 3 5
0
0 0.9
0
0
0 1.0
13 14
ON: 0
OFF: 10 14
ON: 10 14
OFF: 0
NOTE
When ignition switch is

turned to ON: ON
B135
12
B135
12
B135
B136
B136
24
23
12
5
2.8
0
5
2.8
0
Back-up power supply
B136
10 13
13 14
Control module power supply
B136
B136
B136
B137
B134
B134
B134
B134
B134
B134
3
4
17
25
23
24
17
27
34
33
10 13
10 13
5
5
0
0
10 13
10 13
10 13
10 13
13 14
13 14
5
5
1 3.4
1 3.4
1 14
1 14
1 14
1 14
When connected: 0
Ignition switch OFF:

10 13
Waveform
Waveform
Waveform
Waveform
Waveform
Waveform
B135
44
0.5 or less
0.5 or less
B134
27
0.5 or less
0.5 or less
Sensor power supply 1

Sensor power supply 2
1
Ignition control
2
#1
#2
Fuel injector
#3
#4
Fuel pump relay control
(Model with immobilizer)
(Model without immobilizer)

Signal (V)
Ignition SW ON
Engine ON
(engine OFF)
(idling)
ON: 0.5 or less
ON: 0.5 or less
OFF: 10 13
OFF: 13 14
ON: 0.5 or less
ON: 0.5 or less
OFF: 10 13
OFF: 13 14
ON: 0.5 or less
ON: 0.5 or less
OFF: 10 13
OFF: 13 14
10 13
13 14
Connector
No.
Terminal
No.
A/C relay control
B135
35
Radiator fan relay 1 control
B134
10
B134
Self-shutoff control
B135
14
B135
15
1 or less
Engine speed output
B135
27
B134
B134
B134
B134
B134
13
12
3
4
B135
ON: 1 or less
OFF: 10 13
0 or 10 13
0 or 10 13
0 or 10 13
0 or 10 13
ON: 1 or less
OFF: 10 13
0 13 or more
ON: 1 or less
OFF: 13 14
0 or 13 14
0 or 13 14
0 or 13 14
0 or 13 14
ON: 1 or less
OFF: 13 14
B136
35
2.05 2.25
B136
33
2.05 2.25
B136
34
B136
20
4.0 4.8
1.1 1.9
B136
28
3.3 3.5
3.3 3.5
B135
16
SSM communication line
B135
32
Main switch
B137
14
Clutch switch
B137
22
Brake switch 1
B137
12
Brake switch 2
B137
13
Cruise control command

switch
B136
21
GND (sensor 1)
B136
18
0 6.5
Less than 1 More
than 4
ON: 0
OFF: 10 13
When clutch pedal is
depressed: 0
released: 10 13
When brake pedal is
depressed: 0
When brake pedal is
released: 10 13
When brake pedal is
depressed: 10 13
When brake pedal is
released: 0
When operating nothing: 3.5 4.5
When operating RES/
ACC: 2.5 3.5
When operating SET/
COAST: 0.5 1.5
When operating CANCEL: 0 0.5
0
0 6.5
Less than 1 More
than 4
ON: 0
OFF: 13 14
depressed: 0
released: 13 14
When brake pedal is
depressed: 0
When brake pedal is
released: 13 14
When brake pedal is
depressed: 13 14
When brake pedal is
released: 0
When operating RES/
ACC: 2.5 3.5
When operating SET/
COAST: 0.5 1.5
0
DESCRIPTION
EGR solenoid
valve
Signal A+
Signal A
Signal B+
Signal B
Power steering switch

signal 1
signal 2
shield
Manifold absolute pressure
sensor
Generator control
NOTE
Light ON: 1 or less

Light OFF: 10 14
Waveform
intake air temperature:

25C (75F)

DESCRIPTION
GND (sensor 2)
GND (injector)
GND (power supply)
GND (control system)
GND (oxygen sensor heater
1)
2)
GND (Electronic throttle
control)
Signal (V)
Ignition SW ON
Engine ON
(engine OFF)
(idling)
0
0
0
0
0
0
0
0
0
0
0
0
Connector
No.
Terminal
No.
B137
B134
B134
B137
B136
B136
31
7
2
1
5
6
B135
B135
B136
B136
1
2
0
0
0
0
NOTE
Engine Condition Data

6. Engine Condition Data

Remarks
SPECIFICATION
1.6 2.9 (%): Idling
6.4 12.8 (%): 2,500 rpm Racing
Engine load
Measuring condition:
After engine is warmed-up.
Gear position is in N or P range.
A/C is turned OFF.
All accessory switches are turned OFF.
Data Link Connector

7. Data Link Connector

A: NOTE
This connector is used for Subaru Select Monitor.
CAUTION:
Do not connect any scan tools except for GENERAL scan tool and Subaru Select Monitor, because
the circuit for Subaru Select Monitor may be damaged.
9 10 11 12 13 14 15 16
EN-00037
Terminal No.
1
2
3
4
5
6
7
8
Remarks
Power supply
Empty
Empty
Empty
Empty
Empty
Empty
Empty
Terminal No.
9
10
11
12
13
14
15
16
Remarks
Empty
Subaru Select Monitor signal
Empty
Ground
Ground
Empty
Empty
Empty
General Scan Tool

8. General Scan Tool

A: OPERATION
1. HOW TO USE GENERAL SCAN TOOL
1) Prepare a general scan tool required by SAE
J1978.
2) Connect the general scan tool to data link connector located in the lower portion of instrument
panel (on drivers side).
3) Using the general scan tool, call up DTC and

freeze frame data.
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
DTC
(4) MODE $04: Clear/Reset emission-related
diagnostic information
Read out the data according to repair procedures.
(For detailed operation procedures, refer to the operation manual of general scan tool.)
NOTE:
For details concerning DTC, refer to List of Diagnostic Trouble Code (DTC). <Ref. to EN(H4SO
2.0)(diag)-66, List of Diagnostic Trouble Code
(DTC).>
EN-02533
2. MODE $01 (CURRENT POWERTRAIN DIAGNOSTIC DATA)

Refer to data denoting the current operating condition of analog input/output, digital input/output 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
1C
21
24
Data
Number of emission-related powertrain DTC, malfunction indicator light status and diagnosis
support information
Fuel system control status
Calculated engine load value
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 manifold absolute pressure sensor
Throttle valve absolute opening angle
Check whether oxygen sensor is installed.
Oxygen sensor output voltage and short term fuel trim associated with oxygen sensorbank
1 sensor 2
Supporting OBD system
Driving distance after MIL illuminates
A/F value and A/F sensor output voltage
Unit of measure
%
C
%
%
kPa
rpm
km/h
C
g/sec
%
V and %
km
and V
NOTE:
Refer to general scan tool manufacturers operation manual to access generic OBD-II PIDs (MODE $01).
General Scan Tool

3. MODE $02 (POWERTRAIN FREEZE FRAME DATA)

Refer to data denoting the operating condition when trouble is detected by on-board diagnosis system.
PID
02
03
04
05
06
07
0B
0C
0D
Data
DTC that caused CARB to require freeze frame data storage
Long term fuel trim
Engine revolution
Vehicle speed
Unit of measure
%
C
%
%
kPa
rpm
km/h
NOTE:
Refer to general scan tool manufacturers operation manual to access freeze frame data (MODE $02).
4. MODE $03 (EMISSION-RELATED POWERTRAIN DIAGNOSTIC TROUBLE CODE (DTC))

Refer to Read Diagnostic Trouble Code (DTC) for information about data denoting emission-related powertrain DTC. <Ref. to EN(H4SO 2.0)(diag)-31, Read Diagnostic Trouble Code (DTC).>
5. MODE $04 (CLEAR/RESET EMISSION-RELATED DIAGNOSTIC INFORMATION)

Refer to the mode used to clear or reset emission-related diagnostic information (OBD-II trouble diagnostic
information).
NOTE:
Refer to general scan tool manufacturers operation manual to clear or reset emission-related diagnostic information (MODE $04).

9. Subaru Select Monitor

A: OPERATION
5) Turn the ignition switch to ON (engine OFF) and

Subaru Select Monitor switch to ON.
(A)
1. HOW TO USE SUBARU SELECT MONITOR

1) Prepare the Subaru Select Monitor kit. <Ref. to
EN(H4SO 2.0)(diag)-7, PREPARATION TOOL,
EN-00040
(A) Power switch
6) Using the Subaru Select Monitor, call up DTCs

and data, then record them.
EN-00038
2) Connect the diagnosis cable to Subaru Select

Monitor.
3) Insert the cartridge to Subaru Select Monitor.
<Ref. to EN(H4SO 2.0)(diag)-7, PREPARATION
TOOL, General Description.>
2. READ DIAGNOSTIC TROUBLE CODE

(DTC) FOR ENGINE (NORMAL MODE)
Refer to Read Diagnostic Trouble Code (DTC) for
information about how to indicate DTCs. <Ref. to
EN(H4SO 2.0)(diag)-31, Read Diagnostic Trouble
Code (DTC).>

(DTC) FOR ENGINE (OBD MODE)
Code (DTC).>
EN-00039
4) Connect the Subaru Select Monitor to data link

connector.
(1) Data link connectors is located in the lower
portion of instrument panel (on the drivers side).
EN-02533
(2) Connect the diagnosis cable to data link

connector.
CAUTION:
Do not connect the scan tools except for general scan tool and Subaru Select Monitor.

4. READ CURRENT DATA FOR ENGINE. (NORMAL 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} and press the [YES] key.
3) Press the [YES] key after the information of engine type has been displayed.
4) On the Engine Diagnosis display screen, select the {Current Data Display/Save}, and then 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, scroll the display screen up or down until the desired data is shown.
A list of the support data is shown in the following table.
Remarks
Display
Unit
of measure
%
C
%
%
kpa
Note (at idling)
Engine load
Engine coolant temperature signal
A/F correction 1
A/F learning 1
Engine Load
Coolant Temp.
A/F Correction #1
A/F Learning #1
Mani. Absolute Pressure
Engine speed signal
Engine Speed
rpm
Vehicle speed signal

Ignition timing signal
Intake air temperature signal
Throttle opening angle signal
Rear oxygen sensor voltage
Battery voltage
Injection 1 pulse width
Knock sensor correction
Atmospheric pressure signal
Vehicle Speed
Ignition Timing
Intake Air Temp.
Throttle Opening Angle
Rear O2 Sensor
Battery Voltage
Fuel Injection #1 Pulse
Knocking Correction
Atmosphere Pressure
km/h
deg
C
%
V
V
ms
deg
kpa
Intake manifold relative pressure
Mani. Relative Pressure
kpa
Learned ignition timing

Acceleration opening angle signal
Rear O2 heater current
Learned Ignition Timing

Accel. Opening Angle
1 3%
75 C
10 +10%
15 +15%
200 300 kpa
600 800 rpm (Agree
with the tachometer indication)
0 km/h (at parking)
10 15 deg
(Ambient air temperature)
1 2%
0.01 0.85 V
12 14 V
2 4 ms
0.0 deg
(Atmosphere pressure)
(Mani. Absolute Pressure
Atmosphere pressure)
2 2
0.0%
Rear O2 Heater Current
0.9 1.1 A
CPC Valve Duty Ratio

No. of EGR Steps
ALT Duty
A/F Sensor #1 Resistance
A/F Sensor #1
A/F Correction #3
A/F Heater Current
Main-Throttle Sensor
Closed Position Voltage
AT Vehicle ID Signal
Test Mode Signal
Neutral Position Switch
Idle Switch Signal
Ignition Switch
P/S Switch
A/C Switch
Handle Switch
Starter Switch
%
STEP
%
0 3%
0
0 100%
ohm
25 27 mA
%
A
0.85 1.15
3.5 6.5%
5 10 A
0.3 0.7 V
ON/OFF
OFF
ON
ON
ON
OFF (At OFF)
OFF (At OFF)
RHD/LHD
OFF
OFF
Purge control solenoid duty ratio

EGR steps
Generator duty ratio
A/F sensor resistance value 1
A/F sensor output lambda 1
A/F correction 3
Front oxygen (A/F) sensor current
Main-throttle position sensor fully closed voltage
AT/MT identification terminal
Test mode terminal
Neutral position switch signal
Soft idle switch signal
Ignition switch signal
Power steering switch input signal
Air conditioning switch signal
Handle switch signal
Starter switch signal
Rear O2 monitor
Rear O2 Rich Signal

Remarks
Display
Knocking signal
Crankshaft position sensor signal
Camshaft position sensor signal
Rear defogger switch signal
Blower fan switch signal
Light switch signal
Wiper switch signal
A/C middle pressure switch signal
Air conditioner compressor relay output signal
Radiator fan relay 1 signal
Fuel pump relay signal
AT coordinate retard angle demand signal
AT coordinate fuel cut demand signal
AT coordinate permission demand
Throttle motor duty
Throttle power supply voltage
Sub throttle sensor voltage
Main throttle sensor voltage
Sub acceleration sensor voltage
Main acceleration sensor voltage
Memory vehicle speed
Fuel level sensor resistance
ETC motor relay signal
Clutch switch signal
Stop light switch signal
SET/COAST switch signal
RES/ACC switch signal
Brake switch signal
Main switch signal
Integrated unit data reception
Integrated unit data update
Knocking Signal
Crankshaft Position Sig.
Camshaft Position Sig.
Rear Defogger SW
Blower Fan SW
Light Switch
Wiper Switch
A/C Mid Pressure Switch
A/C Compressor Signal
Radiator Fan Relay #1
Fuel Pump Relay
Retard Signal from AT
Fuel Cut Signal from AT
Torque Permission Signal
Throttle Motor Duty
Throttle Motor Voltage
Sub-throttle Sensor
Main-throttle Sensor
Sub-accelerator Sensor
Main-accelerator Sensor
Memorized Cruise
Speed
Fuel Level Resistance
ETC Motor Relay
Clutch Switch
Stop Light Switch
SET/COAST Switch
RESUME/ACCEL Switch
Brake Switch
Main Switch
Body Int. Unit Data
Body Int. Unit Count
Unit
of measure
Note (at idling)

OFF
OFF
OFF
OFF (At OFF)
OFF (At OFF)
OFF (At OFF)
OFF (At OFF)
OFF (At OFF)
OFF (At OFF)
OFF (At OFF)
OFF (At OFF)
ON
OFF
OFF
ON
%
V
V
V
V
V
5 10%
(Battery voltage)
1.48 1.50 V
0.62 V
0.5 1.5 V
0.5 1.5 V
km/h
0 km/h
0 100
ON
OFF (At OFF)
OFF (At OFF)
OFF (At OFF)
OFF (At OFF)
OFF (At OFF)
OFF (At OFF)
ON
ON
NOTE:
For detailed operation procedure, refer to SUBARU SELECT MONITOR OPERATION MANUAL.

5. READ CURRENT DATA FOR ENGINE (OBD MODE)

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.
7) Using the scroll key, move the display screen up or down until the desired data is shown.
DESCRIPTION
Number of diagnosis code
Condition of malfunction indicator light
Monitoring test of misfire
Monitoring test of fuel system
Monitoring test of comprehensive component
Test of catalyst
Test of heating-type 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
Display
Number of Diag. 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
Unit of measure
0
OFF
complete
complete
no support
no support
no support
no support
complete
complete
incomplete
NOTE:
6. READ FREEZE FRAME DATA FOR ENGINE (OBD MODE)

2) On the System Selection Menu display screen, select the {Engine Control System} and press the [YES]
key.
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 support data is shown in the following table.
Contents
DTC for freeze frame data
Air fuel ratio control system for bank 1
Engine load data
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
Display
Freeze frame data
Fuel system for Bank1
Engine Load
Coolant Temp.
Short term fuel trim B1
Long term fuel trim B1
Engine Speed
Vehicle Speed
Unit of measure
DTC
%
C or F
%
%
mmHg, kPa, inHg or psi
rpm
km/h or MPH
NOTE:

7. LED OPERATION MODE FOR ENGINE

[YES] key.
5) On the Data Display Menu display screen, select the {Data & LED Display} and press the [YES] key.
Remarks
AT/MT identification signal
Test mode signal
Display
Test Mode Signal
Message
ON or OFF
ON or OFF
ON or OFF
Idle switch signal
Idle Switch Signal
ON or OFF
Ignition Switch
ON or OFF
Power steering switch signal
P/S Switch
ON or OFF
A/C Switch
ON or OFF
Handle SW
RHD or LHD

Rear oxygen sensor rich signal
Knocking signal
signal
Starter Switch
ON or OFF
Rear O2 Rich Signal
ON or OFF
Knocking Signal
ON or OFF
Crankshaft Position Signal
ON or OFF
Camshaft Position Signal
ON or OFF
Rear Defogger Switch
ON or OFF
Blower Fan Switch
ON or OFF
Light switch signal
Light Switch
ON or OFF
Small light switch signal
Light Switch
ON or OFF
Windshield wiper switch signal Wiper Switch
ON or OFF
A/C middle pressure switch

signal
ON or OFF
Air conditioning relay signal
ON or OFF
ON or OFF
ON or OFF
Fuel Pump Relay
ON or OFF
AT retard angle demand signal Retard Signal
ON or OFF
AT fuel cut signal
ON or OFF
Fuel Cut
LED ON requirements
Illuminate (AT model)
D check
When neutral position signal is
entered.
When idle switch signal is
entered.
When ignition switch is turned
ON.
When power steering switch is
entered.
When air conditioning switch is
input.
When handle switch signal is
input.
When starter switch is input.
When rear oxygen sensor mixture ratio is rich.
When knocking signal is input.
When crankshaft position sensor signal is input.
When camshaft position sensor signal is entered.
When rear defogger switch is
turned ON.
When blower fan switch is
turned ON.
When light switch is turned
ON.
When small light switch is
turned ON.
When windshield wiper switch
is turned ON.
When A/C middle pressure
switch is turned ON.
When air conditioning relay is
in function.
When radiator fan relay 1 is in
function.
function.
ON output
When AT retard angle demand
signal is input.
When AT fuel cut signal is
input.

Remarks
AT coordinate permission signal
Display
Message
Torque Control Permission
ON or OFF
Clutch Switch
ON or OFF
Stop Light Switch
ON or OFF
SET/COAST Switch
ON or OFF
RESUME/ACCEL Switch
ON or OFF
Brake switch signal
Brake Switch
ON or OFF
Main switch signal
Main Switch
ON or OFF
Cancel switch signal
Cancel Switch
ON or OFF

motor relay signal
ETC Motor Relay
ON or OFF
Data reception signal
Body Int. Unit Data
ON or OFF
Counter update signal
ON or OFF
LED ON requirements
When AT coordinate permission signal is input.
When clutch switch is turned
to ON.
When stop switch is turned to
ON.
When SET/COAST switch is
turned to ON.
When RES/ACC switch is
turned to ON.
When brake switch is turned to
ON.
When main switch is turned to
ON.
When cancel switch is turned
to ON.
When electronic throttle control motor relay is in function.
When data reception signal is
entered.
When counter update signal is
entered.
NOTE:
Read Diagnostic Trouble Code (DTC)

10.Read Diagnostic Trouble

Code (DTC)
A: OPERATION
1. SUBARU SELECT MONITOR (NORMAL
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} and press the [YES]
key.
4) On the Engine Diagnosis screen, select the
{DTC Display}, and then press the [YES] key.
5) On the Diagnostic Code(s) Display screen,
select the {Current Diagnostic Code(s)} or {History
Diagnostic Code(s)}, and then press the [YES] key.
NOTE:
(DTC).>
2. SUBARU SELECT MONITOR (OBD

MODE)
key.
5) On the OBD Menu display screen, select the
{DTC Display} and press the [YES] key.
6) Make sure DTC is shown on the screen.
NOTE:
(DTC).>
Inspection Mode
11.Inspection Mode
A: OPERATION
Carry out trouble diagnosis shown in the following DTC table.
When performing trouble diagnosis which is not shown in the DTC table, refer to the next item Drive cycle.
<Ref. to EN(H4SO 2.0)(diag)-36, Drive Cycle.>
P0031
P0032
P0037
P0038
P0107
P0108
P0112
P0113
P0117
P0118
P0122
P0123
P0131
DTC
Item
HO2S Heater Control Circuit Low (Bank 1 Sensor 1)
HO2S Heater Control Circuit High (Bank 1 Sensor 1)
Manifold Absolute Pressure/Barometric Pressure Circuit Low Input
Manifold Absolute Pressure/Barometric Pressure Circuit High Input
Intake Air Temperature Circuit Low Input
Intake Air Temperature Circuit High Input
Engine Coolant Temperature Circuit Low Input
Engine Coolant Temperature Circuit High Input
Throttle/Pedal Position Sensor/Switch A Circuit Low Input
Throttle/Pedal Position Sensor/Switch A Circuit High Input
O2 Sensor Circuit Low Voltage (Bank 1 Sensor 1)
P0132
O2 Sensor Circuit High Voltage (Bank 1 Sensor 1)
P0134
O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 1)
P0137
P0138
P0222
P0223
P0327
P0328
P0335
P0340
P0458
P0459
P0462
P0463
P0500
P0512
P0513
P0519
P0558
P0600
P0604
P0605
P0607
P0638
P0691
P0692
P0851
P0852
P1160
P1134
P1518
P1560
Throttle/Pedal Position Sensor/Switch B Circuit Low Input

Throttle/Pedal Position Sensor/Switch B Circuit High Input
Knock Sensor 1 Circuit Low Input (Bank 1 or Single Sensor)
Knock Sensor 1 Circuit High Input (Bank 1 or Single Sensor)
Crankshaft Position Sensor A Circuit
Camshaft Position Sensor A Circuit (Bank 1 or Single Sensor)
Evaporative Emission Control System Purge Control Valve Circuit Low
Canister Purge Solenoid Circuit (High)
Fuel Level Sensor Circuit Low Input
Fuel Level Sensor Circuit High Input
Vehicle Speed Sensor
Starter Request Circuit
Incorrect Immobilizer Key
Idle Control System Malfunction (Fail-Safe)
Generator Circuit Low Input
Serial Communication Link
Internal Control Module Random Access Memory (RAM) Error
Internal Control Module Read Only Memory (ROM) Error
Control Module Performance
Throttle Actuator Control Range/Performance (Bank 1)
Cooling Fan 1 Control Circuit Low
Cooling Fan 1 Control Circuit High
Neutral Switch Input Circuit Low
Neutral Switch Input Circuit High
Return Spring Failure
A/F Sensor Micro-Computer Problem
Starter Switch Circuit Low Input
Back-up Voltage Circuit Malfunction
Inspection Mode
DTC
P1570
P1571
P1572
P1574
P1576
P1577
P1578
P2101
P2102
P2103
P2109
P2100
P2111
P2122
P2123
P2127
P2128
P2135
P2138
Item
Antenna
Reference Code Incompatibility
IMM Circuit Failure (Except Antenna Circuit)
Key Communication Failure
EGI Control Module EEPROM
IMM Control Module EEPROM
Meter Failure
Throttle Actuator Control Motor Circuit Range/Performance
Throttle Actuator Control Motor Circuit Low
Throttle Actuator Control Motor Circuit High
Throttle/Pedal Position Sensor A Minimum Stop Performance
Throttle Control Motor Circuit Open
Throttle Actuator Control System - Stuck Open
Throttle/Pedal Position Sensor/Switch D Circuit Low Input
Throttle/Pedal Position Sensor/Switch D Circuit High Input
Throttle/Pedal Position Sensor/Switch E Circuit Low Input
Throttle/Pedal Position Sensor/Switch E Circuit High Input
Throttle/Pedal Position Sensor/Switch A/B Voltage Rationality
Throttle/Pedal Position Sensor/Switch D/E Voltage Rationality
1. PREPARATION FOR THE INSPECTION

MODE
1) Check that the battery voltage is more than 12 V
and fuel remains half [20 40 2 (5.3 10.6 US
gal, 4.4 8.8 Imp gal)].
2) Lift-up the vehicle using a garage jack and place
it on rigid racks, or drive the vehicle onto free rollers.
Since the rear wheels will also rotate, do not

place anything near them. Also, make sure that
nobody goes in front of the vehicle.
WARNING:
Before lifting-up the vehicle, ensure parking
brakes are applied.
Do not use a pantograph jack in place of a rigid rack.
Secure a rope or wire to the front or rear towing hooks to prevent the lateral runout of front
wheels.
Do not abruptly depress/release clutch pedal
or accelerator pedal during works even when
the 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 rigid racks
and vehicle.
(A)
(B)
(A) Rigid rack

(B) Free rollers
EN-00041
Inspection Mode
2. SUBARU SELECT MONITOR

1) After clearing the memory, check for any remaining unresolved trouble data. <Ref. to EN(H4SO
2.0)(diag)-38, Clear Memory Mode.>
2) Idle the engine.

connector located in the lower portion of the instrument panel (on the drivers side).
EN-02533
EN-00038
CAUTION:
Do not connect the scan tools except for Subaru Select Monitor.
turn Subaru Select Monitor switch to ON.

Monitor.
(A)
EN-00040
(A) Power switch
EN-00039
6) Connect the test mode connector (A) located at

the lower portion of glove box.
(A)
EN-02424

key.
{D Check} and press the [YES] key.
13) When the Perform D Check? is shown on the
screen, press the [YES] key.
14) Perform subsequent procedures as instructed
on the display screen.
If trouble still remains in the memory, the corresponding DTC appears on the display screen.
NOTE:
For the details concerning DTCs, refer to List of
Diagnostic Trouble Code (DTC).
<Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic
Trouble Code (DTC).>
Release the parking brake.
Inspection Mode
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 function.
3. GENERAL SCAN TOOL

1) After clearing memory, check for any remaining
unresolved trouble data: <Ref. to EN(H4SO 2.0)(diag)-38, Clear Memory Mode.>
2) Warm up the engine.
3) Connect the test mode connector (A) at the lower side of instrument panel (on the drivers side).
9) Place the select lever or shift lever in D position

(AT model) or 1st gear (MT model) and drive the
vehicle at 5 to 10 km/h (3 to 6 MPH).
NOTE:
On AWD vehicles, release the parking brake.
wheels may light ABS warning light, but this indicates no malfunctions. When the engine control diagnosis is finished, perform the ABS memory
clearance procedure of self-diagnosis system.
10) Using the general scan tool, check for DTC and
record the result(s).
NOTE:
For detailed operation procedures, refer to the
operation manual of general scan tool.
For details concerning DTC, refer to List of Diagnostic Trouble Code (DTC).
(A)
EN-02424
4) Connect the general scan tool to its data link

connector in the lower portion of instrument panel
(on the drivers side).
CAUTION:
Do not connect the scan tools except for Subaru Select Monitor and general scan tool.
EN-02533

NOTE:
Ensure the select lever is placed in P position
before starting. (AT model)
Depress the clutch pedal when starting engine.
(MT model)
6) Using the select lever or shift lever, turn the P
position switch and N position switch to ON.
7) Depress the brake pedal to turn brake switch
ON. (AT model)
8) Keep the engine speed in 2,500 3,000 rpm
range for 40 seconds.
Drive Cycle
12.Drive Cycle
A: PROCEDURE
There are three drive patterns for the trouble diagnosis. Driving in the specified pattern allows to diagnose
malfunctioning items listed below. After the malfunctioning items listed below are repaired, always check
whether they correctly resume their functions by driving in the required drive pattern.
1. PREPARATION FOR DRIVE CYCLE

1) Make sure that the fuel remains approx. half amount [20 40 2 (5.3 10.6 US gal, 4.4 8.8 Imp gal)],
and battery voltage is 12V or more.
2) After performing the diagnostics and cleaning memory, check for any remaining unresolved trouble data.
<Ref. to EN(H4SO 2.0)(diag)-38, Clear Memory Mode.>
3) Separate the test mode connector.
NOTE:
Except for the water temperature specified items at starting, the diagnosis is carried out after engine warm
up.
Carry out the diagnosis which is marked * on DTC twice, then, after finishing first diagnosis, stop the engine
and do second time at the same condition.
2. AFTER RUNNING 20 MINUTES AT 80 KM/H (50 MPH), IDLE ENGINE FOR 1 MINUTE.
DTC
*P0125
Item
Insufficient Coolant Temperature for Closed Loop Fuel Control
Condition
Coolant temperature at start is
less than 20C (68F).
*P0133
O2 Sensor Circuit Slow Response (Bank 1 Sensor 1)
*P0171
*P0172
*P0420
*P0483
System too Lean (Bank 1)

System too Rich (Bank 1)
Catalyst System Efficiency Below Threshold (Bank 1)
Cooling Fan Rationality Check
O2 Sensor Circuit (Bank1 Sensor1)
P1137
Drive Cycle
3. DRIVE ACCORDING TO THE FOLLOWING DRIVE PATTERN
(H)
(C)
96 (60)
(D)
(G)
(F)
65 (40)
(E)
(B)
(A)
0
50
150
100
(I)
EN-00195
(A)
(B)
(C)
Idle engine for 1 minute.

Accelerate to 96 km/h (60 MPH)
within 20 seconds.
Drive vehicle at 96 km/h (60 MPH)
for 20 seconds.
DTC
*P0030
(D)
(E)
Decelerate with throttle fully

closed to 65 km/h (40 MPH).
for 10 seconds.
(F)
(G)
(H)
(I)
P0130
Item
HO2S Heater Control Circuit (Bank 1 Sensor 1)
*P0139
P0301
Cylinder 1 Misfire Detected
P0302
P0303
P0304
P0400
P0559
P0700
P1134
P1492
P1493
P1494
P1495
P1496
P1497
P1498
P1499
P1521
Exhaust gas recirculation flow

Generator Circuit High Input
Transmission Control System (MIL Request)
A/F Sensor Micro-Computer Problem
EGR Solenoid Valve Signal #1 Circuit Malfunction (Low Input)
EGR Solenoid Valve Signal #1 Circuit Malfunction (High Input)
Brake Switch Circuit Range/Performance Problem (High Input)

within 10 seconds.
Stop vehicle with throttle fully
closed.
Vehicle speed km/h (MPH)
Seconds
Condition
Diagnosis frequency is different

from misfire ratio.
from misfire ratio.
from misfire ratio.
from misfire ratio.
Clear Memory Mode

13.Clear Memory Mode

A: OPERATION
MODE)
key.
4) On the Engine Diagnosis display screen, select the {Memory Clear} and press the [YES] key.
5) When the Done and Turn Ignition Switch OFF
are shown on the display screen, turn the ignition
switch to OFF and then Subaru Select Monitor
switch to OFF.
NOTE:
performed after memory clearance. For this reason, start the engine after 10 seconds or more have

MODE)
key.
{DTC Clear} and press the [YES] key.
6) When the Perform Diagnostic Code(s) Clear?
is shown on the screen, press the [YES] key.
7) Turn the ignition switch to OFF and then turn the
Subaru Select Monitor switch to OFF.
NOTE:
Compulsory Valve Operation Check Mode

14.Compulsory Valve Operation

Check Mode

connector located in the lower portion of instrument
panel (on the drivers side).
A: PROCEDURE
EN-02533
EN-00038

Monitor.
CAUTION:
(A)
EN-00040
(A) Power switch

EN-00039

(A)
EN-02424

key.
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 valve operation check mode. The display will
then return to the Actuator ON/OFF Operation
screen.

A list of the support data is shown in the following

table.
DESCRIPTION
Compulsory fuel pump relay operation check
Compulsory radiator fan relay
operation check
Compulsory air conditioning relay
operation check
Compulsory purge control solenoid valve operation check
Display
Fuel Pump
Radiator Fan Relay
A/C Compressor Relay
CPC Solenoid
NOTE:
The following parts will be displayed but not functional.
Display
EGR Solenoid
ASV Solenoid
FICD Solenoid
Pressure switching solenoid 1
Wastegate control solenoid
PCV Solenoid
Vent Control Solenoid
AAI Solenoid
Fuel Tank Sensor Control Valve
Malfunction Indicator Light

15.Malfunction Indicator Light

A: PROCEDURE
1. Activation of malfunction indicator light. <Ref. to EN(H4SO 2.0)(diag)-42, ACTIVATION OF MALFUNCTION INDICATOR
LIGHT, Malfunction Indicator Light.>
2. Check that the malfunction indicator light does not come on. <Ref. to EN(H4SO 2.0)(diag)-43, MALFUNCTION INDICATOR
LIGHT DOES NOT COME ON, Malfunction Indicator Light.>
3. Check that the malfunction indicator light does not go off. <Ref. to EN(H4SO 2.0)(diag)-45, MALFUNCTION INDICATOR
LIGHT DOES NOT GO OFF., Malfunction Indicator Light.>
4. Check that the malfunction indicator light does not blink. <Ref. to EN(H4SO 2.0)(diag)-46, MALFUNCTION INDICATOR LIGHT
DOES NOT BLINK., Malfunction Indicator Light.>
5. Check that the malfunction indicator light remains blinking. <Ref. to EN(H4SO 2.0)(diag)-49, MALFUNCTION INDICATOR
LIGHT REMAINS BLINKING., Malfunction Indicator Light.>

B: ACTIVATION OF MALFUNCTION
INDICATOR LIGHT
1) When the ignition switch is turned to ON (engine
OFF), the malfunction indicator light (A) in the combination meter illuminates.
(3) Malfunction indicator light blinks at a cycle of

3 Hz after diagnosis if there is no trouble. Malfunction indicator light illuminates if faulty.
(1)
NOTE:
If the malfunction indicator light does not illuminate,
perform the diagnosis of malfunction indicator light
circuit or the combination meter circuit. <Ref. to
EN(H4SO 2.0)(diag)-43, MALFUNCTION INDICATOR LIGHT DOES NOT COME ON, Malfunction
Indicator Light.>
(2)
(4)
(3)
EN-01681
(1)
(2)
(3)
(4)
(A)
ON
OFF
Ignition switch ON
1 second
EN-01984
2) After starting the engine, the malfunction indicator light goes out. If it does not, either the engine or
emission control system is malfunctioning.
(1)
(3)
(4)
(2)
(3)
(4)
(5)
(6)
EN-01679
(1)
(2)
(3)
(4)
(5)
(6)
No faulty
Trouble occurs
ON
OFF
Ignition switch ON
Engine start
3) Turn the ignition switch to OFF and connect the

test mode connector.
(1) When the ignition switch is turned to ON
(engine OFF), the malfunction indicator light illuminates.
0.5 Hz after starting the engine. (During diagnosis)

C: MALFUNCTION INDICATOR LIGHT DOES NOT COME ON

DIAGNOSIS:
The malfunction indicator light circuit is open or shorted.
TROUBLE SYMPTOM:
When the ignition switch is turned to ON (engine OFF), malfunction indicator light does not come on.
WIRING DIAGRAM:
B72
IGNITION
SWITCH
BATTERY
SBF-7
No.5
3
3
4
SBF-1
COMBINATION
METER
16
i10
i3
15
B38
B135 ECM
B72
B135
1 2 3
4 5 6
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
24 25
26 27
20 21 22 23
32 33
34 35
28 29 30 31
i10
1 2 3 4 5
11 12 13 14 15 16
6 7 8 9 10
17 18 19 20 21 22
B38
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
EN-02425

Step
CHECK OUTPUT SIGNAL FROM ECM.
2) Measure the voltage between ECM connector and chassis ground.
(B135) No. 15 (+) Chassis ground ():
CHECK POOR CONTACT.
Check for poor connection by shaking or pulling ECM connector and harness.
CHECK ECM CONNECTOR.
Check the connection of ECM connector.
CHECK HARNESS BETWEEN COMBINATION METER AND ECM CONNECTOR.

2) Remove the combination meter. <Ref. to
IDI-16, Combination Meter.>
3) Disconnect the connector from ECM and
combination meter.
between ECM and combination meter connector.
(B135) No. 15 (i10) No. 16:
Check
Is the voltage less than 1 V?
Yes
Go to step 4.
Does the malfunction indicator Repair the poor

light illuminate?
contact in ECM
connector.
Is the ECM connector correctly Replace the ECM.
connected?
<Ref. to FU(H4SO
2.0)-34, Engine
Control Module
(ECM).>
Go to step 5.
?
CHECK POOR CONTACT.

Is there poor contact in combi- Repair the poor
Check poor contact in combination meter con- nation meter connector?
contact in combinector.
nation meter connector.
Is the voltage more than 10 V? Replace the board
CHECK HARNESS BETWEEN COMBINAof combination
TION METER AND IGNITION SWITCH CONmeter. <Ref. to IDINECTOR.
16, Combination
Meter.>
2) Measure the voltage between combination
meter connector and chassis ground.
(i10) No. 3 (+) Chassis ground ():
No
Go to step 2.
Go to step 3.
Repair the connection of ECM

connector.
Repair the 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.
Check the following and repair if

necessary.
NOTE:
Blown out fuse
(No. 5)
Open or short
circuit in harness
between fuse (No.
5) and battery terminal
Poor contact in
ignition switch connector

D: MALFUNCTION INDICATOR LIGHT DOES NOT GO OFF.

DIAGNOSIS:
The malfunction indicator light circuit is shorted.
TROUBLE SYMPTOM:
Although malfunction indicator light comes on when the engine runs, DTC is not shown on the Subaru Select
Monitor display.
WIRING DIAGRAM:
B72
IGNITION
SWITCH
BATTERY
SBF-7
No.5
3
3
4
SBF-1
COMBINATION
METER
16
i10
i3
15
B38
B135 ECM
B72
B135
1 2 3
4 5 6
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
24 25
26 27
20 21 22 23
32 33
34 35
28 29 30 31
i10
1 2 3 4 5
11 12 13 14 15 16
6 7 8 9 10
17 18 19 20 21 22
B38
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
EN-02425
Step
Check
Yes
Does the malfunction indicator Repair the short
light illuminate?
circuit in harness
between combination meter and
ECM connector.
No
Replace the ECM.
<Ref. to FU(H4SO
2.0)-34, Engine
Control Module
(ECM).>

E: MALFUNCTION INDICATOR LIGHT DOES NOT BLINK.

DIAGNOSIS:
Test mode connector circuit is in open.
TROUBLE SYMPTOM:
Malfunction indicator light does not blink during inspection mode.
WIRING DIAGRAM:
LHD model
IGNITION
SWITCH
B72
BATTERY
SBF-7
No.5
3
3
4
SBF-1
COMBINATION
METER
i10
B75
B76
B122
B21
E2
i3
36
16
2
1
B24
B15
B38
ECM
B: B135
B21
B75
B72
i10
B38
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
1
2
1 2 3
4 5 6
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B122
1 2 3 4
5 6 7 8
B: B135
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
32 33
34 35
28 29 30 31
EN-02426

RHD model
IGNITION
SWITCH
B72
BATTERY
SBF-7
No.5
3
3
4
SBF-1
COMBINATION
METER
16
i10
B83
1
B75
B76
i3
B29
B15
B24
B38
B: B135
B75
B72
1
2
1 2 3
4 5 6
ECM
i10
1 2 3 4 5
11 12 13 14 15 16
6 7 8 9 10
17 18 19 20 21 22
B38
B83
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
1 2 3 4
5 6 7 8
B: B135
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
32 33
34 35
28 29 30 31
EN-02427

Step
CHECK STATUS OF MALFUNCTION INDICATOR LIGHT.
2) Disconnect the test mode connectors.
3) Turn the ignition switch to ON. (engine
OFF)
Check
Yes
light illuminate?

CHECK HARNESS BETWEEN TEST MODE
CONNECTOR AND CHASSIS GROUND.
between test mode connector and chassis
ground.
(B76) No. 1 Chassis ground:

light illuminate?
circuit in harness
ECM connector.
Go to step 4.
Repair the har?
ness and connector.
CHECK POOR CONTACT.


connector?
CHECK HARNESS BETWEEN ECM AND

TEST MODE CONNECTOR.
between ECM and chassis ground.
CHECK POOR CONTACT.

?

connector?
Repair the poor

contact in ECM
connector.
Go to step 6.
Repair the poor

contact in ECM
connector.
No
Repair the malfunction indictor
light circuit. <Ref.
to EN(H4SO
2.0)(diag)-43,
MALFUNCTION
INDICATOR
LIGHT DOES
NOT COME ON,
Malfunction Indicator Light.>
Go to step 3.
NOTE:
the following:
Open circuit in
harness between
test mode connector and chassis
ground
Go to step 5.
Repair the open

circuit in harness
between ECM and
Replace the ECM.

<Ref. to FU(H4SO
2.0)-34, Engine
Control Module
(ECM).>

F: MALFUNCTION INDICATOR LIGHT REMAINS BLINKING.

DIAGNOSIS:
Test mode connector circuit is shorted.
TROUBLE SYMPTOM:
Malfunction indicator light blinks when test mode connector is not connected.
WIRING DIAGRAM:
LHD model
IGNITION
SWITCH
B72
BATTERY
SBF-7
No.5
3
3
4
SBF-1
COMBINATION
METER
i10
B75
B76
B122
B21
E2
i3
36
16
2
1
B24
B15
B38
ECM
B: B135
B21
B75
B72
i10
B38
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
1
2
1 2 3
4 5 6
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B122
1 2 3 4
5 6 7 8
B: B135
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
32 33
34 35
28 29 30 31
EN-02426

RHD model
IGNITION
SWITCH
B72
BATTERY
SBF-7
No.5
3
3
4
SBF-1
COMBINATION
METER
16
i10
B83
1
B75
B76
i3
B29
B15
B24
B38
B: B135
B75
B72
1
2
1 2 3
4 5 6
ECM
i10
1 2 3 4 5
11 12 13 14 15 16
6 7 8 9 10
17 18 19 20 21 22
B38
B83
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
1 2 3 4
5 6 7 8
B: B135
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
32 33
34 35
28 29 30 31
EN-02427
Step
CHECK TEST MODE CONNECTOR.
Check
Yes
light blink?
CHECK HARNESS BETWEEN ECM CONIs the resistance less than 5

NECTOR AND CHASSIS GROUNDING TER- ?
MINAL.
between ECM connector and chassis ground.
No
System is in good
order.
NOTE:
Malfunction indicator light blinks at a
cycle of 3 Hz when
test mode connector is connected.
Repair the short
Replace the ECM.
circuit in harness <Ref. to FU(H4SO
between ECM and 2.0)-34, Engine
test mode connec- Control Module
tor.
(ECM).>
Diagnostics for Engine Starting Failure

16.Diagnostics for Engine Starting Failure

A: PROCEDURE
1. Check for fuel amount.
2. Inspection of starter motor circuit. <Ref. to EN(H4SO 2.0)(diag)-52, STARTER MOTOR CIRCUIT, Diagnostics for Engine Starting Failure.>
3. Inspection of ECM power supply and ground line. <Ref. to EN(H4SO 2.0)(diag)-55, CHECK POWER SUPPLY AND GROUND
LINE OF ENGINE CONTROL MODULE (ECM), Diagnostics for Engine Starting Failure.>
4. Inspection of ignition control system. <Ref. to EN(H4SO 2.0)(diag)-58, IGNITION CONTROL SYSTEM, Diagnostics for Engine
Starting Failure.>
5. Inspection of fuel pump circuit. <Ref. to EN(H4SO 2.0)(diag)-61, FUEL PUMP CIRCUIT, Diagnostics for Engine Starting Failure.>
6. Inspection of fuel injector circuit. <Ref. to EN(H4SO 2.0)(diag)-64, FUEL INJECTOR CIRCUIT, Diagnostics for Engine Starting
Failure.>

B: STARTER MOTOR CIRCUIT

CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)38, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO 2.0)(diag)-32, OPERATION, Inspection Mode.>.
WIRING DIAGRAM:
IGNITION
SWITCH
B72
BATTERY
SBF-1
SBF-7
16
LHD
14
RHD
13
13
16
RHD
14
15
LHD
15
No.21
3
2
STARTER
RELAY
B225
MT
AT
11
12
12
B12
T3
T7
MT
STARTER MOTOR
AT
E
M
23
B14
B135
ECM
B225
B72
1 2 3
4 5 6
B135
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
1
8 9
20 21
28 29
2
3
10 11 12 13
22 23
30 31
4 5 6
7
14 15 16 17 18 19
24 25
26 27
32 33
34 35
B12
T7
1 2 3 4
5 6 7 8
9 10 11 12
1 2 3 4 5 6
7 8 9 10 11 12
EN-02428

1
2
3
Step
Check
CHECK BATTERY.
Is the voltage more than 12 V?
Check the battery voltage.
CHECK OPERATION OF STARTER MOTOR. Does the starter motor operate?
CHECK DTC.
Is DTC displayed? <Ref. to
EN(H4SO 2.0)(diag)-31,
OPERATION, Read Diagnostic
Yes
Go to step 2.
Go to step 3.
Inspect the relevant DTC using

List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(H4SO
2.0)(diag)-66, List
of Diagnostic Trouble Code (DTC).>
CHECK INPUT SIGNAL FOR STARTER MO- Is the voltage more than 10 V? Go to step 5.
TOR.
2) Disconnect the connector from starter
motor.
3) Turn the ignition switch to START.
4) Measure the power supply voltage between
starter motor connector terminal and engine
ground.
(B14) No. 1 (+) Engine ground ():
NOTE:
Place the select lever in the P or N range.
CHECK GROUND CIRCUIT OF STARTER
MOTOR.
2) Disconnect the ground cable terminal from
starter motor.
3) Measure the resistance of ground cable
between ground cable terminal and engine
ground.
CHECK HARNESS BETWEEN BATTERY
AND IGNITION SWITCH CONNECTOR.
1) Disconnect the connector from ignition
switch.
ignition switch connector and chassis ground.
CHECK IGNITION SWITCH.
switch.
2) Measure the resistance between ignition
switch terminals after turning the ignition
switch to START position.
Terminals
No. 2 No. 3:

?
Check the starter

motor. <Ref. to
SC(H4SO 2.0)-6,
Starter.>
No
Charge or replace
the battery.
Go to step 4.
Repair the poor
contact in ECM
connector.
Go to step 6.
Repair the open

circuit of ground
cable.
Repair the open

circuit in harness
between ignition
switch and battery, and check
fuse SBF No. 7
and SBF No. 1.

?
Replace the ignition switch.
Go to step 8.

10
Step
CHECK INPUT VOLTAGE OF STARTER RELAY.
2) Disconnect the connector from starter relay.
3) Connect the connector to ignition switch.
4) Measure the input voltage between starter
relay connector and chassis ground after turning the ignition switch to START position.
LHD MODEL
RHD MODEL
CHECK STARTER RELAY.
1) Connect the battery to starter relay terminals No. 15 and No. 16.
2) Measure the resistance between starter
relay terminals.
Terminals
No. 13 No. 14:
CHECK INPUT VOLTAGE FROM ECM.
2) Connect the connector to starter relay.
3) Disconnect the connectors from ECM.
4) Measure the voltage between ECM and
chassis ground.
Check
Yes
No
Repair the open
circuit in harness
between starter
fan relay and ignition switch.

?
Replace the
starter relay.
Go to step 10.
Is the voltage more than 10 V? Replace the ECM.

<Ref. to FU(H4SO
2.0)-34, Engine
Control Module
(ECM).>
Repair the open or

ground short circuit in harness
between ECM and
starter relay.

C: CHECK POWER SUPPLY AND GROUND LINE OF ENGINE CONTROL MODULE (ECM)
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
TO IGNITION COIL
3
5
SBF-8
6
4
No.13
1
2
B72
B47
IGNITION
SWITCH
BATTERY
No.12
SBF-7
3
C7
B13
B14
C3
C4
SBF-1
A: B134
B: B135
ECM
C: B136
35
37
34
36
52
B5
B6
C1
C2
A7
C5
C6
A2
D1
D: B137
B21
E2
E
A:
B134
B:
C: B136
B135
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
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
32 33
34 35
28 29 30 31
D:
B72
1 2 3
4 5 6
5 6
14 15 16
25 26 27
33 34 35
B137
B47
1
3
5
2
4
6
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
28 29
30 31
26 27
EN-02429

Step
CHECK MAIN RELAY.
2) Remove the main relay.
3) Connect the battery to main relay terminals
No. 1 and No. 2.
4) Measure the resistance between main relay
terminals.
Terminals
No. 3 No. 5:
No. 4 No. 6:
CHECK GROUND CIRCUIT FOR ECM.
CHECK INPUT VOLTAGE OF ECM.
Measure the voltage between ECM connector
and chassis ground.
CHECK INPUT VOLTAGE OF MAIN RELAY.
Measure the voltage between main relay connector and chassis ground.
Check
?
Yes
Go to step 2.
No
Replace the main
relay.

?
Go to step 3.
Repair the open

circuit in harness
between ECM
connector and
engine grounding
terminal.
Repair the open or

ground short circuit of power supply circuit.
Repair the open or

Repair the open

circuit in harness
between ECM
connector and
main relay connector.
Repair the open or
between ECM
connector and

1) Connect the connectors to ECM and main
relay.
CHECK INPUT VOLTAGE OF MAIN RELAY. Is the voltage more than 10 V? Go to step 8.
Repair the open or

ground short circuit in harness of
power supply circuit.

Step
Check
Yes
Is the voltage more than 10 V? Check ignition
control system.
<Ref. to EN(H4SO
2.0)(diag)-58,
IGNITION CONTROL SYSTEM,
Diagnostics for
Engine Starting
Failure.>
No
Repair the open or
between ECM
connector and

D: IGNITION CONTROL SYSTEM

CAUTION:
WIRING DIAGRAM:
ECM
24
23
B134
B72
IGNITION
SWITCH
BATTERY
No.12
SBF-7
6
SBF-1
15
13
49
B21
E2
3
2
4
1
E12
IGNITION COIL
&
IGNITOR ASSY
E12
B72
1 2 3 4
1 2 3
4 5 6
B225
1
B21
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
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
B134
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
EN-02430

Step
Check
CHECK IGNITION SYSTEM FOR SPARKS. Does spark occur at each cyl1) Remove the plug cord cap from each spark inder?
plug.
2) Install a new spark plug on plug cord cap.
Yes
No
Check fuel pump Go to step 2.
system. <Ref. to
EN(H4SO
2.0)(diag)-61,
FUEL PUMP CIRCUIT, Diagnostics
for Engine Starting Failure.>
CAUTION:
Do not remove the spark plug from engine.
3) Contact the spark plugs thread portion on
engine.
4) While opening the throttle valve fully, crank
the engine to check that spark occurs at each
cylinder.
CHECK POWER SUPPLY CIRCUIT FOR IG- Is the voltage more than 10 V? Go to step 3.
NITION COIL & IGNITOR ASSY.
2) Disconnect the connector from ignition coil
& ignitor ASSY.
ignition coil & ignitor ASSY connector and
engine ground.
(E12) No. 1 (+) Engine ground ():
CHECK HARNESS OF IGNITION COIL & IG- Is the resistance less than 5
NITOR ASSY GROUND CIRCUIT.
?
coil & ignitor ASSY connector and engine
ground.
(E12) No. 3 Engine ground:
Go to step 4.
CHECK IGNITION COIL & IGNITOR ASSY. Is the resistance 10 15 k? Go to step 5.

1) Remove the spark plug cords.
2) Measure the resistance between spark
plug cord contact portions to check secondary
coil.
Terminals
No. 1 No. 2:
No. 3 No. 4:
Go to step 6.
CHECK INPUT SIGNAL FOR IGNITION COIL Does the voltage vary more
than 10 V?
& IGNITOR ASSY.
1) Connect the connector to ignition coil &
ignitor ASSY.
2) Check if voltage varies synchronously with
engine speed when cranking, while monitoring
voltage between ignition coil & ignitor ASSY
connector and engine ground.

NOTE:
the following:
Open circuit in
harness between
ignition coil & ignitor ASSY, and
main relay connector
Poor contact in
coupling connector
Blown out fuse
NOTE:
the following:
Open circuit in
harness between
ignition coil & ignitor ASSY connector and engine
grounding terminal
Replace the ignition coil & ignitor
ASSY. <Ref. to
IG(H4SO 2.0)-8,
Ignition Coil and
Ignitor Assembly.>

ASSY. <Ref. to
IG(H4SO 2.0)-8,
Ignition Coil and
Ignitor Assembly.>

Step
Check
CHECK HARNESS BETWEEN ECM AND IG- Is the resistance less than 1
NITION COIL & IGNITOR ASSY CONNEC?
TOR.
& ignitor ASSY.
between ECM and ignition coil & ignitor ASSY
connector.
(B134) No. 23 (E12) No. 4:
(B134) No. 24 (E12) No. 2:
Yes
Go to step 7.
CHECK HARNESS BETWEEN ECM AND IGNITION COIL & IGNITOR ASSY CONNECTOR.
Measure the resistance of harness between
ECM and engine ground.
Connector & terminal:
(B134) No. 23 Engine ground:
CHECK POOR CONTACT.

M?
Go to step 8.

connector?
Repair the poor

contact in ECM
connector.
No
NOTE:
the following:
Open circuit in
harness between
ECM and ignition
coil & ignitor ASSY
connector
Poor contact in
coupling connector
Repair the ground
short circuit in harness between
ECM and ignition
coil & ignitor ASSY
connector.
Check the fuel

pump circuit. <Ref.
to EN(H4SO
2.0)(diag)-61,

E: FUEL PUMP CIRCUIT

CAUTION:
WIRING DIAGRAM:
No.11
B72
IGNITION
SWITCH
BATTERY
SBF-7
No.12
FUEL PUMP
RELAY
SBF-1
2
3
4
1
17
B135 ECM
RHD
LHD
B362
B97
16
B98
R1
LHD
R2
FUEL PUMP
FUEL PUMP
CONDENSER
RHD
1
2
5
6
R142
R58
B362
1 2
3
4
B72
R142
B97
B98
R58
B135
1 2 3
4 5 6
1
2
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
1
2 3
4 5 6 7 8
1 2
3 4
5 6
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
32 33
34 35
28 29 30 31
5
7 8
6
EN-02431

Step
CHECK OPERATING SOUND OF FUEL
PUMP.
Check if the fuel pump is in operation for two
seconds when turning the ignition switch to
ON.
Check
Does the fuel pump produce
operating sound?
NOTE:
Fuel pump operation can also be executed using Subaru Select Monitor.
Mode for procedures. <Ref. to EN(H4SO
Check Mode.>
CHECK GROUND CIRCUIT OF FUEL PUMP. Is the resistance less than 5
?
2) Remove the fuel pump access hole lid.
4) Measure the resistance of harness connector between fuel pump and chassis ground.
(R58) No. 6 Chassis ground:
Yes
No
Check the fuel
Go to step 2.
injector circuit.
<Ref. to EN(H4SO
2.0)(diag)-64,
FUEL INJECTOR
CIRCUIT, Diagnostics for Engine
Starting Failure.>
Go to step 3.
CHECK POWER SUPPLY TO FUEL PUMP. Is the voltage more than 10 V?

2) Measure the voltage of power supply circuit
between fuel pump connector and chassis
ground.
(R58) No. 5 (+) Chassis ground ():
CHECK HARNESS BETWEEN FUEL PUMP Is the resistance less than 1
AND FUEL PUMP RELAY CONNECTOR.
?
2) Measure the resistance of harness connector between fuel pump and fuel pump relay.
(R58) No. 5 (B362) No. 1:
Replace the fuel

pump. <Ref. to
FU(H4SO 2.0)-47,
Fuel Pump.>
CHECK HARNESS BETWEEN FUEL PUMP

fuel pump and fuel pump relay connector.
CHECK FUEL PUMP RELAY.
1) Disconnect the connectors from fuel pump
relay and main relay.
2) Remove the fuel pump relay and main relay
with bracket.
3) Connect the battery to fuel pump relay connector terminals No. 3 and No. 4.
4) Measure the resistance between connector
terminals of fuel pump relay.
Terminals
No. 2 No. 1:

M?
Go to step 6.

?
Go to step 7.
Go to step 5.

NOTE:
the following:
Open circuit in
harness between
fuel pump connector and chassis
grounding terminal
Go to step 4.

NOTE:
the following:
Open circuit in
harness between
grounding terminal
Poor contact in
coupling connector
Repair the short
circuit in harness
between fuel pump
and fuel pump
relay connector.
Replace the fuel
pump relay. <Ref.
to FU(H4SO 2.0)47, Fuel Pump.>

Step
FUEL PUMP RELAY CONNECTOR.
between ECM and fuel pump relay connector.
(B135) No. 17 (B362) No. 4:
CHECK POOR CONTACT.
Check
?
Yes
Go to step 8.
No
Repair the open
circuit in harness
between ECM and
fuel pump relay
connector.

connector?
Repair the poor

contact in ECM
connector.
Check the fuel

injector circuit.
<Ref. to EN(H4SO
2.0)(diag)-64,
FUEL INJECTOR
Starting Failure.>

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(H4SO 2.0)(diag)-38, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO 2.0)(diag)-32, OPERATION, Inspection Mode.>.
WIRING DIAGRAM:
MAIN RELAY
5
3
BATTERY
SBF-8
6
4
2
1
B47
33
34
45
44
27
43
42
48
17
B134 ECM
B21
E2
E17
2
E6
E16
E5
E
FUEL INJECTOR
No. 2
FUEL INJECTOR
No. 1
E5
E16
E6
E17
1 2
B47
1
3
5
2
4
6
FUEL INJECTOR
No. 3
FUEL INJECTOR
No. 4
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B134
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
EN-02432

Step
Check
CHECK OPERATION OF EACH FUEL INJEC- Does the fuel pump emit operTOR.
ating sound?
While cranking the engine, check each fuel
injector emits operating sound. Use a sound
scope or apply a screwdriver to the injector for
this check.
CHECK POWER SUPPLY TO EACH FUEL
INJECTOR.
fuel injector terminal and engine ground.
#1 (E5) No. 2 (+) Engine ground ():
Yes
No
Check the fuel
Go to step 2.
pressure. <Ref. to
ME(H4SO 2.0)-27,
INSPECTION,
Fuel Pressure.>
Go to step 3.

NOTE:
the following:
Open circuit in
harness between
main relay and fuel
injector connector
Poor contact in
Poor contact in
coupling connector
Poor contact in
fuel injector connector

FUEL INJECTOR CONNECTOR.
between ECM and fuel injector connector.
#1 (B134) No. 17 (E5) No. 1:
#2 (B134) No. 27 (E16) No. 1:
#3 (B134) No. 34 (E6) No. 1:
#4 (B134) No. 33 (E17) No. 1:

?

ECM and fuel injector connector.
#1 (B134) No. 17 Chassis ground:
CHECK EACH FUEL INJECTOR.
2) Measure the resistance between each fuel
injector terminals.
Terminals
No. 1 No. 2:
CHECK POOR CONTACT.

M?
Go to step 5.
Is the resistance 5 20 ?
Go to step 6.
Replace the faulty

fuel injector.

connector?
Repair the poor

contact in ECM
connector.
Inspection using
General Diagnostic Table <Ref. to
EN(H4SO
2.0)(diag)-224,
INSPECTION,
Go to step 4.
NOTE:
the following:
Open circuit in
harness between
ECM and fuel
injector connector
Poor contact in
coupling connector
Repair the ground
ECM and fuel
injector connector.
List of Diagnostic Trouble Code (DTC)

17.List of Diagnostic Trouble Code (DTC)

A: LIST
DTC
P0030
Item
HO2S Heater Control Circuit (Bank 1
Sensor 1)
P0031
HO2S Heater Control Circuit Low

(Bank 1 Sensor 1)
P0032
HO2S Heater Control Circuit High

(Bank 1 Sensor 1)
P0037

(Bank 1 Sensor 2)
P0038

(Bank 1 Sensor 2)
P0107
P0108
P0112
Intake Air Temperature Circuit Low

Input
P0113
Intake Air Temperature Circuit High

Input
P0117
Engine Coolant Temperature Circuit

Low Input
P0118

High Input
P0122
Throttle/Pedal Position Sensor/

Switch A Circuit Low Input
P0123

Switch A Circuit High Input
P0125
Insufficient Coolant Temperature for

Closed Loop Fuel Control
P0130
O2 Sensor Circuit (Bank 1 Sensor 1)
P0131
O2 Sensor Circuit Low Voltage (Bank

1 Sensor 1)
P0132
O2 Sensor Circuit High Voltage

(Bank 1 Sensor 1)
P0133
O2 Sensor Circuit Slow Response

(Bank 1 Sensor 1)
NOTE
<Ref. to EN(H4SO 2.0)(diag)-71, DTC P0030 HO2S HEATER CONTROL
CIRCUIT (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
CIRCUIT LOW (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic
CIRCUIT HIGH (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic
<Ref. to EN(H4SO 2.0)(diag)-83, DTC P0107 MANIFOLD ABSOLUTE
PRESSURE/BAROMETRIC PRESSURE CIRCUIT LOW INPUT, Diagnostic
Procedure with Diagnostic Trouble Code (DTC).>
PRESSURE/BAROMETRIC PRESSURE CIRCUIT HIGH INPUT, Diagnostic
<Ref. to EN(H4SO 2.0)(diag)-89, DTC P0112 INTAKE AIR TEMPERATURE
SENSOR 1 CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
SENSOR 1 CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
<Ref. to EN(H4SO 2.0)(diag)-94, DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
<Ref. to EN(H4SO 2.0)(diag)-96, DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
<Ref. to EN(H4SO 2.0)(diag)-99, DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT LOW, Diagnostic Procedure with
Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4SO 2.0)(diag)-102, DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT HIGH, Diagnostic Procedure with
<Ref. to EN(H4SO 2.0)(diag)-105, DTC P0125 INSUFFICIENT COOLANT
TEMPERATURE FOR CLOSED LOOP FUEL CONTROL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4SO 2.0)(diag)-107, DTC P0130 O2 SENSOR CIRCUIT
(BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to EN(H4SO 2.0)(diag)-110, DTC P0131 O2 SENSOR CIRCUIT LOW
VOLTAGE (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic
<Ref. to EN(H4SO 2.0)(diag)-112, DTC P0132 O2 SENSOR CIRCUIT HIGH
SLOW RESPONSE (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>

DTC
P0134
Item
O2 Sensor Circuit No Activity
Detected (Bank 1 Sensor 1)
P0137

1 Sensor 2)
P0138

(Bank 1 Sensor 2)
P0139

(Bank 1 Sensor 2)
P0171
System Too Lean (Bank 1)
P0172
System Too Rich (Bank 1)
P0222

Switch B Circuit Low Input
P0223

Switch B Circuit High Input
P0301
P0302
P0303
P0304
P0327
Knock Sensor 1 Circuit Low Input

(Bank 1 or Single Sensor)
P0328
Knock Sensor 1 Circuit High Input

P0335
P0340
Camshaft Position Sensor A Circuit

P0400
Exhaust Gas Recirculation Flow
P0420
Catalyst System Efficiency Below

Threshold (Bank 1)
P0458
P0459
Evaporative Emission Control System Purge Control Valve Circuit High
P0462
NOTE
<Ref. to EN(H4SO 2.0)(diag)-116, DTC P0134 O2 SENSOR CIRCUIT NO
ACTIVITY DETECTED (BANK 1 SENSOR 1), Diagnostic Procedure with
<Ref. to EN(H4SO 2.0)(diag)-126, DTC P0171 SYSTEM TOO LEAN (BANK
1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4SO 2.0)(diag)-126, DTC P0172 SYSTEM TOO RICH (BANK
<Ref. to EN(H4SO 2.0)(diag)-128, DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT LOW, Diagnostic Procedure with
<Ref. to EN(H4SO 2.0)(diag)-131, DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT HIGH, Diagnostic Procedure with
<Ref. to EN(H4SO 2.0)(diag)-134, DTC P0301 CYLINDER 1 MISFIRE
DETECTED, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4SO 2.0)(diag)-142, DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW (BANK 1 OR SINGLE SENSOR), Diagnostic Procedure with
<Ref. to EN(H4SO 2.0)(diag)-144, DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH (BANK 1 OR SINGLE SENSOR), Diagnostic Procedure with
<Ref. to EN(H4SO 2.0)(diag)-146, DTC P0335 CRANKSHAFT POSITION
SENSOR A CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to EN(H4SO 2.0)(diag)-148, DTC P0340 CAMSHAFT POSITION
SENSOR A CIRCUIT (BANK 1 OR SINGLE SENSOR), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4SO 2.0)(diag)-150, DTC P0400 EXHAUST GAS RECIRCULATION FLOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4SO 2.0)(diag)-153, DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4SO 2.0)(diag)-155, DTC P0458 EVAPORATIVE EMISSION
SYSTEM PURGE CONTROL VALVE CIRCUIT LOW, Diagnostic Procedure
with Diagnostic Trouble Code (DTC).>
SYSTEM PURGE CONTROL VALVE CIRCUIT HIGH, Diagnostic Procedure
<Ref. to EN(H4SO 2.0)(diag)-159, DTC P0462 FUEL LEVEL SENSOR A
CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>

DTC
P0463
P0500
P0512
P0513
P0519
P0558
P0559
P0600
P0604
P0605
P0607
P0638
P0691
P0692
P0700
P0851
P0852
P1134
P1137
P1160
P1492
P1493
Item
NOTE
CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to EN(H4SO 2.0)(diag)-159, DTC P0500 VEHICLE SPEED SENSOR
A, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4SO 2.0)(diag)-160, DTC P0512 STARTER REQUEST CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to IM(diag)-17, DTC P0513 INCORRECT IMMOBILIZER KEY, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Idle Control System Malfunction
<Ref. to EN(H4SO 2.0)(diag)-163, DTC P0519 IDLE AIR CONTROL SYS(Fail-Safe)
TEM PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to EN(H4SO 2.0)(diag)-163, DTC P0558 GENERATOR CIRCUIT
LOW INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4SO 2.0)(diag)-165, DTC P0600 SERIAL COMMUNICATION
LINK, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Internal Control Module Read
<Ref. to EN(H4SO 2.0)(diag)-166, DTC P0604 INTERNAL CONTROL MODAccess Memory (RAM) Error
ULE RANDOM ACCESS MEMORY (RAM) ERROR, Diagnostic Procedure
Internal Control Module Read Only
<Ref. to EN(H4SO 2.0)(diag)-167, DTC P0605 INTERNAL CONTROL MODMemory (ROM) Error
ULE READ ONLY MEMORY (ROM) ERROR, Diagnostic Procedure with
<Ref. to EN(H4SO 2.0)(diag)-168, DTC P0607 CONTROL MODULE PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Throttle Actuator Control Range/Per- <Ref. to EN(H4SO 2.0)(diag)-169, DTC P0638 THROTTLE ACTUATOR
formance (Bank 1)
CONTROL RANGE/PERFORMANCE (BANK 1), Diagnostic Procedure with
<Ref. to EN(H4SO 2.0)(diag)-170, DTC P0691 FAN 1 CONTROL CIRCUIT
LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Transmission Control System (MIL
<Ref. to EN(H4SO 2.0)(diag)-170, DTC P0700 TRANSMISSION CONTROL
Request)
SYSTEM (MIL REQUEST), Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
<Ref. to EN(H4SO 2.0)(diag)-171, DTC P0851 PARK/NEUTRAL SWITCH
INPUT CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
INPUT CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
A/F Sensor Micro-Computer Problem <Ref. to EN(H4SO 2.0)(diag)-176, DTC P1134 A/F SENSOR MICRO-COMPUTER PROBLEM (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
O2 Sensor Circuit (Bank1 Sensor1)
(BANK1 SENSOR1), Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to EN(H4SO 2.0)(diag)-181, DTC P1160 RETURN SPRING FAILURE,
Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EGR Solenoid Valve Signal #1 Cir<Ref. to EN(H4SO 2.0)(diag)-181, DTC P1492 EGR SOLENOID VALVE
cuit Malfunction (Low Input)
SIGNAL #1 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Procedure
cuit Malfunction (High Input)
SIGNAL #1 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Procedure

DTC
P1494
Item
P1495
P1496
P1497
P1498
P1499
P1518
P1521
P1560
Back-Up Voltage Circuit Malfunction
P1570
Antenna
P1571
P1572
IMM Circuit Failure (Except antenna

circuit)
P1574
P1576
P1577
P1578
Meter Failure
P2100
P2101
P2102
P2103
P2109
Throttle/Pedal Position Sensor A

Minimum Stop Performance
NOTE
<Ref. to EN(H4SO 2.0)(diag)-181, DTC P1494 EGR SOLENOID VALVE
<Ref. to EN(H4SO 2.0)(diag)-186, DTC P1518 STARTER SWITCH CIRCUIT LOW INPUT, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to EN(H4SO 2.0)(diag)-189, DTC P1521 BRAKE SWITCH CIRCUIT
RANGE/PERFORMANCE PROBLEM (HIGH INPUT), Diagnostic Procedure
<Ref. to EN(H4SO 2.0)(diag)-191, DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to IM(diag)-18, DTC P1570 ANTENNA, Diagnostic Procedure with
<Ref. to IM(diag)-21, DTC P1571 REFERENCE CODE INCOMPATIBILITY,
<Ref. to IM(diag)-22, DTC P1572 IMM CIRCUIT FAILURE (EXCEPT
ANTENNA CIRCUIT), Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to IM(diag)-25, DTC P1574 KEY COMMUNICATION FAILURE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to IM(diag)-25, DTC P1576 EGI CONTROL MODULE EEPROM, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to IM(diag)-25, DTC P1577 IMM CONTROL MODULE EEPROM,
<Ref. to IM(diag)-26, DTC P1578 METER FAILURE, Diagnostic Procedure
<Ref. to EN(H4SO 2.0)(diag)-192, DTC P2100 THROTTLE ACTUATOR
CONTROL MOTOR CIRCUIT OPEN, Diagnostic Procedure with Diagnostic
CONTROL MOTOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
CONTROL MOTOR CIRCUIT LOW, Diagnostic Procedure with Diagnostic
CONTROL MOTOR CIRCUIT HIGH, Diagnostic Procedure with Diagnostic
<Ref. to EN(H4SO 2.0)(diag)-205, DTC P2109 THROTTLE/PEDAL POSITION SENSOR A MINIMUM STOP PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>

DTC
P2111
Item
Throttle Actuator Control System Stuck Open
P2122

Switch D Circuit Low Input
P2123

Switch D Circuit High Input
P2127

Switch E Circuit Low Input
P2128

Switch E Circuit High Input
P2135

Switch A/B Voltage Rationality
P2138

Switch D/E Voltage Rationality
NOTE
CONTROL SYSTEM - STUCK OPEN, Diagnostic Procedure with Diagnostic
<Ref. to EN(H4SO 2.0)(diag)-206, DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT LOW INPUT, Diagnostic Procedure
<Ref. to EN(H4SO 2.0)(diag)-209, DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT HIGH INPUT, Diagnostic Procedure
<Ref. to EN(H4SO 2.0)(diag)-211, DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT LOW INPUT, Diagnostic Procedure
<Ref. to EN(H4SO 2.0)(diag)-214, DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT HIGH INPUT, Diagnostic Procedure
<Ref. to EN(H4SO 2.0)(diag)-216, DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH A / B VOLTAGE CORRELATION, Diagnostic
<Ref. to EN(H4SO 2.0)(diag)-220, DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH D / E VOLTAGE CORRELATION, Diagnostic
Diagnostic Procedure with Diagnostic Trouble Code (DTC)

18.Diagnostic Procedure with Diagnostic Trouble Code (DTC)

A: DTC P0030 HO2S HEATER CONTROL CIRCUIT (BANK 1 SENSOR 1)
DTC DETECTING CONDITION:
Two consecutive driving cycles with fault
CAUTION:
WIRING DIAGRAM:
BATTERY
MAIN RELAY
SBF-6
5
3
1
3
5
E2
2
4
6
FRONT OXYGEN
(A/F) SENSOR
E24
E24
1
2
B47
2
4
B21
4
3
51
E2
1
3
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B2
B3
C33
C35
C34
E
B: B135
B135
B: B1
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
32 33
34 35
28 29 30 31
ECM
C: B136
B5
B6
E
C: B136
52
2
1
B21
4
6
B47
50
B21
E2
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
E
EN-02433

Step
FRONT OXYGEN (A/F) SENSOR CONNECTOR.
1) Start and warm-up the engine.
3) Disconnect the connectors from ECM and
front oxygen (A/F) sensor.
between ECM and front oxygen (A/F) sensor
connector.
(B135) No. 2 (E24) No. 3:
(B135) No. 3 (E24) No. 3:
ECM and front oxygen (A/F) sensor connector.
(B136) No. 33 (E24) No. 1:
(B136) No. 35 (E24) No. 2:
CHECK HARNESS BETWEEN MAIN RELAY
AND FRONT OXYGEN (A/F) SENSOR CONNECTOR.
main relay and front oxygen (A/F) sensor connector.
(B47) No. 3 (E24) No. 4:
CHECK FRONT OXYGEN (A/F) SENSOR.
Measure the resistance between front oxygen
(A/F) sensor connector terminals.
Terminals
No. 3 No. 4:
Check
?
Yes
Go to step 2.
No
Repair the open
circuit in harness
between ECM and
front oxygen (A/F)
sensor connector.

?
Go to step 3.
Repair the open

circuit in harness
between ECM and
front oxygen (A/F)
sensor connector.

?
Go to step 4.
Repair the open

circuit in harness
between ECM and
front oxygen (A/F)
sensor connector.

?
Go to step 5.
Replace the front

oxygen (A/F) sensor. <Ref. to
FU(H4SO 2.0)-32,
Front Oxygen (A/
F) Sensor.>
CHECK POOR CONTACT.
Is there poor contact in ECM or Repair the poor
Replace the front
Check the poor contact in ECM and front oxy- front oxygen (A/F) sensor con- contact in ECM or oxygen (A/F) sengen (A/F) sensor connector.
nector?
front oxygen (A/F) sor. <Ref. to
sensor connector. FU(H4SO 2.0)-32,
Front Oxygen (A/
F) Sensor.>

B: DTC P0031 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 1)

Immediately at fault recognition
CAUTION:
WIRING DIAGRAM:
BATTERY
MAIN RELAY
SBF-6
5
3
1
3
5
E2
2
4
6
FRONT OXYGEN
(A/F) SENSOR
E24
E24
1
2
B47
2
4
B21
4
3
51
E2
1
3
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B2
B3
C33
C35
C34
E
B: B135
B135
B: B1
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
32 33
34 35
28 29 30 31
ECM
C: B136
B5
B6
E
C: B136
52
2
1
B21
4
6
B47
50
B21
E2
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
E
EN-02433

Step
CHECK ANY OTHER DTC ON DISPLAY.
CHECK POWER SUPPLY TO FRONT OXYGEN (A/F) SENSOR.

2) Disconnect the connector from front oxygen
(A/F) sensor.
4) Measure the voltage between front oxygen
(A/F) sensor connector and engine ground.

ECM connector and chassis ground.
Check
Yes
Do DTC P0031 and P0037
Go to step 2.
appear at the same time on the
Subaru Select Monitor?

?
Is the current more than 0.2 A?

CHECK CURRENT DATA.
2) Read the data of front oxygen (A/F) sensor
heater current using Subaru Select Monitor.
NOTE:
For detailed operation procedure, refer to
READ CURRENT DATA FOR ENGINE. <Ref.
to EN(H4SO 2.0)(diag)-25, Subaru Select Monitor.>
CHECK INPUT SIGNAL FROM ECM.

1) Start and idle the engine.
and chassis ground.
Go to step 4.
Repair the poor

contact connector.
Repair the power

supply line.
NOTE:
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
NOTE:
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.
NOTE:
the following:
Poor contact in
front oxygen (A/F)
sensor connector
Poor contact in
ECM connector
Go to step 7.
Go to step 6.
Does the voltage change by

Repair the poor
shaking the ECM harness and contact in ECM
connector while monitoring the connector.
value of voltage meter?
No
Go to step 5.
Go to step 7.

Step
Check
?
2) Measure the resistance between front oxygen (A/F) sensor connector terminals.
Terminals
No. 3 No. 4:
Yes
No
Repair the harReplace the front
ness and connec- oxygen (A/F) sentor.
sor. <Ref. to
FU(H4SO 2.0)-32,
NOTE:
In this case, repair Front Oxygen (A/
F) Sensor.>
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

C: DTC P0032 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 1)

CAUTION:
WIRING DIAGRAM:
BATTERY
MAIN RELAY
SBF-6
5
3
1
3
5
E2
2
4
6
FRONT OXYGEN
(A/F) SENSOR
E24
E24
1
2
B47
2
4
B21
4
3
51
E2
1
3
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B2
B3
C33
C35
C34
E
B: B135
B135
B: B1
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
32 33
34 35
28 29 30 31
ECM
C: B136
B5
B6
E
C: B136
52
2
1
B21
4
6
B47
50
B21
E2
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
E
EN-02433

Step
Check
CHECK FRONT OXYGEN (A/F) SENSOR
HEATER CURRENT.
2) Repair the battery short circuit in harness
connector.
NOTE:
Measure the voltage between ECM connector shaking the ECM harness and
connector?
and chassis ground.
Yes
Go to step 2.
No
Go to step 3.
Replace the ECM. END.

<Ref. to FU(H4SO
2.0)-34, Engine
Control Module
(ECM).>
Repair the battery END.

ECM and front
oxygen (A/F) sensor connector.

D: DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 2)

CAUTION:
WIRING DIAGRAM:
B83
MAIN RELAY
BATTERY
B138
B47
T5
SBF-6
5
3
1 2
3 4
2
4
6
1 2 3 4
5 6 7 8
B19
2
T5
2
1
B21
REAR
OXYGEN SENSOR
B47
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
T5
B19
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B83
:LHD
A: B134
B138 :RHD
C18
C30
1
8 9
18 19
28 29
A: B134
B: B135
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B: B135
ECM
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
32 33
34 35
28 29 30 31
B5
B6
C: B136
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B21
52
A1
6
4
1
7
C19
6
4
1
3
5
E2
5 6
14 15 16
25 26 27
33 34 35
E
EN-02435

Step
Check
CHECK GROUND CIRCUIT OF ECM.
?
Yes
Go to step 2.
CHECK CURRENT DATA.

2) Read the data of rear oxygen sensor heater
current using Subaru Select Monitor.
Repair the connector.
NOTE:

and chassis ground.
1) Disconnect the connector from rear oxygen
sensor.
No
NOTE:
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.
NOTE:
the following:
Poor contact in
rear oxygen sensor connector
Poor contact in
rear oxygen sensor connecting
harness connector
Poor contact in
ECM connector
Go to step 6.
Go to step 4.

Repair the poor
Go to step 5.
Repair the battery

ECM and rear oxygen sensor connector. After
repair, replace the
ECM. <Ref. to
FU(H4SO 2.0)-34,
Engine Control
Module (ECM).>
Replace the ECM.

<Ref. to FU(H4SO
2.0)-34, Engine
Control Module
(ECM).>

Step
Check
Yes
CHECK POWER SUPPLY TO REAR OXYIs the voltage more than 10 V? Go to step 7.
GEN SENSOR.
sensor.
4) Measure the voltage between rear oxygen
sensor connector and chassis ground.
CHECK REAR OXYGEN SENSOR.

?
2) Measure the resistance between rear oxygen (A/F) sensor connector terminals.
Terminals
No. 1 No. 2:
No
Repair the power
supply line.
NOTE:
the following:
Open circuit in
harness between
main relay and
Poor contact in
Poor contact in
coupling connector
Repair the harReplace the rear
ness and connec- oxygen sensor.
tor.
<Ref. to FU(H4SO
2.0)-33, Rear OxyNOTE:
In this case, repair gen Sensor.>
the following:
Open circuit in
harness between
rear oxygen sensor and ECM connector
Poor contact in
Poor contact in
ECM connector
Poor contact in
coupling connector

E: DTC P0038 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 2)

CAUTION:
WIRING DIAGRAM:
B83
MAIN RELAY
BATTERY
B138
B47
T5
SBF-6
5
3
1 2
3 4
2
4
6
1 2 3 4
5 6 7 8
B19
2
T5
2
1
B21
REAR
OXYGEN SENSOR
B47
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
T5
B19
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B83
:LHD
A: B134
B138 :RHD
C18
C30
1
8 9
18 19
28 29
A: B134
B: B135
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B: B135
ECM
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
32 33
34 35
28 29 30 31
B5
B6
C: B136
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B21
52
A1
6
4
1
7
C19
6
4
1
3
5
E2
5 6
14 15 16
25 26 27
33 34 35
E
EN-02435

Step
Check
and chassis ground.
CHECK CURRENT DATA.
Is the current more than 7 A?
between ECM and rear oxygen sensor connector.
NOTE:
CHECK POOR CONTACT.
connector?
Yes
Go to step 2.
No
Go to step 3.

<Ref. to FU(H4SO
2.0)-34, Engine
Control Module
(ECM).>
Repair the poor

contact in ECM
connector.
END.

F: DTC P0107 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE

CIRCUIT LOW INPUT
CAUTION:
WIRING DIAGRAM:
E21
MANIFOLD
ABSOLUTE
PRESSURE
SENSOR
1
2
3
1 2 3
E21
B83
B183
1 2 3 4
5 6 7 8
B21
19
7
20
E2
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B183 :RHD
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
18
20
17
:LHD
B83
B136
ECM
EN-02437

Step
CHECK CURRENT DATA.
2) Read the data of intake manifold absolute
pressure signal using Subaru Select Monitor.
Check
Yes
Is the value less than 13.3 kPa Go to step 3.
(100 mmHg, 3.94 inHg)?
NOTE:
CHECK POOR CONTACT.
Check the poor contact in ECM and manifold manifold pressure sensor con- contact in ECM or
pressure sensor connector.
nector?
manifold pressure
sensor connector.

and chassis ground.
and chassis ground.
Measure the voltage between ECM and chassis ground.
CHECK INPUT SIGNAL FOR ECM (USING
SUBARU SELECT MONITOR).
Read the data of atmospheric absolute pressure signal using Subaru Select Monitor.
Is the voltage more than 4.5 V? Go to step 5.

Repair the poor
connector?
connector.
Is the voltage less than 0.2 V? Go to step 7.
Is the value more than 13.3

kPa (100 mmHg, 3.94 inHg)
when shaking the ECM harness and connector?
Repair the poor

contact in ECM
connector.
NOTE:
MANIFOLD ABSOLUTE PRESSURE SENSOR CONNECTOR.
2) Disconnect the connector from manifold
absolute pressure sensor.
4) Measure the voltage between manifold
absolute pressure sensor connector and
engine ground.
No
Go to step 2.
Even if the malfunction indicator

light illuminates,
the circuit has
returned to a normal condition at
this time.
Go to step 4.
Replace the ECM.

<Ref. to FU(H4SO
2.0)-34, Engine
Control Module
(ECM).>
Go to step 6.
Go to step 7.
Repair the open

circuit in harness
between ECM and
manifold absolute
pressure sensor
connector.

Step
between ECM and manifold absolute pressure
sensor connector.
(B136) No. 18 (E21) No. 1:
CHECK POOR CONTACT.
Check poor contact in manifold absolute pressure sensor connector.
Check
?
Yes
Go to step 9.
No
Repair the open
circuit in harness
between ECM and
manifold absolute
pressure sensor
connector.
Is there poor contact in manifold absolute pressure sensor

connector?
Repair the poor

contact in manifold absolute pressure sensor
connector.
Replace the manifold absolute pressure sensor. <Ref.

to FU(H4SO 2.0)26, Manifold Absolute Pressure Sensor.>

G: DTC P0108 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE

CIRCUIT HIGH INPUT
CAUTION:
WIRING DIAGRAM:
E21
MANIFOLD
ABSOLUTE
PRESSURE
SENSOR
1
2
3
1 2 3
E21
B83
B183
1 2 3 4
5 6 7 8
B21
19
7
20
E2
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B183 :RHD
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
18
20
17
:LHD
B83
B136
ECM
EN-02437

Step
CHECK CURRENT DATA.
NOTE:
and chassis ground.
and chassis ground.
and chassis ground.
Check
kPa (896.5 mmHg, 35.29
inHg)?
Yes
Go to step 10.
No
Go to step 2.
Go to step 3.

Repair the poor
connector?
connector.
Replace the ECM.

<Ref. to FU(H4SO
2.0)-34, Engine
Control Module
(ECM).>
Go to step 5.

Repair the poor

contact in ECM
connector.
NOTE:
engine ground.
Go to step 8.
MANIFOLD ABSOLUTE PRESSURE SEN?
SOR CONNECTOR.
sensor connector.
(B136) No. 20 (E21) No. 2:
Go to step 6.
Repair the open

circuit in harness
between ECM and
manifold absolute
pressure sensor
connector.
Repair the open

circuit in harness
between ECM and
manifold absolute
pressure sensor
connector.

10
Step
ECM and manifold absolute pressure sensor
connector.
(B136) No. 18 (E21) No. 1:
CHECK POOR CONTACT.
Check
?
Yes
Go to step 9.

connector?
Repair the poor

connector.

kPa (896.5 mmHg, 35.29
MANIFOLD ABSOLUTE PRESSURE SENinHg)?
SOR CONNECTOR.
1) Turn the ignition switch to OFF, and the
NOTE:
No
Repair the open
circuit in harness
between ECM and
manifold absolute
pressure sensor
connector.

Repair the battery Replace the manishort in harness
fold absolute presbetween ECM and sure sensor. <Ref.
manifold absolute to FU(H4SO 2.0)pressure sensor
26, Manifold Absoconnector.
lute Pressure Sensor.>

H: DTC P0112 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT LOW

TROUBLE SYMPTOM:
Erroneous idling
Poor driving performance
CAUTION:
WIRING DIAGRAM:
E20
INTAKE AIR
TEMPERATURE
SENSOR
1
2
1 2
B83
E20
B183
1 2 3 4
5 6 7 8
E2
6
19
B21
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B136
5
:LHD
B183 :RHD
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
28
18
B83
B136
ECM
EN-02438

Step
CHECK CURRENT DATA.
2) Read the data of intake air temperature
sensor signal using Subaru Select Monitor.
Check
Is the intake air temperature
more than 120C (248F)?
NOTE:
CHECK HARNESS BETWEEN INTAKE AIR

TEMPERATURE SENSOR AND ECM CONNECTOR.
2) Disconnect the connector from intake air
temperature sensor.

less than 40C (40F)?
NOTE:
Yes
Go to step 2.
No
Repair the poor
contact.
NOTE:
the following:
Poor contact in
intake air temperature sensor
Poor contact in
ECM
Poor contact in
coupling connector
Poor contact in
joint connector
Replace the intake Repair the ground
air temperature
short circuit in harsensor. <Ref. to
ness between
FU(H4SO 2.0)-27, intake air temperaIntake Air Temper- ture sensor and
ature Sensor.>
ECM connector.

I:
DTC P0113 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT HIGH

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
E20
INTAKE AIR
TEMPERATURE
SENSOR
1
2
1 2
B83
E20
B183
1 2 3 4
5 6 7 8
E2
6
19
B21
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B136
5
:LHD
B183 :RHD
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
28
18
B83
B136
ECM
EN-02438

Step
CHECK CURRENT DATA.
Check
Yes
Go to step 2.
No
Repair the poor
contact.
NOTE:
the following:
NOTE:
Poor contact in
Poor contact in
ECM
Poor contact in
coupling connector
Poor contact in
joint connector
CHECK HARNESS BETWEEN INTAKE AIR Is the voltage more than 10 V? Repair the battery Go to step 3.
short circuit in harTEMPERATURE SENSOR AND ECM CONness between
NECTOR.
intake air tempera1) Turn the ignition switch to OFF.
ture sensor and
2) Disconnect the connector from intake air
ECM connector.
temperature sensor.
3) Measure the voltage between intake air
temperature sensor connector and engine
ground.
CHECK HARNESS BETWEEN INTAKE AIR Is the voltage more than 10 V? Repair the battery Go to step 4.
short circuit in harTEMPERATURE SENSOR AND ECM CONness between
NECTOR.
intake air tempera1) Turn the ignition switch to ON.
ture sensor and
2) Measure the voltage between intake air
ECM connector.
ground.
CHECK HARNESS BETWEEN INTAKE AIR Is the voltage more than 3 V? Go to step 5.
Repair the harTEMPERATURE SENSOR AND ECM CONness and connecNECTOR.
tor.
Measure the voltage between intake air temNOTE:
perature sensor connector and engine ground.
the following:
Open circuit in
harness between
intake air temperature sensor and
ECM connector
Poor contact in
Poor contact in
ECM
Poor contact in
coupling connector
Poor contact in
joint connector

Step
CHECK HARNESS BETWEEN INTAKE AIR
TEMPERATURE SENSOR AND ECM CONNECTOR.
between intake air temperature sensor connector and engine ground.
Check
?
Yes
Replace the intake
air temperature
sensor. <Ref. to
FU(H4SO 2.0)-27,
Intake Air Temperature Sensor.>
No
NOTE:
the following:
Open circuit in
harness between
ECM connector
Poor contact in
Poor contact in
ECM
Poor contact in
joint connector

J: DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW

TROUBLE SYMPTOM:
Hard to start
Erroneous idling
CAUTION:
WIRING DIAGRAM:
ENGINE
COOLANT
TEMPERATURE
SENSOR
E8
2
1
1 2
E8
B83
B183
1 2 3 4
5 6 7 8
8
19
E2
B21
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B83
:LHD
B183 :RHD
B136
5 6
14 15 16
25 26 27
33 34 35
22
18
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B136
ECM
EN-02439

Step
CHECK CURRENT DATA.
2) Read the data of engine coolant temperature sensor signal using Subaru Select Monitor.
NOTE:
CHECK HARNESS BETWEEN ENGINE

COOLANT TEMPERATURE SENSOR AND
ECM CONNECTOR.
2) Disconnect the connectors from the engine
coolant temperature sensor.
Check
Yes
Is the engine coolant tempera- Go to step 2.
ture more than 150C (302F)?
No
Repair the poor
contact.
NOTE:
the following:
Poor contact in
engine coolant
temperature sensor
Poor contact in
ECM
Poor contact in
coupling connector
Poor contact in
joint connector
Is the engine coolant tempera- Replace the
Repair the ground
ture less than 40C (40F)? engine coolant
short circuit in hartemperature sen- ness between
sor. <Ref. to
engine coolant
FU(H4SO 2.0)-20, temperature senEngine Coolant
sor and ECM conTemperature Sen- nector.
sor.>
NOTE:

K: DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH

TROUBLE SYMPTOM:
Hard to start
Erroneous idling
CAUTION:
WIRING DIAGRAM:
ENGINE
COOLANT
TEMPERATURE
SENSOR
E8
2
1
1 2
E8
B83
B183
1 2 3 4
5 6 7 8
8
19
E2
B21
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B83
:LHD
B183 :RHD
B136
5 6
14 15 16
25 26 27
33 34 35
22
18
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B136
ECM
EN-02439

Step
CHECK CURRENT DATA.
NOTE:
Check
Yes
ture less than 40C (40F)?
No
Repair the poor
contact.
NOTE:
the following:
Poor contact in
engine coolant
temperature sensor
Poor contact in
ECM
Poor contact in
coupling connector
Poor contact in
joint connector
Is the voltage more than 10 V? Repair the battery Go to step 3.
ECM and engine
coolant temperature sensor connector.

ECM CONNECTOR.
2) Disconnect the connectors from engine
3) Measure the voltage between engine coolant temperature sensor connector and engine
ground.
ECM CONNECTOR.
ground.
ECM CONNECTOR.
Measure the voltage between engine coolant
ground.
Repair the battery Go to step 4.

ECM and engine
Go to step 5.

NOTE:
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

Step
ECM CONNECTOR.
between engine coolant temperature sensor
Check
?
Yes
Replace the
engine coolant
temperature sensor. <Ref. to
FU(H4SO 2.0)-20,
Engine Coolant
Temperature Sensor.>
No
NOTE:
the following:
Open circuit in
harness between
ECM and engine
Poor contact in
engine coolant
Poor contact in
ECM connector
Poor contact in
coupling connector
Poor contact in
joint connector

L: DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT

LOW
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:

WIRING DIAGRAM:
BATTERY
ELECTRONIC
THROTTLE
CONTROL RELAY
SBF-8
B362
7
5
6
8
D7
D6
D9
MAIN RELAY
ECM
C30
C1
C2
C5
C6
A2
D1
D: B137
D24
D23
C: B136
C17
D4
D5
D2
D3
C18
A: B134
B83
:LHD
B83
:LHD
B138 :RHD
B20
16
15
38
19
20
39
35
B21
37
36
B138 :RHD
E2
2
5
3
1
4
6
E1
ELECTRONIC
THROTTLE CONTROL
E78
B362
B83
B21
B138
1 2
3
4
1 2 3 4
5 6 7 8
5
7 8
6
2
10
20
30
1
5
9
13
2
6
10
14
3
7
11
15
E78
4
8
12
16
1 2 3
4 5 6
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
A: B134
1
8 9
18 19
28 29
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
B20
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
C:
B136
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
D:
B137
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
EN-02440

Step
CHECK SENSOR OUTPUT.
2) Read the data of main throttle sensor signal
using Subaru Select Monitor.
CHECK POOR CONTACT.
Check poor contact in connector between
ECM and electronic throttle control.
Check
Yes
No
Go to step 3.
Is there poor contact in conRepair the poor

nector between ECM and eleccontact.
tronic throttle control?

ELECTRONIC THROTTLE CONTROL.
3) Disconnect the connectors from electronic
throttle control.
4) Measure the resistance between ECM connector and electronic throttle control connector.
(B137) No. 23 (E78) No. 5:
(B136) No. 17 (E78) No. 4:
Measure the resistance between ECM connector and chassis ground.
CHECK POWER SUPPLY OF ELECTRONIC
THROTTLE CONTROL.
1) Connect the ECM connector.
3) Measure the voltage between electronic
throttle control connector and engine ground.

?
Go to step 4.
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.

M?
Go to step 5.
Is the voltage 4.5 5.5 V?
Go to step 6.
Repair the chassis short circuit of

harness.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
to FU(H4SO 2.0)34, Engine Control Module
(ECM).>
CHECK SHORT CIRCUIT INSIDE THE ECM. Is the resistance more than 10 Repair the poor
Repair the poor
?
contact of eleccontact in ECM
2) Measure the resistance between electronic
tronic throttle conconnector.
trol connector.
Replace the ECM
Replace the accel- if defective. <Ref.
erator position
to FU(H4SO 2.0)sensor if defective. 34, Engine Control Module
(ECM).>

M: DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT

HIGH
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:

WIRING DIAGRAM:
BATTERY
ELECTRONIC
THROTTLE
CONTROL RELAY
SBF-8
B362
7
5
6
8
D7
D6
D9
MAIN RELAY
ECM
C30
C1
C2
C5
C6
A2
D1
D: B137
D24
D23
C: B136
C17
D4
D5
D2
D3
C18
A: B134
B83
:LHD
B83
:LHD
B138 :RHD
B20
16
15
38
19
20
39
35
B21
37
36
B138 :RHD
E2
2
5
3
1
4
6
E1
ELECTRONIC
THROTTLE CONTROL
E78
B362
B83
B21
B138
1 2
3
4
1 2 3 4
5 6 7 8
5
7 8
6
2
10
20
30
1
5
9
13
2
6
10
14
3
7
11
15
E78
4
8
12
16
1 2 3
4 5 6
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
A: B134
1
8 9
18 19
28 29
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
B20
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
C:
B136
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
D:
B137
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
EN-02440

Step
CHECK POOR CONTACT.
Check
Is the voltage less than 4.63
V?
Yes
Go to step 2.

throttle control.
(B137) No. 23 (E78) No. 5:
(B136) No. 18 (E78) No. 1:

?
Go to step 4.

?
Go to step 5.


CHECK SENSOR OUTPUT POWER SUPPLY.
Measure the voltage between electronic throttle control connector and engine ground.

M?
3) Measure the resistance between ECM connectors.
(B137) No. 23 (B136) No. 17:
No
Go to step 3.
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
(ECM).>
Go to step 6.
Repair the battery
ECM connector
and electronic
throttle control
connector.
Repair the poor
Repair the short
contact in harness. circuit to sensor
Repair the elecpower supply.
tronic throttle control.

N: DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP

FUEL CONTROL
TROUBLE SYMPTOM:
Engine would not return to idling.
CAUTION:
WIRING DIAGRAM:
ENGINE
COOLANT
TEMPERATURE
SENSOR
E8
2
1
1 2
E8
B83
B183
1 2 3 4
5 6 7 8
8
19
E2
B21
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B83
:LHD
B183 :RHD
B136
5 6
14 15 16
25 26 27
33 34 35
22
18
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B136
ECM
EN-02439

Step
CHECK THERMOSTAT.
Check
Is any other DTC displayed?
Does the thermostat remain

opened?
Yes
No
Check DTC using Go to step 2.
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(H4SO
2.0)(diag)-66, List
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0125.
Replace the thermostat. <Ref. to
CO(H4SO 2.0)-18,
Thermostat.>
Replace the
engine coolant
FU(H4SO 2.0)-20,
Engine Coolant

O: DTC P0130 O2 SENSOR CIRCUIT (BANK 1 SENSOR 1)

CAUTION:
WIRING DIAGRAM:
BATTERY
MAIN RELAY
SBF-6
5
3
1
3
5
E2
2
4
6
FRONT OXYGEN
(A/F) SENSOR
E24
3
B47
E24
1
2
2
1
B21
4
6
B47
50
2
4
B21
4
3
51
E2
1
3
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B2
B3
C33
C35
C34
E
B: B135
B135
B: B1
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
32 33
34 35
28 29 30 31
ECM
B5
B6
C: B136
E
52
C: B136
B21
E2
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
E
EN-02433
Step
Check
Yes
No
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(H4SO
2.0)(diag)-66, List

Step
Check
CHECK FRONT OXYGEN (A/F) SENSOR DA- Is the voltage 0.85 1.15 V?
TA.
2) While observing the Subaru Select Monitor
or 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.
signal using Subaru Select Monitor or general
scan tool.
Yes
Go to step 3.
NOTE:
to EN(H4SO 2.0)(diag)-25, Subaru Select
Monitor.>
General scan tool
For detailed operation procedures, refer to
General Scan Tool Instruction Manual.
CHECK FRONT OXYGEN (A/F) SENSOR DA- Is the voltage more than 1.1 V? Go to step 6.
TA.
1) Race the engine at speeds from idling to
5,000 rpm for a total of 5 cycles.
signal during racing using Subaru Select Monitor or general scan tool.
NOTE:
Air fuel ratio is rich at normal condition or
during racing.
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.
FRONT OXYGEN (A/F) SENSOR.
front oxygen (A/F) sensor connector.
3) Measure the resistance between ECM and
Connector & terminals
(B136) No. 33 (E24) No. 1:
(B136) No. 35 (E24) No. 2:
Measure the resistance between ECM and
chassis ground.
No
Go to step 4.
Go to step 4.

?
Go to step 5.
Repair the open

circuit between
ECM and front
oxygen (A/F) sensor.

M?
Go to step 6.
Repair the ground

short circuit
between ECM and
front oxygen (A/F)
sensor.

Step
CHECK EXHAUST SYSTEM.
Check exhaust system parts.
Check
Is there any fault in exhaust
system?
NOTE:
Check the following items.
Loose part of exhaust system and incomplete installation
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
Yes
Repair or replace
faulty parts.
No
Replace the front
FU(H4SO 2.0)-32,
Front Oxygen (A/
F) Sensor.>

P: DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1)

CAUTION:
WIRING DIAGRAM:
BATTERY
MAIN RELAY
SBF-6
5
3
1
3
5
E2
2
4
6
FRONT OXYGEN
(A/F) SENSOR
E24
E24
1
2
B47
2
4
B21
4
3
51
E2
1
3
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B2
B3
C33
C35
C34
E
B: B135
B135
B: B1
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
32 33
34 35
28 29 30 31
ECM
C: B136
B5
B6
E
C: B136
52
2
1
B21
4
6
B47
50
B21
E2
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
E
EN-02433

Step
Check
M?
Yes
Replace the front
FU(H4SO 2.0)-32,
Front Oxygen (A/
F) Sensor.>
No
Repair the ground
ECM and front

Q: DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1)

CAUTION:
WIRING DIAGRAM:
BATTERY
MAIN RELAY
SBF-6
5
3
1
3
5
E2
2
4
6
FRONT OXYGEN
(A/F) SENSOR
E24
E24
1
2
B47
2
4
B21
4
3
51
E2
1
3
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B2
B3
C33
C35
C34
E
B: B135
B135
B: B1
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
32 33
34 35
28 29 30 31
ECM
C: B136
B5
B6
E
C: B136
52
2
1
B21
4
6
B47
50
B21
E2
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
E
EN-02433

Step
Check
(A/F) sensor.
3) Measure the voltage of harness between
Yes
Replace the front
FU(H4SO 2.0)-32,
Front Oxygen (A/
F) Sensor.>
No
Repair the battery
ECM and front

R: DTC P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1)

CAUTION:
WIRING DIAGRAM:
BATTERY
MAIN RELAY
SBF-6
5
3
1
3
5
E2
2
4
6
FRONT OXYGEN
(A/F) SENSOR
E24
E24
1
2
B47
2
4
B21
4
3
51
E2
1
3
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B2
B3
C33
C35
C34
E
B: B135
B135
B: B1
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
32 33
34 35
28 29 30 31
ECM
C: B136
B5
B6
E
C: B136
52
2
1
B21
4
6
B47
50
B21
E2
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
E
EN-02433

Step
Check

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 a hole
Yes
No
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(H4SO
2.0)(diag)-66, List
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0133.
Repair the exhaust Replace the front
system.
FU(H4SO 2.0)-32,
Front Oxygen (A/
F) Sensor.>

S: DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 1)

CAUTION:
WIRING DIAGRAM:
BATTERY
MAIN RELAY
SBF-6
5
3
1
3
5
E2
2
4
6
FRONT OXYGEN
(A/F) SENSOR
E24
E24
1
2
B47
2
4
B21
4
3
51
E2
1
3
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B2
B3
C33
C35
C34
E
B: B135
B135
B: B1
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
32 33
34 35
28 29 30 31
ECM
C: B136
B5
B6
E
C: B136
52
2
1
B21
4
6
B47
50
B21
E2
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
E
EN-02433

Step
connector.
(B136) No. 33 (E24) No. 1:
(B136) No. 35 (E24) No. 2:
Check
?
CHECK POOR CONTACT.

Check poor contact in front oxygen (A/F) sensor connector.
Is there poor contact in front

oxygen (A/F) sensor connector?
Yes
Go to step 2.
No
NOTE:
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
Repair the poor
Replace the front
contact in front
oxygen (A/F) senoxygen (A/F) sensor. <Ref. to
FU(H4SO 2.0)-32,
sor connector.
Front Oxygen (A/
F) Sensor.>

T: DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2)

CAUTION:
WIRING DIAGRAM:
B83
MAIN RELAY
BATTERY
B138
B47
T5
SBF-6
5
3
1 2
3 4
2
4
6
1 2 3 4
5 6 7 8
B19
2
T5
2
1
B21
REAR
OXYGEN SENSOR
B47
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
T5
B19
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B83
:LHD
A: B134
B138 :RHD
C18
C30
1
8 9
18 19
28 29
A: B134
B: B135
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B: B135
ECM
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
32 33
34 35
28 29 30 31
B5
B6
C: B136
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B21
52
A1
6
4
1
7
C19
6
4
1
3
5
E2
5 6
14 15 16
25 26 27
33 34 35
E
EN-02435

Step
Check
Is the voltage more than 490

CHECK REAR OXYGEN SENSOR DATA.
mV?
1) Warm-up the engine until engine coolant
temperature is above 70C (158F), and keep
the engine speed at 5,000 rpm.
2) Read the data of rear oxygen sensor signal
NOTE:
REAR OXYGEN SENSOR CONNECTOR.
?
rear oxygen sensor.
3) Measure the resistance in harness
(B136) No. 19 (B19) No. 4:
(B136) No. 18 (B19) No. 3:
CHECK HARNESS BETWEEN REAR OXY- Is the voltage 0.2 0.5 V?
GEN SENSOR AND ECM CONNECTOR.
sensor.
sensor harness connector and chassis ground.
Yes
No
Inspect the DTC
Go to step 2.
using List of Diagnostic Trouble
Code (DTC).
<Ref. to EN(H4SO
2.0)(diag)-66, List
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0137.
Go to step 5.
Go to step 3.
Repair the open

Go to step 4.
circuit in harness
between ECM and
rear oxygen sensor connector.
Replace the rear

oxygen sensor.
<Ref. to FU(H4SO
2.0)-33, Rear Oxygen Sensor.>

NOTE:
the following:
Open circuit in
harness between
Poor contact in
Poor contact in
ECM connector

Step
Check
system?
NOTE:
sensor
Yes
Repair or replace
the faulty part.
No
Replace the rear
oxygen sensor.
<Ref. to FU(H4SO

U: DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2)

CAUTION:
WIRING DIAGRAM:
B83
MAIN RELAY
BATTERY
B138
B47
T5
SBF-6
5
3
1 2
3 4
2
4
6
1 2 3 4
5 6 7 8
B19
2
T5
2
1
B21
REAR
OXYGEN SENSOR
B47
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
T5
B19
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B83
:LHD
A: B134
B138 :RHD
C18
C30
1
8 9
18 19
28 29
A: B134
B: B135
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B: B135
ECM
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
32 33
34 35
28 29 30 31
B5
B6
C: B136
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B21
52
A1
6
4
1
7
C19
6
4
1
3
5
E2
5 6
14 15 16
25 26 27
33 34 35
E
EN-02435

Step
Check

mV?
temperature is above 70C (158F), and lower
the engine speed rapidly from 5,000 rpm.
NOTE:
?
rear oxygen sensor.
(B136) No. 19 (B19) No. 4:
(B136) No. 18 (B19) No. 3:
sensor.
Yes
No
Inspect the DTC
Go to step 2.
Code (DTC).
<Ref. to EN(H4SO
2.0)(diag)-66, List
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0138.
Go to step 5.
Go to step 3.
Repair the open

Go to step 4.
circuit in harness
between ECM and
Replace the rear

oxygen sensor.
<Ref. to FU(H4SO

NOTE:
the following:
Open circuit in
harness between
Poor contact in
Poor contact in
ECM connector

Step
Check
system?
NOTE:
sensor
Yes
Repair or replace
the faulty part.
No
Replace the rear
oxygen sensor.
<Ref. to FU(H4SO

V: DTC P0139 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 2)

CAUTION:
WIRING DIAGRAM:
B83
MAIN RELAY
BATTERY
B138
B47
T5
SBF-6
5
3
1 2
3 4
2
4
6
1 2 3 4
5 6 7 8
B19
2
T5
2
1
B21
REAR
OXYGEN SENSOR
B47
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
T5
B19
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B83
:LHD
A: B134
B138 :RHD
C18
C30
1
8 9
18 19
28 29
A: B134
B: B135
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B: B135
ECM
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
32 33
34 35
28 29 30 31
B5
B6
C: B136
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B21
52
A1
6
4
1
7
C19
6
4
1
3
5
E2
5 6
14 15 16
25 26 27
33 34 35
E
EN-02435

Step
Check
Yes
Check DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(H4SO
2.0)(diag)-66, List
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0139.
No
Replace the rear
oxygen sensor.
<Ref. to FU(H4SO

W: DTC P0171 SYSTEM TOO LEAN (BANK 1)

Refer to DTC P0172 for diagnostic procedure. <Ref. to EN(H4SO 2.0)(diag)-126, DTC P0172 SYSTEM TOO
RICH (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
X: DTC P0172 SYSTEM TOO RICH (BANK 1)

TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
Step
CHECK AIR INTAKE SYSTEM.
CHECK EGR VALVE.
Check
Are there holes or loose bolts
on exhaust system?
Are there holes, loose bolts or
disconnection of hose on air
intake system?
Is the EGR valve stuck?
CHECK PURGE CONTROL SOLENOID

VALVE.
Is the purge control solenoid

valve stuck?
CHECK PCV VALVE.
Is the PCV valve stuck?
Is fuel pressure 284 314

CHECK FUEL PRESSURE.
kPa (2.9 3.2 kg/cm2, 41
Warning:
Place NO FIRE signs near the working 46 psi)?
area.
(2) Disconnect the connector from fuel
pump relay.
(3) Start the engine and run it until it stalls.
(4) After the engine stalls, crank it for five
more seconds.
(5) Turn the ignition switch to OFF.
6) Connect the connector to fuel pump relay.
7) Disconnect the fuel delivery hose, and connect the fuel pressure gauge.
8) Install the fuel filler cap.
9) Start the engine and idle while gear position is neutral.
10)Measure the fuel pressure while disconnecting pressure regulator vacuum hose from
intake manifold.
Warning:
Release fuel pressure before removing the
fuel pressure gauge,.
NOTE:
If fuel pressure does not increase, squeeze fuel
return hose 2 to 3 times, then measure fuel
pressure again.
Yes
No
Repair the exhaust Go to step 2.
system.
Repair the air
Go to step 3.
intake system.
Replace the EGR
valve.
Replace the purge
control solenoid
valve.
Replace the PCV
valve.
Go to step 7.
Go to step 4.
Go to step 5.
Go to step 6.
Repair the following items.
Fuel pressure is
too high:
Clogged fuel
return line or
bent hose
Fuel pressure is
too low:
Improper fuel
pump discharge
Clogged fuel
supply line

Step
After connecting the pressure regulator vacuum hose, measure fuel pressure.
Check
Yes
Is measured value 206 235 Go to step 8.
kPa (2.1 2.4 kg/cm2, 30
34 psi)?
Warning:
fuel pressure gauge,.
NOTE:
If fuel pressure does not increase, squeeze
fuel return hose 2 to 3 times, then measure
fuel pressure again.
If the measured value at this step is out of
specification, check or replace pressure regulator and pressure regulator vacuum hose.
CHECK ENGINE COOLANT TEMPERATURE Is the engine coolant tempera- Go to step 9.

ture 70 100C (158
SENSOR.
1) Start the engine and warm-up completely. 212F)?
NOTE:
CHECK MANIFOLD PRESSURE SENSOR
SIGNAL.
1) Start and warm-up the engine until engine
coolant temperature is above 60C (140F).
2) Place the select lever in N or P position.
3) Turn the A/C switch to OFF.
4) Turn all accessory switches to OFF.
5) Read the data of manifold pressure sensor
signal using Subaru Select Monitor.
Is the measurement value 24.0

41.3 kPa (180 310
mmHg, 7.09 12.20 inHg)
when idling and 73.3 106.6
kPa (550 800 mmHg, 21.65
31.50 inHg) when the ignition turns to ON?
NOTE:
Replace the ECM.

<Ref. to FU(H4SO
2.0)-34, Engine
Control Module
(ECM).>
No
Fuel pressure is
too high:
Faulty pressure regulator
Clogged fuel
return line or
bent hose
Fuel pressure is
too low:
Improper fuel
pump discharge
Clogged fuel
supply line
Replace the
engine coolant
FU(H4SO 2.0)-20,
Engine Coolant
Replace the manifold pressure sensor. <Ref. to

FU(H4SO 2.0)-26,
Manifold Absolute
Pressure Sensor.>

Y: DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT

LOW
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:

WIRING DIAGRAM:
BATTERY
ELECTRONIC
THROTTLE
CONTROL RELAY
SBF-8
B362
7
5
6
8
D7
D6
D9
MAIN RELAY
ECM
C30
C1
C2
C5
C6
A2
D1
D: B137
D24
D23
C: B136
C17
D4
D5
D2
D3
C18
A: B134
B83
:LHD
B83
:LHD
B138 :RHD
B20
16
15
38
19
20
39
35
B21
37
36
B138 :RHD
E2
2
5
3
1
4
6
E1
ELECTRONIC
THROTTLE CONTROL
E78
B362
B83
B21
B138
1 2
3
4
1 2 3 4
5 6 7 8
5
7 8
6
2
10
20
30
1
5
9
13
2
6
10
14
3
7
11
15
E78
4
8
12
16
1 2 3
4 5 6
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
A: B134
1
8 9
18 19
28 29
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
B20
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
C:
B136
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
D:
B137
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
EN-02440

Step
Check
Yes
2) Read the data of sub throttle sensor signal
CHECK POOR CONTACT.
Is there poor contact?
Repair the poor
contact.
throttle control.
(B137) No. 24 (E78) No. 2:
(B136) No. 17 (E78) No. 4:
CHECK SENSOR POWER SUPPLY.

?
Go to step 4.

M?
Go to step 5.
Go to step 6.
No
Go to step 3.
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.

harness.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
(ECM).>
Repair the poor
?
trol connector.
Replace the ECM
Replace the elec- if defective. <Ref.
tronic throttle con- to FU(H4SO 2.0)trol if defective.
34, Engine Control Module
(ECM).>

Z: DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT

HIGH
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:

WIRING DIAGRAM:
BATTERY
ELECTRONIC
THROTTLE
CONTROL RELAY
SBF-8
B362
7
5
6
8
D7
D6
D9
MAIN RELAY
ECM
C30
C1
C2
C5
C6
A2
D1
D: B137
D24
D23
C: B136
C17
D4
D5
D2
D3
C18
A: B134
B83
:LHD
B83
:LHD
B138 :RHD
B20
16
15
38
19
20
39
35
B21
37
36
B138 :RHD
E2
2
5
3
1
4
6
E1
ELECTRONIC
THROTTLE CONTROL
E78
B362
B83
B21
B138
1 2
3
4
1 2 3 4
5 6 7 8
5
7 8
6
2
10
20
30
1
5
9
13
2
6
10
14
3
7
11
15
E78
4
8
12
16
1 2 3
4 5 6
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
A: B134
1
8 9
18 19
28 29
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
B20
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
C:
B136
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
D:
B137
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
EN-02440

Step
CHECK POOR CONTACT.
Check
V?
Yes
Go to step 2.

throttle control.
(B136) No. 18 (E78) No. 1:
(B137) No. 24 (E78) No. 2:

?
Go to step 4.

?
Go to step 5.


Go to step 6.

M?
terminals.
(B137) No. 24 (B136) No. 17:
Repair the poor

contact. Replace
the electronic
throttle control.
No
Go to step 3.
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
(ECM).>
Repair the battery
ECM connector
and electronic
throttle control
connector.
Sensor power supply circuit may be
shorted.

AA:DTC P0301 CYLINDER 1 MISFIRE DETECTED

NOTE:
For the diagnostic procedure, refer to DTC P0304. <Ref. to EN(H4SO 2.0)(diag)-135, DTC P0304 CYLINDER 4 MISFIRE DETECTED, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
AB:DTC P0302 CYLINDER 2 MISFIRE DETECTED

NOTE:
AC:DTC P0303 CYLINDER 3 MISFIRE DETECTED

NOTE:

AD:DTC P0304 CYLINDER 4 MISFIRE DETECTED

Immediately at fault recognition (A misfire which could damage catalyst occurs.)
TROUBLE SYMPTOM:
Engine stalls.
Erroneous idling
Rough driving
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
5
3
BATTERY
SBF-8
6
4
2
1
B47
33
34
45
44
27
43
42
48
17
B134 ECM
B21
E2
E17
2
E6
E16
E5
E
FUEL INJECTOR
No. 2
FUEL INJECTOR
No. 1
E5
E16
E6
E17
1 2
B47
1
3
5
2
4
6
FUEL INJECTOR
No. 3
FUEL INJECTOR
No. 4
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B134
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
EN-02432

Step

2) Measure the voltage between ECM connector and chassis ground on faulty cylinders.
#1 (B134) No. 17 (+) Chassis ground ():
CHECK HARNESS BETWEEN FUEL INJECTOR AND ECM CONNECTOR.
2) Disconnect the connector from fuel injector
on faulty cylinders.
3) Measure the resistance between ECM connector and engine ground on faulty cylinders.
#1 (E5) No. 1 Engine ground:
Measure the resistance of harness connector
between ECM connector and fuel injector on
faulty cylinders.
#1 (B134) No. 17 (E5) No. 1:
#2 (B134) No. 27 (E16) No. 1:
#3 (B134) No. 34 (E6) No. 1:
#4 (B134) No. 33 (E17) No. 1:
CHECK FUEL INJECTOR.

Measure the resistance between fuel injector
terminals on faulty cylinder.
Terminals
No. 1 No. 2:
Check
Yes
No
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(H4SO
2.0)(diag)-66, List
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0301,
P0302,
P0303 and P0304.
Go to step 3.

M?
Go to step 4.
Repair the ground

short circuit in harness between fuel
injector and ECM
connector.

?
Go to step 5.
Go to step 6.
NOTE:
the following:
Open circuit in
harness between
ECM and fuel
injector connector
Poor contact in
coupling connector
Replace the faulty
fuel injector. <Ref.
to FU(H4SO 2.0)29, Fuel Injector.>

10
11
Step
CHECK POWER SUPPLY LINE.
2) Measure the voltage between fuel injector
and engine ground on faulty cylinders.
Check
Yes
Is the voltage more than 10 V? Repair the poor
contact in all connectors in fuel
injector circuit.
No
NOTE:
the following:
Open circuit in
harness between
main relay and fuel
injector connector
on faulty cylinders
Poor contact in
coupling connector
Poor contact in
Poor contact in
fuel injector connector on faulty
cylinders
ECM and fuel
injector. After
repair, replace the
ECM. <Ref. to
FU(H4SO 2.0)-34,
Engine Control
Module (ECM).>

on faulty cylinder.
?
2) Measure the resistance between fuel injector terminals on faulty cylinder.
Terminals
No. 1 No. 2:
Replace the faulty

fuel injector <Ref.
and ECM <Ref. to
FU(H4SO 2.0)-34,
Engine Control
Module (ECM).>
CHECK INSTALLATION OF CAMSHAFT PO- Is the camshaft position sensor Tighten the camSITION SENSOR/CRANKSHAFT POSITION or crankshaft position sensor shaft position senSENSOR.
loosely installed?
sor or crankshaft
position sensor.
CHECK CRANKSHAFT SPROCKET.
Is the crankshaft sprocket
Replace the crankRemove the timing belt cover.
rusted or does it have broken shaft sprocket.
teeth?
<Ref. to ME(H4SO
2.0)-50, Crank
Sprocket.>
CHECK INSTALLATION CONDITION OF
Is the timing belt dislocated
Repair the installaTIMING BELT.
from its proper position?
tion condition of
Turn the crankshaft using ST, and align aligntiming belt. <Ref.
ment mark on crankshaft sprocket with alignto ME(H4SO 2.0)ment mark on cylinder block.
43, Timing Belt.>
ST 499987500 CRANKSHAFT SOCKET
Go to step 9.
Go to step 10.
Go to step 11.
Go to step 12.

12
13
14
Step
CHECK FUEL LEVEL.
Check
Is the fuel meter indication
higher than the Lower level?
Yes
Go to step 13.
CHECK STATUS OF MALFUNCTION INDI- Does the malfunction indicator

CATOR LIGHT.
light illuminate or blink?
1) Clear the memory using Subaru Select
Monitor.
2) Start the engine, and drive the vehicle more
than 10 minutes.
CHECK CAUSE OF MISFIRE DIAGNOSED. Was the cause of misfire identified when the engine is running. Ex. Disconnection of
spark plug cord.
Go to step 15.
Finish diagnostics
operation, if the
engine has no
abnormality.
No
Replenish fuel so
fuel meter indication is higher than
the Lower level.
After replenishing
fuel, Go to step 13.
Go to step 14.
1. Repair the poor

contact.
NOTE:
the following:
Poor contact in
ignitor connector
Poor contact in
ignition coil connector
Poor contact in
cylinders
Poor contact in
ECM connector
Poor contact in
coupling connector
1. If there is no
poor contact,
check the followings and contact
with your Subaru
distributor service.
Fuel condition
Whether
addition agent
is used or not
Plug condition
Plug cord
condition
Engine oil
condition

15
16
17
18
19
20
21
Step
Check
Is there any fault in air intake
system?
CHECK MISFIRE SYMPTOM.

2) Read the DTC.
<Ref. to EN(H4SO 2.0)(diag)-25, Subaru
Select Monitor.>
General scan tool
General Scan Tool Operation Manual.
NOTE:
Perform diagnosis according to the items listed
below.
CHECK DIAGNOSTIC TROUBLE CODE
(DTC) ON DISPLAY.
(DTC) ON DISPLAY.
(DTC) ON DISPLAY.
(DTC) ON DISPLAY.
ONLY ONE CYLINDER
Yes
Repair the air
intake system.
No
Go to step 16.
NOTE:
Are there air
leaks or air suction
caused by loose or
dislocated nuts
and bolts?
Are there cracks
or any disconnection of hoses?
Does the Subaru Select Moni- Go to step 21.
Go to step 17.
tor or general scan tool display
only one DTC?
Does the Subaru Select Monitor or general scan tool indicate DTC P0301 and P0302?
Is there any 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.
Go to DTC P0171.
<Ref. to EN(H4SO
2.0)(diag)-126,
NOTE:
Check the follow- DTC P0171 SYSTEM TOO LEAN
ing items.
(BANK 1), Diag Spark plug
Spark plug cord nostic Procedure
with Diagnostic
Fuel injector
Trouble Code
Compression
(DTC).>
ratio

22
Step
GROUP OF #1 AND #2 CYLINDERS
Check
Are there any faults in #1 and
#2 cylinders?
23

#4 cylinders?
24

#3 cylinders?
Yes
Repair or replace
faulty parts.
No
Go to DTC P0171.
<Ref. to EN(H4SO
2.0)(diag)-126,
NOTE:
DTC P0171 SYS Check the folTEM TOO LEAN
lowing items.
Spark plugs (BANK 1), Diag Fuel injectors nostic Procedure
with Diagnostic
Ignition coil
Trouble Code
Compres(DTC).>
sion ratio
If no abnormal is
discovered, check
for IGNITION
CONTROL SYSTEM of #1 and #2
cylinders side.
<Ref. to EN(H4SO
2.0)(diag)-58,
Diagnostics for
Engine Starting
Failure.>
Repair or replace Go to DTC P0171.
<Ref. to EN(H4SO
faulty parts.
2.0)(diag)-126,
NOTE:
DTC P0171 SYS Check the folTEM TOO LEAN
lowing items.
Spark plugs (BANK 1), Diag Fuel injectors nostic Procedure
with Diagnostic
Ignition coil
If no abnormal is Trouble Code
discovered, check (DTC).>
for 16. D: IGNITION CONTROL
SYSTEM of #3
and #4 cylinders
side. <Ref. to
EN(H4SO
2.0)(diag)-58,
Diagnostics for
Engine Starting
Failure.>
Repair or replace Go to DTC P0171.
<Ref. to EN(H4SO
faulty parts.
2.0)(diag)-126,
NOTE:
ing items.
(BANK 1), Diag Spark plugs
nostic Procedure
Fuel injectors
Skipping timing with Diagnostic
Trouble Code
belt teeth
(DTC).>

25
Step
Check
#4 cylinders?
26
CYLINDER AT RANDOM
Is the engine idle rough?
Yes
Repair or replace
faulty parts.
No
Go to DTC P0171.
<Ref. to EN(H4SO
2.0)(diag)-126,
NOTE:
ing items.
nostic Procedure
Fuel injectors
with Diagnostic
Compression
Trouble Code
ratio
Skipping timing (DTC).>
belt teeth
Go to DTC P0170. Repair or replace
<Ref. to EN(H4SO faulty parts.
2.0)(diag)-126,
NOTE:
DTC P0171 SYS- Check the followTEM TOO LEAN ing items.
nostic Procedure Fuel injectors
with Diagnostic
Compression
Trouble Code
ratio
(DTC).>

AE:DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW (BANK 1 OR SINGLE SENSOR)

TROUBLE SYMPTOM:
Knocking occurs.
CAUTION:
WIRING DIAGRAM:
KNOCK
SENSOR
E14
2
1 2
E14
B20
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
13
E1
12
23
B20
5 6
14 15 16
25 26 27
33 34 35
B136
ECM
E
EN-02442

Step
Check
CHECK HARNESS BETWEEN KNOCK SEN- Is the resistance more than
SOR AND ECM CONNECTOR.
700 k?
3) Measure the resistance between ECM harness connector and chassis ground.
Yes
Go to step 2.
CHECK KNOCK SENSOR.

Is the resistance more than
1) Disconnect the connector from knock sen- 700 k?
sor.
2) Measure the resistance between knock
sensor connector terminal and engine ground.
Terminals
No. 2 Engine ground:
Go to step 3.
CHECK CONDITION OF KNOCK SENSOR

INSTALLATION.
No
NOTE:
the following:
Open circuit in
harness between
knock sensor and
ECM connector
Poor contact in
knock sensor connector
Poor contact in
coupling connector
NOTE:
the following:
Poor contact in
Is the knock sensor installation Replace the knock Tighten the knock
bolt tightened securely?
sensor. <Ref. to
sensor installation
FU(H4SO 2.0)-23, bolt securely.
Knock Sensor.>

AF:DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH (BANK 1 OR SINGLE SENSOR)

TROUBLE SYMPTOM:
Knocking occurs.
CAUTION:
WIRING DIAGRAM:
KNOCK
SENSOR
E14
2
1 2
E14
B20
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
13
E1
12
23
B20
5 6
14 15 16
25 26 27
33 34 35
B136
ECM
E
EN-02442

Step
CHECK HARNESS BETWEEN KNOCK SENSOR AND ECM CONNECTOR.
CHECK KNOCK SENSOR.
1) Disconnect the connector from knock sensor.
Terminals
Check
Yes
Is the resistance less than 400 Go to step 2.
k?
No
Go to step 3.
Is the resistance less than 400 Replace the knock

k?
sensor. <Ref. to
FU(H4SO 2.0)-23,
Knock Sensor.>
Repair the ground

knock sensor connector and ECM
connector.

1) Connect the connectors to ECM and knock
sensor.
chassis ground.

light illuminates,
the circuit has
this time. (However, the possibility
of poor contact still
remains.)
NOTE:
the following:
Poor contact in
Poor contact in
ECM connector
Poor contact in
coupling connector
NOTE:
The harness between both connectors
are
shielded. Repair
the short circuit in
harness covered
with shield.
Repair the poor
contact in ECM
connector.

AG:DTC P0335 CRANKSHAFT POSITION SENSOR A CIRCUIT

TROUBLE SYMPTOM:
Engine stalls.
Failure of engine to start
CAUTION:
WIRING DIAGRAM:
CRANKSHAFT
POSITION
SENSOR
E10
2
1
1 2
E10
B20
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
E1
8
7
B122
B20
B138
1 2 3 4
5 6 7 8
: WITH IMMOBILIZER: 27
WITHOUT IMMOBILIZER: 26
B138 :LHD
B122 :RHD
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
*
32
24
B136
B136
ECM
E
EN-02443

Step
Check
CHECK HARNESS BETWEEN CRANKIs the resistance more than
SHAFT POSITION SENSOR AND ECM CON- 100 k?
NECTOR.
2) Disconnect the connector from crankshaft
position sensor.
between crankshaft position sensor connector
and engine ground.
CHECK HARNESS BETWEEN CRANKIs the resistance less than 10

SHAFT POSITION SENSOR AND ECM CON- ?
NECTOR.
crankshaft position sensor connector and
engine ground.

NECTOR.
engine ground.
Yes
No
Repair the harGo to step 2.
ness and connector.
NOTE:
the following:
Open circuit in
harness between
crankshaft position sensor and
ECM connector
Poor contact in
ECM connector
Poor contact in
coupling connector
Repair the ground Go to step 3.
ECM connector.
NOTE:
are
shielded. Repair
the ground short
circuit in harness
with shield.
Go to step 4.
NOTE:
the following:
Open circuit in
harness between
ECM connector
Poor contact in
ECM connector
Poor contact in
coupling connector
CHECK CONDITION OF CRANKSHAFT PO- Is the crankshaft position sen- Go to step 5.
Tighten the crankSITION SENSOR.
sor installation bolt tightened
shaft position sensecurely?
sor installation bolt
securely.
CHECK CRANKSHAFT POSITION SENSOR. Is the resistance 1 4 k?
Repair the poor
Replace the crank1) Remove the crankshaft position sensor.
contact in crankshaft position sen2) Measure the resistance between connector
shaft position sensor. <Ref. to
terminals of crankshaft position sensor.
sor connector.
FU(H4SO 2.0)-21,
Terminals
Crankshaft PosiNo. 1 No. 2:
tion Sensor.>

AH:DTC P0340 CAMSHAFT POSITION SENSOR A CIRCUIT (BANK 1 OR SINGLE SENSOR)

TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
WIRING DIAGRAM:
CAMSHAFT
POSITION
SENSOR
E15
2
1
1 2
E15
B20
1
5
9
13
2
6
10
14
3
7
11
15
B122
B20
B138
6
5
E1
4
8
12
16
1 2 3 4
5 6 7 8
B138 :LHD
B122 :RHD
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
*
32
25
B136
B136
ECM
E
EN-02444

Step
CHECK HARNESS BETWEEN CAMSHAFT
POSITION SENSOR AND ECM CONNECTOR.
2) Disconnect the connector from camshaft
position sensor.
between camshaft position sensor connector
and engine ground.
Check
100 k?

camshaft position sensor connector and
engine ground.

?

engine ground.

?
Yes
No
ness and connector.
NOTE:
the following:
Open circuit in
harness between
camshaft position
sensor and ECM
connector
Poor contact in
ECM connector
Poor contact in
coupling connector
camshaft position
sensor and ECM
connector.
NOTE:
are
shielded. Repair
the ground short
circuit in harness
with shield.
Go to step 4.
NOTE:
the following:
Open circuit in
harness between
camshaft position
sensor and ECM
connector
Poor contact in
ECM connector
Poor contact in
coupling connector
CHECK CONDITION OF CAMSHAFT POSI- Is the camshaft position sensor Go to step 5.
Tighten the camTION SENSOR.
installation bolt tightened
securely.
CHECK CAMSHAFT POSITION SENSOR.
Is the resistance 1 4 k?
Repair the poor
Replace the cam1) Remove the camshaft position sensor.
contact in camshaft position sen2) Measure the resistance between connector
terminals of camshaft position sensor.
sor connector.
FU(H4SO 2.0)-22,
Terminals
Camshaft Position
No. 1 No. 2:
Sensor.>

AI: DTC P0400 EXHAUST GAS RECIRCULATION FLOW

TROUBLE SYMPTOM:
Movement performance problem when engine is low speed.
Erroneous idling
Movement performance problem
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
E18
5
3
BATTERY
1 2 3
4 5 6
SBF-5
6
4
B47
B21
48
2
1
1
3
5
E2
2
4
6
5
2
B47
B21
EGR
VALVE
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
E18
6
3
4
1
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
30
25
29
26
E2
B21
A4
A13
A3
A12
A: B134
1
8 9
18 19
28 29
A: B134
C: B136
ECM
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
D: B137
A2
D1
C5
C6
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B21
5 6
14 15 16
25 26 27
33 34 35
35
36
D: B137
E2
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
28 29
30 31
26 27
E
EN-02445

Step
Check
Yes
No
Inspect the DTC
Go to step 2.
Code (DTC).
<Ref. to EN(H4SO
2.0)(diag)-66, List
Make sure that the Go to step 3.
CHECK CURRENT DATA.
kPa (400 mmHg, 15.75 inHg)? EGR valve, mani1) Start the engine.
fold absolute pres2) Read the data of intake manifold absolute
sure sensor and
throttle body are
NOTE:
installed securely.
Repair the open
CHECK THE POWER SUPPLY OF EGR SO- Is the voltage more than 10 V? Go to step 4.
circuit in harness
LENOID VALVE.
between main
1) Detach the connector from EGR solenoid
relay and EGR
valve.
solenoid valve
connector.
3) Measure the voltage between EGR solenoid valve and engine ground.
CHECK EGR SOLENOID VALVE.
Is the resistance 20 30 ? Go to step 5.
Replace the EGR
Measure the resistance between EGR solesolenoid valve.
noid valve terminals.
<Ref. to FU(H4SO
2.0)-28, EGR
NOTE:
Valve.>
Make sure there is no foreign material between
EGR solenoid valve and valve seat.
Terminals
No. 1 No. 2:
No. 3 No. 2:
No. 4 No. 5:
No. 6 No. 5:
Is the voltage 0 10 V?
Repair the poor
Go to step 6.
contact portion in
ECM connector.
2) Connect the connector to ECM and EGR
solenoid valve.
chassis ground.

Step
CHECK HARNESS BETWEEN EGR SOLENOID VALVE AND ECM CONNECTOR.
valve and ECM.
between EGR solenoid valve and ECM connector.
(B134) No. 4 (E18) No. 6:
(B134) No. 12 (E18) No. 1:
(B134) No. 3 (E18) No. 4:
(B134) No. 13 (E18) No. 3:
EGR solenoid valve and chassis ground.
CHECK POOR CONTACT.
Check poor contact for ECM and EGR solenoid valve connector.
Check
?
Yes
Go to step 7.
No
Repair the open
circuit in harness
between ECM and
EGR solenoid
valve connector.

M?
Go to step 8.
Repair the short

circuit in harness
between main
relay and EGR
solenoid valve
connector.
Is there poor contact for ECM

and EGR solenoid valve connector?
Repair the poor

contact of ECM
and EGR solenoid
valve connector.

light illuminates,
the circuit has
returned to the
specified condition at this time.

AJ:DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK

1)
TROUBLE SYMPTOM:
Engine stalls.
Idle mixture is out of specifications.
CAUTION:
WIRING DIAGRAM:
B83
MAIN RELAY
BATTERY
B138
B47
T5
SBF-6
5
3
2
4
6
1 2 3 4
5 6 7 8
B19
2
T5
2
1
B21
REAR
OXYGEN SENSOR
B47
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
T5
B19
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B83
:LHD
A: B134
B138 :RHD
C18
C30
1
8 9
18 19
28 29
A: B134
B: B135
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B: B135
ECM
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
32 33
34 35
28 29 30 31
B5
B6
C: B136
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B21
52
A1
6
4
1
7
C19
6
4
1
3
5
1 2
3 4
E2
5 6
14 15 16
25 26 27
33 34 35
E
EN-02435

Step

Check for gas leaks or air suction caused by
loose or dislocated nuts and bolts, and open
hole at exhaust pipes.
Check

system?
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 CATALYTIC CONVERTER.
Yes
No
Inspect the releGo to step 2.
vant DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(H4SO
2.0)(diag)-66, List
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0420.
Repair or replace Go to step 3.
the exhaust system. <Ref. to
EX(H4SO 2.0)-2,
Is there damage at rear face or Replace the cata- Go to step 5.

front face of front catalyst?
lytic converter.
<Ref. to EC(H4SO
2.0)-3, Front Catalytic Converter.>
CHECK REAR OXYGEN SENSOR GROUND Is the resistance less than 1
Go to step 5.
Repair the open
HARNESS.
?
circuit in harness
1) Disconnect the rear oxygen sensor and
between ECM and
ECM connectors.
rear oxygen sen2) Measure the resistance between rear oxysor.
gen sensor connector and ECM connector.
(B19) No. 3 (B136) No. 18:
CHECK SHIELD HARNESS.
Is the shield harness opened? Repair the shield Contact with your
harness.
Subaru distributor
service.

AK:DTC P0458 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE

CIRCUIT LOW
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
E4
5
3
BATTERY
1 2
SBF-8
6
4
2
1
B47
1
3
5
B47
2
4
6
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
B134 ECM
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B134
48
41
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B21
E2
1
2
E4
PURGE CONTROL
SOLENOID VALVE
EN-02446

Step
chassis ground.
Check
Yes
Is the voltage more than 10 V? Even if the malfunction indicator
light illuminates,
the circuit has
this time.
CHECK HARNESS BETWEEN PURGE CON- Is the resistance more than 1 Go to step 3.
TROL SOLENOID VALVE AND ECM CONM?
NECTOR.
2) Disconnect the connectors from purge control solenoid valve and ECM.
between purge control solenoid valve connector and engine ground.
CHECK HARNESS BETWEEN PURGE CON- Is the resistance less than 1
Go to step 4.
TROL SOLENOID VALVE AND ECM CON?
NECTOR.
ECM and purge control solenoid valve.
(B134) No. 8 (E4) No. 2:

VALVE.
1) Remove the purge control solenoid valve.
2) Measure the resistance between purge
control solenoid valve terminals.
Terminals
No. 1 No. 2:
CHECK POWER SUPPLY TO PURGE CONTROL SOLENOID VALVE.
2) Measure the voltage between purge control
solenoid valve and engine ground.
CHECK POOR CONTACT.
Check poor contact in purge control solenoid
valve connector.
No
Go to step 2.
Repair the ground

ECM and purge
control solenoid
valve connector.
Repair the open

circuit in harness
between ECM and
purge control solenoid valve connector.
NOTE:
the following:
Open circuit in
harness between
ECM and purge
control solenoid
valve connector
Poor contact in
coupling connector
Replace the purge
control solenoid
valve. <Ref. to
EC(H4SO 2.0)-7,
Purge Control
Solenoid Valve.>
Repair the open

circuit in harness
between main
relay and purge
control solenoid
valve connector.
Is there poor contact in purge Repair the poor

control solenoid valve connec- contact in purge
tor?
control solenoid
valve connector.
Replace the ECM.

<Ref. to FU(H4SO
2.0)-34, Engine
Control Module
(ECM).>

AL:DTC P0459 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE

CIRCUIT HIGH
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
E4
5
3
BATTERY
1 2
SBF-8
6
4
2
1
B47
1
3
5
B47
2
4
6
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
B134 ECM
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B134
48
41
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B21
E2
1
2
E4
PURGE CONTROL
SOLENOID VALVE
EN-02446

Step
Check
2) Connect the test mode connector at the
lower portion of instrument panel (on the
drivers side).
4) While operating the purge control solenoid
valve, measure voltage between ECM and
chassis ground.
Yes
Go to step 2.
NOTE:
Purge control solenoid valve operation can be
executed using Subaru Select Monitor. Refer to
Compulsory Valve Operation Check Mode for
procedures. <Ref. to EN(H4SO 2.0)(diag)-39,
Compulsory Valve Operation Check Mode.>
chassis ground.
CHECK POOR CONTACT.
Repair the poor
connector?
contact in ECM
connector.
No
light illuminates,
the circuit has
this time. In this
case, repair the
poor contact in
ECM connector.
Go to step 3.
Replace the ECM.

<Ref. to FU(H4SO
2.0)-34, Engine
Control Module
(ECM).>
CHECK HARNESS BETWEEN PURGE CON- Is the voltage more than 10 V? Repair the battery Go to step 5.
short circuit in harTROL SOLENOID VALVE AND ECM CONness between
NECTOR.
ECM and purge
control solenoid
2) Disconnect the connector from purge convalve connector.
trol solenoid valve.
After repair,
replace the ECM.
<Ref. to FU(H4SO
chassis ground.
2.0)-34, Engine
Control Module
(ECM).>
Replace the purge Go to step 6.
VALVE.
?
control solenoid
valve <Ref. to
EC(H4SO 2.0)-7,
Purge Control
Terminals
Solenoid Valve.>
No. 1 No. 2:
and ECM. <Ref. to
FU(H4SO 2.0)-34,
Engine Control
Module (ECM).>
CHECK POOR CONTACT.
Repair the poor
Replace the ECM.
connector?
contact in ECM
<Ref. to FU(H4SO
connector.
2.0)-34, Engine
Control Module
(ECM).>

AM:DTC P0462 FUEL LEVEL SENSOR A CIRCUIT LOW

CAUTION:
WIRING DIAGRAM:
Step
Check
Does DTC P0462 appear on
the Subaru Select Monitor?
Yes
Check the combination meter.
<Ref. to IDI-3,
Combination
Meter System.>
No
Temporary poor
contact occurs.
AN:DTC P0463 FUEL LEVEL SENSOR A CIRCUIT HIGH

CAUTION:
WIRING DIAGRAM:
Step
Check
Yes
<Ref. to IDI-3,
Combination
Meter System.>
No
Temporary poor
contact occurs.
AO:DTC P0500 VEHICLE SPEED SENSOR A

CAUTION:
Step
CHECK DTC OF ABS.
Check DTC of ABS.
Check
Is DTC of ABS displayed?
Yes
No
Perform the diag- Repair the poor
nosis according to contact in ECM.
DTC. <Ref. to
ABS(diag)-39, List

AP:DTC P0512 STARTER REQUEST CIRCUIT

TROUBLE SYMPTOM:
CAUTION:

WIRING DIAGRAM:
IGNITION
SWITCH
B72
BATTERY
SBF-1
SBF-7
13
RHD
14
15
LHD
16
No.21
3
2
STARTER
RELAY
16
LHD
14
15
RHD
13
B225
P
AT
11
12
MT
12
B12
T3
T7
MT
STARTER MOTOR
AT
E
M
23
B14
B135
ECM
B225
B72
1 2 3
4 5 6
B135
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
1
8 9
20 21
28 29
2
3
10 11 12 13
22 23
30 31
4 5 6
7
14 15 16 17 18 19
24 25
26 27
32 33
34 35
B12
T7
1 2 3 4
5 6 7 8
9 10 11 12
1 2 3 4 5 6
7 8 9 10 11 12
EN-02428

Step
Check
CHECK OPERATION OF STARTER MOTOR. Does the starter motor operTurn the ignition switch to ON.
ate?
NOTE:
Place the inhibitor switch in each position.
Yes
Repair the battery
short circuit in
starter motor circuit.
No
Check starter
motor circuit. <Ref.
to EN(H4SO
2.0)(diag)-52,
STARTER
MOTOR CIRCUIT, Diagnostics

AQ:DTC P0519 IDLE AIR CONTROL SYSTEM PERFORMANCE

TROUBLE SYMPTOM:
Engine keeps running at higher revolution than specified idling revolution.
CAUTION:
Step

3) Check the following items:
Loose installation of intake manifold and
throttle body
Cracks of intake manifold gasket and throttle
body gasket
Disconnections of vacuum hoses
CHECK ELECTRONIC THROTTLE CONTROL.
2) Replace the electronic throttle control.
3) Check the electronic throttle control.
Check

system?
Are foreign matters found

inside the electronic throttle
control?
Yes
No
Go to step 2.
Inspect the DTC
Code (DTC).
<Ref. to EN(H4SO
2.0)(diag)-66, List
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0519.
Repair air suction Go to step 3.
and leaks.
Remove foreign
matters from the
electronic throttle
control.
Perform the diagnosis of DTC

P2101.
AR:DTC P0558 GENERATOR CIRCUIT LOW INPUT

CAUTION:
For diagnostic procedure, refer to DTC P0559. <Ref. to EN(H4SO 2.0)(diag)-164, DTC P0559 GENERATOR CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>.

AS:DTC P0559 GENERATOR CIRCUIT HIGH

CAUTION:
WIRING DIAGRAM:
B135
ECM
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
32 33
34 35
28 29 30 31
16
B135
F26
1 2 3
F26
GENERATOR
EN-02447

Step
CHECK HARNESS BETWEEN GENERATOR
AND ECM CONNECTOR.
2) Disconnect the connectors from generator
and ECM.
between generator connector and engine
ground.
(F26) No. 3 Engine ground:
AND ECM CONNECTOR.
ECM and generator of harness connector.
(B136) No. 16 (F26) No. 3:
Check
M?
Yes
Go to step 2.
No
Repair the ground
ECM and purge
control solenoid
valve connector.

?
Repair the poor

Repair the open
contact in connec- circuit in harness
tor.
between ECM and
generator connector.
NOTE:
the following:
Open circuit in
harness between
ECM and generator connector
Poor contact in
coupling connector
AT:DTC P0600 SERIAL COMMUNICATION LINK

NOTE:
For the diagnostic procedure, refer to LAN section. <Ref. to LAN(diag)-2, Basic Diagnostic Procedure.>

AU:DTC P0604 INTERNAL CONTROL MODULE RANDOM ACCESS MEMORY

(RAM) ERROR
TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
TO IGNITION COIL
3
5
SBF-8
6
4
No.13
1
2
B72
B47
IGNITION
SWITCH
BATTERY
No.12
SBF-7
3
C7
B13
B14
C3
C4
SBF-1
A: B134
B: B135
ECM
C: B136
B21
35
37
34
36
52
B5
B6
C1
C2
A7
C5
C6
A2
D1
D: B137
E2
E
A:
B134
B:
C: B136
B135
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
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
32 33
34 35
28 29 30 31
D:
5 6
14 15 16
25 26 27
33 34 35
B137
B47
B72
1 2 3
4 5 6
1
3
5
2
4
6
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
28 29
30 31
26 27
EN-02429

Step
Check
Yes
No
Inspect the releTemporary poor
vant DTC using
contact occurs.
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(H4SO
2.0)(diag)-66, List
AV:DTC P0605 INTERNAL CONTROL MODULE READ ONLY MEMORY (ROM)

ERROR
NOTE:
For the diagnostic procedure, refer to DTC P0607. <Ref. to EN(H4SO 2.0)(diag)-168, DTC P0607 CONTROL MODULE PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>

AW:DTC P0607 CONTROL MODULE PERFORMANCE

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
TO IGNITION COIL
3
5
SBF-8
6
4
No.13
1
2
B72
B47
IGNITION
SWITCH
BATTERY
No.12
SBF-7
3
C7
B13
B14
C3
C4
SBF-1
A: B134
B: B135
ECM
C: B136
B21
35
37
34
36
52
B5
B6
C1
C2
A7
C5
C6
A2
D1
D: B137
E2
E
A:
B134
B:
C: B136
B135
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
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
32 33
34 35
28 29 30 31
D:
5 6
14 15 16
25 26 27
33 34 35
B137
B47
B72
1 2 3
4 5 6
1
3
5
2
4
6
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
28 29
30 31
26 27
EN-02429

Step
Check
CHECK ECM GROUND HARNESS.
and chassis ground.
Yes
Go to step 2.
No
Repair the open or
Go to step 3.
Repair the open or

Repair the poor

Further tighten the
contact in ECM
engine ground terconnector.
minal.
Replace the ECM
if defective. <Ref.
(ECM).>
AX:DTC P0638 THROTTLE ACTUATOR CONTROL RANGE/PERFORMANCE

(BANK 1)
NOTE:
For diagnostic procedure, refer to DTC P2101. <Ref. to EN(H4SO 2.0)(diag)-193, DTC P2101 THROTTLE
ACTUATOR CONTROL MOTOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>

AY:DTC P0691 FAN 1 CONTROL CIRCUIT LOW

TROUBLE SYMPTOM:
Radiator fan does not operate properly.
Overheating
CAUTION:
Step
Check
Yes
No
Check the radiator Temporary poor
fan system. <Ref. contact occurs.
to CO(H4SO 2.0)7, Radiator Fan
System.>
AZ:DTC P0692 FAN 1 CONTROL CIRCUIT HIGH

TROUBLE SYMPTOM:
Overheating
CAUTION:
Step
Check
Yes
No
Check the radiator Temporary poor
System.>
BA:DTC P0700 TRANSMISSION CONTROL SYSTEM (MIL REQUEST)

NOTE:
For the diagnostic procedure, refer to AT section. <Ref. to 4AT(diag)-2, Basic Diagnostic Procedure.>

BB:DTC P0851 PARK/NEUTRAL SWITCH INPUT CIRCUIT LOW

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
B135
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
12
B135 ECM
B25
1 2
AT
MT
B25
2
B12
T2
NEUTRAL
POSITION
SWITCH
1 2 3 4
5 6 7 8
9 10 11 12
INHIBITOR SWITCH
P
11
T2
12
T7
12
B25
B12
T7
1 2 3 4 5 6
7 8 9 10 11 12
RHD
LHD
T3
B122
LHD
1 2 3 4
5 6 7 8
1
B122
STARTER MOTOR
B21
LHD
36
RHD
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
E3
LHD
M
B14
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
EN-02448

Step

2) Place the select lever other than N and
P range.
chassis ground.
TRANSMISSION HARNESS CONNECTOR.
transmission harness connector (T3).
CHECK TRANSMISSION HARNESS CONNECTOR.
1) Disconnect the connector from inhibitor
switch.
between transmission harness connector and
engine ground.
(T3) No. 11 Engine ground:
CHECK INHIBITOR SWITCH.
Measure the resistance between inhibitor
switch connector receptacles terminals with
select lever at other than N and P range.
Terminals
No. 7 No. 12:
CHECK SELECT CABLE CONNECTION.
Check
Yes
No
Inspect the DTC
Go to step 2.
Code (DTC).
<Ref. to EN(H4SO
2.0)(diag)-66, List
Is the voltage more than 10 V? Even if the malGo to step 3.
function indicator
light illuminates,
the circuit has
this time.
M?
Go to step 4.
Repair the ground

ECM and transmission harness
connector.

M?
Go to step 5.
Repair the ground

transmission harness connector
and inhibitor
switch connector.

M?
Go to step 6.
Replace the inhibitor switch. <Ref. to

4AT-52, Inhibitor
Switch.>
Is there any fault in select

cable connection to inhibitor
switch?
Repair the select

cable connection.
<Ref. to CS-14,
INSPECTION,
Select Cable.>
Replace the ECM.

<Ref. to FU(H4SO
2.0)-34, Engine
Control Module
(ECM).>

BC:DTC P0852 PARK/NEUTRAL SWITCH INPUT CIRCUIT HIGH

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
B135
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
12
B135 ECM
B25
1 2
AT
MT
B25
2
B12
T2
NEUTRAL
POSITION
SWITCH
1 2 3 4
5 6 7 8
9 10 11 12
INHIBITOR SWITCH
P
11
T2
12
T7
12
B25
B12
T7
1 2 3 4 5 6
7 8 9 10 11 12
RHD
LHD
T3
B122
LHD
1 2 3 4
5 6 7 8
1
B122
STARTER MOTOR
B21
LHD
36
RHD
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
E3
LHD
M
B14
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
EN-02448

Step
Check

chassis ground with select lever at N and P
range.
Measure the voltage between ECM and chassis ground with select lever at other than N
and P range.
CHECK POOR CONTACT.
Yes
No
Inspect the DTC
Go to step 2.
Code (DTC).
<Ref. to EN(H4SO
2.0)(diag)-66, List
Go to step 3.
Go to step 5.

connector?
Replace the ECM.

<Ref. to FU(H4SO
2.0)-34, Engine
Control Module
(ECM).>
short circuit in harMeasure the voltage between ECM and chasness between
sis ground.
ECM and inhibitor
switch connector.
CHECK HARNESS BETWEEN ECM AND IN- Is the resistance less than 1
Go to step 7.
Repair the harHIBITOR SWITCH CONNECTOR.
?
ness and connec1) Turn the ignition switch to OFF.
tor.
NOTE:
inhibitor switch.
the following:
between ECM and inhibitor switch connector.
Open circuit in
harness between
(B135) No. 12 (T7) No. 11:
ECM and inhibitor
switch connector
Poor contact in
coupling connector
Poor contact in
inhibitor switch
connector
Poor contact in
ECM connector
Repair the poor

contact in ECM
connector.
Go to step 5.

Step
Check
CHECK INHIBITOR SWITCH GROUND LINE. Is the resistance less than 5
?
inhibitor switch connector and engine ground.

select lever at N and P range.
Terminals
No. 7 No. 12:
Yes
Go to step 8.

?
Go to step 9.

switch?
Repair the select

cable connection.
<Ref. to CS-14,
INSPECTION,
Select Cable.>
No
Repair the open
circuit in harness
between inhibitor
switch connector
and ground line.
NOTE:
the following:
Open circuit in
harness between
inhibitor switch
connector and
ground line
4AT-52, Inhibitor
Switch.>
Replace the ECM.

<Ref. to FU(H4SO
2.0)-34, Engine
Control Module
(ECM).>

BD:DTC P1134 A/F SENSOR MICRO-COMPUTER PROBLEM (BANK 1 SENSOR

1)
CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.0)(diag)38, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO 2.0)(diag)-32, Inspection Mode.>.
WIRING DIAGRAM:
BATTERY
MAIN RELAY
SBF-6
5
3
1
3
5
E2
2
4
6
FRONT OXYGEN
(A/F) SENSOR
E24
E24
1
2
B47
2
4
B21
4
3
51
E2
1
3
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B2
B3
C33
C35
C34
E
B: B135
B135
B: B1
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
32 33
34 35
28 29 30 31
ECM
C: B136
B5
B6
E
C: B136
52
2
1
B21
4
6
B47
50
B21
E2
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
E
EN-02433

Step
Check
Yes
Check DTC using
the List of Diagnostic Trouble
Code (DTC). <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
It is not necessary
to inspect DTC
P1134.
No
Replace the ECM.
<Ref. to FU(H4SO
2.0)-34, Engine
Control Module
(ECM).>

BE: DTC P1137 O2 SENSOR CIRCUIT (BANK1 SENSOR1)

CAUTION:
WIRING DIAGRAM:
BATTERY
MAIN RELAY
SBF-6
5
3
1
3
5
E2
2
4
6
FRONT OXYGEN
(A/F) SENSOR
E24
E24
1
2
B47
2
4
B21
4
3
51
E2
1
3
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B2
B3
C33
C35
C34
E
B: B135
B135
B: B1
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
32 33
34 35
28 29 30 31
ECM
C: B136
B5
B6
E
C: B136
52
2
1
B21
4
6
B47
50
B21
E2
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
E
EN-02433

Step
Check
CHECK FRONT OXYGEN (A/F) SENSOR DA- Is the voltage 0.85 1.15 V?
TA.
2) While observing the Subaru Select Monitor
or 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.
signal during idling using Subaru Select Monitor or general scan tool.
Yes
No
Inspect DTC using Go to step 2.
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(H4SO
2.0)(diag)-66, List
Go to step 3.
Go to step 4.
NOTE:
Monitor.>
General scan tool
General Scan Tool Instruction Manual.
CHECK FRONT OXYGEN (A/F) SENSOR DA- Is the voltage more than 1.1 V? Go to step 6.
TA.
Race the engine at speeds from idling to 5,000
rpm for a total of 5 cycles.
NOTE:
Air fuel ratio is rich at normal condition or
during racing.
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.
(B136) No. 33 (E24) No. 1:
(B136) No. 35 (E24) No. 2:
Measure the resistance between ECM and
chassis ground.
Go to step 4.

?
Go to step 5.
Repair the open

circuit between
ECM and front

M?
Go to step 6.
Repair the ground

short circuit
between ECM and
front oxygen (A/F)
sensor.

Step
Check
system?
NOTE:
Looseness of front oxygen (A/F) sensor
sensor
Yes
Repair or replace
faulty parts.
No
Replace the front
FU(H4SO 2.0)-32,
Front Oxygen (A/
F) Sensor, .>

BF:DTC P1160 RETURN SPRING FAILURE

NOTE:
BG:DTC P1492 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION

(LOW INPUT)
NOTE:
For the diagnostic procedure, refer to DTC P1498. <Ref. to EN(H4SO 2.0)(diag)-182, DTC P1498 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
BH:DTC P1493 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION

(HIGH INPUT)
NOTE:
For the diagnostic procedure, refer to DTC P1499. <Ref. to EN(H4SO 2.0)(diag)-184, DTC P1499 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
BI: DTC P1494 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION

(LOW INPUT)
NOTE:
BJ:DTC P1495 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION

(HIGH INPUT)
NOTE:
BK:DTC P1496 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION

(LOW INPUT)
NOTE:
BL:DTC P1497 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION

(HIGH INPUT)
NOTE:

BM:DTC P1498 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION

(LOW INPUT)
TROUBLE SYMPTOM:
Erroneous idling
Engine breathing
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
E18
5
3
BATTERY
1 2 3
4 5 6
SBF-5
6
4
B47
B21
48
2
1
1
3
5
E2
2
4
6
5
2
B47
B21
EGR
VALVE
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
E18
6
3
4
1
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
30
25
29
26
E2
B21
A4
A13
A3
A12
A: B134
1
8 9
18 19
28 29
A: B134
C: B136
ECM
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
D: B137
A2
D1
C5
C6
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B21
5 6
14 15 16
25 26 27
33 34 35
35
36
D: B137
E2
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
E
EN-02445

Step
CHECK POWER SUPPLY TO EGR SOLENOID VALVE.
2) Disconnect the connector from EGR solenoid valve.
4) Measure the voltage between EGR solenoid valve connector and engine ground.
Check
Yes

EGR SOLENOID VALVE CONNECTOR.
?
EGR solenoid valve connector.
DTC P1492; (B134) No. 13 (E18) No. 3:
DTC P1494; (B134) No. 12 (E18) No. 1:
DTC P1496; (B134) No. 3 (E18) No. 4:
DTC P1498; (B134) No. 4 (E18) No. 6:
Go to step 3.

2) Measure the resistance between ECM connector and chassis ground.
DTC P1492; (B134) No. 13 Chassis
ground:
ground:
ground:
ground:
CHECK POOR CONTACT.
Check poor contact in ECM connector and

M?
Go to step 4.

connector or EGR solenoid
valve connector?
Repair the poor

contact in ECM
connector or EGR
solenoid valve
connector.
No
NOTE:
the following:
Open circuit in
harness between
EGR solenoid
valve and main
relay connector
Poor contact in
coupling connector
NOTE:
the following:
Open circuit in
harness between
ECM and EGR
solenoid valve
connector
Poor contact in
coupling connector
Repair the ground
short in harness
between ECM and
EGR solenoid
valve connector.
Replace the EGR

solenoid valve.
<Ref. to FU(H4SO
2.0)-28, EGR
Valve.>

BN:DTC P1499 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION

(HIGH INPUT)
TROUBLE SYMPTOM:
Erroneous idling
Engine breathing
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
E18
5
3
BATTERY
1 2 3
4 5 6
SBF-5
6
4
B47
B21
48
2
1
1
3
5
E2
2
4
6
5
2
B47
B21
EGR
VALVE
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
E18
6
3
4
1
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
30
25
29
26
E2
B21
A4
A13
A3
A12
A: B134
1
8 9
18 19
28 29
A: B134
C: B136
ECM
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
D: B137
A2
D1
C5
C6
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B21
5 6
14 15 16
25 26 27
33 34 35
35
36
D: B137
E2
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
E
EN-02445

Step
Check

?
Yes
No
Inspect the DTC
Go to step 2.
Code (DTC).
<Ref. to EN(H4SO
2.0)(diag)-66, List
Go to step 3.
NOTE:
the following:
Open circuit in
harness between
ECM connector
and engine ground
terminal
Poor contact in
ECM connector
Poor contact in
coupling connector
Is the voltage more than 10 V? Repair the battery Replace the ECM.
short in harness
<Ref. to FU(H4SO
EGR solenoid
Control Module
2) Disconnect the connector from EGR solevalve connector.
(ECM).>
noid valve.
After repairing,
replace the ECM.
4) Measure the voltage between ECM con<Ref. to FU(H4SO
nector and chassis ground.
2.0)-34, Engine
Control Module
DTC P1493; (B134) No. 13 (+) Chassis
(ECM).>
ground ():
DTC P1495; (B134) No. 12 (+) Chassis
ground ():
DTC P1497; (B134) No. 3 (+) Chassis
ground ():
ground ():

BO:DTC P1518 STARTER SWITCH CIRCUIT LOW INPUT

TROUBLE SYMPTOM:
CAUTION:

WIRING DIAGRAM:
IGNITION
SWITCH
B72
BATTERY
SBF-1
SBF-7
13
RHD
14
15
LHD
16
No.21
3
2
STARTER
RELAY
16
LHD
14
15
RHD
13
B225
P
AT
11
12
MT
12
B12
T3
T7
MT
STARTER MOTOR
AT
E
M
23
B14
B135
ECM
B225
B72
1 2 3
4 5 6
B135
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
1
8 9
20 21
28 29
2
3
10 11 12 13
22 23
30 31
4 5 6
7
14 15 16 17 18 19
24 25
26 27
32 33
34 35
B12
T7
1 2 3 4
5 6 7 8
9 10 11 12
1 2 3 4 5 6
7 8 9 10 11 12
EN-02428

Step
Check
Yes
No
CHECK OPERATION OF STARTER MOTOR. Does the starter motor operate Repair the harCheck starter
Place the inhibitor switch in the P or N
when ignition switch to
ness and connec- motor circuit. <Ref.
range.
START?
tor.
to EN(H4SO
2.0)(diag)-52,
NOTE:
In this case, repair STARTER
MOTOR CIRthe following:
Open or ground CUIT, Diagnostics
short circuit in har- for Engine Starting Failure.>
ness between
ECM and starter
motor connector
Poor contact in
ECM connector

BP:DTC P1521 BRAKE SWITCH CIRCUIT RANGE/PERFORMANCE PROBLEM

(HIGH INPUT)
CAUTION:
WIRING DIAGRAM:
BATTERY
No.4
SBF-9
SBF-1
E
BREKE SWITCH
12
B65
B137
ECM
B65
1 2
3 4
B137
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
28 29
30 31
26 27
EN-02545

Step
chassis ground.
2) Measure the voltage between brake switch
connectors.
CHECK BRAKE SWITCH.
chassis ground with brake pedal depressed.
Terminal
(B65) No. 1 (B65) No. 4:
CHECK BRAKE SWITCH.
Measure the resistance between brake switch
connectors with brake pedal depressed.
Terminal
(B65) No. 1 (B65) No. 4:
Check
Yes
No
Go to step 3.

short circuit
between ECM and
brake switch.

?
Go to step 4.
Replace the brake

switch. <Ref. to
CC-6, Stop Light &
Brake Switch.>

M?
Check the poor

contact in ECM
connector.
Replace the brake

switch. <Ref. to
CC-6, Stop Light &
Brake Switch.>

BQ:DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION

CAUTION:
WIRING DIAGRAM:
MAIN RELAY
TO IGNITION COIL
3
5
SBF-8
6
4
No.13
1
2
B72
B47
IGNITION
SWITCH
BATTERY
No.12
SBF-7
3
C7
B13
B14
C3
C4
SBF-1
A: B134
B: B135
ECM
C: B136
B21
35
37
34
36
52
B5
B6
C1
C2
A7
C5
C6
A2
D1
D: B137
E2
E
A:
B134
B:
C: B136
B135
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
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
32 33
34 35
28 29 30 31
D:
5 6
14 15 16
25 26 27
33 34 35
B137
B47
B72
1 2 3
4 5 6
1
3
5
2
4
6
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
28 29
30 31
26 27
EN-02429

Step
chassis ground.
MAIN FUSE BOX CONNECTOR.
CHECK FUSE No. 13.
Check
Yes
contact in ECM
connector.
No
Go to step 2.

?

ECM connector
and battery terminal.
Replace the fuse.

NOTE:
the following:
Open circuit in
harness between
ECM and battery
Poor contact in
ECM connector
Poor contact in
battery terminal
BR:DTC P2100 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT OPEN

NOTE:
Refer to DTC P2101 for diagnostic procedure. <Ref. to EN(H4SO 2.0)(diag)-193, DTC P2101 THROTTLE

BS:DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/

PERFORMANCE
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:

WIRING DIAGRAM:
BATTERY
ELECTRONIC
THROTTLE
CONTROL RELAY
SBF-8
B362
7
5
6
8
D7
D6
D9
MAIN RELAY
ECM
C30
C1
C2
C5
C6
A2
D1
D: B137
D24
D23
C: B136
C17
D4
D5
D2
D3
C18
A: B134
B83
:LHD
B83
:LHD
B138 :RHD
B20
16
15
38
19
20
39
35
B21
37
36
B138 :RHD
E2
2
5
3
1
4
6
E1
ELECTRONIC
THROTTLE CONTROL
E78
B362
B83
B21
B138
1 2
3
4
1 2 3 4
5 6 7 8
5
7 8
6
2
10
20
30
1
5
9
13
2
6
10
14
3
7
11
15
E78
4
8
12
16
1 2 3
4 5 6
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
A: B134
1
8 9
18 19
28 29
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
B20
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
C:
B136
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
D:
B137
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
EN-02440

Step
CHECK ELECTRONIC THROTTLE CONTROL RELAY.
2) Remove the electronic throttle control relay.
3) Connect the battery to electronic throttle
control relay terminals No. 5 and No. 6.
throttle control relay terminals.
Terminals
No. 7 No. 8:
THROTTLE CONTROL RELAY.
throttle control relay connector and chassis
ground.
ELECTRONIC THROTTLE CONTROL RELAY.
ground.
ground.
Measure the resistance between ECM connector and electronic throttle control relay connector.
(B137) No. 9 (B362) No. 6:
(B137) No. 6 (B362) No. 8:
(B137) No. 7 (B362) No. 8:
1) Connect all the connectors.
3) Measure the voltage between ECM connector terminals.
(B137) No. 24 (+) (B136) No. 8 ():
Check
?
Yes
Go to step 2.
No
Replace the electronic throttle control relay.
Repair the open or

Is the voltage more than 10 V? Repair the power Go to step 4.

supply short circuit in harness
between ECM and
electronic throttle
control.

M?
Go to step 5.
Repair the ground

ECM and electronic throttle control relay.

?
Go to step 6.
Repair the open

circuit in harness
between ECM and
electronic throttle
control relay.
Go to step 9.

10
11
Step
terminals.
(B137) No. 23 (+) (B136) No. 18 ():
CHECK POOR CONTACT.
throttle control.
(B136) No. 17 (E78) No. 4:
(B137) No. 23 (E78) No. 5:
(B137) No. 24 (E78) No. 2:
Check
Yes
No
Go to step 9.
Repair the poor

contact.
Go to step 13.

?
Go to step 10.
Repair the open

circuit of harness
connector.

M?
Go to step 11.
Repair the ground

short circuit of harness.
Go to step 12.
Go to step 14.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
(ECM).>
Repair the poor
contact in ECM
connector.
Replace the ECM
if defective. <Ref.
(ECM).>
Go to step 16.
Go to step 15.
Go to step 16.
Repair the poor

contact.
Go to step 21.
12
CHECK SHORT CIRCUIT IN ECM.

Is the resistance more than 10 Go to step 13.
?
13

Read the data of sub throttle sensor signal
CHECK POOR CONTACT.
14
15

16
17
18
19
20
21
22
Step
throttle control.
(B136) No. 18 (E78) No. 1:
(B137) No. 23 (E78) No. 5:
(B137) No. 24 (E78) No. 2:
Check
?
Yes
Go to step 17.
No
Repair the open
circuit of harness
connector.

?
Go to step 18.

2) Remove the ECM.
(B137) No. 23 (B136) No. 17:
(B137) No. 24 (B136) No. 17:
2) Connect the connectors except for the electric control throttle relay.
Go to step 19.
Go to step 20.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
(ECM).>
Repair the battery
ECM connector
and electronic
throttle control
connector.
Repair the short
circuit in harness
between ECM
connector and
electronic throttle
control connector.

M?
Go to step 21.
Repair the short

circuit to sensor
power supply.
Go to step 22.
Go to step 23.
Repair the poor

contact of electronic throttle control connector.
Replace the electronic throttle control if defective.
Repair the poor
contact in ECM
connector.

23
24
25
26
27
28
Step
ELECTRONIC THROTTLE CONTROL MOTOR.
throttle control.
(B137) No. 2 (E78) No. 3:
(B137) No. 3 (E78) No. 3:
(B137) No. 4 (E78) No. 6:
(B137) No. 5 (E78) No. 6:
1) Connect the connector to ECM.
CHECK ELECTRONIC THROTTLE CONTROL MOTOR HARNESS.
Measure the resistance between electronic
throttle control connector terminals.
(E78) No. 3 (E78) No. 6:
CHECK ELECTRONIC THROTTLE CONTROL GROUND CIRCUIT.
throttle control terminals.
Terminals
No. 1 No. 2:
Check
?
Yes
Go to step 24.
No
Repair the open
circuit of harness
connector.
Go to step 25.
Repair the power

between ECM and
electronic throttle
control.

M?
Go to step 26.
Repair the short

circuit of harness.

M?
Go to step 27.
Repair the short

circuit of harness.

?
Go to step 28.
Repair the open

circuit of harness.

?
Go to step 29.
Replace the electronic throttle control.

29
Step
Move the throttle valve to the fully open and
fully closed positions with fingers.
Check that the valve returns to the specified
position when releasing fingers.
Check
Does the valve return to the
specified position?
from fully closed position
Yes
No
Repair the poor
Replace the eleccontact in ECM
tronic throttle conconnector.
trol.
Replace the ECM
if defective. <Ref.
(ECM).>

BT:DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW

TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:

WIRING DIAGRAM:
BATTERY
ELECTRONIC
THROTTLE
CONTROL RELAY
SBF-8
B362
7
5
6
8
D7
D6
D9
MAIN RELAY
ECM
C30
C1
C2
C5
C6
A2
D1
D: B137
D24
D23
C: B136
C17
D4
D5
D2
D3
C18
A: B134
B83
:LHD
B83
:LHD
B138 :RHD
B20
16
15
38
19
20
39
35
B21
37
36
B138 :RHD
E2
2
5
3
1
4
6
E1
ELECTRONIC
THROTTLE CONTROL
E78
B362
B83
B21
B138
1 2
3
4
1 2 3 4
5 6 7 8
5
7 8
6
2
10
20
30
1
5
9
13
2
6
10
14
3
7
11
15
E78
4
8
12
16
1 2 3
4 5 6
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
A: B134
1
8 9
18 19
28 29
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
B20
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
C:
B136
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
D:
B137
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
EN-02440

Step
Terminals
No. 7 No. 8:
ground.
ground.
ground.
(B137) No. 9 (B362) No. 6:
(B137) No. 6 (B362) No. 8:
(B137) No. 7 (B362) No. 8:
Check
?
Yes
Go to step 2.
No
Repair the open or

Is the voltage more than 10 V? Repair the power Go to step 4.

between ECM and
electronic throttle
control relay.

M?
Go to step 5.
Repair the ground


?
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
(ECM).>
Repair the open

circuit in harness
between ECM and
electronic throttle
control relay.

BU:DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH

TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:

WIRING DIAGRAM:
BATTERY
ELECTRONIC
THROTTLE
CONTROL RELAY
SBF-8
B362
7
5
6
8
D7
D6
D9
MAIN RELAY
ECM
C30
C1
C2
C5
C6
A2
D1
D: B137
D24
D23
C: B136
C17
D4
D5
D2
D3
C18
A: B134
B83
:LHD
B83
:LHD
B138 :RHD
B20
16
15
38
19
20
39
35
B21
37
36
B138 :RHD
E2
2
5
3
1
4
6
E1
ELECTRONIC
THROTTLE CONTROL
E78
B362
B83
B21
B138
1 2
3
4
1 2 3 4
5 6 7 8
5
7 8
6
2
10
20
30
1
5
9
13
2
6
10
14
3
7
11
15
E78
4
8
12
16
1 2 3
4 5 6
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
A: B134
1
8 9
18 19
28 29
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
B20
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
C:
B136
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
D:
B137
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
EN-02440

Step
Terminals
No. 7 No. 8:
CHECK POWER SUPPLY SHORT CIRCUIT
OF ELECTRONIC THROTTLE CONTROL
RELAY.
ground.
Check
M?
Yes
Go to step 2.
No
Go to step 3.
Repair the power

between ECM and
electronic throttle
control relay.

M?
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
(ECM).>
Repair the ground

BV:DTC P2109 THROTTLE/PEDAL POSITION SENSOR A MINIMUM STOP

PERFORMANCE
NOTE:
BW:DTC P2111 THROTTLE ACTUATOR CONTROL SYSTEM - STUCK OPEN

NOTE:

BX:DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT

LOW INPUT
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
MAIN
SUB
B315
ACCELERATOR
PEDAL POSITION
SENSOR
1 2 3 4 5 6
B138
B122
B315
B83
MT
AT
1
5
B138 :LHD
1 2 3 4
5 6 7 8
B122 :RHD
AT
B83
B21
:LHD
B138 :RHD
C18
D30
C17
D31
D29
D25
D19
2
1
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 45
46 47
48 49 50 51 52 53 54
A: B134
C: B136
ECM
1
8 9
18 19
28 29
D1
A2
C5
C6
C2
A: B134
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
C: B136
35
36
B21
37
C1
D: B137
E2
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
D: B137
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
E
EN-02449

Step
Check
Yes
CHECK ACCELERATOR POSITION SENIs the voltage more than 0.4 V? Go to step 2.
SOR OUTPUT.
2) Read the data of main accelerator position
CHECK POOR CONTACT.
Repair the poor
contact.
ECM and accelerator position sensor.
CHECK HARNESS BETWEEN ECM AND ACCELERATOR POSITION SENSOR.
3) Disconnect the connector from accelerator
position sensor.
4) Measure the resistance between ECM connector and accelerator position sensor connector.
(B137) No. 29 (B315) No. 5:
(B137) No. 25 (B315) No. 3:
CHECK POWER SUPPLY OF ACCELERATOR POSITION SENSOR.
3) Measure the voltage between accelerator
position sensor connector and engine ground.
CHECK ACCELERATOR POSITION SENSOR.
Measure the resistance of accelerator position
sensor.
Terminals
No. 3 No. 4:
sensor.
Terminals
No. 5 No. 4:
Check the measured value is within the specification without depressing the accelerator
pedal.
No
Go to step 3.
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.

?
Go to step 4.

M?
Go to step 5.

harness.
Go to step 6.
Is the resistance 1.2 4.8

k?
Go to step 7.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
(ECM).>
Replace the accelerator position
sensor.

k?
Go to step 8.

sensor.

Step
Check
CHECK ACCELERATOR POSITION SENIs the resistance 0.5 2.5
SOR.
k?
sensor.
Terminals
No. 5 No. 4:
Check the measured value is within the specification with the accelerator pedal depressed.
Yes
No
Repair the poor
Replace the accelcontact in ECM
erator position
connector.
sensor.
Replace the ECM
if defective. <Ref.
(ECM).>

BY:DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT

HIGH INPUT
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
MAIN
SUB
B315
ACCELERATOR
PEDAL POSITION
SENSOR
1 2 3 4 5 6
B138
B122
B315
B83
MT
AT
1
5
B138 :LHD
1 2 3 4
5 6 7 8
B122 :RHD
AT
B83
B21
:LHD
B138 :RHD
C18
D30
C17
D31
D29
D25
D19
2
1
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 45
46 47
48 49 50 51 52 53 54
A: B134
C: B136
ECM
1
8 9
18 19
28 29
D1
A2
C5
C6
C2
A: B134
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
C: B136
35
36
B21
37
C1
D: B137
E2
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
D: B137
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
E
EN-02449

Step
Check
Yes
CHECK ACCELERATOR POSITION SENIs the voltage less than 4.8 V? Go to step 2.
SOR OUTPUT.
CHECK POOR CONTACT.
Repair the poor
contact.
position sensor.
(B137) No. 31 (B315) No. 4:
2) Measure the resistance between accelerator position sensor connector and engine
ground.

?
Go to step 4.

?
Go to step 5.
CHECK HARNESS BETWEEN ECM AND AC- Is the voltage less than 6 V?
CELERATOR POSITION SENSOR.
CHECK HARNESS BETWEEN ECM AND AC- Is the resistance more than 1
M?
(B137) No. 29 (B137) No. 25:
(B137) No. 29 (B136) No. 17:
Go to step 6.
No
Go to step 3.
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
(ECM).>
Repair the battery
ECM connector
and accelerator
position sensor
connector.
Repair the poor

Repair the short
contact in acceler- circuit to sensor
ator position sen- power supply.
sor connector.
sensor if defective.

BZ:DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT

LOW INPUT
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
MAIN
SUB
B315
ACCELERATOR
PEDAL POSITION
SENSOR
1 2 3 4 5 6
B138
B122
B315
B83
MT
AT
1
5
B138 :LHD
1 2 3 4
5 6 7 8
B122 :RHD
AT
B83
B21
:LHD
B138 :RHD
C18
D30
C17
D31
D29
D25
D19
2
1
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 45
46 47
48 49 50 51 52 53 54
A: B134
C: B136
ECM
1
8 9
18 19
28 29
D1
A2
C5
C6
C2
A: B134
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
C: B136
35
36
B21
37
C1
D: B137
E2
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
D: B137
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
E
EN-02449

Step
CHECK ACCELERATOR POSITION SENSOR OUTPUT.
2) Read the data of sub accelerator position
CHECK POOR CONTACT.
Check
Yes
No
Go to step 3.
Repair the poor

contact.

position sensor.
(B137) No. 30 (B315) No. 2:
(B136) No. 17 (B315) No. 1:

?
Go to step 4.
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.

M?
Go to step 5.

harness.
Go to step 6.

k?
Go to step 7.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
(ECM).>
sensor.

k?
Go to step 8.

sensor.
Terminals
No. 1 No. 6:
1) Measure the resistance of accelerator position sensor.
Terminals
No. 2 No. 6:
2) Check the measured value is within the
specification without depressing the accelerator pedal.

sensor.

Step
Check
SOR.
k?
Terminals
No. 2 No. 6:
specification with the accelerator pedal
depressed.
Yes
No
Repair the poor
erator position
connector.
sensor.
Replace the ECM
if defective. <Ref.
(ECM).>

CA:DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT

HIGH INPUT
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
MAIN
SUB
B315
ACCELERATOR
PEDAL POSITION
SENSOR
1 2 3 4 5 6
B138
B122
B315
B83
MT
AT
1
5
B138 :LHD
1 2 3 4
5 6 7 8
B122 :RHD
AT
B83
B21
:LHD
B138 :RHD
C18
D30
C17
D31
D29
D25
D19
2
1
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 45
46 47
48 49 50 51 52 53 54
A: B134
C: B136
ECM
1
8 9
18 19
28 29
D1
A2
C5
C6
C2
A: B134
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
C: B136
35
36
B21
37
C1
D: B137
E2
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
D: B137
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
E
EN-02449

Step
CHECK POOR CONTACT.
Check
Yes
No
Go to step 3.
Repair the poor

contact.

position sensor.
(B136) No. 18 (B315) No. 6:
ground.

?
Go to step 4.
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.

?
Go to step 5.
M?
(B137) No. 30 (B137) No. 25:
(B137) No. 30 (B136) No. 17:
Go to step 6.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
(ECM).>
Repair the battery
ECM connector
and accelerator
position sensor
connector.
Repair the poor

Repair the short
sor connector.

CB:DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH A / B

VOLTAGE CORRELATION
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:

WIRING DIAGRAM:
BATTERY
ELECTRONIC
THROTTLE
CONTROL RELAY
SBF-8
B362
7
5
6
8
D7
D6
D9
MAIN RELAY
ECM
C30
C1
C2
C5
C6
A2
D1
D: B137
D24
D23
C: B136
C17
D4
D5
D2
D3
C18
A: B134
B83
:LHD
B83
:LHD
B138 :RHD
B20
16
15
38
19
20
39
35
B21
37
36
B138 :RHD
E2
2
5
3
1
4
6
E1
ELECTRONIC
THROTTLE CONTROL
E78
B362
B83
B21
B138
1 2
3
4
1 2 3 4
5 6 7 8
5
7 8
6
2
10
20
30
1
5
9
13
2
6
10
14
3
7
11
15
E78
4
8
12
16
1 2 3
4 5 6
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
A: B134
1
8 9
18 19
28 29
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
B20
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
C:
B136
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
D:
B137
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
EN-02440

Step
CHECK POOR CONTACT.
3) Disconnect the connectors from the electronic throttle control.
(B137) No. 23 (E78) No. 5:
(B137) No. 24 (E78) No. 2:
(B136) No. 17 (E78) No. 4:
Check
Yes
No
Go to step 4.
Go to step 4.
Repair the poor

contact.
Go to step 14.

?
Go to step 5.
Repair the open

circuit of harness
connector.

M?
Go to step 6.
Repair the ground

Go to step 7.

V?
Go to step 9.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
(ECM).>
Repair the poor
contact in ECM
connector.
Replace the ECM
if defective. <Ref.
(ECM).>
Go to step 11.

V?
Go to step 10.
Go to step 11.

?


10
11
12
13
14
15
16
Step
CHECK POOR CONTACT.
Check
Yes
Repair the poor
contact.

throttle control.
(B137) No. 23 (E78) No. 5:
(B137) No. 24 (E78) No. 2:
(B136) No. 17 (E78) No. 4:

?
Go to step 12.

?
Go to step 13.

(B137) No. 23 (B136) No. 17:
(B137) No. 24 (B136) No. 17:
CHECK ELECTRONIC THROTTLE CONTROL HARNESS.
throttle control.
(E78) No. 5 (E78) No. 2:
Go to step 14.
Go to step 15.
Repair the short

circuit in harness
between ECM
connector and
electronic throttle
control connector.

M?
Go to step 16.
Repair the short

circuit to sensor
power supply.

M?
Repair the poor

Repair the short
contact in ECM
circuit of harness.
connector.
Replace the ECM
if defective. <Ref.
(ECM).>
No
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
(ECM).>
Repair the battery
ECM connector
and electronic
throttle control
connector.

CC:DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH D / E

VOLTAGE CORRELATION
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
MAIN
SUB
B315
ACCELERATOR
PEDAL POSITION
SENSOR
1 2 3 4 5 6
B138
B122
B315
B83
MT
AT
1
5
B138 :LHD
1 2 3 4
5 6 7 8
B122 :RHD
AT
B83
B21
:LHD
B138 :RHD
C18
D30
C17
D31
D29
D25
D19
2
1
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 45
46 47
48 49 50 51 52 53 54
A: B134
C: B136
ECM
1
8 9
18 19
28 29
D1
A2
C5
C6
C2
A: B134
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
C: B136
35
36
B21
37
C1
D: B137
E2
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
D: B137
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
E
EN-02449

Step
sensor signal and sub accelerator position
CHECK POOR CONTACT.
position sensor.
(B137) No. 29 (B315) No. 5:
(B137) No. 25 (B315) No. 3:
(B137) No. 30 (B315) No. 2:
(B136) No. 17 (B315) No. 1:
sensor.
Terminals
No. 3 No. 4:
sensor.
Terminals
No. 1 No. 6:
sensor without depressing the accelerator
pedal.
Terminals
No. 5 No. 4:
Check
Yes
No
Go to step 3.
Repair the poor

contact.
Go to step 12.

?
Go to step 4.
Repair the open

circuit of harness
connector.

M?
Go to step 5.
Repair the ground

Go to step 6.

k?
Go to step 7.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
(ECM).>
sensor.

k?
Go to step 8.

sensor.

k?
Go to step 9.

sensor.

10
11
12
13
14
15
16
Step
pedal.
Terminals
No. 2 No. 6:
sensor with the accelerator pedal depressed.
Terminals
No. 5 No. 4:
Terminals
No. 2 No. 6:
and sub accelerator position sensor signal
CHECK POOR CONTACT.
position sensor.
(B137) No. 31 (B315) No. 4:
(B136) No. 18 (B315) No. 6:
ground.
Check
k?
Yes
Go to step 10.
No
sensor.

k?
Go to step 11.

sensor.

k?
Go to step 12.

sensor.
Go to step 14.
Repair the poor

contact.
Go to step 18.

?
Go to step 15.
Repair the open

circuit of harness
connector.

?
Go to step 16.
Go to step 17.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
(ECM).>
Repair the battery
ECM connector
and accelerator
position sensor
connector.

17
18
Step
(B137) No. 29 (B137) No. 25:
(B137) No. 29 (B136) No. 17:
(B137) No. 30 (B137) No. 25:
(B137) No. 30 (B136) No. 17:
3) Disconnect the connector from the accelerator position sensor.
terminals of accelerator position sensor.
(B315) No. 5 (B315) No. 2:
Check
M?
Yes
Go to step 18.
No
Repair the short
circuit to sensor
power supply.

M?
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
(ECM).>
Repair the short

circuit in harness
between ECM
connector and
accelerator position sensor connector.

19.General Diagnostic Table

A: INSPECTION
1. ENGINE
NOTE:
Malfunction of parts other than those listed is also possible. <Ref. to ME(H4SO 2.0)-83, Engine Trouble in
General.>
Symptom
Problem parts
1) Manifold absolute pressure sensor
2) Intake air temperature sensor
3) Ignition parts (*1)
1. Engine stalls during idling.
4) Engine coolant temperature sensor (*2)
5) Crankshaft position sensor (*3)
6) Camshaft position sensor (*3)
7) Fuel injection parts (*4)
5) Air intake system (*5)
2. Rough idling
7) Electronic throttle control
10) Oxygen sensor
11) Fuel pump and fuel pump relay
12) EGR valve
1) Engine coolant temperature sensor
3. Engine does not return to idle.
5) EGR valve
4. Poor acceleration
9) A/C switch and A/C cut relay
10) Engine torque control signal circuit
12) EGR valve
5. Engine stalls, engine sags or hesitates at accel- 5) Camshaft position sensor (*3)
eration.
6) Purge control solenoid valve
10) EGR valve

Symptom
6. Surge
7. Spark knock
8. After burning in exhaust system
Problem parts
9) EGR valve
4) Knock sensor
7) EGR valve
*1: Check ignition coil & ignitor ASSY and spark plug.
*2: Indicate the symptom occurring only in cold temperatures.
*3: Ensure the secure installation.
*4: Check the fuel injector and fuel pressure regulator.
*5: Inspect air leak in air intake system.

FUEL INJECTION
(FUEL SYSTEMS)
FU(H4SO 2.5)
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
Throttle Body.............................................................................................11
Intake Manifold..........................................................................................12
Knock Sensor............................................................................................23
Mass Air Flow and Intake Air Temperature Sensor ..................................26
Intake Air Temperature Sensor .................................................................27
Tumble Generator Valve Assembly ..........................................................28
Tumble Generator Valve Actuator.............................................................29
EGR Valve ................................................................................................30
Fuel Injector ..............................................................................................31
Main Relay ................................................................................................37
Fuel Pump Relay.......................................................................................38
Fuel ...........................................................................................................40
Fuel Tank ..................................................................................................41
Fuel Filler Pipe ..........................................................................................47
Fuel Pump.................................................................................................49
Fuel Filter ..................................................................................................53
Fuel Damper Valve ...................................................................................54
General Description
A: SPECIFICATION
Fuel tank
Fuel pump
Capacity
Location
Type
Discharge
Fuel filter
64 2(16.9 US gal, 14.1 Imp gal)

Under rear seat
Impeller
441 686 kPa (4.50 7.00 kg/cm2, 64.0 99.5 psi)
75 2 (19.8 US gal, 16.5 Imp gal)/h or more
[12 V at 300 kPa (3.06 kg/cm2, 43.5 psi)]
In-tank type
FU(H4SO 2.5)-2
General Description
B: COMPONENT
1. INTAKE MANIFOLD
T2
(7)
T2
(18)
T2
T4
T6
T4
(17)
(9)
T4
T4
T2
T2
T4
T4
(8)
(10)
(17)
T6
T3
(24)
(11)
T4
T4
T3
T3
T6
(23)
(15)
(1)
(13)
(12)
(14)
(15)
(25)
T4
T2
(2)
(11)
(13)
(16)
(12)
T4
T4
(14)
T5
(5)
T5
(5)
T7
(2)
(3)
(15)
T7
(15)
(13)
(13)
(12)
(14)
(6)
T4
(12)
(14)
(3)
(4)
T1
(22)
(20)
(21)
(4)
(6)
(21)
(19)
(21)
T1
T1
(20)
T2
T1
(21)
FU-02096
FU(H4SO 2.5)-3
General Description
(1)
(2)
(3)
Intake manifold
Gasket (EC, EK and K4 model)
Tumble generator valve ASSY
(EC, EK and K4 model)
(4)
(5)
Gasket
Tumble generator valve actuator
(6)
(7)
(8)
Guide pin
PCV pipe (EC, EK and K4 model)
EGR valve (EC, EK and K4
model)
(9)
(10)

(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
Fuel injector pipe

Fuel injector
O-ring
O-ring
O-ring
Plug cord holder
Nipple
Fuel pipe ASSY
Fuel hose
Clip
Pressure regulator
Gasket (EC, EK and K4 model)
FU(H4SO 2.5)-4
(24)
(25)
Nipple (RHD model)

Nipple (LHD model)

T1: 1.5 (0.15, 1.1)
T2: 6.4 (0.65, 4.7)
T3: 8.75 (0.89, 6.5)
T4: 19 (1.9, 13.7)
T5: 25 (2.5, 18.1)
T6: 17 (1.7, 12.5)
T7: 6 (0.61, 4.4)
General Description
T2
T1
(3)
(4)
(1)
(2)
FU-01079
(1)
(2)
(3)
Gasket
Throttle body
(4)
O-ring
FU(H4SO 2.5)-5

T1: 2.0 (0.2, 1.5)
T2: 8 (0.8, 5.8)
General Description
T1
T2
(1)
(2)
T1
(4)
(3)
T1
FU-00414
(1)
(2)
(3)

Knock sensor
(4)
FU(H4SO 2.5)-6

T1: 6.4 (0.65, 4.7)
T2: 24 (2.4, 17.4)
General Description
4. FUEL TANK
T1
(19)
(17)
(18)
(15)
(16)
(8)
T1
(17)
(14)
(7)
(15)
(10)
(12)
(9)
(11)
(1)
(13)
(22)
T4
(6)
(22)
(5)
(20)
(3)
(2)
T4
(21)
T4
(4)
T3
T3
T3
T3
(23)
(24)
(25)
T3
T2
T2
T3
FU-01080
FU(H4SO 2.5)-7
General Description
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
Fuel tank
Fuel tank band RH
Fuel tank band LH
Delivery tube
Return tube
Jet pump tube
Fuel pump assembly
Fuel pump gasket
Fuel level sensor
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)

Fuel filler hose
Clamp
Vent hose
Clip
Stopper RH
Stopper LH
FU(H4SO 2.5)-8
(22)
(23)
(24)
(25)
Retainer
Heat shield cover

T1: 4.4 (0.45, 3.3)
T2: 9.0 (0.92, 6.6)
T3: 17.5 (1.78, 12.9)
T4: 33 (3.4, 25)
General Description
5. FUEL LINE
T1
(1)
(28)
(18)
(26)
(23)
(25)
(27)
(15)
(17)
(19)
(1)
(20)
(22)
(14)
(13)
(24)
(21)
T2
(1)
(16)
(1)
(1) (22)
(34)
(11)
(29)
(10)
T2
(12)
T3
T2
(1)
(4)
(5)
A
T2
(1)
(3)
(1)
(2)
(33)
(9)
(1)
(32)
(6)
(1)
(7)
(30)
(31)
(8)
FU-01081
FU(H4SO 2.5)-9
General Description
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
Clip
Fuel return hose
Evaporation hose A
Fuel damper
Fuel damper holder
Fuel damper bracket
Fuel pipe ASSY
Clamp
Canister
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)

Purge hose A
Purge hose B
Two-way valve
Connector
Filler pipe packing
Filler ring
C: CAUTION
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
Filler cap
Tether
Clip
Fuel hose
Purge hose C
Connector
Purge pipe

T1: 4.4 (0.45, 3.2)
T2: 7.5 (0.76, 5.53)
T3: 8.3 (0.85, 6.1)

points.
cable from battery.
D: PREPARATION TOOL
ILLUSTRATION
TOOL NUMBER
24082AA230
DESCRIPTION
CARTRIDGE
REMARKS
22771AA030
SUBARU SELECT
MONITOR KIT

ST24082AA230
ST22771AA030
FU(H4SO 2.5)-10
Throttle Body
2. Throttle Body
A: REMOVAL
IN-00203

3) Disconnect the connectors from the throttle position sensor and manifold absolute pressure sensor.
(B)
(A)
FU-01083
(A) Throttle position sensor

(B) Manifold absolute pressure sensor
4) Disconnect the engine coolant hoses (A) from

throttle body.
5) Remove the bolts (B) which secure throttle body
to intake manifold.
(A)
(B)
(B)
(A)
FU-01084
B: INSTALLATION
NOTE:
Use a new gasket.
Tightening torque:
8 Nm (0.8 kgf-m, 5.8 ft-lb)
FU(H4SO 2.5)-11
Intake Manifold
3. Intake Manifold

temperature sensor.
A: REMOVAL
1) Release the fuel pressure. <Ref. to FU(H4SO
2.5)-40, RELEASING OF FUEL PRESSURE,
PROCEDURE, Fuel.>
filler cap.
FU-00055
IN-00203

chamber. <Ref. to IN(H4SO 2.0)-6, REMOVAL, Air
5) Disconnect the spark plug cords from spark
plugs.
throttle body.
FU-01334
(A)
FU-00056
(A)
FU-01085
7) Disconnect the PCV hose (A) from intake manifold.

8) Disconnect the brake booster hose (B).
9) Disconnect the engine harness connectors (C)
from bulkhead harness connectors.

pump switch (A).
switch (B).
(B)
(A)
(B)
(A)
(C)
FU-01087
FU-01086
FU(H4SO 2.5)-12
Intake Manifold
18) Remove the bolts which secure intake manifold

to cylinder head.
FU-01089
FU-01335
16) Remove the EGR pipe from intake manifold.

B: INSTALLATION
NOTE:
Use a new gasket.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
FU-00148
17) Disconnect the fuel hoses from fuel pipes.

WARNING:
or cloth.
FU-01089
(A)
2) Connect the fuel hoses.

NOTE:
with new ones.
(C)
(A)
(B)
FU-01088

(B) Return hose
(C)
(B)
FU-01088

(B) Return hose
Tightening torque (Hose clamp screw):

1.25 Nm (0.13 kgf-m, 0.94 ft-lb)
FU(H4SO 2.5)-13
Intake Manifold
3) Install the EGR pipe to intake manifold. (EC, EK

and K4 model)
Tightening torque:
34 Nm (3.4 kgf-m, 24.6 ft-lb)
FU-01334
9) Connect the connectors to engine coolant temperature sensor.

FU-00148
4) Connect the connector to camshaft position sensor.
FU-00055
FU-01335

switch (A).
6) Connect the connector to oil pressure switch (B).
10) Connect the PCV hose (A) to intake manifold.

11) Connect the brake booster hose (B).
12) Connect the engine harness connectors (C) to
(B)
(A)
(A)
(C)
(B)
FU-01086
FU-01087
7) Connect the connector to crankshaft position

sensor.
13) Connect the engine coolant hoses (A) to throttle body.

(A)
(A)
FU-01085
14) Connect the spark plug cords to spark plugs.

FU-00056
FU(H4SO 2.5)-14
Intake Manifold
15) Install the air cleaner case and air intake chamber. <Ref. to IN(H4SO 2.0)-7, INSTALLATION, Air

(A) from intake manifold.
(A)
FU-01092

IN-00203
C: DISASSEMBLY
1) Disconnect the engine ground terminal from intake manifold.
FU-01093
FU-01090
2) Remove the ignition coil & ignitor ASSY. <Ref. to

IG(H4SO 2.0)-8, REMOVAL, Ignition Coil and Ignitor Assembly.>
4) Remove the EGR valve. (EC, EK and K4 model)
<Ref. to FU(H4SO 2.5)-30, REMOVAL, EGR
Valve.>
5) Remove the PCV pipe. (EC, EK and K4 model)
FU-01094
9) Disconnect the connectors (A) from fuel injector.

10) Remove the harness band (B) which holds engine harness to injector pipe.
(B)
(A)
FU-01091
FU-01336
11) Remove the tumble generator valve actuator.

(EC, EK and K4 model) <Ref. to FU(H4SO 2.5)-29,
REMOVAL, Tumble Generator Valve Actuator.>
FU(H4SO 2.5)-15
Intake Manifold

<Ref. to EC(H4SO 2.0)-7, REMOVAL, Purge Control Solenoid Valve.>
13) Remove the harness band clips which install
the engine harness.
LH side
FU-01099
FU-01096
14) Remove the bolts which hold the engine harness to intake manifold.
FU-01100
17) Remove the fuel injectors from injector pipe.

RH to fuel hose, and then disconnect the pipe from
fuel hose.
FU-01097
15) Remove the engine harness from intake manifold.

16) Remove the bolts which install injector pipe on
the intake manifold as shown in the figure.
RH side
FU-01101

LH to fuel hose, and then disconnect the pipe from
fuel hose.
FU-01098
FU-01102

21) Remove the bolt which installs pressure regulator on intake manifold.
FU(H4SO 2.5)-16
Intake Manifold
22) Remove the bolt which installs the fuel pipes on

intake manifold.
2) Tighten the bolt which installs the fuel pipes on

intake manifold.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
FU-01337
23) Remove the fuel pipe assembly and pressure

regulator, from intake manifold.
24) Remove the intake manifold. (EC, EK and K4
model)
FU-01337
3) Tighten the bolt which installs pressure regulator

on intake manifold.
Tightening torque:
19 Nm (1.9 kgf-m, 13.7 ft-lb)
4) Connect the fuel injector pipe.
5) Connect the fuel injector pipe LH to fuel hose,
FU-01104
D: ASSEMBLY
1) Install the intake manifold. (EC, EK and K4 model)
NOTE:
Use a new gasket.
Liquid gasket:
FU-01102
6) Connect the fuel injector pipe RH to fuel hose,

Tightening torque:
8.75 Nm (0.89 kgf-m, 6.5 ft-lb)
FU-01101

FU-01104
FU(H4SO 2.5)-17
Intake Manifold
8) Tighten the bolts which install injector pipe on intake manifold.

RH side
Tightening torque:
19 Nm (1.9 kgf-m, 13.7 ft-lb)
11) Tighten the bolts which install engine harness

on intake manifold.
Tightening torque:
16 Nm (1.6 kgf-m, 11.8 ft-lb)
FU-01097
FU-01098
12) Hold the engine harness by harness band clips.
LH side
Tightening torque:
19 Nm (1.9 kgf-m, 13.7 ft-lb)
FU-01096
FU-01099
9) Tighten the two bolts which install fuel pipes on

intake manifold.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
13) Install the purge control solenoid valve. <Ref.

to EC(H4SO 2.0)-7, INSTALLATION, Purge Control Solenoid Valve.>
14) Install the tumble generator valve actuator.
(EC, EK and K4 model) <Ref. to FU(H4SO 2.5)-29,
INSTALLATION, Tumble Generator Valve Actuator.>
15) Connect the connectors (A) to fuel injector.
16) Hold the engine harness to injector pipe by harness band (B).
(B)
FU-01100
10) Install the engine harness onto intake manifold.
FU(H4SO 2.5)-18
(A)
FU-01336
Intake Manifold
21) Install the EGR valve. (EC, EK and K4 model)

<Ref. to FU(H4SO 2.5)-30, INSTALLATION, EGR
Valve.>
<Ref. to FU(H4SO 2.5)-11, INSTALLATION, Throttle Body.>
23) Install the ignition coil & ignitor ASSY. <Ref. to
IG(H4SO 2.0)-8, INSTALLATION, Ignition Coil and
Ignitor Assembly.>
24) Install the engine ground terminal to intake
manifold.

Tightening torque:
19 Nm (1.9 kgf-m, 13.7 ft-lb)
Tightening torque:
19 Nm (1.9 kgf-m, 13.7 ft-lb)
FU-01094

Tightening torque:
19 Nm (1.9 kgf-m, 13.7 ft-lb)
FU-01090
E: INSPECTION
FU-01093
19) Connect the pressure regulator vacuum hose

(A) to intake manifold.
(A)
FU-01092
20) Install the PCV pipe. (EC, EK and K4 model)
FU-01091
FU(H4SO 2.5)-19


Sensor
A: REMOVAL
IN-00203

temperature sensor.
FU-00055
B: INSTALLATION
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
FU(H4SO 2.5)-20

B: INSTALLATION
A: REMOVAL
Tightening torque:
T: 6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
IN-00203
FU-00056
FU-00057
FU(H4SO 2.5)-21
FU-00058

6) Remove the camshaft position sensor itself.
A: REMOVAL
FU-00179
B: INSTALLATION
IN-00203

Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
FU-01335

sensor to the support.
FU-00177
4) Remove the bolt which installs the camshaft position sensor support to camshaft cap LH.
FU-00178
5) Remove the camshaft position sensor and the

support as a unit.
FU(H4SO 2.5)-22
Knock Sensor
7. Knock Sensor
B: INSTALLATION
A: REMOVAL
NOTE:
Tightening torque:
24 Nm (2.4 kgf-m, 17.4 ft-lb)
(A)
IN-00203

60
FU-00413
(A) Front side
FU-01334
FU-01334
3) Install the air cleaner case. <Ref. to IN(H4SO

2.0)-7, INSTALLATION, Air Cleaner Case.>
FU-00519
IN-00203
FU(H4SO 2.5)-23


A: SPECIFICATION
body.
procedure. <Ref. to FU(H4SO 2.5)-11, REMOVAL,
Throttle Body.> <Ref. to FU(H4SO 2.5)-11, INSTALLATION, Throttle Body.>
FU(H4SO 2.5)-24


Sensor
A: REMOVAL
IN-00203
2) Disconnect the connector from manifold absolute pressure sensor.
FU-01105

from throttle body.
B: INSTALLATION
NOTE:
Use new O-rings.
Tightening torque:
2.0 Nm (0.2 kgf-m, 1.5 ft-lb)
FU(H4SO 2.5)-25
Mass Air Flow and Intake Air Temperature Sensor

10.Mass Air Flow and Intake Air

Temperature Sensor
A: REMOVAL
NOTE:
Mass air flow and intake air temperature sensor is
installed to EC, EK and K4 model.
IN-00203

intake air temperature sensor.
3) Remove the mass air flow and intake air temperature sensor.
FU-01106
B: INSTALLATION
Tightening torque:
1.0 Nm (0.10 kgf-m, 0.74 ft-lb)
FU(H4SO 2.5)-26
Intake Air Temperature Sensor

11.Intake Air Temperature Sensor

A: REMOVAL
NOTE:
Intake air temperature sensor is installed to models
except for EC, EK and K4.
IN-00203
2) Disconnect the connector from intake air temperature sensor.

3) Remove the intake air temperature sensor.
FU-02080
B: INSTALLATION
FU(H4SO 2.5)-27
Tumble Generator Valve Assembly

12.Tumble Generator Valve Assembly
7) Remove the tumble generator valve body from

intake manifold.
A: REMOVAL
NOTE:
This component is installed to EC, EK and K4 model.
filler cap.
FU-01104
B: INSTALLATION
NOTE:
Use a new gasket.
Tightening torque:
8.75 Nm (0.89 kgf-m, 6.5 ft-lb)
IN-00203

<Ref. to FU(H4SO 2.5)-12, REMOVAL, Intake
Manifold.>
5) Disconnect the connector from tumble generator
valve actuator.
FU-01107
6) Remove the fuel injectors.

<Ref. to FU(H4SO 2.5)-31, REMOVAL, Fuel Injector.>
FU(H4SO 2.5)-28
Tumble Generator Valve Actuator

13.Tumble Generator Valve Actuator
A: REMOVAL
1. RH SIDE
NOTE:
This component is installed to EC, EK and K4 model.
2) Open the fuel filler flap lid and remove the fuel
filler cap.
IN-00203

valve LH.
5) Remove the tumble generator valve LH.
FU-01109
IN-00203

<Ref. to FU(H4SO 2.5)-12, REMOVAL, Intake
Manifold.>
valve RH.
6) Remove the tumble generator valve RH.
B: INSTALLATION
1. RH SIDE
Tightening torque:
6 Nm (0.61 kgf-m, 4.4 ft-lb)
2. LH SIDE
Tightening torque:
6 Nm (0.61 kgf-m, 4.4 ft-lb)
FU-01108
2. LH SIDE
filler cap.
FU(H4SO 2.5)-29
EGR Valve
14.EGR Valve
A: REMOVAL
NOTE:
EGR valve is installed to EC, EK and K4 model.
IN-00203
FU-01152
FU-01153
B: INSTALLATION
NOTE:
Use a new gasket.
Tightening torque:
19 Nm (1.9 kgf-m, 13.7 ft-lb)
FU(H4SO 2.5)-30
Fuel Injector
15.Fuel Injector

A: REMOVAL
1. RH SIDE
filler cap.
FU-01098

injector pipe.
IN-00203

FU-01110
2. LH SIDE
filler cap.
FU-01094
7) Disconnect the connector (A) from fuel injector.

(B)
FU-01093
6) Disconnect the connector (A) from fuel injector.

(A)
FU-01336
FU(H4SO 2.5)-31
Fuel Injector
B: INSTALLATION
1. RH SIDE
NOTE:
Use new O-rings.
O-ring (B) is used for EC, EK and K4 model.
(B)
(A)
(A)
FU-01338
(A)
(B)

(C)
(D)
FU-02157
(A)
(B)
(C)
(D)
FU-01099
O-ring
O-ring
Fuel injector
O-ring
Tightening torque:
19 Nm (1.9 kgf-m, 13.7 ft-lb)
FU-01100

injector pipe.
FU-01098
Tightening torque:
19 Nm (1.9 kgf-m, 13.7 ft-lb)
FU-01110
FU(H4SO 2.5)-32
FU-01094
Fuel Injector
2. LH SIDE
Tightening torque:
19 Nm (1.9 kgf-m, 13.7 ft-lb)

NOTE:
Use new O-rings.
O-ring (B) is used for EC, EK and K4 model.
(A)
(B)
FU-01093
(C)
(D)
FU-02157
(A)
(B)
(C)
(D)
O-ring
O-ring
Fuel injector
O-ring
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
FU-01100
Tightening torque:
19 Nm (1.9 kgf-m, 13.7 ft-lb)
FU-01099
FU(H4SO 2.5)-33

B: INSTALLATION
A: REMOVAL
removal easier.
SS-30 JET LUBE
CAUTION:
IN-00203
Tightening torque:
21 Nm (2.1 kgf-m, 15.2 ft-lb)

3) Remove the connector of front oxygen (A/F)
sensor.
FU-01114
ME-00859

one minute or more.

sensor.
CAUTION:
ME-00859
FU-01114
IN-00203
FU(H4SO 2.5)-34
Rear Oxygen Sensor

B: INSTALLATION
A: REMOVAL
SS-30 JET LUBE
CAUTION:
IN-00203
Tightening torque:
21 Nm (2.1 kgf-m, 15.2 ft-lb)

FU-01117

FU-01116

minute or more.
CAUTION:
FU-01116

FU-01117
IN-00203
FU(H4SO 2.5)-35

B: INSTALLATION
A: REMOVAL
CAUTION:
Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
IN-00203

Trim.>
FU-02090
5) Remove the nuts (A) which hold the ECM to

bracket.
(B)
(A)
(A)
FU-02091

the ECM.
FU(H4SO 2.5)-36
Main Relay
19.Main Relay
A: REMOVAL
IN-00203

(A)
FU-02092
FU-02093
B: INSTALLATION
FU(H4SO 2.5)-37
Fuel Pump Relay

20.Fuel Pump Relay

A: REMOVAL
IN-00203

(A)
FU-02092
FU-02094
B: INSTALLATION
FU(H4SO 2.5)-38


Relay
A: REMOVAL
IN-00203

(A)
FU-02092
4) Disconnect the connector from electric throttle

control relay.
FU-02095
B: INSTALLATION
FU(H4SO 2.5)-39
Fuel
22.Fuel

the drain plug from fuel tank to drain fuel from fuel
tank.
A: PROCEDURE
WARNING:
box.
FU-01123

NOTE:
Use a new gasket.
FU-01122
2) Start the engine and run it until it stalls.

2. DRAINING FUEL
WARNING:
Tightening torque:
26 Nm (2.65 kgf-m, 19.2 ft-lb)
NOTE:
Use a new nut.
Tightening torque:
Nut
9.0 Nm (0.92 kgf-m, 6.6 ft-lb)
Bolt
17.5 Nm (1.78 kgf-m, 12.9 ft-lb)
IN-00203
filler cap.
FU(H4SO 2.5)-40
Fuel Tank
23.Fuel Tank

and remove service hole cover.
A: REMOVAL
WARNING:
<Ref. to FU(H4SO 2.5)-40, DRAINING FUEL,
PROCEDURE, Fuel.>
(A)
(A)
(B)
FU-01126

sensor.
9) Disconnect the quick connector from the fuel delivery (B) and return hose (C). <Ref. to FU(H4SO
2.5)-55, REMOVAL, Fuel Delivery, Return and
Evaporation Lines.>
(A)
(A)
(A)
(B)
(C)
(B)
FU-01124
FU-01127

11) Remove the bolts which secure the rear brake
FU-01125
FU(H4SO 2.5)-41
FU-01128
Fuel Tank

vehicle body side.
19) Remove the bolts which install the parking

brake cable clamp.
FU-00462

<Ref. to EX(H4SO 2.0)-11, REMOVAL, Rear Exhaust Pipe.>
speed sensor.
FU-01130
FU-01131

CAUTION:
(2) Remove the bolt which installs the rear
shock absorber to rear suspension arm.
FU-01129
FU-01132
FU(H4SO 2.5)-42
Fuel Tank
(3) Remove the bolts which secure the rear

suspension assembly to body.
23) Support the fuel tank with transmission jack, remove the bolts from fuel tank bands, and dismount
WARNING:
FU-01133
FU-01137
B: INSTALLATION
of fuel tank band.
FU-01134
WARNING:

from bracket.
FU-01137
(A)
FU-01135

(A)
(B)
FU-01136
FU(H4SO 2.5)-43
Fuel Tank

clamp.
Tightening torque:
T1: 125 Nm (12.7 kgf-m, 92.2 ft-lb)
T2: 65 Nm (6.2 kgf-m, 48 ft-lb)
T3: 175 Nm (17.8 kgf-m, 129 ft-lb)
(A)
T1
T1
(B)
T1
T1
FU-01136
FU-01150
(2)
(1)
(3)
L/2
T3
T2
T2
T3
FU-00104
FU-01138
(1) Hose
(2) Clip or clamp
(3) Pipe
(3) Tighten the bolts which install the rear shock

absorber to rear suspension arm. <Ref. to RS11, INSTALLATION, Rear Arm.>

Tightening torque:
62 Nm (6.3 kgf-m, 46 ft-lb)
(A)
FU-01135
FU-01132

Tightening torque:
33 Nm (3.4 kgf-m, 25 ft-lb)
CAUTION:
then tighten the bolts which secure the rear suspension assembly to body.
FU(H4SO 2.5)-44
Fuel Tank
6) Tighten the bolts which install the parking brake

cable clamp.

Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
Tightening torque:
33 Nm (3.4 kgf-m, 25 ft-lb)
FU-01130
Tightening torque:
32 Nm (3.3 kgf-m, 23.9 ft-lb)
FU-01128

(B) and return hose (C). <Ref. to FU(H4SO 2.5)-56,
INSTALLATION, Fuel Delivery, Return and Evaporation Lines.>
NOTE:
return side.
FU-01131
7) Connect the connector to rear ABS wheel speed

sensor.
(A)
(C)
(B)
FU-01127

sensor.
FU-01129

10) Install the rear exhaust pipe. <Ref. to EX(H4SO
2.0)-11, INSTALLATION, Rear Exhaust Pipe.>
(A)
(A)
(B)
(A) Bolt
(B) Grommet
FU(H4SO 2.5)-45
FU-01126
Fuel Tank
FU-01125
(A)
(A)
(B)
FU-01124
(A) Bolt
(B) Grommet

C: INSPECTION
1) Check that the fuel tank is not holed, cracked or
otherwise damaged.
FU(H4SO 2.5)-46
Fuel Filler Pipe

24.Fuel Filler Pipe
6) Set a container under the vehicle, and remove

the drain plug from the fuel tank to drain fuel from
fuel tank.
A: REMOVAL
WARNING:
FU-01123

NOTE:
Use a new gasket.
IN-00203
cap.
3) Remove the screws which secure the packing.
Tightening torque:
26 Nm (2.65 kgf-m, 19.2 ft-lb)
10) Remove the bolts which hold the fuel filler pipe
FU-00095

FU-01139

(A)
(B)
FU-00096
FU-01136

vehicle.
FU(H4SO 2.5)-47
Fuel Filler Pipe

B: INSTALLATION
side of apron.
5) Tighten the bolts which hold the fuel filler pipe

Tightening torque:
7.5 Nm (0.75 kgf-m, 5.4 ft-lb)
NOTE:
(A)
FU-01139
(B)
(C)
FU-00103

clamp.
(A)
(B)
FU-00096

FU-01136
(2)
(1)
(3)
L/2
IN-00203
FU-00104
(1) Hose
(2) Clip or clamp
(3) Pipe
FU(H4SO 2.5)-48
Fuel Pump
25.Fuel Pump
7) Remove the nuts which install the fuel pump assembly onto fuel tank.
A: REMOVAL
WARNING:
NOTE:
level sensor.
2) Drain the fuel. <Ref. to FU(H4SO 2.5)-40,
DRAINING FUEL, PROCEDURE, Fuel.>
(A)
(B)
(C)
(A)
FU-01140
(A) Delivery hose

(B) Return hose
(C) Jet pump hose
B: INSTALLATION
NOTE:
Use a new gasket.
Tightening torque:
4.4 Nm (0.45 kgf-m, 3.3 ft-lb)
(A)
1
(B)
FU-01124

5
7
2
FU-01141
C: INSPECTION
FU-01125

of fuel pump and apply the battery power supply to
WARNING:
possible.
FU(H4SO 2.5)-49
Fuel Pump

non-load condition.
2 1
4 3
6 5
FU-01330
FU(H4SO 2.5)-50
Fuel Level Sensor


A: REMOVAL
WARNING:
NOTE:
FU(H4SO 2.5)-49, REMOVAL, Fuel Pump.>
FU-01142
B: INSTALLATION
FU(H4SO 2.5)-51

6) Remove the nuts and bolts which install the fuel

sub level sensor on fuel tank.
A: REMOVAL
WARNING:
(C)
(A)
(B)
FU-01144
(A) Jet pump hose

(B) Delivery hose
(C) Return hose
B: INSTALLATION
(A)

(A)
(B)
FU-01126

sensor.
NOTE:
Use a new gasket.
Tightening torque:
4.4 Nm (0.45 kgf-m, 3.3 ft-lb)
3
1
5
6
2
4
FU-01143
FU-01145
FU-01146
FU(H4SO 2.5)-52
Fuel Filter
28.Fuel Filter
A: SPECIFICATION
<Ref. to FU(H4SO 2.5)-49, REMOVAL, Fuel
Pump.>
Pump.>
FU(H4SO 2.5)-53
Fuel Damper Valve

29.Fuel Damper Valve

A: REMOVAL
1. DELIVERY SIDE
2) Remove the fuel damper valve from fuel delivery
line.
FU-01147
2. RETURN SIDE
pipe RH.
Refer to Intake Manifold for removal. <Ref. to
FU(H4SO 2.5)-15, DISASSEMBLY, Intake Manifold.>
B: INSTALLATION
1. DELIVERY SIDE
Tightening torque:
1.25 Nm (0.13 kgf-m, 0.94 ft-lb)
2. RETURN SIDE
pipe RH.
Refer to Intake Manifold for installation. <Ref. to
FU(H4SO 2.5)-17, ASSEMBLY, Intake Manifold.>
FU(H4SO 2.5)-54


A: REMOVAL
2) Release the fuel pressure. <Ref. to FU(H4SO 2.5)-40, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.>
FU-01148

delivery hoses, return hoses, and evaporation
hose.
(A)
(C)
8) Remove the fuel tank. <Ref. to FU(H4SO 2.5)41, REMOVAL, Fuel Tank.>
covered with dust.
plastic bag, etc.
(B)
FU-01088

(B) Return hose
FU-01333
FU(H4SO 2.5)-55


down.

(A)
CAUTION:
(B)
(C)
(B)
FU-00126
(C)
(A)
FU-00124
(A) Connector
(B) Retainer
(C) Pipe
B: INSTALLATION
(A) Connector
(B) Retainer
(C) Pipe
CAUTION:
securely.
CAUTION:
damaged or dust-covered. If necessary, clean
the seal surface of pipe.
(A)
(A)
(B)
(C)
FU-00127
(B)
(A) Connector
(B) Retainer
(C) Pipe
FU-00125
(A) Seal surface

(B) Pipe

Type A: When the amount to be inserted is specified.
Type B: When the amount to be inserted is not
specified.
FU(H4SO 2.5)-56

2: 2.51.5 mm (0.0980.059 in)

L: 22.52.5 mm (0.8860.098 in)
(1)
(2)
(3)
Type A
L
Type B
FU-00128
(1) Pipe
(2) Clamp
(3) Hose

to the pipe by approx. 15 mm (0.59 in) from hose
end.
Fuel return hose:
L = 22.52.5 mm (0.8850.098 in)
L = 17.52.5 mm (0.6890.098 in)
CAUTION:
(2)
(1)
(3)
L/2
L
FU-00129
(1) Hose
(2) Clip
(3) Pipe
C: INSPECTION
2) Make sure the fuel pipe and fuel hose connections are tightened firmly.
FU(H4SO 2.5)-57


A: INSPECTION
1)
Corrective action
Defective terminal contact
Trouble in electromagnetic or electronic circuit parts

2)
Decline of fuel pump function
3)
Clogged dust or water in the fuel filter
4)
Clogged or bent fuel pipe or hose
5)
Air mixed in the fuel system
6)
Clogged or bent air breather tube or pipe
7)
Damaged diaphragm of pressure regulator
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

Loose joints at air breather tube, air vent tube, and fuel filler
1)
pipe
2)
Defective packing air tightness on the fuel saucer
3)
Inoperative fuel pump modulator or circuit
1)
Defective operation of fuel level sensor
2)
Defective operation of fuel meter
5. Noise
1)
Large operation noise or vibration of fuel pump

securely.
Replace.
Retighten.
Replace.
Replace.
Replace.
tube.
Retighten.
Replace.
Replace.
Replace.
Replace.
NOTE:
When the vehicle is left unused for an extended period of time, water may accumulate in the fuel tank. Fill
fuel fully to prevent those problem. And also drain the water condensation from fuel filter.
fuel system and accumulating water. Fill the water removing agent each time the fuel is reduced to half to
maintain the advantage.
FU(H4SO 2.5)-58
EMISSION CONTROL
EC(H4SO 2.5)
1.
Page
General Description
A: SPECIFICATION
Specifications for 2.5 L model are included in
EC(H4SO 2.0) section. <Ref. to EC(H4SO 2.0)-2,
EC(H4SO 2.5)-2
INTAKE (INDUCTION)
IN(H4SO 2.5)
1.
Page
General Description
INTAKE (INDUCTION)
A: SPECIFICATION
IN(H4SO 2.0) section. <Ref. to IN(H4SO 2.0)-2,
IN(H4SO 2.5)-2
MECHANICAL
ME(H4SO 2.5)
1.
Page
General Description
MECHANICAL
A: SPECIFICATION
ME(H4SO 2.0) section. <Ref. to ME(H4SO 2.0)-2,
ME(H4SO 2.5)-2
EXHAUST
EX(H4SO 2.5)
1.
Page
General Description
EXHAUST
A: SPECIFICATION
EX(H4SO 2.0) section. <Ref. to EX(H4SO 2.0)-2,
EX(H4SO 2.5)-2
COOLING
CO(H4SO 2.5)
1.
Page
General Description
COOLING
A: SPECIFICATION
Specifications for 2.5 L model are the same as 2.0
L model. <Ref. to CO(H4SO 2.0)-2, General Description.>
CO(H4SO 2.5)-2
LUBRICATION
LU(H4SO 2.5)
1.
Page
General Description
LUBRICATION
A: SPECIFICATION
L model. <Ref. to LU(H4SO 2.0)-2, General Description.>
LU(H4SO 2.5)-2
SP(H4SO 2.5)
1.
Page
General Description
A: SPECIFICATION
L model. <Ref. to SP(H4SO 2.0)-2, General Description.>
SP(H4SO 2.5)-2
IGNITION
IG(H4SO 2.5)
1.
Page
General Description
IGNITION
A: SPECIFICATION
IG(H4SO 2.0) section. <Ref. to IG(H4SO 2.0)-2,
IG(H4SO 2.5)-2
SC(H4SO 2.5)
1.
Page
General Description
A: SPECIFICATION
L model. <Ref. to SC(H4SO 2.0)-2, General Description.>
SC(H4SO 2.5)-2
EN(H4SO 2.5)(diag)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
Page
Inspection Mode........................................................................................34
Drive Cycle................................................................................................39


A: PROCEDURE
1. ENGINE
Step
<Ref. to EN(H4SO 2.5)(diag)-3, CHECK,
Check List for Interview.>

INDICATOR LIGHT.

link connector.
PERFORM DIAGNOSIS.
EN(H4SO 2.5)(diag)-41, Clear Memory
Mode.>
EN(H4SO 2.5)(diag)-34, Inspection Mode.>
Check
No
Inspection using
Diagnostics for
Engine Starting
Failure. <Ref. to
EN(H4SO
2.5)(diag)-54,
Diagnostics for
Engine Starting
Failure.>
Inspection using
light illuminate?
EN(H4SO
2.5)(diag)-261,
INSPECTION,
aru Select Monitor?
cause. <Ref. to
NOTE:
EN(H4SO
If DTC is not
2.5)(diag)-70, List shown on display
of Diagnostic Trou- although the enble Code (DTC).> gine warning light
Go to step 4.
illuminates,
perform the diagnostics of malfunction
indicator light circuit or combination
meter. <Ref. to
EN(H4SO 2.5)(diag)-44, Malfunction
Indicator
Light.>
nostic Chart with sis.
<Ref. to EN(H4SO
2.5)(diag)-80,
(DTC).>
Yes
Go to step 2.


A: CHECK
1. CHECK LIST No. 1
NOTE:
Customers name
Date of sale
Date of repair
V.I.N.
Weather
Engine No.
Fuel brand
Fine
Cloudy
Rainy
Snowy
Various/Others:
C (F)
Place
Engine temperature
Engine speed
Vehicle speed
Driving conditions
Headlight
Blower
A/C compressor
Radiator fan
Front wiper
Rear wiper
km
miles
Odometer reading
Hot
Warm
Cool
Cold
Highway
Suburbs
Inner city
Uphill
Downhill
Rough road
Others:
Cold
Warming-up
After warming-up
Any temperature
Others:
rpm
km/h (MPH)
Not affected
At starting
While idling
At racing
While accelerating
While cruising
While decelerating
ON / OFF
ON / OFF
ON / OFF
ON / OFF
ON / OFF
ON / OFF
Rear defogger
Audio
Car phone
ON / OFF
ON / OFF
ON / OFF

2. CHECK LIST No. 2

NOTE:
ABS warning light
b) Fuel level
What:
What:
e) Installing of other parts except for genuine parts: Yes / No
What:
Where:
From where:
What kind:
From where:
What kind:
Rough idling
Poor acceleration
Back fire
After fire
Does not shift.
General Description

point to chassis when measuring voltage and resistance inside the passenger compartment.
A: CAUTION
CAUTION:
All airbag system wiring harnesses and connectors are colored yellow. Do not use electrical test equipment on these circuits.
The fuel injector and other parts will be damaged.
engine is running.
sensor and ECM, be sure to turn the ignition switch
to OFF. Perform the inspection mode after connecting the connectors.
(A)
EN-00001
(A) Stud bolt
9) Use engine grounding terminal or engine as the

grounding point to the chassis when measuring
voltage and resistance in the engine compartment.
FU-01090
10) Use TCM mounting stud bolts as the grounding

CAUTION:
NOTE:
Immobilizer system must be registered when installing the ECM of the model with immobilizer. For
doing so, all ignition keys and ID cards should be
prepared. Refer to REGISTRATION MANUAL
FOR IMMOBILIZER.
7) Connectors of each sensor in the engine compartment and the harness connectors on the engine side and body side are all designed to be
(A)
EN-00154
(A) Stud bolt

not drop them.
CAUTION:
under the steering column, inside of instrument
panel lower trim panel.)
General Description

matching.
special attention to the three items mentioned
above.
the operation of ECM.
three causes must be distinguished clearly when
three causes.
16) For AT models, do not hold the stall for more
than five seconds. (from closed throttle, fully open
throttle to stall engine speed.)
perform the ABS memory clear procedure of selfdiagnosis function.
B: INSPECTION
items which might affect engine problems.
1. BATTERY
electrolyte.
proper grounding.
2. ENGINE GROUND
Make sure the engine grounding terminal is properly connected to engine.
FU-01090
C: NOTE
General Description


D: PREPARATION TOOL
ILLUSTRATION
TOOL NUMBER
24082AA230
DESCRIPTION
CARTRIDGE
REMARKS
22771AA030
SUBARU SELECT
MONITOR KIT

ST24082AA230
ST22771AA030


A: LOCATION
1. ENGINE
Control module
LHD model
(3)
(1)
(4)
(2)
EN-02413
RHD model
(4)
(2)
(3)
(1)
EN-02451
(1)
(2)

(3)
Test mode connector
(4)
Data link connector

(1)
(2)
EN-01147
EN-01966
(4)
(3)
EN-02414
AT-01877

Sensor
(8)
(3)
(9)
(1)
(7)
(4)
(2)
(6)
(5)
(8)
EN-02530
(1)
Mass air flow and intake air temperature sensor (EC, EK and K4
model)
(2)
(3)

(4)
(5)
(6)
(7)
(8)

Knock sensor
Tumble generator valve position
sensor
(9)
Intake air temperature sensor (KA

and KS model)

(1)
(2)
EN-01970
EN-01971
(3)
(4)
EN-01972
EN-02179
(5)
(6)
EN-00011
EN-00010
(7)
(8)
EN-00012
EN-02531

(9)
EN-02547
(1)
(3)
(4)
(2)
EN-01973
(1)
(2)

Rear oxygen sensor
(3)
(1)
(4)
(2)
(4)
(3)
EN-02091
EN-02092

(5)
(4)
(3)
(2)
(3)
(5)
(1)
EN-02452
(1)
(2)

EGR Valve (EC, EK and K4
model)
(3)
(4)
Tumble generator valve actuator

(5)
Fuel injector

(1)
(2)
EN-01975
EN-01976
(4)
(3)
EN-01977
(5)
EN-02453
EN-01978

LHD model
(1)
(8) (7)
(6) (9)
(5) (4) (3)
(2)
(3)
EN-02423
RHD model
(2)
(1)
(8) (7) (6) (9) (5) (4) (3)

EN-01979
(1)
(2)
(3)
Inhibitor switch
Fuel pump
Main relay
(4)
(5)
(6)
Fuel pump relay

(7)
(8)
(9)

Starter

(2)
EN-02093
EN-00178
(3)
(6)
(8)
(4)
(7)
(5)
EN-02094
(9)
EN-02096
EN-02095


B134
1
8 9
18 19
28 29
2
10
20
30
B135
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
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
32 33
34 35
28 29 30 31
B136
B137
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
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
EN-01982
Crankshaft
position sensor
Camshaft
position sensor
Terminal
No.
Signal (+)
Signal ()
Shield
Signal (+)
Signal ()
Shield
B135
B135
B135
B135
B135
B135
10
22
31
11
23
31
Main
B136
18
0.64 0.72
Fully opens: 3.96
Sub
B136
29
1.51 1.58
Fully opens: 4.17
B137
Duty waveform
Duty waveform
Drive frequency: 500 Hz
B137
Duty waveform
Duty waveform
B137
10 13
13 14
B135
35
17
ON: 0
OFF: 13 14
Fully closed: 1
Fully opens: 3.3

turned to ON: ON
B136
ON: 0
OFF: 10 13
Fully closed: 1
Fully opens: 3.3
B136
15
B136
34
B136
28
Signal
Shield
B137
B137
24
31
0
Fully closed: 1
Fully opens: 3.3
0 0.9
0
Sub
0
Fully closed: 1
Fully opens: 3.3
0
0
Electronic
throttle control

motor (+)
motor ()
motor power supply
motor relay
Main
Accelerator
position sensor
Rear oxygen
sensor
Signal (V)
Ignition SW ON
(engine OFF)
0
0
0
0
0
0
Connector
No.
DESCRIPTION
Power
supply
Ground
Engine ON
(idling)
7 +7
0
0
7 +7
0
0
0.64 0.72
(After engine is
warmed-up.)
1.51 1.58
(After engine is
warmed-up.)
NOTE
Fully closed: 0.6

Fully open: 3.96
Fully closed: 1.48
Fully open: 4.17

DESCRIPTION
Connector
No.
Terminal
No.
B134
B134
B135
Signal (V)
Ignition SW ON
(engine OFF)
0 1.0
Engine ON
(idling)
0 1.0
NOTE
0 1.0
0 1.0
0 1.0
0 1.0
B136
14
1.0 1.4
1.0 1.4
B134
19
0 or 10 13
0 or 13 14
B134
18
0 or 10 13
0 or 13 14
B134
29
0 or 10 13
0 or 13 14
B134
28
0 or 10 13
0 or 13 14
B136
27
Front oxygen
Signal 1
(A/F) sensor
Signal 2
heater
Rear oxygen sensor heater
signal
sensor
Tumble generator valve RH
(open)
Tumble generator valve RH
(close)
Tumble generator valve LH
(open)
Tumble generator valve LH
(close)
Tumble generator valve
position sensor RH
Tumble generator valve
position sensor LH
Starter switch
B136
26
B137
Starter relay
B135
32
B137
17
B137
16
B137
14
10 13
13 14
B137
15
10 13
13 14
B137
B137
15
When connected: 0
A/C switch (Model with

immobilizer)
A/C switch (Model without
immobilizer)
Ignition switch (Model with
immobilizer)
Ignition switch (Model without immobilizer)
Fully open: 0.2 1.0

Fully closed: 4.2 4.7
Fully open: 0.2 1.0
Fully closed: 4.2 4.7
0
0
ON: 0
ON: 0
OFF: 10 13
OFF: 13 14
ON: 10 13
ON: 13 14
OFF: 0
OFF: 0
ON: 10 13
ON: 13 14
OFF: 0
OFF: 0
Cranking: 8 14
Switch is ON when select

or shift lever is shifted into
P or N range.
ON: 0
OFF: 120.5
Test mode connector

Test mode connector
Signal
Knock sensor
Shield
B137
14
When connected: 0
B136
B136
25
33
2.8
0
2.8
0
B135
19
10 13
13 14
Control module power supply
B135
B135
B136
B136
B135
B135
B136
B136
B136
B136
6
5
16
15
18
17
6
5
4
3
13 14
13 14
5
5
1 3.4
1 3.4
1 14
1 14
1 14
1 14
B135
27
10 13
10 13
5
5
0
0
10 13
10 13
10 13
10 13
ON: 0.5 or less
OFF: 10 13
Ignition switch OFF: 10

13
Waveform
Waveform
Waveform
Waveform
Waveform
Waveform
0.5 or less
1
2
1
Ignition control
2
#1
#2
Fuel injector
#3
#4
Sensor power
supply

Signal (V)
Ignition SW ON
Engine ON
(engine OFF)
(idling)
ON: 0.5 or less
0.5 or less
OFF: 10 13
ON: 0.5 or less
ON: 0.5 or less
OFF: 10 13
OFF: 13 14
ON: 0.5 or less
ON: 0.5 or less
OFF: 10 13
OFF: 13 14
ON: 0.5 or less
ON: 0.5 or less
OFF: 10 13
OFF: 13 14
DESCRIPTION
Connector
No.
Terminal
No.

B135
26
A/C relay control
B135
33
B134
31
B135
34
B137
16
10 13
13 14
B137
17
10 13
13 14
B134
17
Engine speed output
B134
23
B134
14
B134
B134
B134
B134
11
10
9
8
B137
10
Blower fan switch
B137
13
ON: 1 or less
OFF: 10 13
0 or 10 13
0 or 10 13
0 or 10 13
0 or 10 13
ON: 1 or less
OFF: 10 13
ON: 0
OFF: 10 13
0 13 or more
ON: 1 or less
OFF: 13 14
0 or 10 13
0 or 10 13
0 or 10 13
0 or 10 13
ON: 1 or less
OFF: 13 14
ON: 0
OFF: 13 14
B134
33
2.05 2.25
B134
26
1.75 1.95
B134
25
B136
22
4.0 4.8
1.1 1.9
B136
B136
B136
23
32
31
0
0
0.3 4.5
0
0
B136
13
3.15 3.33
3.15 3.33
B134
22
B137
20
B136
B136
B137
B135
B135
B135
B137
B137
35
34
7
12
4
1
2
1
0 6.5
Less than 1 More
than 4
0
0
0
0
0
0
0
0
0 6.5
Less than 1
More than 4
0
0
0
0
0
0
0
0
intake air temperature:

25C (75F)
B134
Self-shutoff control (Model

with immobilizer)
Self-shutoff control (Model
EGR solenoid
valve
Signal A+
Signal A
Signal B+
Signal B

signal 1
signal 2
shield
Manifold absolute pressure
sensor
Signal
Air flow sensor Shield
Ground
Generator control
GND (sensor)
1
2
GND (injector)
GND (ignition system)
GND (power supply)
1)
NOTE
Light ON: 1 or less

Light OFF: 10 14
Waveform

Connector
No.
Terminal
No.
B134
B137
Main switch
B137
14
Clutch switch
B137
22
Brake switch 1
B137
12
Brake switch 2
B137
13
DESCRIPTION
2)
control)

switch
B136
21
Signal (V)
Ignition SW ON
(engine OFF)
Engine ON
(idling)
NOTE
ON: 0
OFF: 10 13
depressed: 0
released: 10 13
When brake pedal is
depressed: 0
When brake pedal is
released: 10 13
When brake pedal is
depressed: 10 13
When brake pedal is
released: 0
ON: 0
OFF: 13 14
depressed: 0
released: 13 14
When brake pedal is
depressed: 0
When brake pedal is
released: 13 14
When brake pedal is
depressed: 13 14
When brake pedal is
released: 0
When operating
nothing: 3.5 4.5
When operating
RES/ACC:
2.5 3.5
When operating
SET/COAST:
0.5 1.5
When operating
CANCEL: 0 0.5

When operating RES/
ACC: 2.5 3.5
When operating SET/
COAST: 0.5 1.5


Remarks
SPECIFICATION
1.6 2.9 (%): Idling
6.4 12.8 (%): 2,500 rpm Racing
Engine load
A/C is turned OFF.
All accessory switches are turned OFF.
Data Link Connector


A: NOTE
CAUTION:
Do not connect any scan tools except for Subaru Select Monitor or general scan tool, because the
circuit for Subaru Select Monitor may be damaged.
9 10 11 12 13 14 15 16
EN-00037
Terminal No.
1
2
3
4
5
6
7
8
Remarks
Power supply
Empty
Empty
Empty
Empty
Empty
Empty
Empty
Terminal No.
9
10
11
12
13
14
15
16
Remarks
Empty
Empty
Ground
Ground
Empty
Empty
Empty
General Scan Tool


A: OPERATION
J1978.
2) Open the cover and connect the general scan
tool to data link connector located in the lower portion of instrument panel (on the drivers side).
EN-02533

freeze frame data.

data
DTC
(5) MODE $06: Request on-board monitoring
test results for non-continuously monitored systems
(6) MODE $07: Request on-board monitoring
test results for continuously monitored systems
(7) MODE $09: Request vehicle information
Read out the data according to repair procedures.
(For detailed operation procedures, refer to the operation manual of general scan tool.)
NOTE:
(DTC).>

Refer to data denoting the current operating condition of analog input/output, digital input/output and/or the
powertrain system.
PID
01
03
04
05
06
07
0B
0C
0D
0E
0F
10
11
13
15
1C
21
24
Data
Number of emission-related powertrain DTC and malfunction indicator light status and diagnosis support information
Long term fuel trim
Engine revolution
Vehicle speed
Air flow rate from mass air flow sensor
Throttle valve absolute opening angle
Oxygen sensor output voltage and short term fuel trim associated with oxygen sensor
Supporting OBD system
Driving distance after MIL illuminates
A/F value and A/F sensor output voltage
Unit of measure
%
C
%
%
kPa
rpm
km/h
C
g/sec
%
V and %
km
and V
NOTE:
Refer to general scan tool manufacturers instruction manual to access generic OBD-II PIDs (MODE $01).
General Scan Tool


Refer to data denoting the operating condition when trouble is detected by the on-board diagnosis system.
PID
02
03
04
05
06
07
0B
0C
0D
0E
0F
10
11
Data
DTC that caused CARB required freeze frame data storage
Long term fuel trim
Engine speed
Vehicle speed
Air flow rate from mass air flow sensor
Throttle valve opening angle
Unit of measure
%
C
%
%
kPa
rpm
km/h
C
g/sec
%
NOTE:
Refer to general scan tool manufacturers operation manual to access freeze frame data (MODE $02).
4. MODE $03 (EMISSION-RELATED POWERTRAIN DIAGNOSTIC TROUBLE CODE (DTC))

Refer to Read Diagnostic Trouble Code (DTC) for information about data denoting emission-related powertrain DTC. <Ref. to EN(H4SO 2.5)(diag)-33, Read Diagnostic Trouble Code (DTC).>

Refer to the mode used to clear or reset emission-related diagnostic information (OBD-II trouble diagnostic
information).
NOTE:
Refer to general scan tool manufacturers operation manual to clear or reset emission-related diagnostic information (MODE $04).
6. MODE $06
Refer to test value of troubleshooting and data of test limit on support data bit sequence table. List of support
data is shown in the following table.
TID
$01
$02
CID
$01
$81
$02
$81
$02
$03
$04
Test value & Test limit

Catalyst system efficiency below threshold
Exhaust gas recirculation control circuit range/performance
Unit
mmHg
$01
Evaporative emission control system (CPC open malfunction)

Evaporative emission control system small leak
Evaporative emission control system small leak (Immediate normality judgment)
Evaporative emission control system large leak
Evaporative emission control system very small leak (Immediate normality judgment)
Evaporative emission control system very small leak
O2 sensor circuit slow response (Bank 1 Sensor 1) Lean Rich
$02
O2 sensor circuit slow response (Bank 1 Sensor 1) Rich Lean
$06
$81
$02
O2 sensor circuit (Bank 1 Sensor 2) <$81 or $02>
$07
$01
O2 sensor circuit slow response (Bank 1 Sensor 2)
second
$03
$05
$06
$05
pa
pa
pa
pa
pa
millisecond
General Scan Tool

TID
$0B
CID
$81
$02
Test value & Test limit
Unit
O2 sensor heater circuit (Bank 1 Sensor 2) <$81 or $02>
$0C
$01
Coolant thermostat (Coolant temperature below thermostat regulating temperature)
$0D
$01
$82
Evaporative emission control system vent control circuit range/performance
Pa
7. MODE $07
Refer to the data of DTC (pending code) for troubleshooting result about emission in first time.
8. MODE $09
Refer to the data of vehicle specification (VIN, calibration ID, etc.).


A: OPERATION
5) Turn ignition switch to ON (engine OFF) and turn

(A)

EN-00040
(A) Power switch
6) Using the Subaru Select Monitor, call up DTC

EN-00038

Monitor.

Code (DTC).>

Code (DTC).>
EN-00039

connector.
(1) Data link connector is located in the lower
EN-02533

connector.
CAUTION:
Do not connect the scan tools except for Subaru Select Monitor or general scan tool.


[YES] key.
Remarks
Display
Unit
of measure
%
C
%
%
mmHg
Note (at idling)
Engine load
A/F correction 1
A/F learning 1
Engine Load
Coolant Temp.
A/F Correction #1
A/F Learning #1
Engine speed signal
Engine Speed

Amount of intake air
Battery voltage
Mass air flow voltage
Vehicle Speed
Ignition Timing
Intake Air Temp.
Mass Air Flow
Rear O2 Sensor
Battery Voltage
Air Flow Sensor Voltage
Knocking Correction
Atmosphere Pressure
km/h
deg
C
g/s
%
V
V
V
ms
deg
mmHg
mmHg

EGR steps
A/F sensor current value 1

No. of EGR Steps
ALT Duty
A/F Sensor #1 Current
A/F Sensor #1
A/F Correction #3
A/F Learning #3
Throttle Motor Duty
Sub-throttle Sensor
Memorized Cruise
Speed
TGV Position Sensor R
TGV Position Sensor L
%
%
STEP
%
mA
3.5%
75 C
10 +10%
15 +15%
200 300 mmHg
600 800 rpm (Agree
0 km/h (at parking)
12.5 13.5 deg
2.8 3.2 g/s
1.2 1.6%
0.6 0.85 V
12 14 V
1.1 1.2 V
2.56 3.3 ms
0.0 deg
(Atmosphere pressure)
(Mani. Absolute Pressure
Atmosphere pressure)
0.0%
0 3%
0
0%
0.2 0.2 mA
ohm
28 31 mA
%
%
%
V
V
V
V
V
0.85 1.05
5.08%
0%
12 20%
(Battery voltage)
1.48 1.50 V
0.62 V
1.12 V
0.98 1.0 V
km/h
0 km/h
V
V
ON/OFF
0 12
0 12

A/F correction 3
A/F learning 3
Throttle motor duty
TGV position sensor voltage RH
TGV position sensor voltage LH
rpm

Remarks
Display
Unit
of measure
Note (at idling)

4 100
OFF
ON
ON
ON
OFF (At OFF)
OFF (At OFF)
RHD/LHD
OFF

Test mode terminal
Soft idle switch signal
Power steering switch input signal
Rear O2 monitor
Fuel Level Resistance

Test Mode Signal
Idle Switch Signal
Ignition Switch
P/S Switch
A/C Switch
Handle Switch
Starter Switch
Rear O2 Rich Signal
OFF
Knocking signal
Light switch signal
Wiper switch signal
Air conditioner compressor relay output signal
Tumble generator valve output signal
Tumble generated valve drive signal
Knocking Signal
Crankshaft Position Sig.
Camshaft Position Sig.
Rear Defogger SW
Blower Fan SW
Light Switch
Wiper Switch
Fuel Pump Relay
TGV Output
TGV Drive
Retard Signal from AT
Fuel Cut Signal from AT
Torque Permission Signal
ETC Motor Relay
Ban of Torque Down
Request Torque Down
Clutch Switch
Stop Light Switch
SET/COAST Switch
RESUME/ACCEL Switch
Brake Switch
Main Switch
Cancel Switch
Body Int. Unit Data
OFF
OFF
OFF
OFF (At OFF)
OFF (At OFF)
OFF (At OFF)
OFF (At OFF)
OFF (At OFF)
OFF (At OFF)
OFF (At OFF)
OFF (At OFF)
ON
OFF
Open
OFF
OFF
ON
ON
ON/OFF
ON/OFF
OFF (At OFF)
OFF (At OFF)
OFF (At OFF)
OFF (At OFF)
OFF (At OFF)
OFF (At OFF)
OFF (At OFF)
ON
ON
AT coordinate permission demand

ETC motor relay signal
Ban of torque down signal
Request torque down signal
Brake switch signal
Main switch signal
Integrated unit data reception
Integrated unit data update
NOTE:
For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.


5) On the OBD Menu display screen, select the {Current Data Display/Save}, and press the [YES] key.
DESCRIPTION
Test of catalyst
Test of EGR system
Display
MI (MIL)
Misfire monitoring
Catalyst Diagnosis
Heated catalyst
Oxygen sensor
O2 Heater Diagnosis
EGR system
Unit of measure
0
OFF
no support
complete
complete
no support
no support
no support
no support
no support
complete
complete
incomplete
NOTE:


2) On the System Selection Menu display screen, select the {Engine Control System} and press the [YES]
key.
A list of support data is shown in the following table.
Contents
DTC for freeze frame data
Engine load data
Short term fuel trim by front oxygen (A/F) sensor
Long term fuel trim by front oxygen (A/F) sensor
Engine speed signal
Intake air volume
Throttle position signal
Display
Freeze frame data
Engine Load
Coolant Temp.
Engine Speed
Vehicle Speed
Ignition Timing
Mass Air Flow
Intake Air Temp
Unit of measure
DTC
ON or OFF
%
C or F
%
%
rpm
km/h or MPH
g/sec
C
%
NOTE:


[YES] key.
Remarks
Test mode signal
Display
Test Mode Signal
Message
ON or OFF
ON or OFF
Windshield wiper switch signal Wiper SW
ON or OFF

signal
ON or OFF
ON or OFF
ON or OFF
ON or OFF

Tumble generator valve output
signal
Fuel Pump Relay
ON or OFF
LED ON requirements
D check
When clear memory connector is connected.
entered.
entered.
to ON.
entered.
input.
input.
When camshaft position sensor signal is entered.
turned to ON.
turned to ON.
When light switch is turned to
ON.
turned to ON.
is turned to ON.
switch is turned to ON.
in function.
function.
function.
ON output
Clear memory signal
Clear Memory Terminal
ON or OFF
ON or OFF
Idle switch signal
Idle Switch Signal
ON or OFF
Ignition Switch
ON or OFF
P/S Switch
ON or OFF
A/C Switch
ON or OFF
Handle SW
RHD or LHD

Knocking signal
signal
Starter Switch
ON or OFF
Rear O2 Rich Signal
ON or OFF
Knocking Signal
ON or OFF
ON or OFF
ON or OFF
ON or OFF
Blower Fan Switch
ON or OFF
Light switch signal
Light Switch
ON or OFF
Light Switch
ON or OFF
TGV Output
ON or OFF
Yes

Remarks
Tumble generated valve drive
signal
Display
TGV Drive
Message
Open or Close
ON or OFF
AT fuel cut signal
Fuel Cut
ON or OFF
ON or OFF
Clutch Switch
ON or OFF
Stop Light Switch
ON or OFF
SET/COAST Switch
ON or OFF
RESUME/ACCEL Switch
ON or OFF
Brake switch signal
Brake Switch
ON or OFF
Main switch signal
Main Switch
ON or OFF
Cancel Switch
ON or OFF

motor relay signal
ETC Motor Relay
ON or OFF
Body Int. Unit Data
ON or OFF
ON or OFF
LED ON requirements
Opening direction
signal is input.
input.
to ON.
ON.
turned to ON.
turned to ON.
ON.
ON.
to ON.
entered.
entered.
NOTE:


Code (DTC)
A: OPERATION
MODE)
key.
NOTE:
(DTC).>

MODE)
key.
NOTE:
(DTC).>
Inspection Mode
11.Inspection Mode
A: PROCEDURE
Carry out trouble diagnosis shown in the following DTC table.
When performing trouble diagnosis which is not shown in the DTC table, refer to the next item Drive cycle.
<Ref. to EN(H4SO 2.5)(diag)-39, Drive Cycle.>
DTC
P0031
P0032
P0037
P0038
P0102
P0103
P0107
P0108
P0112
P0113
P0117
P0118
P0122
P0123
P0131
Item
Mass or Volume Air Flow Circuit Low Input
Mass or Volume Air Flow Circuit High Input
P0132
P0134
P0137
P0138
P0171
P0172
P0222
P0223
P0327
P0328
P0335
P0340
P0400
P0458
System too Lean (Bank 1)

System too Rich (Bank 1)
Evaporative Emission Control System Purge Control Valve Circuit
Low
P0462
P0463
P0500
P0512
P0513
P0519
P0558
P0600
P0604
P0605
P0607
P0638
P0691
P0692
P0851
Condition
Inspection Mode
DTC
P0852
P1086
P1087
P1088
P1089
P1090
Item
Tumble Generated Valve Position Sensor 2 Circuit Low
Tumble Generated Valve Position Sensor 2 Circuit High
Tumble Generated Valve Position Sensor 1 Circuit Low
Tumble Generated Valve Position Sensor 1 Circuit High
Tumble Generated Valve System 1 (Valve Open)
Condition
Engine coolant temperature is 5 5C (41

41F) at engine start.
Engine coolant temperature is 5 5C (41

41F) at engine start.
P1091
P1092
Tumble Generated Valve System 1 (Valve Close)

Tumble Generated Valve System 2 (Valve Open)
P1093
P1094
P1095
P1096
P1097
P1110
P1111
P1152
Tumble Generated Valve System 2 (Valve Close)

Tumble Generated Valve Signal 1 Circuit Malfunction (Open)
Tumble Generated Valve Signal 1 Circuit Malfunction (Short)
Tumble Generated Valve Signal 2 Circuit Malfunction (Open)
Tumble Generated Valve Signal 2 Circuit Malfunction (Short)
Atmospheric Pressure sensor circuit malfunction (Low input)
Atmospheric Pressure sensor circuit malfunction (High input)
O2 Sensor Circuit Range/Performance (Low) (Bank1 Sensor1)
P1153
O2 Sensor Circuit Range/Performance (High) (Bank1 Sensor1)
P1160
P1492
P1493
P1494
P1495
P1496
P1497
P1498
P1499
P1518
P1560
P1570
P1571
P1572
P1574
P1576
P1577
P1578
P2101
P2102
P2103
P2109
P2122
P2123
P2127
P2128
P2135
P2138

Antenna
IMM Circuit Failure (Except Antenna Circuit)
Meter Failure
Inspection Mode

MODE
1) Check if the battery voltage is more than 12 V
and fuel remains half [20 40 2 (5.3 10.6 US
gal, 4.4 8.8 Imp gal)].
WARNING:
brakes are applied.
wheels.
and vehicle.

1) After clearing the memory, check for any remaining unresolved trouble data. <Ref. to EN(H4SO
2.5)(diag)-41, Clear Memory Mode.>
2) Idle the engine.
EN-00038

Monitor.
EN-00039

(A)
(A)
EN-02424
(B)
EN-00041
(A) Rigid rack

(B) Free rollers
Inspection Mode


wheels may light the ABS warning light, but this indicates no malfunctions. When engine control diagnosis is finished, perform the ABS memory clear
procedure of self-diagnosis function.
EN-02533
1) After performing the diagnostics and clearing

memory, check for any remaining unresolved trouble data: <Ref. to EN(H4SO 2.5)(diag)-41, Clear
Memory Mode.>
3) Connect the test mode connector (A) at the lower side of globe box.
CAUTION:
(A)
(A)
EN-02424

connector in the lower portion of instrument panel
(on the drivers side).
EN-00040
(A) Power switch

key.
NOTE:
For the details concerning DTCs, refer to List of
CAUTION:
EN-02533

NOTE:
Ensure the select lever is placed in P range before starting. (AT model)
Depress the clutch pedal when starting engine.
(MT model)
position switch and N position switch to ON.
7) Depress the brake pedal to turn brake switch
ON. (AT model)
8) Keep the engine speed in 2,500 3,000 rpm
range for 40 seconds.
Inspection Mode
9) Place the select lever or shift lever in D range

(AT model) or 1st gear (MT model) and drive the
vehicle at 5 to 10 km/h (3 to 6 MPH).
NOTE:
On AWD model, release the parking brake.
wheels may light ABS warning light, but this indicates no malfunctions. When the engine control diagnosis is finished, perform the ABS memory
NOTE:
For detailed concerning DTC, refer to List of Diagnostic Trouble Code (DTC).
Drive Cycle
12.Drive Cycle
A: PROCEDURE
There are three drive patterns for the trouble diagnosis. Driving in the specified pattern allows to diagnose
malfunctioning items listed below. After the malfunctioning items listed below are repaired, always check
whether they correctly resume their functions by driving in the required drive pattern.
1. PREPARATION FOR THE DRIVE CYCLE

1) Make sure that the fuel remains approx. half amount [20 40 2 (5.3 10.6 US gal, 4.4 8.8 Imp gal)],
and battery voltage is 12 V or more.
2) After performing the diagnostics and cleaning memory, check for any remaining unresolved trouble data.
NOTE:
Except for the engine coolant temperature specified items at starting, the diagnosis is carried out after engine warm up.
Carry out the diagnosis which is marked * on DTC twice, then, after finishing first diagnosis, stop the engine
and do second time at the same condition.
2. AFTER RUNNING 20 MINUTES AT 80 KM/H (50 MPH), IDLE ENGINE FOR 1 MINUTE.
DTC
Item
Insufficient Coolant Temperature for Closed Loop
*P0125
Fuel Control
O2 Sensor Circuit Slow Response (Bank 1 Sen*P0133
sor 1)
Catalyst System Efficiency Below Threshold
*P0420
(Bank 1)
Evaporative Emission Control System Purge
P0459
Control Valve Circuit High
Condition
Engine coolant temperature is less than 20C (68F) at engine start.
3. IDLE FOR 10 MINUTES

NOTE:
Before the diagnosis, drive the vehicle at 10 km/h (6 MPH) or more.
DTC
P0030
Item
O2 Sensor Heater Circuit Range/Performance
(Bank 1 Sensor 1)
Condition
Drive Cycle
4. DRIVE ACCORDING TO THE FOLLOWING DRIVE PATTERN

(H)
(C)
97 (60)
(D)
64 (40)
(G)
(F)
(E)
(B)
(A)
0
50
100
(I)
150
EN-00842
(A)
(B)
(C)
Idle engine for 10 seconds or

more.
within 20 seconds.
(D)

for 20 seconds.
(F)
DTC
(E)
Decelerate with throttle fully

closed to 64 km/h (40 MPH).
for 20 seconds.
(G)
(H)
(I)
Stop vehicle with throttle fully

closed.
Seconds

within 10 seconds.
*P0139
Item
*P0301
*P0302
*P0303
*P0304
P0559
P0700
Generator circuit high input

Transmission Control System (MIL request)
Condition
In some cases, diagnosis may

complete at once.
complete at once.
complete at once.
complete at once.
Clear Memory Mode


A: OPERATION
MODE)
key.
switch to OFF.
NOTE:

MODE)
key.
NOTE:


Check Mode

connector located in the lower portion of instrument
A: OPERATION
EN-02533
EN-00038

Monitor.
CAUTION:
(A)
EN-00040
(A) Power switch

EN-00039

(A)
EN-02424

key.
the [YES] key.
12) Select the desired compulsory actuator on the
Actuator ON/OFF Operation display screen and
screen.


table.
DESCRIPTION
operation check
operation check
Display
Fuel Pump
Radiator Fan Relay
CPC Solenoid
NOTE:
Display
EGR Solenoid
ASV Solenoid
FICD Solenoid
PCV Solenoid
AAI Solenoid


A: PROCEDURE
1. Activation of malfunction indicator light. <Ref. to EN(H4SO 2.5)(diag)-45, ACTIVATION OF MALFUNCTION INDICATOR
2. Check that the malfunction indicator light does not come on. <Ref. to EN(H4SO 2.5)(diag)-46, MALFUNCTION INDICATOR
3. Check that the malfunction indicator light does not go off. <Ref. to EN(H4SO 2.5)(diag)-48, MALFUNCTION INDICATOR
LIGHT DOES NOT GO OFF., Malfunction Indicator Light.>
4. Check that the malfunction indicator light does not blink. <Ref. to EN(H4SO 2.5)(diag)-50, MALFUNCTION INDICATOR LIGHT
5. Check that the malfunction indicator light remains blinking. <Ref. to EN(H4SO 2.5)(diag)-52, MALFUNCTION INDICATOR

INDICATOR LIGHT

(1)
NOTE:
EN(H4SO 2.5)(diag)-46, MALFUNCTION INDICATOR LIGHT DOES NOT COME ON, Malfunction
Indicator Light.>
(2)
(4)
(3)
EN-01681
(1)
(2)
(3)
(4)
(A)
ON
OFF
Ignition switch ON
1 second
EN-01984
emission control system is malfunctioning.
(1)
(3)
(4)
(2)
(3)
(4)
(5)
(6)
EN-01679
(1)
(2)
(3)
(4)
(5)
(6)
No faulty
Trouble occurs
ON
OFF
Ignition switch ON
Engine start



DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
EC, EK and K4 model
B72
IGNITION
SWITCH
BATTERY
SBF-7
No.5
3
3
4
SBF-1
COMBINATION
METER
16
i10
i3
17
B38
B134 ECM
B134
B72
1 2 3
4 5 6
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
i10
B38
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
EN-01985
KA and KS model
NOTE:
Fuel injection system for KA and KS model is the same as 2.0 L model. Refer to EN(H4SO 2.0) section.

Step
CHECK OPTION CODE.
Check
Is the option code EC, EK or
K4?

CHECK POOR CONTACT.
Check for poor connection by shaking or pulling ECM connector and harness.

combination meter.
(B134) No. 17 (i10) No. 16:
Yes
Go to step 2.
Go to step 5.

light illuminate?
contact in ECM
connector.
connected?
<Ref. to FU(H4SO
2.5)-36, Engine
Control Module
(ECM).>
Go to step 6.
?
CHECK POOR CONTACT.

16, Combination
Meter.>
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
Fuel injection system for KA and KS
model is the same
as 2.0 L model.
Go to step 3.
Go to step 4.

connector.

NOTE:
the following:
Open circuit in
harness between
Poor contact in
coupling connector
Go to step 7.

necessary.
NOTE:
Blown out fuse
(No. 5)
Open or short
circuit in harness
between fuse (No.
Poor contact in


DIAGNOSIS:
TROUBLE SYMPTOM:
Monitor display.
WIRING DIAGRAM:
EC, EK and K4 model
B72
IGNITION
SWITCH
BATTERY
SBF-7
No.5
3
3
4
SBF-1
COMBINATION
METER
16
i10
i3
17
B38
B134 ECM
B134
B72
1 2 3
4 5 6
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
i10
B38
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
EN-01985
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?

Yes
Go to step 2.
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Replace the ECM.
light illuminate?
between combina- 2.5)-36, Engine
tion meter and
Control Module
ECM connector.
(ECM).>


DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
EC, EK and K4 model
B72
IGNITION
SWITCH
BATTERY
SBF-7
No.5
3
3
4
SBF-1
COMBINATION
METER
*1
i10
16
: WITH IMMOBILIZER: D15

WITHOUT IMMOBILIZER: D14
2 : TERMINAL No. RANDOM ARRANGEMENT
LHD
B138
1
B75
B76
B122
2
*
*2
RHD
i3
C19
*1
A17
36
B38
A: B134
C: B136
E2
ECM
D: B137
B75
B72
i10
B38
1
2
1 2 3
4 5 6
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
A:
B138
1 2 3 4
5 6 7 8
1
8 9
18 19
28 29
2
10
20
30
B134
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
C:
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B21
D:
5 6
14 15 16
25 26 27
33 34 35
B21
B137
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 45
46 47
48 49 50 51 52 53 54
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
28 29
30 31
26 27
EN-02454
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?
Yes
Go to step 2.

OFF)

light illuminate?

ground.
Does malfunction indicator

light illuminate?

?
CHECK POOR CONTACT.


connector?

Model with immobilizer
Model without immobilizer
CHECK POOR CONTACT.

?

connector?
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
to EN(H4SO
2.5)(diag)-46,
MALFUNCTION
INDICATOR
LIGHT DOES
NOT COME ON,
Go to step 4.
Repair the short

circuit in harness
ECM connector.
Go to step 5.
Repair the poor

contact in ECM
connector.
Go to step 7.
Repair the poor

contact in ECM
connector.
NOTE:
the following:
Open circuit in
harness between
ground
Go to step 6.
Repair the open

circuit in harness
between ECM and
Replace the ECM.

<Ref. to FU(H4SO
2.5)-36, Engine
Control Module
(ECM).>


DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
EC, EK and K4 model
B72
IGNITION
SWITCH
BATTERY
SBF-7
No.5
3
3
4
SBF-1
COMBINATION
METER
*1
i10
16

2 : TERMINAL No. RANDOM ARRANGEMENT
LHD
B138
1
B75
B76
B122
2
*
*2
RHD
i3
C19
*1
A17
36
B38
A: B134
C: B136
E2
ECM
D: B137
B75
B72
i10
B38
1
2
1 2 3
4 5 6
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
A:
B138
1 2 3 4
5 6 7 8
1
8 9
18 19
28 29
2
10
20
30
B134
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
C:
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B21
D:
5 6
14 15 16
25 26 27
33 34 35
B21
B137
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 45
46 47
48 49 50 51 52 53 54
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
28 29
30 31
26 27
EN-02454
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?

Yes
Go to step 2.

light blink?

MINAL.
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
System is in good
order.
NOTE:
Malfunction indicator light blinks
when test mode
connector is connected.
Repair the short
Replace the ECM.
test mode connec- Control Module
tor.
(ECM).>


A: PROCEDURE
2. Inspection of starter motor circuit. <Ref. to EN(H4SO 2.5)(diag)-55, STARTER MOTOR CIRCUIT, Diagnostics for Engine Starting Failure.>
3. Inspection of ECM power supply and ground line. <Ref. to EN(H4SO 2.5)(diag)-58, CHECK POWER SUPPLY AND GROUND
4. Inspection of ignition control system. <Ref. to EN(H4SO 2.5)(diag)-61, IGNITION CONTROL SYSTEM, Diagnostics for Engine
Starting Failure.>
5. Inspection of fuel pump circuit. <Ref. to EN(H4SO 2.5)(diag)-64, FUEL PUMP CIRCUIT, Diagnostics for Engine Starting Failure.>
6. Inspection of fuel injector circuit. <Ref. to EN(H4SO 2.5)(diag)-67, FUEL INJECTOR CIRCUIT, Diagnostics for Engine Starting
Failure.>


CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)41, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO 2.5)(diag)-34, Inspection Mode.>.
WIRING DIAGRAM:
EC, EK and K4 model
IGNITION
SWITCH
B72
BATTERY
SBF-1
SBF-7
No.21
3
2
15
LHD
13
16
RHD
14
STARTER
RELAY
STARTER MOTOR
15
RHD
13
16
LHD
14
B225
D8
B32
B14
ECM
B: B135
D: B137
B72
B225
B: B135
1 2 3
4 5 6
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
1
8 9
20 21
28 29
3
2
10 11 12 13
22 23
30 31
4 5 6
7
14 15 16 17 18 19
24 25
26 27
32 33
34 35
D: B137
3 4
1
2
5 6
7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
30 31
26 27
28 29
EN-02455

KA and KS model
NOTE:
2
3
4
Step
CHECK OPTION CODE.
Check
K4?
CHECK BATTERY.
CHECK DTC.
EN(H4SO 2.5)(diag)-33,
Yes
Go to step 2.
Go to step 3.
Go to step 4.

List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(H4SO
2.5)(diag)-70, List
TOR.
motor.
ground.
NOTE:
Place the select lever in the P or N range.
MOTOR.
?
starter motor.
ground.
switch.
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Charge or replace
the battery.
Go to step 5.
Repair the poor
contact in ECM
connector.
Go to step 7.
Check the starter

motor. <Ref. to
SC(H4SO 2.0)-6,
Starter.>
Repair the open

circuit of ground
cable.
Go to step 8.
Repair the open

circuit in harness
between ignition
fuse SBF No. 7
and SBF No. 1.

10
11
Step
switch.
switch terminals after turning the ignition
Terminals
No. 2 No. 3:
relay connector and chassis ground after turning the ignition switch to START position.
LHD model
RHD model
relay terminals.
Terminals
No. 13 No. 14:
chassis ground.
Check
?
Yes
Go to step 9.
No
Repair the open

circuit in harness
between starter
fan relay and ignition switch.

?
Replace the
starter relay.
Go to step 11.

<Ref. to FU(H4SO
2.5)-36, Engine
Control Module
(ECM).>
Repair the open or

between ECM and
starter relay.

CAUTION:
WIRING DIAGRAM:
EC, EK and K4 model
MAIN RELAY
TO IGNITION COIL
3
5
SBF-8
6
4
*
*
No.13
3
4
IGNITION
SWITCH
B72
B47
BATTERY
No.12
SBF-7
A: B134
B: B135
*1
: LHD MODEL: 1
*4
: LHD MODEL: 2
ECM
RHD MODEL: 2
RHD MODEL: 1
B21
35
47
37
34
36
A6
A7
B12
D3
D7
D1
D2
B1
B4
D: B137
52
B19
2
B6
*B51
SBF-1
E2
B72
1 2 3
4 5 6
B21
B47
1
3
5
2
4
6
A:
1
8 9
18 19
28 29
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
2
10
20
30
B:
B134
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B135
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
D:
B137
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
28 29
30 31
26 27
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
EN-02456
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?
CHECK MAIN RELAY.

No. 1 and No. 2.
terminals.
Terminals
No. 3 No. 5:
No. 4 No. 6:
and chassis ground.
LHD model
RHD model
Yes
Go to step 2.

?
Go to step 3.

?
Go to step 4.
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Replace the main
relay.
Repair the open

circuit in harness
between ECM
connector and
engine grounding
terminal.
Repair the open or

Repair the open or

Repair the open

circuit in harness
between ECM
connector and

Step
Check
relay.
CHECK INPUT VOLTAGE OF MAIN RELAY. Is the voltage more than 10 V?
Yes
Go to step 8.
No
Repair the open or
between ECM
connector and
Go to step 9.
Repair the open or

Check ignition
control system.
<Ref. to EN(H4SO
2.5)(diag)-61,
Diagnostics for
Engine Starting
Failure.>
Repair the open or

between ECM
connector and


CAUTION:
WIRING DIAGRAM:
EC, EK and K4 model
ECM
17
18
B135
B225 RELAY HOLDER
B47
MAIN RELAY
15A
2
BATTERY
SBF-8
15
13
49
B21
E2
3
4
1
2
E12
IGNITION COIL
&
IGNITOR ASSY
E12
1 2 3 4
B225
B47
1
3
5
2
4
6
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
B21
B135
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
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
32 33
34 35
28 29 30 31
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
EN-01989
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?
CHECK IGNITION SYSTEM FOR SPARKS. Does spark occur at each cyl1) Remove the plug cord cap from each spark inder?
plug.
2) Install a new spark plug on plug cord cap.
Yes
Go to step 2.
Check fuel pump

system. <Ref. to
EN(H4SO
2.5)(diag)-64,
CAUTION:
Do not remove the spark plug from engine.
engine.
4) While opening the throttle valve fully, crank
cylinder.
& ignitor ASSY.
engine ground.
?
ground.
Go to step 5.
CHECK IGNITION COIL & IGNITOR ASSY. Is the resistance 10 15 k? Go to step 6.

2) Measure the resistance between spark
plug cord contact portions to check secondary
coil.
Terminals
No. 1 No. 2:
No. 3 No. 4:
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Go to step 3.

NOTE:
the following:
Open circuit in
harness between
ignition coil & ignitor ASSY and
Poor contact in
coupling connector
Blown out fuse
NOTE:
the following:
Open circuit in
harness between
grounding terminal
ASSY. <Ref. to
IG(H4SO 2.0)-8,
Ignition Coil and
Ignitor Assembly.>

Step
CHECK INPUT SIGNAL FOR IGNITION COIL
& IGNITOR ASSY.
1) Connect the connector to ignition coil &
ignitor ASSY.
2) Check if voltage varies synchronously with
engine speed when cranking, while monitoring
voltage between ignition coil & ignitor ASSY
& ignitor ASSY.
connector.
(B135) No. 18 (E12) No. 1:
(B135) No. 17 (E12) No. 4:
CHECK POOR CONTACT.
Check
Does the voltage vary more
than 10 V?
Yes
Go to step 7.
No
ASSY. <Ref. to
IG(H4SO 2.0)-8,
Ignition Coil and
Ignitor Assembly.>

?
Go to step 8.

M?
Go to step 9.

connector?
Repair the poor

contact in ECM
connector.
NOTE:
the following:
Open circuit in
harness between
ECM and ignition
coil & ignitor ASSY
connector
Poor contact in
coupling connector
Repair the ground
ECM and ignition
coil & ignitor ASSY
connector.
Check fuel pump

circuit. <Ref. to
EN(H4SO
2.5)(diag)-64,


CAUTION:
WIRING DIAGRAM:
EC, EK and K4 model
No.11
B72
IGNITION
SWITCH
BATTERY
SBF-7
No.12
FUEL PUMP
RELAY
SBF-1
2
3
4
1
B135
ECM
LHD
RHD
B362
LHD
R1
RHD
R2
FUEL PUMP
CONDENSER
FUEL PUMP
16
B97
4
B98
1
2
5
6
R142
R58
B362
1 2
3
4
B72
R142
B97
B98
R58
B135
1 2 3
4 5 6
1
2
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
1
2 3
4 5 6 7 8
1 2
3 4
5 6
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
5
7 8
6
EN-02457
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?

PUMP.
Check the fuel pump is in operation for two
ON.

operating sound?
NOTE:
Mode for procedures. <Ref. to EN(H4SO
Check Mode.>
CHECK GROUND CIRCUIT OF FUEL PUMP. Is the resistance less than 5
?
2) Remove the fuel pump access hole lid.
4) Measure the resistance of harness connector between fuel pump and chassis ground.
Yes
Go to step 2.
Check the fuel

injector circuit.
<Ref. to EN(H4SO
2.5)(diag)-67,
FUEL INJECTOR
Starting Failure.>
Go to step 4.
CHECK POWER SUPPLY TO FUEL PUMP. Is the voltage more than 10 V?

2) Measure the voltage of power supply circuit
between fuel pump connector and chassis
ground.
?
2) Measure the resistance of harness connector between fuel pump and fuel pump relay.
(R58) No. 5 (B362) No. 1:
Replace the fuel

pump. <Ref. to
FU(H4SO 2.5)-49,
Fuel Pump.>

fuel pump and fuel pump relay connector.
Go to step 7.

M?
Go to step 6.
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Go to step 3.

NOTE:
the following:
Open circuit in
harness between
grounding terminal
Go to step 5.

NOTE:
the following:
Open circuit in
harness between
grounding terminal
Poor contact in
coupling connector
Repair the short
circuit in harness
between fuel pump
and fuel pump
relay connector.

Step
CHECK FUEL PUMP RELAY.
1) Disconnect the connectors from fuel pump
relay and main relay.
2) Remove the fuel pump relay and main relay
with bracket.
3) Connect the battery to fuel pump relay connector terminals No. 3 and No. 4.
terminals of fuel pump relay.
Terminals
No. 2 No. 1:
FUEL PUMP RELAY CONNECTOR.
between ECM and fuel pump relay connector.
(B135) No. 27 (B362) No. 4:
(B135) No. 26 (B362) No. 4:
CHECK POOR CONTACT.
Check
?
Yes
Go to step 8.
No
Replace the fuel
pump relay. <Ref.
to FU(H4SO 2.5)49, Fuel Pump.>

?
Go to step 9.
Repair the open

circuit in harness
between ECM and
fuel pump relay
connector.

connector?
Repair the poor

contact in ECM
connector.
Check the fuel

injector circuit.
<Ref. to EN(H4SO
2.5)(diag)-67,
FUEL INJECTOR
Starting Failure.>


CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4SO 2.5)(diag)-41, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4SO 2.5)(diag)-34, Inspection
Mode.>.
WIRING DIAGRAM:
EC, EK and K4 model
MAIN RELAY
5
3
BATTERY
SBF-8
6
4
2
1
B47
45
44
5
43
42
48
B136 ECM
B21
E2
E17
2
E6
E16
E5
E
FUEL INJECTOR
No. 2
FUEL INJECTOR
No. 1
E5
E16
E6
E17
1 2
B47
1
3
5
2
4
6
FUEL INJECTOR
No. 3
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
FUEL INJECTOR
No. 4
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
EN-01991
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?
CHECK OPERATION OF EACH FUEL INJEC- Does the fuel pump emit operTOR.
ating sound?
While cranking the engine, check each fuel
injector emits operating sound. Use a sound
scope or apply a screwdriver to the injector for
this check.
INJECTOR.

#1 (B136) No. 6 (E5) No. 1:
#2 (B136) No. 5 (E16) No. 1:
#3 (B136) No. 4 (E6) No. 1:
#4 (B136) No. 3 (E17) No. 1:

?


M?
Yes
Go to step 2.
Check the fuel

pressure. <Ref. to
ME(H4SO 2.0)-27,
INSPECTION,
Fuel Pressure.>
Go to step 4.
Go to step 5.
Go to step 6.
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Go to step 3.

NOTE:
the following:
Open circuit in
harness between
main relay and fuel
injector connector
Poor contact in
Poor contact in
coupling connector
Poor contact in
NOTE:
the following:
Open circuit in
harness between
ECM and fuel
injector connector
Poor contact in
coupling connector
Repair the ground
ECM and fuel
injector connector.

Step
Check
injector terminals.
Terminals
No. 1 No. 2:
CHECK POOR CONTACT.
connector?
Yes
Go to step 7.
No
Replace the faulty
fuel injector.
Repair the poor

contact in ECM
connector.
Inspection using
EN(H4SO
2.5)(diag)-261,
INSPECTION,


A: LIST
1. EC, EK AND K4 MODEL
DTC
P0030
Item
Sensor 1)
P0031

(Bank 1 Sensor 1)
P0032

(Bank 1 Sensor 1)
P0037

(Bank 1 Sensor 2)
P0038

(Bank 1 Sensor 2)
P0102
Mass or Volume Air Flow Circuit Low

Input
P0103
Mass or Volume Air Flow Circuit High

Input
P0107
P0108
P0112

Input
P0113

Input
P0117

Low Input
P0118

High Input
P0122

P0123

P0125

P0131

1 Sensor 1)
NOTE
<Ref. to EN(H4SO 2.5)(diag)-92, DTC P0102 MASS OR VOLUME AIR
FLOW CIRCUIT LOW INPUT, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
<Ref. to EN(H4SO 2.5)(diag)-95, DTC P0103 MASS OR VOLUME AIR
FLOW CIRCUIT HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
<Ref. to EN(H4SO 2.5)(diag)-103, DTC P0112 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT LOW, Diagnostic Procedure with Diagnostic
<Ref. to EN(H4SO 2.5)(diag)-105, DTC P0113 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT HIGH, Diagnostic Procedure with Diagnostic
Code (DTC).>
Code (DTC).>

DTC
P0132
Item
(Bank 1 Sensor 1)
P0133

(Bank 1 Sensor 1)
P0134

P0137

1 Sensor 2)
P0138

(Bank 1 Sensor 2)
P0139

(Bank 1 Sensor 2)
P0171
P0172
P0222

P0223

P0301
Cylinder 1 misfire detected
P0302
P0303
P0304
P0327

P0328

P0335
P0340

P0400
P0420

Threshold (Bank 1)
P0458
NOTE
(DTC).>

DTC
P0459
Item
P0462
P0463
P0500
P0512
P0513
P0519

(Fail-Safe)
P0558
P0559
P0600
P0604

Access Memory (RAM) Error
P0605

Memory (ROM) Error
P0607
P0638
P0691
P0692
P0700

Request)
P0851
P0852
P1086
Tumble Generated Valve Position

Sensor 2 Circuit Low
P1087

Sensor 2 Circuit High
P1088

Sensor 1 Circuit Low
NOTE
(DTC).>
<Ref. to EN(H4SO 2.5)(diag)-178, DTC P0519 IDLE AIR CONTROL SYSTEM PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to EN(H4SO 2.5)(diag)-181, DTC P0604 INTERNAL CONTROL MODULE RANDOM ACCESS MEMORY (RAM) ERROR, Diagnostic Procedure
<Ref. to EN(H4SO 2.5)(diag)-182, DTC P0605 INTERNAL CONTROL MODULE READ ONLY MEMORY (ROM) ERROR, Diagnostic Procedure with
Code (DTC).>
(DTC).>
(DTC).>
<Ref. to EN(H4SO 2.5)(diag)-192, DTC P1086 TUMBLE GENERATED
VALVE POSITION SENSOR 2 CIRCUIT LOW, Diagnostic Procedure with
VALVE POSITION SENSOR 2 CIRCUIT HIGH, Diagnostic Procedure with
VALVE POSITION SENSOR 1 CIRCUIT LOW, Diagnostic Procedure with

DTC
P1089
Item
Sensor 1 Circuit High
P1090
Tumble Generated Valve System 1

(Valve Open)
P1091

(Valve Close)
P1092

(Valve Open)
P1093

(Valve Close)
P1094
Tumble Generated Valve Signal 1

Circuit Malfunction (Open)
P1095

Circuit Malfunction (Short)
P1096

Circuit Malfunction (Open)
P1097

Circuit Malfunction (Short)
P1110
Atmospheric Pressure Sensor Circuit

Malfunction (Low Input)
P1111
Atmospheric Pressure Sensor Circuit

Malfunction (High Input)
P1152
O2 Sensor Circuit Range/Performance (Low) (Bank1 Sensor1)
P1153
O2 Sensor Circuit Range/Performance (High) (Bank1 Sensor1)
P1160
P1492
P1493
P1494
P1495
P1496
NOTE
VALVE POSITION SENSOR 1 CIRCUIT HIGH, Diagnostic Procedure with
VALVE SYSTEM 1 (VALVE OPEN), Diagnostic Procedure with Diagnostic
VALVE SYSTEM 1 (VALVE CLOSE), Diagnostic Procedure with Diagnostic
VALVE SYSTEM 2 (VALVE OPEN), Diagnostic Procedure with Diagnostic
VALVE SYSTEM 2 (VALVE CLOSE), Diagnostic Procedure with Diagnostic
VALVE SIGNAL 1 CIRCUIT MALFUNCTION (OPEN), Diagnostic Procedure
VALVE SIGNAL 1 CIRCUIT MALFUNCTION (SHORT), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
VALVE SIGNAL 2 CIRCUIT MALFUNCTION (OPEN), Diagnostic Procedure
VALVE SIGNAL 2 CIRCUIT MALFUNCTION (SHORT), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4SO 2.5)(diag)-214, DTC P1110 ATMOSPHERIC PRESSURE SENSOR CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4SO 2.5)(diag)-215, DTC P1111 ATMOSPHERIC PRESSURE SENSOR CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
RANGE/PERFORMANCE (LOW) (BANK1 SENSOR1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
RANGE/PERFORMANCE (HIGH) (BANK1 SENSOR1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>

DTC
P1497
Item
P1498
P1499
P1518
P1560
P1570
Antenna
P1571
P1572
IMM Circuit Failure (Except Antenna

Circuit)
P1574
P1576
P1577
P1578
Meter Failure
P2101
P2102
P2103
P2109

P2122

P2123

P2127

P2128

P2135

NOTE
(DTC).>
(DTC).>
(DTC).>

DTC
P2138
Item
NOTE
2. KA AND KS MODEL
DTC
P0030
Item
Sensor 1)
P0031

(Bank 1 Sensor 1)
P0032

(Bank 1 Sensor 1)
P0037

(Bank 1 Sensor 2)
P0038

(Bank 1 Sensor 2)
P0107
P0108
P0112

Input
P0113

Input
P0117

Low Input
P0118

High Input
P0122

P0123

P0125

P0130
O2 Sensor Circuit (Bank 1 Sensor 1)
P0131

1 Sensor 1)
P0132

(Bank 1 Sensor 1)
NOTE
Code (DTC).>
Code (DTC).>
Code (DTC).>
Code (DTC).>
(BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>

DTC
P0133
Item
(Bank 1 Sensor 1)
P0134

P0137

1 Sensor 2)
P0138

(Bank 1 Sensor 2)
P0139

(Bank 1 Sensor 2)
P0171
P0172
P0222

P0223

P0301
P0302
P0303
P0304
P0327

P0328

P0335
P0340

P0400
P0420

Threshold (Bank 1)
P0458
P0459
NOTE
(DTC).>

DTC
P0462
P0463
P0500
P0512
P0513
P0519
P0558
P0559
P0600
P0604
P0605
P0607
P0638
P0691
P0692
P0700
P0851
P0852
P1134
P1137
P1160
P1492
Item
NOTE
Fuel Level Sensor Circuit High Input <Ref. to EN(H4SO 2.0)(diag)-159, DTC P0463 FUEL LEVEL SENSOR A
(DTC).>
<Ref. to EN(H4SO 2.0)(diag)-163, DTC P0519 IDLE AIR CONTROL SYS(Fail-Safe)
TEM PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to EN(H4SO 2.0)(diag)-166, DTC P0604 INTERNAL CONTROL MODAccess Memory (RAM) Error
ULE RANDOM ACCESS MEMORY (RAM) ERROR, Diagnostic Procedure
<Ref. to EN(H4SO 2.0)(diag)-167, DTC P0605 INTERNAL CONTROL MODMemory (ROM) Error
ULE READ ONLY MEMORY (ROM) ERROR, Diagnostic Procedure with
Throttle Actuator Control Range/Per- <Ref. to EN(H4SO 2.0)(diag)-169, DTC P0638 THROTTLE ACTUATOR
formance (Bank 1)
Request)
Code (DTC).>
(DTC).>
(DTC).>
A/F Sensor Micro-Computer Problem <Ref. to EN(H4SO 2.0)(diag)-176, DTC P1134 A/F SENSOR MICRO-COMPUTER PROBLEM (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
O2 Sensor Circuit (Lamda=1) (Bank1 <Ref. to EN(H4SO 2.0)(diag)-178, DTC P1137 O2 SENSOR CIRCUIT
Sensor1)
(BANK1 SENSOR1), Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
cuit Malfunction (Low Input)

DTC
P1493
Item
P1494
P1495
P1496
P1497
P1498
P1499
P1518
P1521
P1560
P1570
Antenna
P1571
P1572
IMM Circuit Failure (Except antenna

circuit)
P1574
P1576
P1577
P1578
Meter Failure
P2100
P2101
P2102
P2103
NOTE
(DTC).>
<Ref. to EN(H4SO 2.0)(diag)-189, DTC P1521 BRAKE SWITCH CIRCUIT
RANGE/PERFORMANCE PROBLEM (HIGH INPUT), Diagnostic Procedure
(DTC).>
(DTC).>
CONTROL MOTOR CIRCUIT OPEN, Diagnostic Procedure with Diagnostic

DTC
P2109
Item
P2111
Throttle Actuator Control System Stuck Open
P2122

P2123

P2127

P2128

P2135

P2138

NOTE
CONTROL SYSTEM - STUCK OPEN, Diagnostic Procedure with Diagnostic


A: DTC P0030 HO2S HEATER CONTROL CIRCUIT (BANK 1 SENSOR 1)
CAUTION:
WIRING DIAGRAM:
EC, EK and K4 model
OXYGEN (A/F)
SENSOR RELAY
BATTERY
B327
SBF-6
6
4
B21
2
1
E2
2
4
6
5
3
1
3
5
50
FRONT OXYGEN
(A/F) SENSOR
E24
E24
1 2 3
4 5 6
1
3
B327
B21
4
3
51
E2
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
B21
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
E
2
3
26
33
25
B134
ECM
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
6
7
B134
1
8 9
18 19
28 29
52
E
B21
E2
E
EN-01992
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?

1) Start and warm-up the engine.
connector.
(B134) No. 2 (E24) No. 6:
(B134) No. 3 (E24) No. 6:
(B134) No. 26 (E24) No. 1:
(B134) No. 33 (E24) No. 3:
(B327) No. 4 (E24) No. 4:
Terminals
No. 4 No. 6:
Yes
Go to step 2.
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Repair the open
circuit in harness
between ECM and
front oxygen (A/F)
sensor connector.

?
Go to step 3.

?
Go to step 4.
Repair the open

circuit in harness
between ECM and
front oxygen (A/F)
sensor connector.

?
Go to step 5.
Repair the open

circuit in harness
between ECM and
front oxygen (A/F)
sensor connector.

?
Go to step 6.
Replace the front

FU(H4SO 2.5)-34,
Front Oxygen (A/
F) Sensor.>
CHECK POOR CONTACT.
Replace the front
Check the poor contact in ECM and front oxy- front oxygen (A/F) sensor con- contact in ECM or oxygen (A/F) sengen (A/F) sensor connector.
nector?
sensor connector. FU(H4SO 2.5)-34,
Front Oxygen (A/
F) Sensor.>

B: DTC P0031 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 1)

Immediately at fault recognition.
CAUTION:
WIRING DIAGRAM:
EC, EK and K4 model
OXYGEN (A/F)
SENSOR RELAY
BATTERY
B327
SBF-6
6
4
B21
2
1
E2
2
4
6
5
3
1
3
5
50
FRONT OXYGEN
(A/F) SENSOR
E24
E24
1 2 3
4 5 6
1
3
B327
B21
4
3
51
E2
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
B21
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
E
2
3
26
33
25
B134
ECM
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
6
7
B134
1
8 9
18 19
28 29
52
E
B21
E2
E
EN-01992
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?
CHECK POWER SUPPLY TO FRONT OXYGEN (A/F) SENSOR.

(A/F) sensor.

Yes
Go to step 2.
Do DTC P0031 and P0037

Go to step 3.
appear at the same time on the

?
CHECK CURRENT DATA.

NOTE:
For detailed operation procedure, refer to the
Go to step 5.
Repair the poor

contact connector.
NOTE:
the following:
Poor contact in
front oxygen (A/F)
sensor connector
Poor contact in
ECM connector.
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Go to step 6.
Repair the power

supply line.
NOTE:
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
NOTE:
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 6.

Step
and chassis ground.
Terminals
No. 4 No. 6:
Check
Yes
Go to step 8.
Repair the poor


?
No
Go to step 7.
Go to step 8.

sor. <Ref. to
FU(H4SO 2.5)-34,
NOTE:
In this case, repair Front Oxygen (A/
F) Sensor.>
the following:
Open or ground
Poor contact in
front oxygen (A/F)
sensor connector
Poor contact in
ECM connector

C: DTC P0032 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 1)

CAUTION:
WIRING DIAGRAM:
EC, EK and K4 model
OXYGEN (A/F)
SENSOR RELAY
BATTERY
B327
SBF-6
6
4
B21
2
1
E2
2
4
6
5
3
1
3
5
50
FRONT OXYGEN
(A/F) SENSOR
E24
E24
1 2 3
4 5 6
1
3
B327
B21
4
3
51
E2
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
B21
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
E
2
3
26
33
25
B134
ECM
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
6
7
B134
1
8 9
18 19
28 29
52
E
B21
E2
E
EN-01992
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?

HEATER CURRENT.
connector.
NOTE:
connector?
and chassis ground.
Yes
Go to step 2.
Go to step 3.
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Go to step 4.

<Ref. to FU(H4SO
2.5)-36, Engine
Control Module
(ECM).>

ECM and front


CAUTION:
WIRING DIAGRAM:
EC, EK and K4 model
OXYGEN SENSOR
RELAY
BATTERY
B83
B327
B19
SBF-6
5
3
1
3
5
1 2
3 4
2
4
6
1 2 3 4
5 6 7 8
6
4
B21
REAR
OXYGEN SENSOR
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
B19
B327
2
1
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B83
RHD
RHD
LHD
LHD
A: B134
1
8 9
18 19
28 29
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
C35
D31
D24
B2
B83
2
10
20
30
B: B135
A: B134
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
B: B135
ECM
C: B136
D: B137
A6
A7
C: B136
52
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
B21
D: B137
E2
: TERMINAL No. RANDOM ARRANGEMENT
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
EN-02458
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?
CHECK GROUND CIRCUIT OF ECM.

?
Go to step 3.

CHECK CURRENT DATA.
NOTE:
Yes
Go to step 2.

and chassis ground.
NOTE:
model is the same
as 2.0 L model.
NOTE:
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 4.
NOTE:
the following:
Poor contact in
Poor contact in
rear oxygen sensor connecting
harness connector
Poor contact in
ECM connector
Go to step 7.
Go to step 5.

Repair the poor
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
Go to step 6.

Step
Check
sensor.
Yes
Replace the ECM.
<Ref. to FU(H4SO
2.5)-36, Engine
Control Module
(ECM).>

CHECK POWER SUPPLY TO REAR OXYGEN SENSOR.
sensor.

?
2) Measure the resistance between rear oxygen (A/F) sensor connector terminals.
Terminals
No. 1 No. 2:
No
Repair the battery
repair, replace the
ECM. <Ref. to
FU(H4SO 2.5)-36,
Engine Control
Module (ECM).>
Repair the power
supply line.
NOTE:
the following:
Open circuit in
harness between
main relay and
Poor contact in
Poor contact in
coupling connector
tor.
<Ref. to FU(H4SO
2.5)-35, Rear OxyNOTE:
In this case, repair gen Sensor.>
the following:
Open circuit in
harness between
Poor contact in
Poor contact in
ECM connector
Poor contact in
coupling connector


CAUTION:
WIRING DIAGRAM:
EC, EK and K4 model
OXYGEN SENSOR
RELAY
BATTERY
B83
B327
B19
SBF-6
5
3
1
3
5
1 2
3 4
2
4
6
1 2 3 4
5 6 7 8
6
4
B21
REAR
OXYGEN SENSOR
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
B19
B327
2
1
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B83
RHD
RHD
LHD
LHD
A: B134
1
8 9
18 19
28 29
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
C35
D31
D24
B2
B83
2
10
20
30
B: B135
A: B134
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
B: B135
ECM
C: B136
D: B137
A6
A7
C: B136
52
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
B21
D: B137
E2
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
EN-02458
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?

and chassis ground.
CHECK CURRENT DATA.
NOTE:
CHECK POOR CONTACT.
connector?
Yes
Go to step 2.
Go to step 3.
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Go to step 4.

<Ref. to FU(H4SO
2.5)-36, Engine
Control Module
(ECM).>
Repair the poor

contact in ECM
connector.
END.

F: DTC P0102 MASS OR VOLUME AIR FLOW CIRCUIT LOW INPUT

TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
EC, EK and K4 model
MAIN RELAY
5
3
BATTERY
SBF-8
6
4
2
1
B47
MASS AIR FLOW AND
INTAKE AIR TEMPERATURE
SENSOR
2
31
3
23
13
5
32
B3
B83
RHD
*
*
RHD
2
8
LHD
LHD
35
B83
B136
B3
1 2 3 4 5
B47
1
3
5
2
4
6
ECM
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B83
5 6
14 15 16
25 26 27
33 34 35
1 2 3 4
5 6 7 8
EN-02459
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?
READ THE DATA CONNECTING SUBARU Is the voltage 0.2 4.7 V?

SELECT MONITOR.
link connector.
5) Read the voltage of mass air flow sensor
NOTE:
READ CURRENT DATA SHOWN ON DISPLAY FOR ENGINE. <Ref. to EN(H4SO
2.5)(diag)-26, Subaru Select Monitor.>
CHECK INPUT SIGNAL OF ECM.

and chassis ground while engine is idling.
CHECK POWER SUPPLY TO MASS AIR
FLOW SENSOR.
2) Disconnect the connector from mass air
flow sensor.
4) Measure voltage between mass air flow
Yes
Go to step 2.

light illuminates,
the circuit has
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.
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Go to step 3.
NOTE:
the following:
Open or ground
mass air flow sensor and ECM connector
Poor contact in
mass air flow sensor or ECM connector
Go to step 4.

shaking the harness and connector of ECM while monitoring the value with Subaru
Select Monitor?
Repair the poor

contact in ECM
connector.
Go to step 6.
Replace the ECM.

<Ref. to FU(H4SO
2.5)-36, Engine
Control Module
(ECM).>
Repair the open
circuit between
mass air flow sensor and main relay

Step
MASS AIR FLOW SENSOR CONNECTOR.
between ECM and mass air flow sensor connector.
(B136) No. 23 (B3) No. 3:
(B136) No. 31 (B3) No. 2:
(B136) No. 35 (B3) No. 5:
ECM and chassis ground.
CHECK POOR CONTACT.
Check poor contact in mass air flow sensor
connector.
Check
?
Yes
Go to step 7.
No
Repair the open
circuit between
ECM and mass air
flow sensor connector.

M?
Go to step 8.
Repair the ground

short circuit
between ECM and
mass air flow sensor connector.
Is there poor contact in mass

air flow sensor connector?
Repair the poor

contact in mass air
Replace the mass

air flow and intake
air temperature
sensor. <Ref. to
FU(H4SO 2.5)-26,
Mass Air Flow and

G: DTC P0103 MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT

TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
EC, EK and K4 model
MAIN RELAY
5
3
BATTERY
SBF-8
6
4
2
1
B47
MASS AIR FLOW AND
SENSOR
2
31
3
23
13
5
32
B3
B83
RHD
*
*
RHD
2
8
LHD
LHD
35
B83
B136
B3
1 2 3 4 5
B47
1
3
5
2
4
6
ECM
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B83
5 6
14 15 16
25 26 27
33 34 35
1 2 3 4
5 6 7 8
EN-02459
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?

SELECT MONITOR.
link connector.
NOTE:
2) Disconnect the connector from mass airflow sensor.
?
between ECM connector and mass air flow
sensor connector.
(B3) No. 2 (B136) No. 31:
Yes
Go to step 2.

light illuminates,
the circuit has
this time.
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Go to step 3.

mass air flow sensor connector and
ECM connector.
Replace the mass

air flow sensor.
<Ref. to FU(H4SO
2.5)-26, Mass Air
Flow and Intake
Air Temperature
Sensor.>
Repair the open

circuit in harness
between mass air
flow sensor connector and ECM
connector.

H: DTC P0107 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE

CIRCUIT LOW INPUT
CAUTION:
WIRING DIAGRAM:
EC, EK and K4 model
E21
MANIFOLD
ABSOLUTE
PRESSURE
SENSOR
2
1
3
1 2 3
B83
E21
B122
B138
1 2 3 4
5 6 7 8
19
7
20
E2
B21
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
B83
RHD
RHD
LHD
LHD
B138 : LHD
B122 : RHD
B83
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
35
22
16
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B136
ECM
EN-02460
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?
CHECK CURRENT DATA.

Yes
Go to step 2.
Is the value less than 13.3 kPa Go to step 4.

(100 mmHg, 3.94 inHg)?
NOTE:
CHECK POOR CONTACT.
Check the poor contact in ECM and manifold manifold pressure sensor con- contact in ECM or
pressure sensor connector.
nector?
manifold pressure
sensor connector.

and chassis ground.
and chassis ground.
CHECK INPUT SIGNAL TO ECM.
CHECK INPUT SIGNAL TO ECM (USING
Does the voltage change when Repair the poor

connector?
connector.

NOTE:
Repair the poor

contact in ECM
connector.
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Go to step 3.

light illuminates,
the circuit has
this time.
Go to step 5.
Replace the ECM.

<Ref. to FU(H4SO
2.5)-36, Engine
Control Module
(ECM).>
Go to step 7.
Go to step 8.

10
Step
engine ground.
sensor connector.
(B136) No. 35 (E21) No. 2:
CHECK POOR CONTACT.
Check
Yes
No
Repair the open
circuit in harness
between ECM and
manifold absolute
pressure sensor
connector.

?
Go to step 10.
Repair the open

circuit in harness
between ECM and
manifold absolute
pressure sensor
connector.

connector?
Repair the poor

connector.


I:
DTC P0108 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE

CIRCUIT HIGH INPUT

CAUTION:
WIRING DIAGRAM:
EC, EK and K4 model
E21
MANIFOLD
ABSOLUTE
PRESSURE
SENSOR
2
1
3
1 2 3
B83
E21
B122
B138
1 2 3 4
5 6 7 8
19
7
20
E2
B21
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
B83
RHD
RHD
LHD
LHD
B138 : LHD
B122 : RHD
B83
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
35
22
16
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B136
ECM
EN-02460
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?
CHECK CURRENT DATA.

NOTE:
and chassis ground.
and chassis ground.
CHECK INPUT SIGNAL TO ECM.
and chassis ground.
CHECK INPUT SIGNAL TO ECM (USING

kPa (896.5 mmHg, 35.29
inHg)?
Yes
Go to step 2.
Go to step 11.
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Go to step 3.
Go to step 4.
Does the voltage change when Repair the poor

connector?
connector.
Replace the ECM.

<Ref. to FU(H4SO
2.5)-36, Engine
Control Module
(ECM).>
Go to step 6.

Repair the poor

contact in ECM
connector.
NOTE:
engine ground.
Go to step 7.
Repair the open

circuit in harness
between ECM and
manifold absolute
pressure sensor
connector.

10
11
Step
sensor connector.
(B136) No. 22 (E21) No. 1:
connector.
(B136) No. 35 (E21) No. 2:
CHECK POOR CONTACT.
Check
?
Yes
Go to step 9.
No
Repair the open
circuit in harness
between ECM and
manifold absolute
pressure sensor
connector.

?
Go to step 10.
Repair the open

circuit in harness
between ECM and
manifold absolute
pressure sensor
connector.

connector?

Repair battery
Replace the manishort in harness
fold absolute presbetween ECM and sure sensor. <Ref.
manifold absolute to FU(H4SO 2.5)pressure sensor
25, Manifold Absoconnector.
lute Pressure Sensor.>

kPa (896.5 mmHg, 35.29
MANIFOLD ABSOLUTE PRESSURE SENinHg)?
SOR CONNECTOR.
1) Turn the ignition switch to OFF, and the
NOTE:
Repair the poor

connector.

J: DTC P0112 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT LOW

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
EC, EK and K4 model
MAIN RELAY
5
3
BATTERY
SBF-8
6
4
2
1
B47
MASS AIR FLOW AND
SENSOR
2
31
3
23
13
5
32
B3
B83
RHD
*
*
RHD
2
8
LHD
LHD
35
B83
B136
B3
1 2 3 4 5
B47
1
3
5
2
4
6
ECM
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B83
5 6
14 15 16
25 26 27
33 34 35
1 2 3 4
5 6 7 8
EN-02459
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?
CHECK CURRENT DATA.

2) Read the data of mass air flow and intake
air temperature sensor signal using Subaru
Select Monitor.

Yes
Go to step 2.
Go to step 3.
NOTE:
CHECK HARNESS BETWEEN MASS AIR

FLOW AND INTAKE AIR TEMPERATURE
SENSOR AND ECM CONNECTOR.
flow and intake air temperature sensor.
Select Monitor.

NOTE:
Replace the mass

air flow and intake
air temperature
sensor. <Ref. to
FU(H4SO 2.5)-26,
Mass Air Flow and
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Repair the poor
contact.
NOTE:
the following:
Poor contact in
mass air flow and
Poor contact in
ECM
Poor contact in
coupling connector
Poor contact in
joint connector
Repair the ground
mass air flow and
ECM connector.

K: DTC P0113 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT HIGH

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
EC, EK and K4 model
MAIN RELAY
5
3
BATTERY
SBF-8
6
4
2
1
B47
MASS AIR FLOW AND
SENSOR
2
31
3
23
13
5
32
B3
B83
RHD
*
*
RHD
2
8
LHD
LHD
35
B83
B136
B3
1 2 3 4 5
B47
1
3
5
2
4
6
ECM
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B83
5 6
14 15 16
25 26 27
33 34 35
1 2 3 4
5 6 7 8
EN-02459
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?

CHECK CURRENT DATA.
2) Read the data of air flow and intake air temperature sensor signal using Subaru Select
Monitor.
NOTE:
Yes
Go to step 2.
Go to step 3.
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Repair the poor
contact.
NOTE:
the following:
Poor contact in
mass air flow and
Poor contact in
ECM
Poor contact in
coupling connector
Poor contact in
joint connector
mass air flow and
ECM connector.

flow and intake air temperature sensor.
3) Measure the voltage between mass air flow
and intake air temperature sensor connector
and engine ground.
and engine ground.

mass air flow and
ECM connector.

Step
Measure the voltage between mass air flow
and engine ground.
Check

?
between mass air flow and intake air temperature sensor connector and engine ground.
Yes
Go to step 6.
No
NOTE:
the following:
Open circuit in
harness between
mass air flow and
ECM connector
Poor contact in
mass air flow and
Poor contact in
ECM
Poor contact in
coupling connector
Poor contact in
joint connector
Replace the mass Repair the harair flow and intake ness and connecair temperature
tor.
sensor. <Ref. to
NOTE:
FU(H4SO 2.5)-26, In this case, repair
Mass Air Flow and the following:
Intake Air Temper- Open circuit in
ature Sensor.>
harness between
mass air flow and
ECM connector
Poor contact in
mass air flow and
Poor contact in
ECM
Poor contact in
joint connector

L: DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW

TROUBLE SYMPTOM:
Hard to start
Erroneous idling
CAUTION:
WIRING DIAGRAM:
EC, EK and K4 model
ENGINE
COOLANT
TEMPERATURE
SENSOR
E8
2
1
1 2
E8
B83
1 2 3 4
5 6 7 8
8
19
E2
B21
B83
RHD
RHD
LHD
LHD
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B83
B136
5 6
14 15 16
25 26 27
33 34 35
14
35
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B136
ECM
EN-02461
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?
CHECK CURRENT DATA.

NOTE:

ECM CONNECTOR.
Yes
Go to step 2.

ture more than 150C (302F)?
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Repair the poor
contact.
NOTE:
the following:
Poor contact in
engine coolant
temperature sensor
Poor contact in
ECM
Poor contact in
coupling connector
Poor contact in
joint connector
Is the engine coolant tempera- Replace the
Repair the ground
ture less than 40C (40F)? engine coolant
sor. <Ref. to
engine coolant
FU(H4SO 2.5)-20, temperature senEngine Coolant
sor.>
NOTE:

M: DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH

TROUBLE SYMPTOM:
Hard to start
Erroneous idling
CAUTION:
WIRING DIAGRAM:
EC, EK and K4 model
ENGINE
COOLANT
TEMPERATURE
SENSOR
E8
2
1
1 2
E8
B83
1 2 3 4
5 6 7 8
8
19
E2
B21
B83
RHD
RHD
LHD
LHD
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B83
B136
5 6
14 15 16
25 26 27
33 34 35
14
35
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B136
ECM
EN-02461
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?
CHECK CURRENT DATA.

NOTE:
Yes
Go to step 2.

ture less than 40C (40F)?
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Repair the poor
contact.
NOTE:
the following:
Poor contact in
engine coolant
temperature sensor
Poor contact in
ECM
Poor contact in
coupling connector
Poor contact in
joint connector
ECM and engine

ECM CONNECTOR.
2) Disconnect the connectors from engine
ground.
ECM CONNECTOR.
ground.

ECM and engine

Step
ECM CONNECTOR.
ground.
Check

ECM CONNECTOR.

?
Yes
Go to step 6.
Replace the
engine coolant
FU(H4SO 2.5)-20,
Engine Coolant
No
NOTE:
the following:
Open circuit in
harness between
ECM and engine
Poor contact in
engine coolant
Poor contact in
ECM connector
Poor contact in
coupling connector
Poor contact in
joint connector
NOTE:
the following:
Open circuit in
harness between
ECM and engine
Poor contact in
engine coolant
Poor contact in
ECM connector
Poor contact in
coupling connector
Poor contact in
joint connector

N: DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT

LOW
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:

WIRING DIAGRAM:
EC, EK and K4 model
BATTERY
ELECTRONIC
THROTTLE
CONTROL RELAY
SBF-8
B362
7
5
6
8
B35
D6
MAIN RELAY
ECM
C19
C29
C16
D4
D5
C35
D3
D1
D2
B1
B4
D: B137
C: B136
C18
B: B135
B83
LHD
LHD
: TERMINAL NO. RANDOM ARRANGEMENT
B138 : LHD
B138
B122 : RHD
RHD
RHD
*
*
LHD
15
B20
16
37
36
35
20
39
38
19
B83
B21
RHD
E2
1
E1
36
B122
B21
5
1
2
3
E2
ELECTRONIC
THROTTLE CONTROL
E57
B362
B122
B21
B20
B83
1 2
3
4
B138
5
7 8
6
1 2 3 4
5 6 7 8
B:
1
8 9
20 21
28 29
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
B135
2
3
10 11 12 13
22 23
30 31
4 5 6
7
14 15 16 17 18 19
24 25
26 27
32 33
34 35
C:
1
5
9
13
2
6
10
14
3
7
11
15
E57
4
8
12
16
1 2 3 4 5 6
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B136
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
D:
B137
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
EN-02462
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?
Yes
Go to step 2.

CHECK POOR CONTACT.

throttle control.
(B136) No. 18 (E57) No. 6:
(B136) No. 16 (E57) No. 5:
THROTTLE CONTROL.

?
Go to step 5.

M?
Go to step 6.
Go to step 7.

No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Go to step 4.
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.

harness.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
(ECM).>
Repair the poor
?
trol connector.
Replace the ECM
erator position
to FU(H4SO 2.5)sensor if defective. 36, Engine Control Module
(ECM).>

O: DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT

HIGH
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:

WIRING DIAGRAM:
EC, EK and K4 model
BATTERY
ELECTRONIC
THROTTLE
CONTROL RELAY
SBF-8
B362
7
5
6
8
B35
D6
MAIN RELAY
ECM
C19
C29
C16
D4
D5
C35
D3
D1
D2
B1
B4
D: B137
C: B136
C18
B: B135
B83
LHD
LHD
B138 : LHD
B138
B122 : RHD
RHD
RHD
*
*
LHD
15
B20
16
37
36
35
20
39
38
19
B83
B21
RHD
E2
1
E1
36
B122
B21
5
1
2
3
E2
ELECTRONIC
THROTTLE CONTROL
E57
B362
B122
B21
B20
B83
1 2
3
4
B138
5
7 8
6
1 2 3 4
5 6 7 8
B:
1
8 9
20 21
28 29
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
B135
2
3
10 11 12 13
22 23
30 31
4 5 6
7
14 15 16 17 18 19
24 25
26 27
32 33
34 35
C:
1
5
9
13
2
6
10
14
3
7
11
15
E57
4
8
12
16
1 2 3 4 5 6
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B136
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
D:
B137
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
EN-02462
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?
Yes
Go to step 2.

2)Read the data of main throttle sensor signal
CHECK POOR CONTACT.

V?
Go to step 3.

throttle control.
(B136) No. 18 (E57) No. 6:
(B136) No. 35 (E57) No. 3:

?
Go to step 5.

?
Go to step 6.



M?
(B136) No. 18 (B136) No. 16:
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Go to step 4.
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
(ECM).>
Go to step 7.
Repair the battery
ECM connector
and electronic
throttle control
connector.
Repair the poor
Repair the short
Replace the elecpower supply.

P: DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP

FUEL CONTROL
TROUBLE SYMPTOM:
Engine will not return to idling.
CAUTION:
WIRING DIAGRAM:
EC, EK and K4 model
ENGINE
COOLANT
TEMPERATURE
SENSOR
E8
2
1
1 2
E8
B83
1 2 3 4
5 6 7 8
8
19
E2
B21
B83
RHD
RHD
LHD
LHD
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B83
B136
5 6
14 15 16
25 26 27
33 34 35
14
35
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B136
ECM
EN-02461
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?
CHECK ENGINE COOLING SYSTEM.

NOTE:
Thermostat open stuck
Coolant level
Coolant freeze
Tire diameter
Is there any fault in engine

cooling system?
Yes
Go to step 2.

List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(H4SO
2.5)(diag)-70, List
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0125.
CO(H4SO 2.0)-18,
Thermostat.>
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Go to step 3.
Replace the
engine coolant
FU(H4SO 2.5)-20,
Engine Coolant

Q: DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1)

CAUTION:
WIRING DIAGRAM:
EC, EK and K4 model
OXYGEN (A/F)
SENSOR RELAY
BATTERY
B327
SBF-6
6
4
B21
2
1
E2
2
4
6
5
3
1
3
5
50
FRONT OXYGEN
(A/F) SENSOR
E24
E24
1 2 3
4 5 6
1
3
B327
B21
4
3
51
E2
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
B21
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
E
2
3
26
33
25
B134
ECM
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
6
7
B134
1
8 9
18 19
28 29
52
E
B21
E2
E
EN-01992
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?


M?
Yes
Go to step 2.
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Replace the front Repair the ground
oxygen (A/F) sen- short circuit in harsor. <Ref. to
ness between
FU(H4SO 2.5)-34, ECM and front
Front Oxygen (A/ oxygen (A/F) senF) Sensor.>
sor connector.

R: DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1)

CAUTION:
WIRING DIAGRAM:
EC, EK and K4 model
OXYGEN (A/F)
SENSOR RELAY
BATTERY
B327
SBF-6
6
4
B21
2
1
E2
2
4
6
5
3
1
3
5
50
FRONT OXYGEN
(A/F) SENSOR
E24
E24
1 2 3
4 5 6
1
3
B327
B21
4
3
51
E2
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
B21
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
E
2
3
26
33
25
B134
ECM
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
6
7
B134
1
8 9
18 19
28 29
52
E
B21
E2
E
EN-01992
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?

(A/F) sensor.
Yes
Go to step 2.
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Replace the front Repair the battery
oxygen (A/F) sen- short circuit in harsor. <Ref. to
ness between
FU(H4SO 2.5)-34, ECM and front
Front Oxygen (A/ oxygen (A/F) senF) Sensor.>
sor connector.

S: DTC P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1)

CAUTION:
WIRING DIAGRAM:
EC, EK and K4 model
OXYGEN (A/F)
SENSOR RELAY
BATTERY
B327
SBF-6
6
4
B21
2
1
E2
2
4
6
5
3
1
3
5
50
FRONT OXYGEN
(A/F) SENSOR
E24
E24
1 2 3
4 5 6
1
3
B327
B21
4
3
51
E2
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
B21
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
E
2
3
26
33
25
B134
ECM
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
6
7
B134
1
8 9
18 19
28 29
52
E
B21
E2
E
EN-01992
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?

NOTE:

system?
Yes
Go to step 2.

List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(H4SO
2.5)(diag)-70, List
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Go to step 3.
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0133.
Repair the exhaust Replace the front
system.
FU(H4SO 2.5)-34,
Front Oxygen (A/
F) Sensor.>

T: DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 1)

CAUTION:
WIRING DIAGRAM:
EC, EK and K4 model
OXYGEN (A/F)
SENSOR RELAY
BATTERY
B327
SBF-6
6
4
B21
2
1
E2
2
4
6
5
3
1
3
5
50
FRONT OXYGEN
(A/F) SENSOR
E24
E24
1 2 3
4 5 6
1
3
B327
B21
4
3
51
E2
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
B21
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
E
2
3
26
33
25
B134
ECM
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
6
7
B134
1
8 9
18 19
28 29
52
E
B21
E2
E
EN-01992
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?

connector.
(B134) No. 26 (E24) No. 1:
(B134) No. 33 (E24) No. 3:

?
CHECK POOR CONTACT.


Yes
Go to step 2.
Go to step 3.
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
NOTE:
the following:
Open circuit in
harness between
ECM and front
Poor contact in
front oxygen (A/F)
sensor connector
Poor contact in
ECM connector
Replace the front
Repair the poor
contact in front
sor connector.
FU(H4SO 2.5)-34,
Front Oxygen (A/
F) Sensor.>

U: DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2)

CAUTION:
WIRING DIAGRAM:
EC, EK and K4 model
OXYGEN SENSOR
RELAY
BATTERY
B83
B327
B19
SBF-6
5
3
1
3
5
1 2
3 4
2
4
6
1 2 3 4
5 6 7 8
6
4
B21
REAR
OXYGEN SENSOR
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
B19
B327
2
1
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B83
RHD
RHD
LHD
LHD
A: B134
1
8 9
18 19
28 29
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
C35
D31
D24
B2
B83
2
10
20
30
B: B135
A: B134
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
B: B135
ECM
C: B136
D: B137
A6
A7
C: B136
52
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
B21
D: B137
E2
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
EN-02458
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?

mV?
NOTE:
?
rear oxygen sensor.
(B137) No. 24 (B19) No. 3:
(B136) No. 35 (B19) No. 4:
Yes
Go to step 2.
Inspect the DTC

Code (DTC).
<Ref. to EN(H4SO
2.5)(diag)-70, List
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Go to step 3.
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0137.
Go to step 6.
Go to step 4.
Repair the open

Go to step 5.
circuit in harness
between ECM and

Step
Check
sensor.
Yes
Replace the rear
oxygen sensor.
<Ref. to FU(H4SO

Repair or replace
the faulty part.

system?
NOTE:
sensor
No
NOTE:
the following:
Open circuit in
harness between
Poor contact in
Poor contact in
ECM connector
Replace the rear
oxygen sensor.
<Ref. to FU(H4SO

V: DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2)

CAUTION:
WIRING DIAGRAM:
EC, EK and K4 model
OXYGEN SENSOR
RELAY
BATTERY
B83
B327
B19
SBF-6
5
3
1
3
5
1 2
3 4
2
4
6
1 2 3 4
5 6 7 8
6
4
B21
REAR
OXYGEN SENSOR
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
B19
B327
2
1
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B83
RHD
RHD
LHD
LHD
A: B134
1
8 9
18 19
28 29
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
C35
D31
D24
B2
B83
2
10
20
30
B: B135
A: B134
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
B: B135
ECM
C: B136
D: B137
A6
A7
C: B136
52
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
B21
D: B137
E2
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
EN-02458
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?

mV?
NOTE:
?
rear oxygen sensor.
(B137) No. 24 (B19) No. 3:
(B136) No. 35 (B19) No. 4:
Yes
Go to step 2.
Inspect the DTC

Code (DTC).
<Ref. to EN(H4SO
2.5)(diag)-70, List
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Go to step 3.
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0138.
Go to step 6.
Go to step 4.
Repair the open

Go to step 5.
circuit in harness
between ECM and

Step
Check
sensor.
Yes
Replace the rear
oxygen sensor.
<Ref. to FU(H4SO

Repair or replace
the faulty part.

system?
NOTE:
sensor
No
NOTE:
the following:
Open circuit in
harness between
Poor contact in
Poor contact in
ECM connector
Replace the rear
oxygen sensor.
<Ref. to FU(H4SO

W: DTC P0139 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 2)

CAUTION:
WIRING DIAGRAM:
EC, EK and K4 model
OXYGEN SENSOR
RELAY
BATTERY
B83
B327
B19
SBF-6
5
3
1
3
5
1 2
3 4
2
4
6
1 2 3 4
5 6 7 8
6
4
B21
REAR
OXYGEN SENSOR
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
B19
B327
2
1
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B83
RHD
RHD
LHD
LHD
A: B134
1
8 9
18 19
28 29
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
C35
D31
D24
B2
B83
2
10
20
30
B: B135
A: B134
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
B: B135
ECM
C: B136
D: B137
A6
A7
C: B136
52
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
B21
D: B137
E2
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
EN-02458
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?
Yes
Go to step 2.
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Replace the rear
Inspect the releoxygen sensor.
vant DTC using
List of Diagnostic <Ref. to FU(H4SO
2.5)-35, Rear OxyTrouble Code
gen Sensor.>
(DTC). <Ref. to
EN(H4SO
2.5)(diag)-70, List
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0139.
X: DTC P0171 SYSTEM TOO LEAN (BANK 1)

Refer to DTC P0172 for diagnostic procedure. <Ref. to EN(H4SO 2.5)(diag)-137, DTC P0172 SYSTEM TOO

Y: DTC P0172 SYSTEM TOO RICH (BANK 1)

TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
Step
CHECK OPTION CODE.
Check
K4?
CHECK EGR VALVE.

on exhaust system?
intake system?

VALVE.

valve stuck?
CHECK PCV VALVE.
Yes
Go to step 2.
Repair exhaust
system.
Repair air intake
system.
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Go to step 3.
Go to step 4.
Replace the EGR Go to step 5.

valve.
control solenoid
valve.
Replace the PCV Go to step 7.
valve.

Step
Warning:
Place NO FIRE signs near the working
area.
pump relay.
more seconds.
6) Measure the fuel pressure while disconnecting pressure regulator vacuum hose from
intake manifold.
Check
kPa (2.9 3.2 kg/cm2, 41
46 psi)?
Yes
Go to step 8.
No
Fuel pressure is
too high:
Clogged fuel
return line or
bent hose
Fuel pressure is
too low:
Improper fuel
pump discharge
Clogged fuel
supply line
Warning:
fuel pressure gauge.
NOTE:
pressure again.
After connecting the pressure regulator vackPa (2.1 2.4 kg/cm2, 30
uum hose, measure fuel pressure.
34 psi)?
Warning:
NOTE:
If the measured value at this step is out of
specification, check or replace pressure regulator and pressure regulator vacuum hose.
ture between 70C (158F) and
SENSOR.
1) Start the engine and warm-up completely. 100C (212F)?
NOTE:

Fuel pressure is
too high:
Clogged fuel
return line or
bent hose
Fuel pressure is
too low:
Improper fuel
pump discharge
Clogged fuel
supply line
Replace the
engine coolant
FU(H4SO 2.5)-20,
Engine Coolant

10
Step
SIGNAL.
coolant temperature is above 60C (140F).
2) Place the select lever in N or P position.
Check
Is the measurement value 24.0
41.3 kPa (180 310
mmHg, 7.09 12.20 inHg)
when idling and 73.3 106.6
kPa (550 800 mmHg, 21.65
31.50 inHg) when the ignition turns to ON?
NOTE:
Yes
Replace the ECM.
<Ref. to FU(H4SO
2.5)-36, Engine
Control Module
(ECM).>
No
Replace the manifold pressure sensor. <Ref. to
FU(H4SO 2.5)-25,
Manifold Absolute
Pressure Sensor.>

Z: DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT

LOW
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:

WIRING DIAGRAM:
EC, EK and K4 model
BATTERY
ELECTRONIC
THROTTLE
CONTROL RELAY
SBF-8
B362
7
5
6
8
B35
D6
MAIN RELAY
ECM
C19
C29
C16
D4
D5
C35
D3
D1
D2
B1
B4
D: B137
C: B136
C18
B: B135
B83
LHD
LHD
B138 : LHD
B138
B122 : RHD
RHD
RHD
*
*
LHD
15
B20
16
37
36
35
20
39
38
19
B83
B21
RHD
E2
1
E1
36
B122
B21
5
1
2
3
E2
ELECTRONIC
THROTTLE CONTROL
E57
B362
B122
B21
B20
B83
1 2
3
4
B138
5
7 8
6
1 2 3 4
5 6 7 8
B:
1
8 9
20 21
28 29
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
B135
2
3
10 11 12 13
22 23
30 31
4 5 6
7
14 15 16 17 18 19
24 25
26 27
32 33
34 35
C:
1
5
9
13
2
6
10
14
3
7
11
15
E57
4
8
12
16
1 2 3 4 5 6
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B136
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
D:
B137
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
EN-02462
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?
Yes
Go to step 2.

CHECK POOR CONTACT.
Repair the poor
contact.
throttle control.
(B136) No. 29 (E57) No. 4:
(B136) No. 16 (E57) No. 5:

?
Go to step 5.

M?
Go to step 6.
Go to step 7.
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Go to step 4.
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.

harness.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
(ECM).>
Repair the poor
?
trol connector.
Replace the ECM
tronic throttle con- to FU(H4SO 2.5)trol if defective.
36, Engine Control Module
(ECM).>

AA:DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT

HIGH
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:

WIRING DIAGRAM:
EC, EK and K4 model
BATTERY
ELECTRONIC
THROTTLE
CONTROL RELAY
SBF-8
B362
7
5
6
8
B35
D6
MAIN RELAY
ECM
C19
C29
C16
D4
D5
C35
D3
D1
D2
B1
B4
D: B137
C: B136
C18
B: B135
B83
LHD
LHD
B138 : LHD
B138
B122 : RHD
RHD
RHD
*
*
LHD
15
B20
16
37
36
35
20
39
38
19
B83
B21
RHD
E2
1
E1
36
B122
B21
5
1
2
3
E2
ELECTRONIC
THROTTLE CONTROL
E57
B362
B122
B21
B20
B83
1 2
3
4
B138
5
7 8
6
1 2 3 4
5 6 7 8
B:
1
8 9
20 21
28 29
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
B135
2
3
10 11 12 13
22 23
30 31
4 5 6
7
14 15 16 17 18 19
24 25
26 27
32 33
34 35
C:
1
5
9
13
2
6
10
14
3
7
11
15
E57
4
8
12
16
1 2 3 4 5 6
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B136
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
D:
B137
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
EN-02462
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?
Yes
Go to step 2.

CHECK POOR CONTACT.

V?
Go to step 3.

throttle control.
(B136) No. 35 (E57) No. 3:
(B136) No. 29 (E57) No. 4:

?
Go to step 5.

?
Go to step 6.


Go to step 7.

M?
terminals.
(B136) No. 29 (B136) No. 16:
Repair the poor

contact. Replace
the electronic
throttle control.
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Go to step 4.
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
(ECM).>
Repair the battery
ECM connector
and electronic
throttle control
connector.
Sensor power supply circuit may be
shorted.

AB:DTC P0301 CYLINDER 1 MISFIRE DETECTED

NOTE:
AC:DTC P0302 CYLINDER 2 MISFIRE DETECTED

NOTE:
AD:DTC P0303 CYLINDER 3 MISFIRE DETECTED

NOTE:

AE:DTC P0304 CYLINDER 4 MISFIRE DETECTED

TROUBLE SYMPTOM:
Engine stalls.
Erroneous idling
Rough driving
CAUTION:
WIRING DIAGRAM:
EC, EK and K4 model
MAIN RELAY
5
3
BATTERY
SBF-8
6
4
2
1
B47
45
44
5
43
42
48
B136 ECM
B21
E2
E17
2
E6
E16
E5
E
FUEL INJECTOR
No. 2
FUEL INJECTOR
No. 1
E5
E16
E6
E17
1 2
B47
1
3
5
2
4
6
FUEL INJECTOR
No. 3
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
FUEL INJECTOR
No. 4
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
EN-01991
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?

on faulty cylinders.
faulty cylinders.
#1 (B136) No. 6 (E5) No. 1:
#2 (B136) No. 5 (E16) No. 1:
#3 (B136) No. 4 (E6) No. 1:
#4 (B136) No. 3 (E17) No. 1:

Terminals
No. 1 No. 2:
Yes
Go to step 2.
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Go to step 3.

List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(H4SO
2.5)(diag)-70, List
Go to step 4.

M?
Go to step 5.
Repair the ground

injector and ECM
connector.

?
Go to step 6.
Go to step 7.
NOTE:
the following:
Open circuit in
harness between
ECM and fuel
injector connector
Poor contact in
coupling connector
Replace the faulty

10
11
12
Step
Check
Yes
injector circuit.
No
NOTE:
the following:
Open circuit in
harness between
main relay and fuel
injector connector
on faulty cylinders
Poor contact in
coupling connector
Poor contact in
Poor contact in
cylinders
ECM and fuel
injector. After
repair, replace the
ECM. <Ref. to
FU(H4SO 2.5)-36,
Engine Control
Module (ECM).>

on faulty cylinder.
?
Terminals
No. 1 No. 2:
Replace the faulty

fuel injector <Ref.
and ECM <Ref. to
FU(H4SO 2.5)-36,
Engine Control
Module (ECM).>
CHECK INSTALLATION OF CAMSHAFT PO- Is the camshaft position sensor Tighten the camSITION SENSOR/CRANKSHAFT POSITION or crankshaft position sensor shaft position senSENSOR.
loosely installed?
sor or crankshaft
position sensor.
CHECK CRANK SPROCKET.
Is the crank sprocket rusted or Replace the crank
Remove the timing belt cover.
does it have broken teeth?
sprocket. <Ref. to
ME(H4SO 2.0)-50,
Crank Sprocket.>
Is the timing belt dislocated
Repair the installaTIMING BELT.
tion condition of
timing belt. <Ref.
Turn the crankshaft, and align alignment mark
on crank sprocket with alignment mark on cylto ME(H4SO 2.0)43, Timing Belt.>
inder block.
Go to step 10.
Go to step 11.
Go to step 12.
Go to step 13.

13
14
15
16
17
Step
CHECK FUEL LEVEL.
Check
higher than the Lower level?
Yes
Go to step 14.
CHECK STATUS OF MALFUNCTION INDI- Does the malfunction indicator

CATOR LIGHT.
light come on or blink?
Monitor. <Ref. to EN(H4SO 2.5)(diag)-41,
Clear Memory Mode.>
than 10 minutes.
CHECK CAUSE OF MISFIRE DIAGNOSED. Was the cause of misfire diagnosed when the engine is running?
Go to step 16.
CHECK CYLINDER.

system?
Finish the diagnostics operation,

if the engine has
no abnormality.
Repair the air

intake system.
No
Replenish the fuel
so fuel meter indication is higher
than the Lower
level. After replenishing fuel, Go to
step 14.
Go to step 15.
Repair the poor

contact.
NOTE:
the following:
Poor contact in
Poor contact in
cylinders
Poor contact in
ECM connector
Poor contact in
coupling connector
Go to step 17.
NOTE:
Are there air
caused by loose or
dislocated nuts
and bolts?
Are there cracks
Repair or replace Go to DTC P0171
the faulty parts.
and P0172. <Ref.
to EN(H4SO
NOTE:
Check the follow- 2.5)(diag)-136,
DTC P0171 SYSing items.
TEM TOO LEAN
Spark plug
(BANK 1), Diag Fuel injector
nostic Procedure
Compression
with Diagnostic
pressure
Trouble Code
(DTC).>

AF:DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW (BANK 1 OR SINGLE SENSOR)

TROUBLE SYMPTOM:
Knocking occurs.
CAUTION:
WIRING DIAGRAM:
EC, EK and K4 model
KNOCK
SENSOR
E14
2
1 2
E14
B20
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
13
E1
33
25
B20
5 6
14 15 16
25 26 27
33 34 35
B136
ECM
E
EN-01998
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?
Yes
Go to step 2.

700 k?
Go to step 3.
CHECK KNOCK SENSOR.

sor.
Terminals
Go to step 4.

INSTALLATION.
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
NOTE:
the following:
Open circuit in
harness between
knock sensor and
ECM connector
Poor contact in
Poor contact in
coupling connector
NOTE:
the following:
Poor contact in
Is the knock sensor installation Replace the knock Tighten knock senbolt tightened securely?
sensor. <Ref. to
FU(H4SO 2.5)-23, securely.
Knock Sensor.>

AG:DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH (BANK 1 OR SINGLE SENSOR)

TROUBLE SYMPTOM:
Knocking occurs.
CAUTION:
WIRING DIAGRAM:
EC, EK and K4 model
KNOCK
SENSOR
E14
2
1 2
E14
B20
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
13
E1
33
25
B20
5 6
14 15 16
25 26 27
33 34 35
B136
ECM
E
EN-01998
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?

CHECK KNOCK SENSOR.
Terminals
Yes
Go to step 2.

k?

k?
sensor. <Ref. to
FU(H4SO 2.5)-23,
Knock Sensor.>

sensor.
chassis ground.

light illuminates,
the circuit has
remains.)
NOTE:
the following:
Poor contact in
Poor contact in
ECM connector
Poor contact in
coupling connector
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Go to step 4.
Repair the ground

connector.
NOTE:
are
shielded. Repair
harness covered
with shield.
Repair the poor
contact in ECM
connector.

AH:DTC P0335 CRANKSHAFT POSITION SENSOR A CIRCUIT

TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
WIRING DIAGRAM:
EC, EK and K4 model
CRANKSHAFT
POSITION
SENSOR
E10
2
1
1 2
E10
B20
1
5
9
13
E1
2
6
10
14
3
7
11
15
4
8
12
16
8
7
B122
B20
B138
1 2 3 4
5 6 7 8
B135
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
32 33
34 35
28 29 30 31
3
4
B138 : LHD
22
10
31
B122 : RHD
B135
ECM
E
EN-02463
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?

NECTOR.
2) Disconnect the connector from crankshaft
position sensor.
and engine ground.

NECTOR.
engine ground.

NECTOR.
engine ground.
Yes
Go to step 2.
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Go to step 3.
NOTE:
the following:
Open circuit in
harness between
ECM connector
Poor contact in
ECM connector
Poor contact in
coupling connector
short circuitrepair
the ground short
circuit in harness
between crankshaft position sensor and ECM
connector.
NOTE:
are
shielded. Repair
the ground short
circuit in harness
with shield.
Go to step 5.
NOTE:
the following:
Open circuit in
harness between
ECM connector
Poor contact in
ECM connector
Poor contact in
coupling connector

Step
Check
Yes
SITION SENSOR.
securely?
Terminals
No. 1 No. 2:
No
Tighten the crankshaft position sensor installation bolt
securely.
Repair the poor
Replace the crankcontact in crankshaft position senshaft position sensor. <Ref. to
sor connector.
FU(H4SO 2.5)-21,
Crankshaft Position Sensor.>

AI: DTC P0340 CAMSHAFT POSITION SENSOR A CIRCUIT (BANK 1 OR SINGLE SENSOR)
TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
WIRING DIAGRAM:
EC, EK and K4 model
CAMSHAFT
POSITION
SENSOR
E15
2
1
1 2
E15
B20
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
B122
E1
6
5
B138
B20
1 2 3 4
5 6 7 8
B135
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
32 33
34 35
28 29 30 31
7
4
B138 : LHD
23
11
31
B122 : RHD
B135
ECM
E
EN-02464
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?
Yes
Go to step 2.

position sensor.
and engine ground.

100 k?

engine ground.

?

engine ground.

?
CHECK CONDITION OF CAMSHAFT POSITION SENSOR.
Is the camshaft position sensor Go to step 6.

securely?
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Go to step 3.
NOTE:
the following:
Open circuit in
harness between
camshaft position
sensor and ECM
connector
Poor contact in
ECM connector
Poor contact in
coupling connector
camshaft position
sensor and ECM
connector.
NOTE:
are
shielded. Repair
the ground short
circuit in harness
with shield.
Go to step 5.
NOTE:
the following:
Open circuit in
harness between
camshaft position
sensor and ECM
connector
Poor contact in
ECM connector
Poor contact in
coupling connector
Tighten the camshaft position sensor installation bolt
securely.

Step
Check
1) Remove the camshaft position sensor.
Terminals
No. 1 No. 2:
Yes
Repair the poor
contact in camshaft position sensor connector.
No
Replace the camshaft position sensor. <Ref. to
FU(H4SO 2.5)-22,
Camshaft Position
Sensor.>

AJ:DTC P0400 EXHAUST GAS RECIRCULATION FLOW

TROUBLE SYMPTOM:
Movement performance problem when engine is low speed.
Erroneous idling
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
E18
5
3
BATTERY
1 2 3
4 5 6
SBF-5
6
4
B47
B21
48
2
1
1
3
5
E2
2
4
6
5
2
B47
B21
EGR
VALVE
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
E18
6
3
4
1
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
30
25
29
26
E2
B21
A11
A8
A9
A10
A: B134
1
8 9
18 19
28 29
A: B134
B: B135
ECM
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
D: B137
B1
B4
D1
D2
B: B135
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
32 33
34 35
28 29 30 31
B21
35
36
D: B137
E2
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
28 29
30 31
26 27
E
EN-02001

Step
Check
Yes
No
Inspect the DTC
Go to step 2.
Code (DTC).
<Ref. to EN(H4SO
2.5)(diag)-70, List
CHECK CURRENT DATA.
fold absolute pres2) Read the data of intake manifold absolute
sure sensor and
throttle body are
NOTE:
installed securely.
Repair the open
circuit in harness
LENOID VALVE.
between main
relay and EGR
valve.
solenoid valve
connector.
3) Measure the voltage between EGR solenoid valve and engine ground.
Replace the EGR
Measure the resistance between EGR solesolenoid valve.
<Ref. to FU(H4SO
2.5)-30, EGR
NOTE:
Valve.>
Terminals
No. 1 No. 2:
No. 3 No. 2:
No. 4 No. 5:
No. 6 No. 5:
Repair the poor
Go to step 6.
contact portion in
ECM connector.
solenoid valve.
chassis ground.

Step
valve and ECM.
(B134) No. 8 (E18) No. 6:
(B134) No. 10 (E18) No. 1:
(B134) No. 9 (E18) No. 4:
(B134) No. 11 (E18) No. 3:
CHECK POOR CONTACT.
Check poor contact for ECM and EGR solenoid valve connector.
Check
?
Yes
Go to step 7.
No
Repair the open
circuit in harness
between ECM and
EGR solenoid
valve connector.

M?
Go to step 8.
Repair the short

circuit in harness
between main
relay and EGR
solenoid valve
connector.
Is there poor contact for ECM

and EGR solenoid valve connector?
Repair the poor

contact of ECM
and EGR solenoid
valve connector.

light illuminates,
the circuit has
returned to the
specified condition at this time.

AK:DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK

1)
TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
WIRING DIAGRAM:
EC, EK and K4 model
OXYGEN SENSOR
RELAY
BATTERY
B83
B327
B19
SBF-6
5
3
1
3
5
1 2
3 4
2
4
6
1 2 3 4
5 6 7 8
6
4
B21
REAR
OXYGEN SENSOR
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
B19
B327
2
1
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B83
RHD
RHD
LHD
LHD
A: B134
1
8 9
18 19
28 29
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
C35
D31
D24
B2
B83
2
10
20
30
B: B135
A: B134
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
B: B135
ECM
C: B136
D: B137
A6
A7
C: B136
52
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
B21
D: B137
E2
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
28 29
30 31
26 27
EN-02458
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?


system?
Yes
Go to step 2.

List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(H4SO
2.5)(diag)-70, List
NOTE:
model is the same
as 2.0 L model.
Go to step 3.
NOTE:
In this case, it is not
necessary to inspect DTC P0420.
the exhaust system. <Ref. to
EX(H4SO 2.0)-2,
NOTE:
pipe
catalytic converter
Is there damage at rear face of Replace the front
CHECK REAR CATALYTIC CONVERTER.
Separate the rear catalytic converter from rear rear catalyst?
catalytic conexhaust pipe.
verter. <Ref. to
EC(H4SO 2.0)-3,
Front Catalytic
Converter.> and
rear catalytic converter <Ref. to
EC(H4SO 2.0)-4,
Rear Catalytic
Converter.>
CHECK FRONT CATALYTIC CONVERTER. Is there damage at rear face or Replace the front
Remove the front catalytic converter.
catalytic converter. <Ref. to
EC(H4SO 2.0)-3,
Front Catalytic
Converter.>
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
Go to step 5.
Contact Subaru
distributor service.
NOTE:
Inspection by DTM
is required, because
probable
cause is deterioration of multiple
parts.

AL:DTC P0458 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE

CIRCUIT LOW
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
EC, EK and K4 model
MAIN RELAY
E4
5
3
BATTERY
1 2
SBF-8
6
4
2
1
B47
1
3
5
B47
2
4
6
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
B134 ECM
14
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B134
48
41
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B21
E2
1
2
E4
PURGE CONTROL
SOLENOID VALVE
E
EN-02002
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?
Yes
Go to step 2.

light illuminates,
the circuit has
this time.
NECTOR.
Go to step 5.
NECTOR.
ECM and purge control solenoid valve.
(B134) No. 14 (E4) No. 2:
chassis ground.

VALVE.
Terminals
No. 1 No. 2:
CHECK POWER SUPPLY TO PURGE CON- Is the voltage more than 10 V? Go to step 7.
TROL SOLENOID VALVE.
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Go to step 3.
Repair the ground

ECM and purge
control solenoid
valve connector.
Repair the open

circuit in harness
between ECM and
NOTE:
the following:
Open circuit in
harness between
ECM and purge
control solenoid
valve connector
Poor contact in
coupling connector
Replace the purge
control solenoid
valve. <Ref. to
EC(H4SO 2.0)-7,
Purge Control
Solenoid Valve.>
Repair the open
circuit in harness
between main
relay and purge
control solenoid
valve connector.

Step
CHECK POOR CONTACT.
valve connector.
Check
Yes
tor?
control solenoid
valve connector.
No
Replace the ECM.
<Ref. to FU(H4SO
2.5)-36, Engine
Control Module
(ECM).>

AM:DTC P0459 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE

CIRCUIT HIGH
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
EC, EK and K4 model
MAIN RELAY
E4
5
3
BATTERY
1 2
SBF-8
6
4
2
1
B47
1
3
5
B47
2
4
6
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
B134 ECM
14
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B134
48
41
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B21
E2
1
2
E4
PURGE CONTROL
SOLENOID VALVE
E
EN-02002
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?
lower portion of glove box.
chassis ground.
Yes
Go to step 2.
Go to step 3.
NOTE:
procedures. <Ref. to EN(H4SO 2.5)(diag)-42,
chassis ground.
CHECK POOR CONTACT.
Repair the poor
connector?
contact in ECM
connector.
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
light illuminates,
the circuit has
this time. In this
case, repair the
poor contact in
ECM connector.
Go to step 4.
Replace the ECM.

<Ref. to FU(H4SO
2.5)-36, Engine
Control Module
(ECM).>
NECTOR.
ECM and purge
control solenoid
After repair,
replace the ECM.
<Ref. to FU(H4SO
chassis ground.
2.5)-36, Engine
Control Module
(ECM).>
VALVE.
?
control solenoid
valve <Ref. to
EC(H4SO 2.0)-7,
Purge Control
Terminals
Solenoid Valve.>
No. 1 No. 2:
and ECM. <Ref. to
FU(H4SO 2.5)-36,
Engine Control
Module (ECM).>

Step
CHECK POOR CONTACT.
Check
connector?
Yes
Repair the poor
contact in ECM
connector.
No
Replace the ECM.
<Ref. to FU(H4SO
2.5)-36, Engine
Control Module
(ECM).>

AN:DTC P0462 FUEL LEVEL SENSOR A CIRCUIT LOW

CAUTION:
Step
CHECK OPTION CODE.
Check
K4?
Yes
Go to step 2.
Is DTC P0462 displayed on the Check the combiSubaru Select Monitor?

nation meter system. <Ref. to IDI-3,
Combination
Meter System.>
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Temporary poor
contact occurs.

AO:DTC P0463 FUEL LEVEL SENSOR A CIRCUIT HIGH

CAUTION:
Step
CHECK OPTION CODE.
Check
K4?
Yes
Go to step 2.
Is DTC P0463 displayed on the Check the combiSubaru Select Monitor?

nation meter system. <Ref. to IDI-3,
Combination
Meter System.>
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Temporary poor
contact occurs.

AP:DTC P0500 VEHICLE SPEED SENSOR A

CAUTION:
Step
CHECK OPTION CODE.
CHECK DTC OF ABS.

Check DTC of ABS.
Check
K4?
Yes
Go to step 2.
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
DTC. <Ref. to
ABS(diag)-39, List

AQ:DTC P0512 STARTER REQUEST CIRCUIT

TROUBLE SYMPTOM:
CAUTION:

WIRING DIAGRAM:
EC, EK and K4 model
IGNITION
SWITCH
B72
BATTERY
SBF-1
SBF-7
No.21
3
2
15
RHD
13
LHD
14
13
16
RHD
14
15
LHD
16
STARTER
RELAY
STARTER MOTOR
B225
D8
B32
B14
ECM
B: B135
D: B137
B72
B225
B: B135
1 2 3
4 5 6
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
1
8 9
20 21
28 29
3
2
10 11 12 13
22 23
30 31
4 5 6
7
14 15 16 17 18 19
24 25
26 27
32 33
34 35
D: B137
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
EN-02455
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?

Turn the ignition switch to ON.
NOTE:
Yes
Go to step 2.
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Repair the battery Check starter
short circuit in
starter motor cir- to EN(H4SO
cuit.
2.5)(diag)-55,
STARTER

AR:DTC P0519 IDLE AIR CONTROL SYSTEM PERFORMANCE

TROUBLE SYMPTOM:
CAUTION:
Step
CHECK OPTION CODE.
Check
K4?

throttle body
body gasket
2) Remove the electronic throttle control.

system?

control?
Yes
Go to step 2.
Inspect the DTC

Code (DTC).
<Ref. to EN(H4SO
2.5)(diag)-70, List
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Go to step 3.
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0519.
and leaks.
Remove foreign
matters from the
electronic throttle
control.

P2101.
AS:DTC P0558 GENERATOR CIRCUIT LOW INPUT

CAUTION:
For diagnostic procedure, refer to DTC P0559. <Ref. to EN(H4SO 2.5)(diag)-179, DTC P0559 GENERATOR CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>.

AT:DTC P0559 GENERATOR CIRCUIT HIGH

CAUTION:
WIRING DIAGRAM:
EC, EK and K4 model
B134
ECM
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
28 29
30 31
26 27
22
B134
F26
1 2 3
F26
GENERATOR
EN-02465
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?

AND ECM CONNECTOR.
2) Disconnect the connectors from generator
and ECM.
ground.
AND ECM CONNECTOR.
ECM and generator of harness connector.
(B134) No. 22 (F26) No. 3:
Yes
Go to step 2.
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Repair the ground
ECM and purge
control solenoid
valve connector.

M?
Go to step 3.

?
Repair the poor

Repair the open
contact in connec- circuit in harness
tor.
between ECM and
NOTE:
the following:
Open circuit in
harness between
Poor contact in
coupling connector
AU:DTC P0600 SERIAL COMMUNICATION LINK

NOTE:

AV:DTC P0604 INTERNAL CONTROL MODULE RANDOM ACCESS MEMORY

(RAM) ERROR
TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
WIRING DIAGRAM:
EC, EK and K4 model
MAIN RELAY
TO IGNITION COIL
3
5
SBF-8
6
4
No.13
* 34
*
IGNITION
SWITCH
B72
B47
BATTERY
No.12
SBF-7
A: B134
B: B135
*1
*2
ECM
: LHD MODEL: 1
: LHD MODEL: 2
RHD MODEL: 2
RHD MODEL: 1
B21
35
47
37
34
36
A6
A7
B12
D3
D7
D1
D2
B1
B4
D: B137
52
B19
2
B6
*B51
SBF-1
E2
B72
1 2 3
4 5 6
B21
B47
1
3
5
2
4
6
A:
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
1
8 9
18 19
28 29
2
10
20
30
B:
B134
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B135
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
D:
B137
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
28 29
30 31
26 27
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
EN-02456
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?
Yes
Go to step 2.

List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(H4SO
2.5)(diag)-70, List
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Temporary poor
contact occurs.
AW:DTC P0605 INTERNAL CONTROL MODULE READ ONLY MEMORY (ROM)

ERROR
NOTE:
For the diagnostic procedure, refer to DTC P0607. <Ref. to EN(H4SO 2.5)(diag)-183, DTC P0607 CONTROL MODULE PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>

AX:DTC P0607 CONTROL MODULE PERFORMANCE

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
EC, EK and K4 model
MAIN RELAY
TO IGNITION COIL
3
5
SBF-8
6
4
No.13
* 34
*
IGNITION
SWITCH
B72
B47
BATTERY
No.12
SBF-7
A: B134
B: B135
*1
: LHD MODEL: 1
*4
: LHD MODEL: 2
ECM
RHD MODEL: 2
RHD MODEL: 1
B21
35
47
37
34
36
A6
A7
B12
D3
D7
D1
D2
B1
B4
D: B137
52
B19
2
B6
*B51
SBF-1
E2
B72
1 2 3
4 5 6
B21
B47
1
3
5
2
4
6
A:
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
1
8 9
18 19
28 29
2
10
20
30
B:
B134
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B135
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
D:
B137
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
28 29
30 31
26 27
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
EN-02456
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?

and chassis ground.
Yes
Go to step 2.
Go to step 3.
Go to step 4.
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Repair the open or
Repair the open or

Repair the poor

Further tighten the
contact in ECM
minal.
Replace the ECM
if defective. <Ref.
(ECM).>
AY:DTC P0638 THROTTLE ACTUATOR CONTROL RANGE/PERFORMANCE

(BANK 1)
NOTE:

AZ:DTC P0691 FAN 1 CONTROL CIRCUIT LOW

TROUBLE SYMPTOM:
Overheating
CAUTION:
Step
CHECK OPTION CODE.
Check
K4?
Yes
Go to step 2.
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Is DTC P0691 displayed on the Check the radiator Temporary poor
System.>

BA:DTC P0692 FAN 1 CONTROL CIRCUIT HIGH

TROUBLE SYMPTOM:
Overheating
CAUTION:
Step
CHECK OPTION CODE.
Check
K4?
Yes
Go to step 2.
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Is DTC P0692 displayed on the Check the radiator Temporary poor
System.>
BB:DTC P0700 TRANSMISSION CONTROL SYSTEM (MIL REQUEST)

NOTE:

BC:DTC P0851 PARK/NEUTRAL SWITCH INPUT CIRCUIT LOW

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
EC, EK and K4 model
B12
B137 ECM
1 2 3 4
5 6 7 8
9 10 11 12
T7
1 2 3 4 5 6
7 8 9 10 11 12
B137
INHIBITOR SWITCH
P
B12
12
12
11
7
T3
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
28 29
30 31
26 27
T7
E
EN-02004
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?
Yes
Go to step 2.
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Go to step 3.
Inspect the DTC

Code (DTC).
<Ref. to EN(H4SO
2.5)(diag)-70, List
Is the voltage more than 10 V? Even if the malGo to step 4.
function indicator
light illuminates,
2) Shift the select lever except for N and P
the circuit has
range.
returned to a nor3) Measure the voltage between ECM and
mal condition at
chassis ground.
this time.
Repair the ground
TRANSMISSION HARNESS CONNECTOR. M?
short circuit in har1) Turn the ignition switch to OFF.
ness between
ECM and transtransmission harness connector (T3).
mission harness
connector.
CHECK TRANSMISSION HARNESS CONIs the resistance more than 1 Go to step 6.
Repair the ground
NECTOR.
M?
short circuit in har1) Disconnect the connector from inhibitor
ness between
switch.
transmission har2) Measure the resistance of harness
ness connector
between transmission harness connector and
and inhibitor
engine ground.
switch connector.
Replace the inhibiCHECK INHIBITOR SWITCH.
M?
tor switch. <Ref. to
4AT-52, Inhibitor
select lever at other than N and P range.
Switch.>
Terminals
No. 7 No. 12:
Repair the select Replace the ECM.
cable connection. <Ref. to FU(H4SO
switch?
<Ref. to CS-14,
2.5)-36, Engine
INSPECTION,
Control Module
Select Cable.>
(ECM).>

BD:DTC P0852 PARK/NEUTRAL SWITCH INPUT CIRCUIT HIGH

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
EC, EK and K4 model
B12
B137 ECM
1 2 3 4
5 6 7 8
9 10 11 12
T7
1 2 3 4 5 6
7 8 9 10 11 12
B137
INHIBITOR SWITCH
P
B12
12
12
11
7
T3
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
28 29
30 31
26 27
T7
E
EN-02004
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?

chassis ground with select lever at N and P
range.
Measure the voltage between ECM and chassis ground with select lever at other than N
and P range.
CHECK POOR CONTACT.
Yes
Go to step 2.
NOTE:
model is the same
as 2.0 L model.
Go to step 3.
Inspect the DTC

Code (DTC).
<Ref. to EN(H4SO
2.5)(diag)-70, List
Go to step 4.
Go to step 6.

connector?
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
Replace the ECM.

<Ref. to FU(H4SO
2.5)-36, Engine
Control Module
(ECM).>
short circuit in harMeasure the voltage between ECM and chasness between
sis ground.
ECM and inhibitor
switch connector.
CHECK HARNESS BETWEEN ECM AND IN- Is the resistance less than 1
Go to step 8.
Repair the harHIBITOR SWITCH CONNECTOR.
?
ness and connec1) Turn the ignition switch to OFF.
tor.
NOTE:
inhibitor switch.
the following:
between ECM and inhibitor switch connector.
Open circuit in
harness between
(B137) No. 9 (T7) No. 12:
ECM and inhibitor
switch connector
Poor contact in
coupling connector
Poor contact in
inhibitor switch
connector
Poor contact in
ECM connector
Repair the poor

contact in ECM
connector.
Go to step 6.

10
Step
Check
CHECK INHIBITOR SWITCH GROUND LINE. Is the resistance less than 5
?
inhibitor switch connector and engine ground.

select lever at N and P range.
Terminals
No. 7 No. 12:
Yes
Go to step 9.

?
Go to step 10.

switch?
Repair the select

cable connection.
<Ref. to CS-14,
INSPECTION,
Select Cable.>
No
Repair the open
circuit in harness
between inhibitor
switch connector
and ground line.
NOTE:
the following:
Open circuit in
harness between
inhibitor switch
connector and
ground line
4AT-52, Inhibitor
Switch.>
Replace the ECM.

<Ref. to FU(H4SO
2.5)-36, Engine
Control Module
(ECM).>

BE:DTC P1086 TUMBLE GENERATED VALVE POSITION SENSOR 2 CIRCUIT

LOW
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
TUMBLE GENERATOR VALVE

POSITION SENSOR LH
E50
1
3
2
1 2 3
E50
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
20
11
19
E2
B21
B83
RHD
RHD
*
*
B83
B122
B138
2
1
LHD
LHD
3
8
1 2 3 4
5 6 7 8
B83
B138 : LHD
B122 : RHD

B136
16
26
35
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
B136 ECM
EN-02466

Step
CHECK CURRENT DATA.
2) Read the data of tumble generator valve
position sensor signal using Subaru Select
Monitor or general scan tool.
Check
Yes
NOTE:
Monitor.>
General scan tool
CHECK INPUT SIGNAL FOR ECM.

and chassis ground.
and chassis ground.

and chassis ground.
CHECK INPUT SIGNAL FOR ECM. (USING
SUBARU SELECT MONITOR)
and chassis ground.
Shake the ECM harness and

connector, while monitoring
value of voltage meter. Does
the voltage change?
Repair the poor

contact in ECM
connector.
Shake the ECM harness and Repair the poor

contact in ECM
value of Subaru Select Moni- connector.
tor. Does the voltage change?
No
Even if malfunction
indicator light
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:
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.
Contact your Subaru distributor service.

NOTE:
Inspection by DTM
probable
parts.
Go to step 5.
Go to step 6.

Step
TUMBLE GENERATOR VALVE POSITION
SENSOR CONNECTOR.
2) Disconnect the connectors from tumble
generator valve position sensor.
4) Measure the voltage between tumble generator valve position sensor connector and
engine ground.
Check
Yes

?
SENSOR CONNECTOR.
between ECM connector and tumble generator
valve position sensor connector.
(B136) No. 26 (E50) No. 3:
Go to step 8.

SENSOR CONNECTOR.
tumble generator valve position sensor connector and engine ground.
CHECK POOR CONTACT.
Check poor contact in tumble generator valve
position sensor connector.
Go to step 9.

M?
Is there poor contact in tumble Repair the poor

generator valve position sen- contact in tumble
sor connector?
generator valve
position sensor
connector.
No
NOTE:
the following:
Open circuit in
harness between
tumble generator
valve position sensor and ECM connector
Poor contact in
tumble generator
Poor contact in
ECM connector
Poor contact in
coupling connector
Poor contact in
joint connector
NOTE:
the following:
Open circuit in
harness between
tumble generator
Poor contact in
ECM connector
Poor contact in
tumble generator
Poor contact in
coupling connector
Repair the ground
short circuit in harness between tumble generator valve
position sensor
and ECM connector.
Replace the tumble generator valve
assembly. <Ref. to
FU(H4SO 2.5)-28,
Tumble Generator
Valve Assembly.>

BF:DTC P1087 TUMBLE GENERATED VALVE POSITION SENSOR 2 CIRCUIT

HIGH
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:

POSITION SENSOR LH
E50
1
3
2
1 2 3
E50
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
20
11
19
E2
B21
B83
RHD
RHD
*
*
B83
B122
B138
2
1
LHD
LHD
3
8
1 2 3 4
5 6 7 8
B83
B138 : LHD
B122 : RHD

B136
16
26
35
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
B136 ECM
EN-02466

Step
CHECK CURRENT DATA.
Check
Yes
NOTE:
Monitor.>
General scan tool
CHECK HARNESS BETWEEN TUMBLE

GENERATOR VALVE POSITION SENSOR
?
AND ECM CONNECTOR.
2) Disconnect the connector from tumble generator valve position sensor.
between tumble generator valve position sensor connector and engine ground.

AND ECM CONNECTOR.
engine ground.
Go to step 3.
Is the voltage more than 4.9 V? Repair the battery

position sensor
and ECM connector. After repair,
replace the ECM.
<Ref. to FU(H4SO
2.5)-36, Engine
Control Module
(ECM).>
No
Even if malfunction
indicator light
temporary poor
cause.
NOTE:
the following:
Poor contact in
tumble generator
Poor contact in
ECM connector
Poor contact in
coupling connector
NOTE:
the following:
Open circuit in
harness between
tumble generator
Poor contact in
coupling connector
Poor contact in
joint connector
assembly. <Ref. to
FU(H4SO 2.5)-28,
Tumble Generator
Valve Assembly.>

BG:DTC P1088 TUMBLE GENERATED VALVE POSITION SENSOR 1 CIRCUIT

LOW
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
E54

POSITION SENSOR RH
1 2 3
1
3
2
B21
E54
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 45
46 47
48 49 50 51 52 53 54
20
10
19
E2
B21
B83
B83
RHD
RHD
2
1
LHD
LHD
*
*
3
8
B122
B138
1 2 3 4
5 6 7 8
B83
B138 : LHD
B122 : RHD

B136
5 6
14 15 16
25 26 27
33 34 35
16
27
35
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B136 ECM
EN-02467

Step
CHECK CURRENT DATA.
Check
Yes
NOTE:
Monitor.>
general scan tool

and chassis ground.
and chassis ground.

and chassis ground.
CHECK INPUT SIGNAL FOR ECM. (USING
SUBARU SELECT MONITOR)
and chassis ground.
Shake the ECM harness and

value of voltage meter. Does
the voltage change?
Repair the poor

contact in ECM
connector.
Shake the ECM harness and Repair the poor

contact in ECM
value of Subaru Select Moni- connector.
tor. Does the voltage change?
No
Even if malfunction
indicator light
temporary poor
cause.
NOTE:
the following:
Poor contact in
tumble generator
Poor contact in
ECM connector
Poor contact in
coupling connector
Go to step 3.
Contact your Subaru distributor service.

NOTE:
Inspection by DTM
probable
parts.
Go to step 5.
Go to step 6.

Step
SENSOR CONNECTOR.
2) Disconnect the connectors from tumble
generator valve position sensor.
engine ground.
Check
Yes

?
SENSOR CONNECTOR.
between ECM connector and tumble generator
valve position sensor connector.
(B136) No. 27 (E54) No. 3:
Go to step 8.

SENSOR CONNECTOR.
tumble generator valve position sensor connector and engine ground.
CHECK POOR CONTACT.
Go to step 9.

M?

generator valve position sen- contact in tumble
sor connector?
generator valve
position sensor
connector.
No
NOTE:
the following:
Open circuit in
harness between
tumble generator
Poor contact in
tumble generator
Poor contact in
ECM connector
Poor contact in
coupling connector
Poor contact in
joint connector
NOTE:
the following:
Open circuit in
harness between
tumble generator
Poor contact in
ECM connector
Poor contact in
tumble generator
Poor contact in
coupling connector
Repair the ground
position sensor
and ECM connector.
assembly. <Ref. to
FU(H4SO 2.5)-28,
Tumble Generator
Valve Assembly.>

BH:DTC P1089 TUMBLE GENERATED VALVE POSITION SENSOR 1 CIRCUIT

HIGH
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
E54

POSITION SENSOR RH
1 2 3
1
3
2
B21
E54
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 45
46 47
48 49 50 51 52 53 54
20
10
19
E2
B21
B83
B83
RHD
RHD
2
1
LHD
LHD
*
*
3
8
B122
B138
1 2 3 4
5 6 7 8
B83
B138 : LHD
B122 : RHD

B136
5 6
14 15 16
25 26 27
33 34 35
16
27
35
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B136 ECM
EN-02467

Step
CHECK CURRENT DATA.
Check
Yes
NOTE:
Monitor.>
General scan tool

?
AND ECM CONNECTOR.
2) Disconnect the connector from tumble generator valve position sensor.
between tumble generator valve position sensor connector and engine ground.

AND ECM CONNECTOR.
engine ground.
Go to step 3.
Is the voltage more than 4.9 V? Repair the battery

position sensor
and ECM connector. After repair,
replace the ECM.
<Ref. to FU(H4SO
2.5)-36, Engine
Control Module
(ECM).>
No
Even if malfunction
indicator light
temporary poor
cause.
NOTE:
the following:
Poor contact in
tumble generator
Poor contact in
ECM connector
Poor contact in
coupling connector
NOTE:
the following:
Open circuit in
harness between
tumble generator
Poor contact in
coupling connector
Poor contact in
joint connector
assembly. <Ref. to
FU(H4SO 2.5)-28,
Tumble Generator
Valve Assembly.>

BI: DTC P1090 TUMBLE GENERATED VALVE SYSTEM 1 (VALVE OPEN)

CAUTION:
Step
Check
Yes
No
vant DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(H4SO
2.5)(diag)-70, List
CHECK TUMBLE GENERATOR VALVE RH. Does the tumble generator
Replace the tum- Clean the tumble
1) Remove the tumble generator valve assem- valve move smoothly? (No dirt ble generator valve generator valve.
bly.
or foreign materials clogged)
assembly. <Ref. to
2) Check the tumble generator valve body.
FU(H4SO 2.5)-28,
Tumble Generator
Valve Assembly.>

BJ:DTC P1091 TUMBLE GENERATED VALVE SYSTEM 1 (VALVE CLOSE)

CAUTION:
Step
Check
Yes
No
vant DTC using
List of Diagnostic
Trouble Code
(DTC) <Ref. to
EN(H4SO
2.5)(diag)-70, List
CHECK TUMBLE GENERATOR VALVE RH. Does the tumble generator
bly.
assembly. <Ref. to
FU(H4SO 2.5)-28,
Tumble Generator
Valve Assembly.>

BK:DTC P1092 TUMBLE GENERATED VALVE SYSTEM 2 (VALVE OPEN)

CAUTION:
Step
Check
Yes
No
vant DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(H4SO
2.5)(diag)-70, List
CHECK TUMBLE GENERATOR VALVE LH. Does the tumble generator
bly.
assembly. <Ref. to
FU(H4SO 2.5)-28,
Tumble Generator
Valve Assembly.>

BL:DTC P1093 TUMBLE GENERATED VALVE SYSTEM 2 (VALVE CLOSE)

CAUTION:
Step
Check
Yes
No
vant DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(H4SO
2.5)(diag)-70, List
CHECK TUMBLE GENERATOR VALVE LH. Does the tumble generator
bly.
assembly. <Ref. to
FU(H4SO 2.5)-28,
Tumble Generator
Valve Assembly.>

BM:DTC P1094 TUMBLE GENERATED VALVE SIGNAL 1 CIRCUIT MALFUNCTION (OPEN)

CAUTION:
WIRING DIAGRAM:
32
21
TUMBLE
GENERATOR VALVE
ACTUATOR RH
E55
E2
18
19
B21
B134 ECM
E55
B21
1 2
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
B134
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
EN-02468

Step
Check
TUMBLE GENERATOR VALVE ACTUATOR ?
CONNECTOR.
2) Disconnect the connector from tumble generator valve and ECM connector.
3) Measure the resistance between tumble
generator valve actuator and ECM connector.
(E55) No. 1 (B134) No. 19:
(E55) No. 2 (B134) No. 18:
CHECK POOR CONTACT.

actuator connector.
Yes
Go to step 2.

generator valve actuator con- contact in tumble
nector?
generator valve
actuator connector.
No
Repair the open
circuit between
ECM and tumble
generator valve
connector.
NOTE:
the following:
Open circuit in
harness between
ECM and tumble
generator valve
actuator connector
Poor contact in
coupling connector
assembly. <Ref. to
FU(H4SO 2.5)-28,
Tumble Generator
Valve Assembly.>

BN:DTC P1095 TUMBLE GENERATED VALVE SIGNAL 1 CIRCUIT MALFUNCTION (SHORT)

CAUTION:
WIRING DIAGRAM:
32
21
TUMBLE
GENERATOR VALVE
ACTUATOR RH
E55
E2
18
19
B21
B134 ECM
E55
B21
1 2
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
B134
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
EN-02468

Step
Check
TUMBLE GENERATOR VALVE ACTUATOR
CONNECTOR.
2) Disconnect the connector from tumble generator valve connector.
3) Measure the voltage between tumble generator valve actuator and chassis ground.
Yes
assembly. <Ref. to
FU(H4SO 2.5)-28,
Tumble Generator
Valve Assembly.>
No
Repair the battery
short circuit
between ECM and
tumble generator
valve actuator.

BO:DTC P1096 TUMBLE GENERATED VALVE SIGNAL 2 CIRCUIT MALFUNCTION (OPEN)

CAUTION:
WIRING DIAGRAM:
33
22
TUMBLE
GENERATOR VALVE
ACTUATOR LH
E51
E2
28
29
B21
B134 ECM
E51
B21
1 2
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
B134
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
EN-02469

Step
Check
TUMBLE GENERATOR VALVE ACTUATOR ?
CONNECTOR.
2) Disconnect the connector from tumble generator valve and ECM connector.
3) Measure the resistance between tumble
generator valve actuator and ECM connector.
(E51) No. 1 (B134) No. 29:
(E51) No. 2 (B134) No. 28:
CHECK POOR CONTACT.

actuator connector.
Yes
Go to step 2.

generator valve actuator con- contact in tumble
nector?
generator valve
actuator connector.
No
Repair the open
circuit between
ECM and tumble
generator valve
connector.
NOTE:
the following:
Open circuit in
harness between
ECM and tumble
generator valve
actuator connector
Poor contact in
coupling connector
assembly. <Ref. to
FU(H4SO 2.5)-28,
Tumble Generator
Valve Assembly.>

BP:DTC P1097 TUMBLE GENERATED VALVE SIGNAL 2 CIRCUIT MALFUNCTION (SHORT)

CAUTION:
WIRING DIAGRAM:
33
22
TUMBLE
GENERATOR VALVE
ACTUATOR LH
E51
E2
28
29
B21
B134 ECM
E51
B21
1 2
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
B134
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
EN-02469

Step
Check
TUMBLE GENERATOR VALVE ACTUATOR
CONNECTOR.
2) Disconnect the connector from tumble generator valve connector.
3) Measure the voltage between tumble generator valve actuator and chassis ground.
Yes
assembly. <Ref. to
FU(H4SO 2.5)-28,
Tumble Generator
Valve Assembly.>
No
Repair the battery
short circuit
between ECM and
tumble generator
valve actuator.

BQ:DTC P1110 ATMOSPHERIC PRESSURE SENSOR CIRCUIT MALFUNCTION

(LOW INPUT)
TROUBLE SYMPTOM:
CAUTION:
Step
CHECK OPTION CODE.
Check
K4?
Yes
Go to step 2.
NOTE:
model is the same
as 2.0 L model.
Replace the ECM.
Inspect the DTC
using List of Diag- <Ref. to FU(H4SO
2.5)-36, Engine
nostic Trouble
Control Module
Code (DTC).
<Ref. to EN(H4SO (ECM).>
2.5)(diag)-70, List
NOTE:
It is not necessary
to inspect DTC
P1110.
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List

BR:DTC P1111 ATMOSPHERIC PRESSURE SENSOR CIRCUIT MALFUNCTION

(HIGH INPUT)
TROUBLE SYMPTOM:
CAUTION:
Step
CHECK OPTION CODE.
Check
K4?
Yes
Go to step 2.
NOTE:
model is the same
as 2.0 L model.
Replace the ECM.
Inspect the DTC
using List of Diag- <Ref. to FU(H4SO
2.5)-36, Engine
nostic Trouble
Control Module
Code (DTC).
<Ref. to EN(H4SO (ECM).>
2.5)(diag)-70, List
NOTE:
It is not necessary
to inspect DTC
P1111.
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List

BS:DTC P1152 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (LOW) (BANK1

SENSOR1)
CAUTION:
WIRING DIAGRAM:
EC, EK and K4 model
OXYGEN (A/F)
SENSOR RELAY
BATTERY
B327
SBF-6
6
4
B21
2
1
E2
2
4
6
5
3
1
3
5
50
FRONT OXYGEN
(A/F) SENSOR
E24
E24
1 2 3
4 5 6
1
3
B327
B21
4
3
51
E2
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
B21
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
E
2
3
26
33
25
B134
ECM
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
6
7
B134
1
8 9
18 19
28 29
52
E
B21
E2
E
EN-01992
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?

connector.
(B134) No. 26 (E24) No. 1:
(B134) No. 33 (E24) No. 3:

?
CHECK POOR CONTACT.


Yes
Go to step 2.
Go to step 3.
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
NOTE:
the following:
Open circuit in
harness between
ECM and front
Poor contact in
front oxygen (A/F)
sensor connector
Poor contact in
ECM connector
Replace the front
Repair the poor
contact in front
sor connector.
FU(H4SO 2.5)-34,
Front Oxygen (A/
F) Sensor.>

BT:DTC P1153 O2 SENSOR CIRCUIT RANGE/PERFORMANCE (HIGH) (BANK1

SENSOR1)
CAUTION:
WIRING DIAGRAM:
EC, EK and K4 model
OXYGEN (A/F)
SENSOR RELAY
BATTERY
B327
SBF-6
6
4
B21
2
1
E2
2
4
6
5
3
1
3
5
50
FRONT OXYGEN
(A/F) SENSOR
E24
E24
1 2 3
4 5 6
1
3
B327
B21
4
3
51
E2
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
B21
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
E
2
3
26
33
25
B134
ECM
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
6
7
B134
1
8 9
18 19
28 29
52
E
B21
E2
E
EN-01992
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?

CHECK OUTPUT SIGNAL FOR ECM.
1) Connect the connector to ECM and front
and chassis ground.
Yes
Go to step 2.

M?
Go to step 3.

M?
Go to step 4.
Is the voltage more than 10 V? Repair the battery

ECM and front
After repair,
replace the ECM.
<Ref. to FU(H4SO
2.5)-36, Engine
Control Module
(ECM).>
Is the voltage more than 4.95 Go to step 7.
Measure the voltage between ECM connector V?
and chassis ground.
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Repair the ground
ECM and front
Repair the ground

ECM and front
Go to step 6.
Repair the poor

contact in ECM
connector.
Replace the front

FU(H4SO 2.5)-34,
Front Oxygen (A/
F) Sensor.>

Step
Check
and chassis ground.
Yes
No
Repair the battery Repair the poor
short circuit in harcontact in ECM
ness between
connector.
ECM and front
After repair,
replace the ECM.
<Ref. to FU(H4SO
2.5)-36, Engine
Control Module
(ECM).>

BU:DTC P1160 RETURN SPRING FAILURE

NOTE:
BV:DTC P1492 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION

(LOW INPUT)
NOTE:
BW:DTC P1493 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION

(HIGH INPUT)
NOTE:
BX:DTC P1494 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION

(LOW INPUT)
NOTE:
BY:DTC P1495 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION

(HIGH INPUT)
NOTE:
BZ:DTC P1496 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION

(LOW INPUT)
NOTE:
CA:DTC P1497 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION

(HIGH INPUT)
NOTE:

CB:DTC P1498 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION

(LOW INPUT)
TROUBLE SYMPTOM:
Erroneous idling
Engine breathing
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
E18
5
3
BATTERY
1 2 3
4 5 6
SBF-5
6
4
B47
B21
48
2
1
1
3
5
E2
2
4
6
5
2
B47
B21
EGR
VALVE
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
E18
6
3
4
1
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
30
25
29
26
E2
B21
A11
A8
A9
A10
A: B134
1
8 9
18 19
28 29
A: B134
B: B135
ECM
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
D: B137
B1
B4
D1
D2
B: B135
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
32 33
34 35
28 29 30 31
B21
35
36
D: B137
E2
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
E
EN-02001

Step
Check
Yes

?
DTC P1492; (B134) No. 11 (E18) No. 3:
DTC P1494; (B134) No. 10 (E18) No. 1:
DTC P1496; (B134) No. 9 (E18) No. 4:
DTC P1498; (B134) No. 8 (E18) No. 6:
Go to step 3.

ground:
ground:
ground:
ground:
CHECK POOR CONTACT.

M?
Go to step 4.

valve connector?
Repair the poor

contact in ECM
connector or EGR
solenoid valve
connector.
No
NOTE:
the following:
Open circuit in
harness between
EGR solenoid
valve and main
relay connector
Poor contact in
coupling connector
NOTE:
the following:
Open circuit in
harness between
ECM and EGR
solenoid valve
connector
Poor contact in
coupling connector
Repair the ground
short in harness
between ECM and
EGR solenoid
valve connector.
Replace the EGR

solenoid valve.
<Ref. to FU(H4SO
2.5)-30, EGR
Valve.>

CC:DTC P1499 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION

(HIGH INPUT)
TROUBLE SYMPTOM:
Erroneous idling
Engine breathing
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
E18
5
3
BATTERY
1 2 3
4 5 6
SBF-5
6
4
B47
B21
48
2
1
1
3
5
E2
2
4
6
5
2
B47
B21
EGR
VALVE
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
E18
6
3
4
1
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
30
25
29
26
E2
B21
A11
A8
A9
A10
A: B134
1
8 9
18 19
28 29
A: B134
B: B135
ECM
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
D: B137
B1
B4
D1
D2
B: B135
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
32 33
34 35
28 29 30 31
B21
35
36
D: B137
E2
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
E
EN-02001

Step
Check

?
Yes
No
Inspect the DTC
Go to step 2.
Code (DTC).
<Ref. to EN(H4SO
2.5)(diag)-70, List
Go to step 3.
NOTE:
the following:
Open circuit in
harness between
ECM connector
and engine ground
terminal
Poor contact in
ECM connector
Poor contact in
coupling connector
Is the voltage more than 10 V? Repair battery
Replace the ECM.
short in harness
<Ref. to FU(H4SO
EGR solenoid
Control Module
(ECM).>
noid valve.
After repairing,
replace the ECM.
4) Measure the voltage between ECM con<Ref. to FU(H4SO
2.5)-36, Engine
Control Module
DTC P1493; (B134) No. 11 (+) Chassis
(ECM).>
ground ():
DTC P1495; (B134) No. 10 (+) Chassis
ground ():
ground ():
ground ():

CD:DTC P1518 STARTER SWITCH CIRCUIT LOW INPUT

TROUBLE SYMPTOM:
CAUTION:

WIRING DIAGRAM:
EC, EK and K4 model
IGNITION
SWITCH
B72
BATTERY
SBF-1
SBF-7
No.21
3
2
15
RHD
13
LHD
14
13
16
RHD
14
15
LHD
16
STARTER
RELAY
STARTER MOTOR
B225
D8
B32
B14
ECM
B: B135
D: B137
B72
B225
B: B135
1 2 3
4 5 6
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
1
8 9
20 21
28 29
3
2
10 11 12 13
22 23
30 31
4 5 6
7
14 15 16 17 18 19
24 25
26 27
32 33
34 35
D: B137
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
EN-02455
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?
Yes
Go to step 2.
CHECK OPERATION OF STARTER MOTOR. Does the starter motor operate Repair the harPlace the inhibitor switch in the P or N
ness and connecrange.
START?
tor.
NOTE:
the following:
Open or ground
ECM and starter
motor connector
Poor contact in
ECM connector
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Check starter
to EN(H4SO
2.5)(diag)-55,
STARTER

CE:DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION

CAUTION:
WIRING DIAGRAM:
EC, EK and K4 model
MAIN RELAY
TO IGNITION COIL
3
5
SBF-8
6
4
*
*
No.13
3
4
IGNITION
SWITCH
B72
B47
BATTERY
No.12
SBF-7
A: B134
B: B135
*1
*2
ECM
: LHD MODEL: 1
: LHD MODEL: 2
RHD MODEL: 2
RHD MODEL: 1
B21
35
47
37
34
36
A6
A7
B12
D3
D7
D1
D2
B1
B4
D: B137
52
B19
2
B6
*B51
SBF-1
E2
B72
1 2 3
4 5 6
B21
B47
1
3
5
2
4
6
A:
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
1
8 9
18 19
28 29
2
10
20
30
B:
B134
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B135
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
D:
B137
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
28 29
30 31
26 27
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
EN-02456
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?

chassis ground.
CHECK FUSE No. 13.
Yes
Go to step 2.

contact in ECM
connector.
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Go to step 3.

?

ECM connector
Replace the fuse.

NOTE:
the following:
Open circuit in
harness between
ECM and battery
Poor contact in
ECM connector
Poor contact in
battery terminal

CF:DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/

PERFORMANCE
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:

WIRING DIAGRAM:
EC, EK and K4 model
BATTERY
ELECTRONIC
THROTTLE
CONTROL RELAY
SBF-8
B362
7
5
6
8
B35
D6
MAIN RELAY
ECM
C19
C29
C16
D4
D5
C35
D3
D1
D2
B1
B4
D: B137
C: B136
C18
B: B135
B83
LHD
LHD
B138 : LHD
B138
B122 : RHD
RHD
RHD
*
*
LHD
15
B20
16
37
36
35
20
39
38
19
B83
B21
RHD
E2
1
E1
36
B122
B21
5
1
2
3
E2
ELECTRONIC
THROTTLE CONTROL
E57
B362
B122
B21
B20
B83
1 2
3
4
B138
5
7 8
6
1 2 3 4
5 6 7 8
B:
1
8 9
20 21
28 29
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
B135
2
3
10 11 12 13
22 23
30 31
4 5 6
7
14 15 16 17 18 19
24 25
26 27
32 33
34 35
C:
1
5
9
13
2
6
10
14
3
7
11
15
E57
4
8
12
16
1 2 3 4 5 6
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B136
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
D:
B137
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
EN-02462
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?

Terminals
No. 7 No. 8:
ground.
ground.
ground.
(B135) No. 35 (B362) No. 6:
(B137) No. 6 (B362) No. 8:

?
Yes
Go to step 2.
Go to step 3.
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Repair the open or

Is the voltage more than 10 V? Repair power sup- Go to step 5.

ply short circuit in
harness between

M?
Go to step 6.
Repair the ground


?
Go to step 7.
Repair the open

circuit in harness
between ECM and
electronic throttle
control relay.

10
11
12
Step
CHECK POOR CONTACT.
throttle control.
(B136) No. 18 (E57) No. 6:
(B136) No. 29 (E57) No. 4:
(B136) No. 16 (E57) No. 5:
Check
Yes
No
Go to step 10.
Go to step 10.
Repair the poor

contact.
Go to step 14.

?
Go to step 11.
Repair the open

circuit of harness
connector.

M?
Go to step 12.
Repair the ground

Go to step 13.
Go to step 15.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
(ECM).>
Repair the poor
contact in ECM
connector.
Replace the ECM
if defective. <Ref.
(ECM).>
Go to step 17.
Go to step 16.
Go to step 17.
13

?
14

Is the voltage 4.63 V?
15

16
17
18
19
20
21
22
23
Step
CHECK POOR CONTACT.
throttle control.
(B136) No. 35 (E57) No. 3:
(B136) No. 18 (E57) No. 6:
(B136) No. 29 (E57) No. 4:

2) Remove the ECM.
(B136) No. 18 (B136) No. 16:
(B136) No. 29 (B136) No. 16:
2) Connect the connectors except for the electric control throttle relay.
Check
Yes
Repair the poor
contact.
No
Go to step 22.

?
Go to step 18.
Repair the open

circuit of harness
connector.

?
Go to step 19.
Go to step 20.
Go to step 21.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
(ECM).>
Repair the battery
ECM connector
and electronic
throttle control
connector.
Repair the short
circuit in harness
between ECM
connector and
electronic throttle
control connector.

M?
Go to step 22.
Repair the short

circuit to sensor
power supply.
Go to step 23.
Go to step 24.
Repair the poor

Repair the poor
contact in ECM
connector.

24
25
26
27
28
29
30
Step
throttle control.
(B137) No. 5 (E57) No. 2:
(B137) No. 4 (E57) No. 1:
(E57) No. 2 (E57) No. 1:
Terminals
No. 1 No. 2:
Check that the valve returns to the specified
position when releasing fingers.
Check
?
Yes
Go to step 25.
No
Repair the open
circuit of harness
connector.
Go to step 26.
Repair power supply short circuit in

harness between

M?
Go to step 27.
Repair the short

circuit of harness.

M?
Go to step 28.
Repair the short

circuit of harness.

?
Go to step 29.
Repair the open

circuit of harness.

?
Go to step 30.

specified position?
Repair the poor

trol.
Replace the ECM
if defective. <Ref.
(ECM).>

CG:DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW

TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:

WIRING DIAGRAM:
EC, EK and K4 model
BATTERY
ELECTRONIC
THROTTLE
CONTROL RELAY
SBF-8
B362
7
5
6
8
B35
D6
MAIN RELAY
ECM
C19
C29
C16
D4
D5
C35
D3
D1
D2
B1
B4
D: B137
C: B136
C18
B: B135
B83
LHD
LHD
B138 : LHD
B138
B122 : RHD
RHD
RHD
*
*
LHD
15
B20
16
37
36
35
20
39
38
19
B83
B21
RHD
E2
1
E1
36
B122
B21
5
1
2
3
E2
ELECTRONIC
THROTTLE CONTROL
E57
B362
B122
B21
B20
B83
1 2
3
4
B138
5
7 8
6
1 2 3 4
5 6 7 8
B:
1
8 9
20 21
28 29
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
B135
2
3
10 11 12 13
22 23
30 31
4 5 6
7
14 15 16 17 18 19
24 25
26 27
32 33
34 35
C:
1
5
9
13
2
6
10
14
3
7
11
15
E57
4
8
12
16
1 2 3 4 5 6
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B136
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
D:
B137
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
EN-02462
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?

Terminals
No. 7 No. 8:
ground.
ground.
ground.
(B135) No. 35 (B362) No. 6:
(B137) No. 6 (B362) No. 8:

?
Yes
Go to step 2.
Go to step 3.
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Repair the open or


harness between

M?
Go to step 6.
Repair the ground


?
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
(ECM).>
Repair the open

circuit in harness
between ECM and
electronic throttle
control relay.

CH:DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH

CAUTION:
WIRING DIAGRAM:
EC, EK and K4 model
BATTERY
ELECTRONIC
THROTTLE
CONTROL RELAY
SBF-8
B362
7
5
6
8
B35
D6
MAIN RELAY
ECM
C19
C29
C16
D4
D5
C35
D3
D1
D2
B1
B4
D: B137
C: B136
C18
B: B135
B83
LHD
LHD
B138 : LHD
B138
B122 : RHD
RHD
RHD
*
*
LHD
15
B20
16
37
36
35
20
39
38
19
B83
B21
RHD
E2
1
E1
36
B122
B21
5
1
2
3
E2
ELECTRONIC
THROTTLE CONTROL
E57
B362
B122
B21
B20
B83
1 2
3
4
B138
5
7 8
6
1 2 3 4
5 6 7 8
B:
1
8 9
20 21
28 29
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
B135
2
3
10 11 12 13
22 23
30 31
4 5 6
7
14 15 16 17 18 19
24 25
26 27
32 33
34 35
C:
1
5
9
13
2
6
10
14
3
7
11
15
E57
4
8
12
16
1 2 3 4 5 6
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B136
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
D:
B137
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
EN-02462

KA and KS model
NOTE:
Step
CHECK OPTION CODE.
Check
K4?

Terminals
No. 7 No. 8:
RELAY.
ground.
Yes
Go to step 2.
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.

M?
Go to step 3.
Go to step 4.

harness between

M?
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
(ECM).>
Repair the ground

CI: DTC P2109 THROTTLE/PEDAL POSITION SENSOR A MINIMUM STOP

PERFORMANCE
NOTE:

CJ:DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT

LOW INPUT
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
EC, EK and K4 model
MAIN
B315
SUB
1 2 3 4 5 6
ACCELERATOR
POSITION
SENSOR
B83
B122
B122
B315
LHD
LHD
RHD
RHD
6
1
B138
1 2 3 4
5 6 7 8
5
1
B21
B138
B122
*
*
B83
RHD
RHD
LHD
1
8
RHD
*
*
LHD
6
1
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
LHD
RHD
C35
C28
C16
C34
C17
C15
C19
B138
B83
B: B135
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
32 33
34 35
28 29 30 31
B: B135
C: B136
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
ECM
D: B137
B4
B1
D2
D1
D3
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
LHD
5 6
14 15 16
25 26 27
33 34 35
35
36
37
B21
D: B137
E2
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
EN-02470
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?
Yes
Go to step 2.
SOR OUTPUT.
CHECK POOR CONTACT.
Repair the poor
contact.
position sensor.
(B136) No. 17 (B315) No. 5:
(B136) No. 15 (B315) No. 3:
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Go to step 4.
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.

?
Go to step 5.

M?
Go to step 6.

harness.
Go to step 7.

SOR.
k?
sensor.
Terminals
No. 3 No. 4:
Go to step 8.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
(ECM).>
sensor.

Step
sensor.
Terminals
No. 5 No. 4:
pedal.
sensor.
Terminals
No. 5 No. 4:
Check
k?
Yes
Go to step 9.

k?
Repair the poor

erator position
connector.
sensor.
Replace the ECM
if defective. <Ref.
(ECM).>
No
sensor.

CK:DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT

HIGH INPUT
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
EC, EK and K4 model
MAIN
B315
SUB
1 2 3 4 5 6
ACCELERATOR
POSITION
SENSOR
B83
B122
B122
B315
LHD
LHD
RHD
RHD
6
1
B138
1 2 3 4
5 6 7 8
5
1
B21
B138
B122
*
*
B83
RHD
RHD
LHD
1
8
RHD
*
*
LHD
6
1
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
LHD
RHD
C35
C28
C16
C34
C17
C15
C19
B138
B83
B: B135
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
32 33
34 35
28 29 30 31
B: B135
C: B136
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
ECM
D: B137
B4
B1
D2
D1
D3
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
LHD
5 6
14 15 16
25 26 27
33 34 35
35
36
37
B21
D: B137
E2
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
EN-02470
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?
Yes
Go to step 2.
SOR OUTPUT.
CHECK POOR CONTACT.
Repair the poor
contact.
position sensor.
(B136) No. 34 (B315) No. 4:
ground.

?
Go to step 5.

?
Go to step 6.
M?
(B136) No. 17 (B136) No. 15:
(B136) No. 17 (B136) No. 16:
Go to step 7.
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Go to step 4.
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
(ECM).>
Repair the battery
ECM connector
and accelerator
position sensor
connector.
Repair the poor

Repair the short
sor connector.

CL:DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT

LOW INPUT
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
EC, EK and K4 model
MAIN
B315
SUB
1 2 3 4 5 6
ACCELERATOR
POSITION
SENSOR
B83
B122
B122
B315
LHD
LHD
RHD
RHD
6
1
B138
1 2 3 4
5 6 7 8
5
1
B21
B138
B122
*
*
B83
RHD
RHD
LHD
1
8
RHD
*
*
LHD
6
1
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
LHD
RHD
C35
C28
C16
C34
C17
C15
C19
B138
B83
B: B135
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
32 33
34 35
28 29 30 31
B: B135
C: B136
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
ECM
D: B137
B4
B1
D2
D1
D3
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
LHD
5 6
14 15 16
25 26 27
33 34 35
35
36
37
B21
D: B137
E2
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
EN-02470
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?
Yes
Go to step 2.
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Go to step 4.

CHECK POOR CONTACT.
Repair the poor

contact.

position sensor.
(B136) No. 28 (B315) No. 2:
(B136) No. 16 (B315) No. 1:

?
Go to step 5.

M?
Go to step 6.

harness.
Go to step 7.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
(ECM).>
sensor.

SOR.
k?
sensor.
Terminals
No. 1 No. 6:
Go to step 8.
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.

Step
Terminals
No. 2 No. 6:
Terminals
No. 2 No. 6:
depressed.
Check
k?
Yes
Go to step 9.

k?
Repair the poor

erator position
connector.
sensor.
Replace the ECM
if defective. <Ref.
(ECM).>
No
sensor.

CM:DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT

HIGH INPUT
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
EC, EK and K4 model
MAIN
B315
SUB
1 2 3 4 5 6
ACCELERATOR
POSITION
SENSOR
B83
B122
B122
B315
LHD
LHD
RHD
RHD
6
1
B138
1 2 3 4
5 6 7 8
5
1
B21
B138
B122
*
*
B83
RHD
RHD
LHD
1
8
RHD
*
*
LHD
6
1
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
LHD
RHD
C35
C28
C16
C34
C17
C15
C19
B138
B83
B: B135
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
32 33
34 35
28 29 30 31
B: B135
C: B136
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
ECM
D: B137
B4
B1
D2
D1
D3
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
LHD
5 6
14 15 16
25 26 27
33 34 35
35
36
37
B21
D: B137
E2
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
EN-02470
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?
Yes
Go to step 2.

CHECK POOR CONTACT.
Repair the poor

contact.

position sensor.
(B136) No. 35 (B315) No. 6:
ground.

?
Go to step 5.

?
Go to step 6.
M?
(B136) No. 28 (B136) No. 15:
(B136) No. 28 (B136) No. 16:
Go to step 7.
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Go to step 4.
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
(ECM).>
Repair the battery
ECM connector
and accelerator
position sensor
connector.
Repair the poor

Repair the short
sor connector.

CN:DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH A / B

VOLTAGE CORRELATION
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:

WIRING DIAGRAM:
EC, EK and K4 model
BATTERY
ELECTRONIC
THROTTLE
CONTROL RELAY
SBF-8
B362
7
5
6
8
B35
D6
MAIN RELAY
ECM
C19
C29
C16
D4
D5
C35
D3
D1
D2
B1
B4
D: B137
C: B136
C18
B: B135
B83
LHD
LHD
B138 : LHD
B138
B122 : RHD
RHD
RHD
*
*
LHD
15
B20
16
37
36
35
20
39
38
19
B83
B21
RHD
E2
1
E1
36
B122
B21
5
1
2
3
E2
ELECTRONIC
THROTTLE CONTROL
E57
B362
B122
B21
B20
B83
1 2
3
4
B138
5
7 8
6
1 2 3 4
5 6 7 8
B:
1
8 9
20 21
28 29
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
B135
2
3
10 11 12 13
22 23
30 31
4 5 6
7
14 15 16 17 18 19
24 25
26 27
32 33
34 35
C:
1
5
9
13
2
6
10
14
3
7
11
15
E57
4
8
12
16
1 2 3 4 5 6
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B136
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
D:
B137
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
EN-02462

KA and KS model
NOTE:
Step
CHECK OPTION CODE.
Check
K4?

CHECK POOR CONTACT.
(B136) No. 18 (E57) No. 6:
(B136) No. 29 (E57) No. 4:
(B136) No. 16 (E57) No. 5:
Yes
Go to step 2.
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Go to step 5.
Go to step 5.
Repair the poor

contact.
Go to step 15.

?
Go to step 6.
Repair the open

circuit of harness
connector.

M?
Go to step 7.
Repair the ground

Go to step 8.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
(ECM).>

10
11
12
13
14
15
Step
Check
Yes
?

CHECK POOR CONTACT.

V?
Go to step 10.
No
Repair the poor
contact in ECM
connector.
Replace the ECM
if defective. <Ref.
(ECM).>
Go to step 12.

V?
Go to step 11.
Go to step 12.
Repair the poor

contact.

throttle control.
(B136) No. 35 (E57) No. 3:
(B136) No. 18 (E57) No. 6:
(B136) No. 29 (E57) No. 4:

?
Go to step 13.
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.

?
Go to step 14.

Go to step 15.
Go to step 16.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
(ECM).>
Repair the battery
ECM connector
and electronic
throttle control
connector.
Repair the short
circuit in harness
between ECM
connector and
electronic throttle
control connector.

16
17
Step
(B136) No. 18 (B136) No. 16:
(B136) No. 29 (B136) No. 16:
(E57) No. 6 (E57) No. 4:
Check
M?
Yes
Go to step 17.

M?
Repair the poor

Repair the short
contact in ECM
circuit of harness.
connector.
Replace the ECM
if defective. <Ref.
(ECM).>
No
Repair the short
circuit to sensor
power supply.

CO:DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH D / E

VOLTAGE CORRELATION
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
EC, EK and K4 model
MAIN
B315
SUB
1 2 3 4 5 6
ACCELERATOR
POSITION
SENSOR
B83
B122
B122
B315
LHD
LHD
RHD
RHD
6
1
B138
1 2 3 4
5 6 7 8
5
1
B21
B138
B122
*
*
B83
RHD
RHD
LHD
1
8
RHD
*
*
LHD
6
1
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
LHD
RHD
C35
C28
C16
C34
C17
C15
C19
B138
B83
B: B135
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
32 33
34 35
28 29 30 31
B: B135
C: B136
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
ECM
D: B137
B4
B1
D2
D1
D3
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
LHD
5 6
14 15 16
25 26 27
33 34 35
35
36
37
B21
D: B137
E2
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
EN-02470
KA and KS model
NOTE:

Step
CHECK OPTION CODE.
Check
K4?

CHECK POOR CONTACT.
position sensor.
(B136) No. 17 (B315) No. 5:
(B136) No. 15 (B315) No. 3:
(B136) No. 28 (B315) No. 2:
(B136) No. 16 (B315) No. 1:
sensor.
Terminals
No. 3 No. 4:
Yes
Go to step 2.
No
Refer to EN(H4SO
2.0) section. <Ref.
to EN(H4SO
2.0)(diag)-66, List
NOTE:
model is the same
as 2.0 L model.
Go to step 4.
Repair the poor

contact.
Go to step 13.

?
Go to step 5.
Repair the open

circuit of harness
connector.

M?
Go to step 6.
Repair the ground

Go to step 7.

k?
Go to step 8.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
(ECM).>
sensor.

10
11
12
13
14
15
Step
sensor.
Terminals
No. 1 No. 6:
pedal.
Terminals
No. 5 No. 4:
pedal.
Terminals
No. 2 No. 6:
Terminals
No. 5 No. 4:
Terminals
No. 2 No. 6:
CHECK POOR CONTACT.
position sensor.
(B136) No. 34 (B315) No. 4:
(B136) No. 35 (B315) No. 6:
Check
k?
Yes
Go to step 9.
No
sensor.

k?
Go to step 10.

sensor.

k?
Go to step 11.

sensor.

k?
Go to step 12.

sensor.

k?
Go to step 13.

sensor.
Go to step 15.
Repair the poor

contact.
Go to step 19.

?
Go to step 16.
Repair the open

circuit of harness
connector.

16
17
18
19
Step
ground.
(B136) No. 17 (B136) No. 15:
(B136) No. 17 (B136) No. 16:
(B136) No. 28 (B136) No. 15:
(B136) No. 28 (B136) No. 16:
(B315) No. 5 (B315) No. 2:
Check
?
Yes
Go to step 17.
Go to step 18.

M?
Go to step 19.
Repair the short

circuit to sensor
power supply.

M?
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
(ECM).>
Repair the short

circuit in harness
between ECM
connector and
No
Repair the poor
contact in ECM
connector.
Replace the ECM
if defective. <Ref.
(ECM).>
Repair the battery
ECM connector
and accelerator
position sensor
connector.


A: INSPECTION
1. ENGINE
NOTE:
Malfunction of parts other than those listed is also possible. <Ref. to ME(H4SO 2.0)-83, Engine Trouble in
General.>
Symptom
Problem parts
2) Mass air flow and intake air temperature sensor
2. Rough idling
10) Oxygen sensor
12) EGR valve
5) EGR valve
12) EGR valve
13) Tumble generator valve
5. Engine stalls, engine sags or hesitates at accel6) Purge control solenoid valve
eration.
10) EGR valve

Symptom
6. Surge
7. Spark knock
Problem parts
9) EGR valve
4) Knock sensor
7) EGR valve
ENGINE SECTION 2

of SUBARU vehicles.
FU(H4DOTC)
EMISSION CONTROL
EC(H4DOTC)
INTAKE (INDUCTION)
IN(H4DOTC)
MECHANICAL
ME(H4DOTC)
EXHAUST
EX(H4DOTC)
COOLING
CO(H4DOTC)
LUBRICATION
LU(H4DOTC)
SP(H4DOTC)
IGNITION
IG(H4DOTC)
SC(H4DOTC)
EN(H4DOTC)(diag)

approval.
G2320GE3
FUEL INJECTION
(FUEL SYSTEMS)
FU(H4DOTC)
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.
Page
Throttle Body.............................................................................................12
Intake Manifold..........................................................................................13
Knock Sensor............................................................................................26
Fuel Injector ..............................................................................................30
Oil Flow Control Solenoid Valve................................................................31
Wastegate Control Solenoid Valve ...........................................................32
Main Relay ................................................................................................36
Fuel Pump Relay.......................................................................................37
Fuel Pump Control Unit.............................................................................39
Fuel ...........................................................................................................40
Fuel Tank ..................................................................................................41
Fuel Filler Pipe ..........................................................................................47
Fuel Pump.................................................................................................49
Fuel Filter ..................................................................................................54
Fuel Bypass Valve ....................................................................................55
General Description
A: SPECIFICATION
Fuel tank
Fuel pump

Discharge
Fuel filter
64 2 (16.9 US gal, 14.1 Imp gal)

Under rear seat
Impeller
Capacity
Location
Type
550 850 kPa (5.61 8.67 kg/cm2, 79.8 123.3 psi)

155 2 (40.9 US gal, 34.1 Imp gal)/h or more.
[12 V at 300 kPa (3.06 kg/cm2, 43.5 psi)]
In-tank type
FU(H4DOTC)-2
General Description
B: COMPONENT
1. INTAKE MANIFOLD
T3
T3
(18)
T3
T3
(15)
T2
(23)
(16)
(19)
(17)
T2
(23)
(4)
(20)
(6)
(5)
T4
T2
(10)
(12)
T4
(1)
T2
T2
(14)
(3)
(2)
T1
(3)
T4
T4
(11)
(22)
(10)
T2
(12)
T4
T5
T4
(21)
(13)
T4
T5
(9)
(11)
(9)
(8)
(7)
(7)
(8)
FU-01154
FU(H4DOTC)-3
General Description
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
Fuel pipe ASSY

Fuel hose
Clip
Vacuum hose
Vacuum control hose
Intake manifold gasket
Guide pin
Intake manifold (lower)
Fuel injector
Seal ring
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
O-ring
(22) Coolant filler tank stay
Fuel injector pipe LH
(23) O-ring
Fuel injector pipe RH
Solenoid valve bracket
T1: 1.5 (0.15, 1.1)
Filter
T2: 6.5 (0.66, 4.8)
Intake manifold
T3: 8.3 (0.85, 6.1)
Wastegate control solenoid valve
T4: 19 (1.94, 13.7)
ASSY
T5: 25 (2.5, 18.1)
Vacuum hose
Ground stay
FU(H4DOTC)-4
General Description
T
(2)
(1)
FU-01155
(1)
(2)

T: 8 (0.8, 5.9)
O-ring
Throttle body
FU(H4DOTC)-5
General Description
T1
(4)
T2
T1
T1
(1)
(6)
(3)
(2)
T1
(5)
T1
FU-01156
(1)
(2)
(3)

Knock sensor
Intake camshaft position sensor
LH
(4)

RH
(5)
Exhaust camshaft position sensor

LH
(6)

RH
FU(H4DOTC)-6

T1: 6.4 (0.65, 4.7)
T2: 24 (2.4, 17.4)
General Description
4. FUEL TANK
T1
(17)
(19)
(18)
(15)
(16)
(8)
T1
(17)
(14)
(7)
(15)
(10)
(12)
(9)
(11)
(1)
(13)
(22)
T4
(6)
(2)
(22)
(5)
(20)
(3)
T4
(21)
T4
(4)
T3
T3
T3
T3
(23)
(24)
(25)
T3
T2
T2
T3
FU-01328
FU(H4DOTC)-7
General Description
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
Fuel tank
Fuel tank band RH
Fuel tank band LH
Delivery tube
Return tube
Jet pump tube
Fuel pump ASSY
Fuel pump gasket
Fuel level sensor
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)

Fuel filler hose
Clamp
Vent hose
Clip
Protector RH (Rear)
Protector LH (Rear)
Stopper RH
Stopper LH
Retainer
FU(H4DOTC)-8
(23)
(24)
(25)
Heat shield cover


T1: 4.4 (0.45, 3.3)
T2: 9.0 (0.92, 6.6)
T3: 17.5 (1.78, 12.9)
T4: 33 (3.4, 25)
General Description
5. FUEL LINE
T1
(1)
(28)
(18)
(26)
(23)
(25)
(27)
(15)
(17)
(19)
(1)
(20)
(22)
(14)
(13)
(24)
(21)
T2
(1)
(16)
(1)
(34)
(1) (22)
(11)
(29)
(10)
T2
(12)
T3
T2
(6)
(5) (1)
(4)
A
T2
(1)
(1)
(8)
(3)
T2
(2)
B
(9)
(1)
T2
(1)
(32)
(33)
(6)
(30)
(31)
(7)
FU-01329
FU(H4DOTC)-9
General Description
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
Clip
Fuel return hose A
Evaporation hose
Fuel bypass valve
Fuel bypass valve bracket
Fuel return hose B
Fuel pipe ASSY
Clamp
Canister
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)

Purge hose A
Purge hose B
Two-way valve
Connector
Filler pipe packing
Filler ring
FU(H4DOTC)-10
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
Filler cap
Tether
Clip
Fuel hose
Purge hose C
Fuel hose connector
Purge pipe

T1: 4.4 (0.45, 3.2)
T2: 7.5 (0.76, 5.53)
T3: 8.3 (0.85, 6.1)
General Description
C: CAUTION

points.
cable from battery.
D: PREPARATION TOOL
ILLUSTRATION
TOOL NUMBER
24082AA230
DESCRIPTION
CARTRIDGE
REMARKS
22771AA030
SUBARU SELECT
MONITOR KIT

ST24082AA230
ST22771AA030
FU(H4DOTC)-11
Throttle Body
2. Throttle Body
B: INSTALLATION
A: REMOVAL
1) Remove the collector cover.

NOTE:
Always use new O-rings.
Tightening torque:
8 Nm (0.8 kgf-m, 5.9 ft-lb)
IN-00203
3) Remove the intercooler. <Ref. to IN(H4DOTC)12, REMOVAL, Intercooler.>

4) Disconnect the connectors from throttle position
sensor.
FU-01157
5) Disconnect the engine coolant hose from throttle

body.
FU-01158
6) Remove the bolts which secure throttle body to

intake manifold.
FU(H4DOTC)-12
FU-01159
Intake Manifold
3. Intake Manifold
13) Disconnect the engine coolant hose from throttle body.
A: REMOVAL
<Ref. to FU(H4DOTC)-40, RELEASING OF FUEL
filler cap.
FU-01158
IN-00203

7) Drain the coolant about 3.0 2 (3.2 US qt, 2.6
Imp qt).
8) Remove the intake duct from air cleaner case.
10) Remove the generator. <Ref. to SC(H4SO
2.0)-14, REMOVAL, Generator.>
11) Remove the coolant filler tank.
<Ref. to CO(H4DOTC)-31, REMOVAL, Coolant
Filler Tank.>
12) Disconnect the PCV hose assembly from cylinder block.
FU-01161
15) Disconnect the engine harness connectors

from bulkhead harness connectors.
FU-01162
FU-01160
FU-01163
FU(H4DOTC)-13
Intake Manifold

coolant temperature sensor (A), oil pressure switch
(B) and crankshaft position sensor (C).
20) Disconnect the connector from the exhaust

camshaft position sensor (A) and exhaust oil flow
control solenoid valve (B).
(A)
(B)
(C)
(B)
FU-01167
FU-00027
21) Disconnect the connector from ignition coil.
IG-00092
FU-01164
18) Disconnect the connector from intake camshaft

position sensor.
22) Remove the engine harness bracket from rocker cover.
FU-01165
19) Disconnect the connector from the intake oil

flow control solenoid valve.
(A)
FU-02155
23) Disconnect the fuel delivery hose, return hose

and evaporation hose.
FU-01166
FU(H4DOTC)-14
Intake Manifold
CAUTION:
or cloth.
NOTE:
with new ones.
FU-01168
FU-01168
24) Remove the bolts which hold intake manifold

onto the cylinder heads.
3) Tighten the hose clamp screws.

Tightening torque:
1.25 Nm (0.13 kgf-m, 0.94 ft-lb)
4) Connect the connector to the exhaust camshaft
position sensor (A) and exhaust oil flow control solenoid valve (B).
FU-01169

(B)
B: INSTALLATION
(A)
FU-01167
5) Connect the connector to intake oil flow control

solenoid valve.
NOTE:
Use a new gasket.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
FU-01166
FU-01169
2) Connect the fuel delivery hose, return hose and

evaporation hose.
FU(H4DOTC)-15
Intake Manifold
6) Connect the connector to the engine coolant

temperature sensor (A), oil pressure switch (B) and
crankshaft position sensor (C).
10) Install the engine harness bracket to rocker

cover.
(A)
(B)
(C)
FU-02155
FU-00027
7) Connect the connector to knock sensor.
11) Connect the engine harness connector to bulkhead harness connector.
FU-01162
FU-01164
8) Connect the connector to intake camshaft position sensor.
FU-01163

FU-01165
9) Connect the connector to ignition coil.
FU-01161
IG-00092
FU(H4DOTC)-16
Intake Manifold
13) Connect the engine coolant hose to throttle

body.
2) Remove the solenoid valve bracket assembly

from intake manifold, and disconnect the connector
from the wastegate control solenoid valve, manifold
absolute pressure sensor and purge control solenoid valve.
FU-01158
14) Connect the PCV hose assembly to cylinder

block.
EC-00219
3) Disconnect the evaporation hoses (A) and filter

assembly (B).
(A)
FU-01160
15) Install the coolant filler tank.

<Ref. to CO(H4DOTC)-31, INSTALLATION, Coolant Filler Tank.>
16) Install the intercooler. <Ref. to IN(H4DOTC)12, INSTALLATION, Intercooler.>
17) Install the intake duct to air cleaner case.
22) Fill with engine coolant.
<Ref. to CO(H4DOTC)-13, FILLING OF ENGINE
23) Install the collector cover.
(B)
FU-01172

sensor.
C: DISASSEMBLY
FU-01157
1) Disconnect the engine ground terminal from

ground stay.
5) Remove the throttle body from intake manifold.
FU-01159
FU-01170
FU(H4DOTC)-17
Intake Manifold
10) Remove the coolant filler tank stay from intake

manifold.
FU-01173
7) Remove the bolt which secures the air bypass

pipe to intake manifold.
FU-01177

RH side
FU-01174
8) Disconnect the PCV pipe (A), harness assembly

(B) and intake duct (C) from intake manifold.
(A)
FU-01178
LH side
(B)
(C)
FU-01175
9) Remove the bolt which holds fuel injector pipe

LH onto the front side of intake manifold.
FU-01179
12) Remove the bolt which holds the fuel pipe to intake manifold.
FU-01176
FU-01180
FU(H4DOTC)-18
Intake Manifold
D: ASSEMBLY
13) Remove the fuel injectors.
1) Install the intake manifold (lower) to intake manifold (upper).

NOTE:
Use new O-rings.
Tightening torque:
8.3 Nm (0.85 kgf-m, 6.1 ft-lb)
FU-01181
14) Remove the bolts which hold the fuel injector

pipe RH onto the lower side of intake manifold.
FU-01184
2) Install the fuel injector pipe.

3) Connect the both fuel injector pipes with a fuel
hose and secure them with clamps.
FU-01182
15) Loosen the clamp which holds fuel hose to injector pipe, and then disconnect the pipe from fuel
hose.
FU-01183
4) Tighten the bolt which secures the fuel injector

pipe RH onto the lower side of intake manifold.
Tightening torque:
6.5 Nm (0.66 kgf-m, 4.8 ft-lb)
FU-01183

17) Remove the intake manifold (upper) from intake manifold (lower).
FU-01182
FU-01184
FU(H4DOTC)-19
Intake Manifold
RH side
FU-01181
FU-01178
6) Tighten the bolt which secures fuel pipe onto intake manifold.
8) Install the coolant filler tank stay to intake manifold.
Tightening torque:
6.5 Nm (0.66 kgf-m, 4.8 ft-lb)
Tightening torque:
19 Nm (1.94 kgf-m, 13.7 ft-lb)
FU-01180
FU-01177
7) Tighten the bolts which secure fuel injector pipe

9) Tighten the bolt which installs fuel injector pipe

LH on the front side of intake manifold.
Tightening torque:
19 Nm (1.94 kgf-m, 13.7 ft-lb)
LH side
Tightening torque:
6.5 Nm (0.66 kgf-m, 4.8 ft-lb)
FU-01176
FU-01179
10) Install the PCV pipe (A), harness assembly (B)

and intake duct (C) to intake manifold.
FU(H4DOTC)-20
Intake Manifold
Tightening torque:
8 Nm (0.8 kgf-m, 5.9 ft-lb)
Tightening torque:
6.5 Nm (0.66 kgf-m, 4.8 ft-lb)
(A)
(B)
(C)
FU-01175
11) Tighten the bolt which secures air bypass pipe

FU-01159
14) Connect the connector to throttle position sensor.
Tightening torque:
6.5 Nm (0.66 kgf-m, 4.8 ft-lb)
FU-01157
FU-01174
15) Connect the evaporation hoses (A) and filter

assembly (B).
12) Connect the connectors to fuel injector.

(A)
(B)
FU-01172
FU-01173

NOTE:
Use new O-rings.
FU(H4DOTC)-21
Intake Manifold
NOTE:
(A)
(B)
EC-00273
(A) To intake manifold

(B) To evaporation pipe
16) Connect the connector to the wastegate control

solenoid valve, manifold absolute pressure sensor
and purge control solenoid valve, and install the solenoid bracket assembly to intake manifold.
Tightening torque:
19 Nm (1.94 kgf-m, 13.7 ft-lb)
EC-00219
17) Install the engine ground terminal to ground

stay.
Tightening torque:
19 Nm (1.94 kgf-m, 13.7 ft-lb)
FU-01170
E: INSPECTION
Make sure that the fuel hoses and fuel pipes are not
cracked and that connections are tight.
FU(H4DOTC)-22


Sensor
A: REMOVAL
IN-00203

4) Drain coolant. <Ref. to CO(H4DOTC)-13,
DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>
temperature sensor.
FU-00055
B: INSTALLATION
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
FU(H4DOTC)-23


A: REMOVAL
Tightening torque:
T: 6.4 Nm (0.65 kgf-m, 4.7 ft-lb)

T
FU-00058
IN-00203
FU-00056
FU-00057
B: INSTALLATION
FU(H4DOTC)-24

4) Remove the sensor cover.
A: REMOVAL
1. INTAKE SIDE
FU-02156
5) Disconnect the connector from camshaft position sensor RH.

6) Remove the camshaft position sensor RH from
the lower side of cylinder head.
IN-00203
3) Disconnect the connector from camshaft position sensor RH.

4) Remove the camshaft position sensor RH from
the rear side of cylinder head.
FU-01186
7) Remove the camshaft position sensor LH in the

same procedure as RH.
B: INSTALLATION
FU-01185
5) Remove the camshaft position sensor LH in the

same procedure as RH.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
2. EXHAUST SIDE
IN-00203

FU(H4DOTC)-25
Knock Sensor
7. Knock Sensor
B: INSTALLATION
A: REMOVAL

NOTE:
Tightening torque:
24 Nm (2.4 kgf-m, 17.4 ft-lb)
(A)
IN-00203

60
FU-00413
(A) Front side
FU-01164

FU-01164
3) Install the intercooler.

<Ref. to IN(H4DOTC)-12, INSTALLATION, Intercooler.>
FU-00519
IN-00203
FU(H4DOTC)-26


A: SPECIFICATION
body.
Refer to Throttle Body for removal and installation. <Ref. to FU(H4DOTC)-12, REMOVAL, Throttle
Body.>
<Ref.
to
FU(H4DOTC)-12,
INSTALLATION, Throttle Body.>
FU(H4DOTC)-27

9. Mass Air Flow and Intake Air

Temperature Sensor
A: REMOVAL
IN-00203

FU-01187
B: INSTALLATION
Tightening torque:
1.0 Nm (0.10 kgf-m, 0.74 ft-lb)
FU(H4DOTC)-28

10.Manifold Absolute Pressure

Sensor
A: REMOVAL
IN-00203
3) Disconnect the connector from manifold absolute pressure sensor (A), and remove the filter assembly (B) from intake manifold.
from solenoid valve bracket.
(A)
(B)
FU-01188
B: INSTALLATION
Tightening torque:
6.5 Nm (0.66 kgf-m, 4.8 ft-lb)
FU(H4DOTC)-29
Fuel Injector
11.Fuel Injector
A: REMOVAL
1. RH SIDE
filler cap.
IN-00203

6) Remove the screw and remove the fuel injector.
IN-00203

Filler Tank.>
7) Remove the screw and remove the fuel injector.
FU-01190
B: INSTALLATION
1. RH SIDE
NOTE:
Use new O-rings.
Tightening torque:
3.5 Nm (0.36 kgf-m, 2.6 ft-lb)
2. LH SIDE
FU-01189
2. LH SIDE
filler cap.
NOTE:
Use new O-rings.
Tightening torque:
3.5 Nm (0.36 kgf-m, 2.6 ft-lb)
FU(H4DOTC)-30
Oil Flow Control Solenoid Valve

12.Oil Flow Control Solenoid

Valve
A: REMOVAL
1. INTAKE SIDE
Oil flow control solenoid valve forms a unit with
camshaft cap.
Refer to Camshaft for removal. <Ref. to
ME(H4DOTC)-53, REMOVAL, Camshaft.>
2. EXHAUST SIDE
IN-00203

4) Remove the oil flow control solenoid valve from
cylinder head.
FU-01191
B: INSTALLATION
1. INTAKE SIDE
2. EXHAUST SIDE
FU(H4DOTC)-31
Wastegate Control Solenoid Valve

13.Wastegate Control Solenoid

Valve
A: REMOVAL
IN-00203
3) Disconnect the connector from wastegate control solenoid valve (A).

4) Disconnect the pressure hose (B) from wastegate control solenoid valve.
5) Remove the wastegate control solenoid valve
from bracket.
(B)
(A)
FU-01192
B: INSTALLATION
Tightening torque:
6.5 Nm (0.66 kgf-m, 4.8 ft-lb)
FU(H4DOTC)-32


A: REMOVAL

sensor.

FU-01193

IN-00203
3) Disconnect the connector from front oxygen (A/

F) sensor.
one minute or more.
CAUTION:
When removing the oxygen (A/F) sensor, wait
until exhaust pipe cools, otherwise it will damage exhaust pipe.
IN-00203
FU-01193
B: INSTALLATION
removal easier.
SS-30 JET LUBE
CAUTION:
Never apply anti-seize compound to protector
of front oxygen (A/F) sensor.
Tightening torque:
21 Nm (2.1 kgf-m, 15.2 ft-lb)
FU(H4DOTC)-33
Rear Oxygen Sensor

Tightening torque:
21 Nm (2.1 kgf-m, 15.2 ft-lb)
A: REMOVAL
FU-01194
IN-00203

minute or more.

CAUTION:
until exhaust pipe cools, otherwise it will damage exhaust pipe.
IN-00203
FU-01194
B: INSTALLATION
1) Before installing rear oxygen (A/F) sensor, apply
anti-seize compound only to the threaded portion of
rear oxygen (A/F) sensor to make the next removal
easier.
SS-30 JET LUBE
CAUTION:
Never apply anti-seize compound to protector
of rear oxygen sensor.
FU(H4DOTC)-34

B: INSTALLATION
A: REMOVAL
CAUTION:
to the fuel injection system.
Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
IN-00203
2) Remove the lower inner trim of passenger side.

<Ref. to EI-60, REMOVAL, Lower Inner Trim.>
3) Detach the floor mat of front passengers seat.
FU-00896
5) Remove the nuts (A) which hold the ECM to

bracket.
(A)
(A)
(B)
FU-00897

the ECM.
FU(H4DOTC)-35
Main Relay
17.Main Relay
A: REMOVAL
IN-00203

(A)
FU-01118
FU-01119
B: INSTALLATION
FU(H4DOTC)-36
Fuel Pump Relay

18.Fuel Pump Relay

A: REMOVAL
IN-00203

(A)
FU-01118
FU-01120
B: INSTALLATION
FU(H4DOTC)-37


Relay
A: REMOVAL
IN-00203

(A)
FU-01118
4) Disconnect the connector from electronic throttle

control relay.
FU-01121
B: INSTALLATION
FU(H4DOTC)-38
Fuel Pump Control Unit

20.Fuel Pump Control Unit

A: REMOVAL
IN-00203
2) Remove the rear quarter trim. <Ref. to EI-63,

REMOVAL, Rear Quarter Trim.>
3) Remove the fuel pump control unit.
FU-01195
4) Disconnect the connector from fuel pump control

unit.
B: INSTALLATION
FU(H4DOTC)-39
Fuel
21.Fuel

drain plug from fuel tank to drain fuel from the fuel
tank.
A: PROCEDURE
WARNING:
box.
FU-01123

NOTE:
Use a new gasket.
Tightening torque:
26 Nm (2.65 kgf-m, 19.2 ft-lb)
FU-01122
2) Start the engine and run it until it stalls.

2. DRAINING FUEL
WARNING:
IN-00203
filler cap.
FU(H4DOTC)-40
Fuel Tank
22.Fuel Tank

A: REMOVAL
WARNING:
<Ref. to FU(H4DOTC)-40, DRAINING FUEL,
PROCEDURE, Fuel.>
(1) Remove the bolt (A).
(A)
(A)
(B)
FU-01126

sensor.
9) Disconnect the quick connector from the fuel delivery (B) and return hose (C).
<Ref. to FU(H4DOTC)-56, REMOVAL, Fuel Delivery, Return and Evaporation Lines.>
(A)
(A)
(A)
(B)
(C)
(B)
FU-01124
FU-01127
10) Remove the rear wheel.

11) Remove the bolts which secure rear brake
FU-01125
FU(H4DOTC)-41
FU-01128
Fuel Tank


cable clamp.
FU-00462

<Ref. to EX(H4DOTC)-11, REMOVAL, Rear Exhaust Pipe.>
speed sensor.
FU-01130
FU-01131

CAUTION:
(2) Remove the bolt which installs the rear
shock absorber to rear suspension arm.
FU-01129
FU-01132
FU(H4DOTC)-42
Fuel Tank
(3) Remove the bolts which secure the rear

suspension assembly to body.
WARNING:
FU-01133
FU-01137
B: INSTALLATION
of fuel tank band.
WARNING:
FU-01134

from bracket.
FU-01137
(A)
FU-01135

(A)
(B)
FU-01136
23) Support the fuel tank with transmission jack, remove the bolts from fuel tank bands and dismount
FU(H4DOTC)-43
Fuel Tank

clamp.
Tightening torque:
T1: 125 Nm (12.7 kgf-m, 92.2 ft-lb)
T2: 65 Nm (6.2 kgf-m, 48 ft-lb)
T3: 175 Nm (17.8 kgf-m, 129 ft-lb)
(A)
T1
T1
(B)
T1
T1
FU-01136
FU-01150
(2)
(1)
(3)
L/2
T3
T2
T2
T3
FU-00104
FU-01138
(1) Hose
(2) Clip or clamp
(3) Pipes
(3) Tighten the bolt which installs the rear shock

absorber to rear suspension arm. <Ref. to RS11, INSTALLATION, Rear Arm.>

Tightening torque:
62 Nm (6.3 kgf-m, 46 ft-lb)
(A)
FU-01135
FU-01132
4) Tighten the bolt of fuel tank band.
Tightening torque:
33 Nm (3.4 kgf-m, 25 ft-lb)
CAUTION:
then tighten the bolts which secure the rear suspension assembly to body.
FU(H4DOTC)-44
Fuel Tank
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
Tightening torque:
33 Nm (3.4 kgf-m, 25 ft-lb)
FU-01130
Tightening torque:
32 Nm (3.3 kgf-m, 23.9 ft-lb)
FU-01128
15) Install the rear wheel.

(B) and return hose (C).
<Ref. to FU(H4DOTC)-57, INSTALLATION, Fuel
Delivery, Return and Evaporation Lines.>
NOTE:
return side.
FU-01131

(A)
(C)
(B)
FU-01127

sensor.
FU-01129
(A)
Tightening torque:
17.5 Nm (1.78 kgf-m, 12.9 ft-lb)
10) Install the rear exhaust pipe.
<Ref. to EX(H4DOTC)-11, INSTALLATION, Rear
Exhaust Pipe.>
14) Tighten the bolts which secure the rear brake
(A)
(B)
(A) Bolt
(B) Grommet
FU(H4DOTC)-45
FU-01126
Fuel Tank
FU-01125
(A)
(A)
(B)
FU-01124
(A) Bolt
(B) Grommet

C: INSPECTION
1) Check that the fuel tank is not holed, cracked or
otherwise damaged.
not cracked and that connections are tight.
FU(H4DOTC)-46
Fuel Filler Pipe

23.Fuel Filler Pipe

drain plug from fuel tank to drain fuel from the fuel
tank.
A: REMOVAL
WARNING:
FU-01123

NOTE:
Use a new gasket.
IN-00203
2) Open the fuel filler flap lid and remove the filler
cap.
3) Remove the screws which secure packing.
Tightening torque:
26 Nm (2.65 kgf-m, 19.2 ft-lb)
10) Remove the bolts which hold the fuel filler pipe
FU-00095

FU-01139
11) Loosen the clamp, and disconnect the fuel filler

(A)
(B)
FU-00096
FU-01136

vehicle.
FU(H4DOTC)-47
Fuel Filler Pipe

B: INSTALLATION
side of apron.
Tightening torque:
7.5 Nm (0.75 kgf-m, 5.4 ft-lb)
NOTE:
(A)
FU-01139
(B)
(C)
FU-00103

pipe (B) to specified position, and then tighten the
clamp.
(A)
FU-00096

(B)
FU-01136
(2)
(1)
(3)
IN-00203
L/2
L
FU-00104
(1) Hose
(2) Clip or clamp
(3) Pipes
5) Tighten the bolts which hold the fuel filler pipe

FU(H4DOTC)-48
Fuel Pump
24.Fuel Pump

A: REMOVAL
WARNING:
NOTE:
level sensor.
filler cap.
(A)
(A)
(B)
FU-01124
FU-01125
IN-00203

fuel tank.
pump hose. <Ref. to FU(H4DOTC)-56, REMOVAL,
Fuel Delivery, Return and Evaporation Lines.>
12) Remove the nuts which install the fuel pump
assembly onto fuel tank.
(B)
(C)
(A)
FU-01123
FU-01140
(A) Delivery hose

(B) Return hose
(C) Jet pump hose
NOTE:
Use a new gasket.
Tightening torque:
26 Nm (2.65 kgf-m, 19.2 ft-lb)
FU(H4DOTC)-49
Fuel Pump
B: INSTALLATION
NOTE:
Use a new gasket.
Ensure the sealing portion is free from fuel or foreign particles before installation.
Tighten the nuts to specified torque in the order
Tightening torque:
4.4 Nm (0.45 kgf-m, 3.3 ft-lb)
1
4
7
2
FU-01141
C: INSPECTION
of fuel pump, and apply the battery power supply to
check whether the pump operate.
WARNING:
possible.
non-load condition.
2 1
4 3
6 5
FU-01330
FU(H4DOTC)-50
Fuel Level Sensor


A: REMOVAL
WARNING:
NOTE:
1) Remove the fuel pump assembly.
<Ref. to FU(H4DOTC)-49, REMOVAL, Fuel
Pump.>
FU-01142
B: INSTALLATION
FU(H4DOTC)-51


sensor.
A: REMOVAL
WARNING:
FU-01143
pump hose. <Ref. to FU(H4DOTC)-56, REMOVAL,
9) Remove the bolts which install the fuel sub level
sensor on fuel tank.
IN-00203

the drain plug from fuel tank to drain the fuel from
fuel tank.
(C)
(A)
(B)
(A) Jet pump hose

(B) Delivery hose
(C) Return hose

FU-01123

Tightening torque:
26 Nm (2.65 kgf-m, 19.2 ft-lb)
(A)
(A)
(B)
FU-01126
FU(H4DOTC)-52
FU-01144

B: INSTALLATION
NOTE:
Use a new gasket.
Ensure the sealing portion is free from fuel and
Tighten the nuts and bolts to specified torque in
Tightening torque:
4.4 Nm (0.45 kgf-m, 3.3 ft-lb)
3
1
5
6
2
4
FU-01145
FU-01146
FU(H4DOTC)-53
Fuel Filter
27.Fuel Filter
A: SPECIFICATION
<Ref. to FU(H4DOTC)-49, REMOVAL, Fuel
Pump.> <Ref. to FU(H4DOTC)-50, INSTALLATION, Fuel Pump.>
FU(H4DOTC)-54
Fuel Bypass Valve

28.Fuel Bypass Valve

A: REMOVAL
2) Disconnect the fuel return line and delivery line
from fuel bypass valve.
3) Remove the fuel bypass valve from vehicle.
(A)
(B)
T
(B)
T
(C)
(D)
(A)
(B)
(C)
(D)
FU-01331
Fuel delivery line

Fuel return line
Fuel bypass valve
B: INSTALLATION
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.53 ft-lb)
(A)
(B)
T
(B)
T
(C)
(D)
(A)
(B)
(C)
(D)
FU-01331
Fuel delivery line

Fuel return line
Fuel bypass valve
FU(H4DOTC)-55


A: REMOVAL
2) Release the fuel pressure. <Ref. to FU(H4DOTC)-40, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.>
3) Open the fuel filler flap lid and remove the fuel filler cap.
FU-01332

(A)
(C)
9) Separate the quick connector of fuel line.

covered with dust.
plastic bag etc.
(B)
FU-01088

(B) Return hose
FU-01333

8) Remove the fuel tank. <Ref. to FU(H4DOTC)41, REMOVAL, Fuel Tank.>

down.
FU(H4DOTC)-56

CAUTION:
securely.
Be sure to inspect hoses and their connections for fuel leakage.
CAUTION:
(B)
(C)
(A)
FU-00124
(A)
(A) Connector
(B) Retainer
(C) Pipes
(B)
(C)
FU-00127
B: INSTALLATION
CAUTION:
(A) Connector
(B) Retainer
(C) Pipes

2: 2.51.5 mm (0.0980.059 in)
(A)
L: 22.52.5 mm (0.8860.098 in)

(B)
(1)
(2)
(3)
Type A
FU-00125
L
(A) Seal surface

(B) Pipes
Type B

FU-00128
(1) Pipes
(2) Clamp
(3) Hose
(A)
(B)
(C)
FU-00126

to pipe by approx. 15 mm (0.59 in) from the hose
end.
Fuel return hose:
L = 22.52.5 mm (0.8850.098 in)
L = 17.52.5 mm (0.6890.098 in)
(A) Connector
(B) Retainer
(C) Pipes
FU(H4DOTC)-57

CAUTION:
Be sure to inspect hoses and their connections
for fuel leakage.
(2)
(1)
(3)
L/2
L
FU-00129
(1) Hose
(2) Clip
(3) Pipes
C: INSPECTION
FU(H4DOTC)-58


A: INSPECTION
1)
Corrective action
Defective terminal contact.
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 air breather tube or pipe.
7)
Damaged diaphragm of pressure regulator.
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 air breather tube or air vent tube.

1)
pipe.
2)
Defective packing air tightness on the fuel saucer.
3)
Inoperative fuel pump modulator or circuit.
1)
Defective operation of fuel level sensor.
2)
Defective operation of fuel meter.
5. Noise
1)
Large operation noise or vibration of fuel pump.

securely.
Replace.
Retightening.
Replace.
Replace.
Replace.
tube.
Retightening.
Replace.
Replace.
Replace.
Replace.
NOTE:
Before using a water removing agent, follow the cautions that noted on the bottle.
FU(H4DOTC)-59

FU(H4DOTC)-60
EMISSION CONTROL
EC(H4DOTC)
1.
2.
3.
4.
5.
6.
7.
Page
Canister.......................................................................................................5
Two-way Valve............................................................................................7
PCV Valve...................................................................................................8
General Description
A: CAUTION
points.
cable from battery.
EC(H4DOTC)-2


A: REMOVAL
1) Remove the center exhaust pipe.
<Ref. to EX(H4DOTC)-6, REMOVAL, Center Exhaust Pipe.>
2) Separate the front catalytic converter (A) from
rear catalytic converter (B).
(A)
(B)
EC-00217
B: INSTALLATION
NOTE:
Always use new gasket.
C: INSPECTION
EC(H4DOTC)-3


A: REMOVAL
2) Separate the rear catalytic converter (B) from
front catalytic converter (A).
(A)
(B)
EC-00217
B: INSTALLATION
NOTE:
C: INSPECTION
EC(H4DOTC)-4
Canister
4. Canister
B: INSTALLATION
A: REMOVAL

NOTE:

3) Remove the rear mud guard LH.
4) Remove the canister protector.
(B)
Tightening torque:
8.3 Nm (0.85 kgf-m, 6.1 ft-lb)
(B)
(A)
(B)
(A)
(B)
EC-02027
EC-02027
C: INSPECTION
cracked or loose.
EC(H4DOTC)-5

B: INSTALLATION
A: REMOVAL

Tightening torque:
19 Nm (1.94 kgf-m, 13.7 ft-lb)
EC-00220
IN-00203
3) Remove the solenoid valve bracket assembly

NOTE:
(A)
EC-00219
4) Disconnect the connector from purge control solenoid valve.

5) Disconnect the evaporation hose from the intake
manifold and fuel pipe assembly.
6) Remove the purge control solenoid valve from
solenoid valve bracket assembly.
(B)
EC-00273
(A) To intake manifold

(B) To fuel pipe ASSY
Tightening torque:
19 Nm (1.94 kgf-m, 13.7 ft-lb)
EC-00220
EC-00219
C: INSPECTION
EC(H4DOTC)-6
Two-way Valve
6. Two-way Valve
A: REMOVAL
valve.
from body.
EC-00221
B: INSTALLATION
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
C: INSPECTION
EC(H4DOTC)-7
PCV Valve
7. PCV Valve
A: REMOVAL
<Ref. to FU(H4DOTC)-13, REMOVAL, Intake Manifold.>
2) Remove the PCV valve from intake manifold.
EC-00222
B: INSTALLATION
NOTE:
valve.
Liquid gasket:
equivalent
Tightening torque:
23 Nm (2.35 kgf-m, 17.0 ft-lb)
EC(H4DOTC)-8
INTAKE (INDUCTION)
IN(H4DOTC)
1.
2.
3.
4.
5.
6.
7.
8.
9.
Page
Air Cleaner Case.........................................................................................8
Air Intake Duct.............................................................................................9
Resonator Chamber..................................................................................10
Intake Duct ................................................................................................11
Intercooler .................................................................................................12
Turbocharger.............................................................................................14
Air By-pass Valve......................................................................................17
General Description
INTAKE (INDUCTION)
A: COMPONENT
1. AIR CLEANER
T1
(3)
(1)
(3)
(2)
(5)
(6)
T2
(4)
T4
(5)
(7)
(13)
T2
(10)
T3
(9)
(11)
(12)
(11)
(12)
(8)
IN-02016
(1)
Mass air flow and intake air temperature sensor
(2)
(3)
(4)
(5)
(6)

Clip
Air intake boot
Clamp
Air cleaner element
(7)
(8)
(9)
(10)
(11)
(12)
(13)

Air intake duct
Clip
Resonator chamber
Cushion
Spacer
Cushion
IN(H4DOTC)-2

T1: 1.0 (0.10, 0.74)
T2: 2.5 (0.25, 1.8)
T3: 6.0 (0.61, 4.4)
T4: 7.5 (0.76, 5.5)
General Description
INTAKE (INDUCTION)
2. INTAKE DUCT
(1)
(2)
T2
(4)
(3)
T2
T2
(2)
(5)
(9)
(8)
(6)
T1
T1
(11)
(7)
(12)
(10)
(13)
IN-00214
(1)
(2)
(3)
(4)
(5)
(6)
PCV hose ASSY

Intake manifold
Solenoid valve bracket ASSY
Intake duct
Engine harness ASSY
Vacuum hose
(7)
(8)
(9)
(10)
(11)
(12)
Vacuum hose
PCV pipe
Vacuum hose
Air by-pass pipe
Clamp
Vacuum hose
IN(H4DOTC)-3
(13)
Brake booster hose

T1: 6.5 (0.66, 4.8)
T2: 19 (1.9, 13.7)
General Description
INTAKE (INDUCTION)
3. INTERCOOLER
T1
T3
(3)
(2)
(4)
T2
(5)
(1)
IN-00215
(1)
(2)
(3)
Intercooler
Gasket
Air by-pass valve
(4)
(5)
Intake duct
Clamp
IN(H4DOTC)-4

T1: 3.0 (0.3, 2.2)
T2: 6.5 (0.66, 4.8)
T3: 16 (1.6, 11.6)
General Description
INTAKE (INDUCTION)
4. TURBOCHARGER
T2
T4
(1)
(2)
(3)
(4)
(2)
(2)
T3
(5)
(6)
T1
(2)
(2)
T1
IN-00216
(1)
(2)
(3)
Oil inlet pipe

Metal gasket
Turbocharger
(4)
(5)
(6)
Water pipe
Gasket
Oil outlet pipe
IN(H4DOTC)-5

T1: 4.7 (0.48, 3.5)
T2: 5.0 (0.51, 3.7)
T3: 23 (2.3, 17.0)
T4: 16 (1.6, 11.8)
General Description
INTAKE (INDUCTION)
B: CAUTION
points.
cable from battery.
IN(H4DOTC)-6
Air Cleaner Element

INTAKE (INDUCTION)
B: INSTALLATION
A: REMOVAL
NOTE:
When installing the air cleaner case (rear), align the
protrusion part of air cleaner case (rear) to the hole
of air cleaner case (front).
IN-00203
2) Disconnect the connector (A) from mass air flow

sensor.
3) Loosen the clamps (B) which connect air intake
boot to intake duct.
4) Remove the clips (C) from air cleaner case.
(C)
(A)
IN-00220
C: INSPECTION
(C)
(B)
(B)
IN-00218
5) Remove the air cleaner case (rear) and air intake boot.
IN(H4DOTC)-7
Air Cleaner Case

INTAKE (INDUCTION)
3. Air Cleaner Case

A: REMOVAL
1) Remove the air intake duct. <Ref. to
IN(H4DOTC)-9, REMOVAL, Air Intake Duct.>
<Ref. to IN(H4DOTC)-7, REMOVAL, Air Cleaner
Element.>
3) Remove the bolts (A) and nut (B) which install air
cleaner case (front) on the body.
(B)
(A)
IN-02017
B: INSTALLATION
Tightening torque:
Bolt: 6.0 Nm (0.61 kgf-m, 4.4 ft-lb)
Nut: 7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
C: INSPECTION
IN(H4DOTC)-8
Air Intake Duct

INTAKE (INDUCTION)
4. Air Intake Duct

A: REMOVAL
Remove the clips which install the air intake duct on
the front side of body.
IN-00217
B: INSTALLATION
C: INSPECTION
1) Check for cracks or loose connection.
duct.
IN(H4DOTC)-9
Resonator Chamber
INTAKE (INDUCTION)
A: REMOVAL
with air cleaner case. <Ref. to IN(H4DOTC)-8, REMOVAL, Air Cleaner Case.>
B: INSTALLATION
Refer to Air Cleaner Case for installation procedure because the resonator chamber forms a single unit with air cleaner case. <Ref. to
IN(H4DOTC)-8, INSTALLATION, Air Cleaner
Case.>
C: INSPECTION
IN(H4DOTC)-10
Intake Duct
INTAKE (INDUCTION)
6. Intake Duct
A: REMOVAL
IN-00203

4) Remove the sensor, engine harness and fuel
pipe attached to the intake manifold. <Ref. to
FU(H4DOTC)-17, DISASSEMBLY, Intake Manifold.>
5) Remove the intake duct from intake manifold.
IN-00221
B: INSTALLATION
Tightening torque:
19 Nm (1.9 kgf-m, 13.7 ft-lb)
IN-00221
IN(H4DOTC)-11
Intercooler
INTAKE (INDUCTION)
7. Intercooler
B: INSTALLATION
A: REMOVAL

2) Loosen the clamp, and then remove the air bypass pipe (A) from air by-pass valve.
3) Loosen the clamp, and then remove the intake
duct (B) from intercooler.
Tightening torque:
16 Nm (1.6 kgf-m, 11.6 ft-lb)
(A)
(B)
IN-00224
IN-00222
4) Remove the bolts which secure intake duct to

turbocharger.
IN-00223
C: DISASSEMBLY
1) Remove the intake ducts from intercooler.
2) Remove the air by-pass valve from intercooler.
IN-00223
5) Remove the bolts which secure intercooler to

bracket, and then remove the intercooler.
IN-00225
IN-00224
IN(H4DOTC)-12
Intercooler
INTAKE (INDUCTION)
D: ASSEMBLY
Tightening torque:
6.5 Nm (0.66 kgf-m, 4.8 ft-lb)
IN-00225
IN(H4DOTC)-13
Turbocharger
INTAKE (INDUCTION)
8. Turbocharger
11) Separate the turbocharger joint pipe from turbocharger.
A: REMOVAL
IN-00227
IN-00203

5) Remove the intercooler bracket RH.
6) Remove the linear motion mounting.
<Ref. to ME(H4DOTC)-37, REMOVAL, Linear Motion Mounting.>
7) Remove the linear motion mounting bracket.
12) Remove the bolts which secure oil pipe bracket

to turbocharger.
13) Remove the oil inlet pipe from turbocharger.
CAUTION:
In order to prevent damaging the oil pipe on the
cylinder head side, fix the section (a) shown in
the figure when loosing the oil inlet pipe flare
nut, and avoid the part from rotating together
while loosening the nut.
(A)
(a)
LU-02510
(B)
IN-00251
(A) Linear motion mounting bracket

(B) Turbocharger bracket

10) Disconnect the engine coolant hose which is
connected to coolant filler tank.
IN-00228
14) Remove the bolts which secure turbocharger to

bracket.
IN-00226
IN-00229
IN(H4DOTC)-14
Turbocharger
INTAKE (INDUCTION)
15) Disconnect the hoses from the oil outlet pipe

(A) and coolant pipe (B) located under the turbocharger.
(B)
3) Temporarily tighten the bolts and flare nuts

which secure the oil inlet pipe to the turbocharger.
NOTE:
Use a new gasket.
(A)
IN-00230
16) Take out the turbocharger from engine compartment.
B: INSTALLATION
CAUTION:
When replacing the turbocharger, check the filter part of union screw for clogging. <Ref. to
LU(H4DOTC)-20, INSPECTING UNION SCREW
WITH FILTER, INSPECTION, Oil Pipe.>
1) Connect the hoses to the oil outlet pipe (A) and
coolant pipe (B) located under the turbocharger.
LU-02512
4) Tighten the union screws and flare nuts which

secure the oil inlet pipe to the turbocharger.
CAUTION:
the figure when tightening the oil inlet pipe flare
while tightening the nut.
(a)
(B)
(A)
LU-02510
IN-00230
2) Install the turbocharger to bracket.

Tightening torque:
33 Nm (3.4 kgf-m, 24.6 ft-lb)
Tightening torque:
T1: 16 Nm (1.6 kgf-m, 11.8 ft-lb)
T2: 20 Nm (2.0 kgf-m, 14.8 ft-lb)
T1
T2
LU-02513
IN-00229
IN(H4DOTC)-15
Turbocharger
INTAKE (INDUCTION)
5) Tighten the bolts which hold the oil inlet pipe stay
to the turbocharger.
10) Install the linear motion mounting bracket.
Tightening torque:
5 Nm (0.5 kgf-m, 3.7 ft-lb)
(A)
(B)
IN-00252

LU-02514
Tightening torque:
40 Nm (4.1 kgf-m, 29.5 ft-lb)
11) Install the linear motion mounting.
12) Install the intercooler bracket RH.
6) Install the joint pipe to turbocharger.

NOTE:
Use a new gasket.
Tightening torque:
35 Nm (3.6 kgf-m, 25.8 ft-lb)
IN-00227
7) Connect the engine coolant hose which is connected to the coolant filler tank.
IN-00226

9) Install the center exhaust pipe.
<Ref. to EX(H4DOTC)-7, INSTALLATION, Center
Exhaust Pipe.>
IN(H4DOTC)-16
Air By-pass Valve

INTAKE (INDUCTION)
9. Air By-pass Valve

A: REMOVAL
2) Disconnect the air by-pass hose (A) from air bypass valve.
3) Remove the air by-pass valve (B) from intercooler.
(B)
(A)
IN-00231
B: INSTALLATION
Tightening torque:
6.5 Nm (0.66 kgf-m, 4.8 ft-lb)
(B)
(A)
IN-00231
(A) Air by-pass hose

(B) Air by-pass valve
IN(H4DOTC)-17
Air By-pass Valve

INTAKE (INDUCTION)
IN(H4DOTC)-18
MECHANICAL
ME(H4DOTC)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
Page
Compression .............................................................................................21
Idle Speed .................................................................................................22
Ignition Timing...........................................................................................23
Fuel Pressure............................................................................................26
Valve Clearance........................................................................................27
Engine Assembly ......................................................................................30
Engine Mounting .......................................................................................36
Linear Motion Mounting.............................................................................37
V-belt.........................................................................................................39
Crank Pulley..............................................................................................41
Timing Belt Cover......................................................................................42
Timing Belt ................................................................................................43
Cam Sprocket ...........................................................................................51
Crank Sprocket .........................................................................................52
Camshaft...................................................................................................53
Cylinder Head ...........................................................................................59
Cylinder Block ...........................................................................................66
Intake and Exhaust Valve .........................................................................86
Piston ........................................................................................................87
Connecting Rod ........................................................................................88
Crankshaft.................................................................................................89
Engine Noise.............................................................................................96
General Description
MECHANICAL
A: SPECIFICATION
Bore Stroke
mm (in)
cm3
Displacement
Compression ratio
Compression pressure
(at 400 rpm)
kPa (kg/cm2, psi)
Intake valve timing

Close
Open
Close
Valve clearance
1,994 (121.67)
9.5
Open
Engine
(cu in)

Belt driven, double overhead camshaft,
4 valves/cylinder
92 75 (3.62 2.95)
mm (in)
Max.retard
Min.advance
Max.retard
Min.advance
Max.retard
Min.advance
Max.retard
Min.advance
Exhaust
rpm
Ignition order
Ignition timing

ATDC 6
BTDC 37
ABDC 62
ABDC 19
BBDC 30
BBDC 60
ATDC 28
BTDC 2
0.20 +0.040.06 (0.0079 +0.00160.0024)
Intake
Idle speed [P/N range]
1,100 1,300 (11.2 13.3, 160 189)
No-load
A/C ON
BTDC/rpm
0.350.05 (0.01380.0020)
65050
82550
1324
143/650
NOTE:
OS: Oversize US: Undersize
Belt tension
adjuster
Belt tensioner
Camshaft
Protrusion of adjuster rod

Spacer O.D.
Tensioner bush I.D.
Clearance between spacer and bush
mm (in)
Side clearance of spacer
mm (in)
Bend limit
Side clearance
mm (in)
Intake
Cam lobe height
mm (in)
Exhaust
Journal O.D.
Cylinder
Head
Valve seat
Valve guide
mm (in)
Clearance at journal
Surface warpage limit
Grinding limit
Standard height
Refacing angle
Contacting width
Inside diameter
mm (in)
mm (in)
Standard
Standard
mm (in)
Standard
Standard
Standard
Front
mm (in) Standard
Center rear
mm (in) Standard
mm (in)
mm (in)
mm (in)
mm (in)
Intake
Exhaust
Standard
Standard
mm (in)
mm (in)
ME(H4DOTC)-2
5.2 6.2 (0.205 0.244)

17.955 17.975 (0.7069 0.7077)
18.0 18.08 (0.7087 0.7118)
0.025 0.125 (0.0010 0.0049)
0.2 0.55 (0.0079 0.0217)
0.020 (0.00079)
0.068 0.116 (0.0027 0.0047)
45.85 45.95 (1.805 1.809)
45.75 45.85 (1.801 1.805)
37.946 37.963 (1.4939 1.4946)
29.946 29.963 (1.1790 1.1796)
0.037 0.072 (0.0015 0.0028)
0.035 (0.0014)
0.3 (0.012)
127.5 (5.02)
90
0.6 1.4 (0.024 0.055)
1.2 1.8 (0.047 0.071)
6.000 6.012 (0.2362 0.2367)
15.8 16.2 (0.622 0.638)
General Description
MECHANICAL
mm (in)
Standard
Standard
Valve stem gap
mm (in) Standard
Intake
Exhaust
Overall length
mm (in)
Head edge thickness

Stem outer diameters
Valve
Intake
Exhaust
Intake
mm (in)
Exhaust
Intake
Exhaust
Free length
Squareness
Valve
springs
mm (in)
Set
Tension/spring height
N (kgf, lb)/mm (in)
Surface warpage limit
(mating with cylinder head)
Grinding limit
Cylinder
block
Piston
Piston pin
Lift
mm (in)
0.025 (0.00098)
mm (in)
0.1 (0.004)
92.005 92.015 (3.6222 3.6226)
91.995 92.005 (3.6218 3.6222)
0.015 (0.0006)
0.010 (0.0004)
0.010 0.010 (0.00039 0.00039)
0.5 (0.020)
92.005 92.015 (3.6222 3.6226)
91.995 92.005 (3.6219 3.6222)
92.245 92.265 (3.6317 3.6467)
92.495 92.515 (3.6415 3.6423)
A
B
Taper
mm (in) Standard
Out-of-roundness
mm (in) Standard
Piston clearance
mm (in) Standard
Boring limit
mm (in)
A
Standard
B
Outer diameter
mm (in)
0.25 (0.0098) OS
0.50 (0.0197) OS
Standard clearance between piston and piston pin
Standard
mm (in)
Cylinder inner diameter
mm (in)
Standard
Degree of fit
Top ring
Ring closed gap
Piston ring
Connecting
rod
Bearing of
large end
Bushing of
small end
1.0 1.4 (0.039 0.055)

1.3 1.7 (0.051 0.067)
5.955 5.970 (0.2344 0.2350)
5.945 5.960 (0.2341 0.2346)
0.030 0.057 (0.0012 0.0022)
0.040 0.067 (0.0016 0.0026)
104.4 (4.110)
104.65 (4.1201)
44.67 (1.759)
2.5, 2.0 mm (0.079 in)
206 236
(21.0 24.1, 46.3 53.1)/36.0 (1.417)
485 537
(49.5 54.8, 109 121)/26.00 (1.024)
Standard
mm (in)
Second ring
Standard
Oil ring
Standard
Top ring
Standard
Ring groove gap
mm (in)
Second ring
Standard
Bend or twist per 100 mm (3.94 in) in length
Limit
mm (in)
Side clearance of large end
mm (in) Standard
Oil clearance
mm (in) Standard
Standard
Bearing size
0.03 (0.0012) US
mm (in) 0.05 (0.0020) US
0.25 (0.0098) US
Clearance between piston pin and bushing
Standard
mm (in)
ME(H4DOTC)-3
0.004 0.008 (0.0002 0.0003)

Piston pin must be fitted into position with
thumb at 20C (68F).
Outer circle side:
0.20 0.25 (0.0079 0.0098)
Inner circle side:
0.20 0.35 (0.0079 0.014)
0.40 0.50 (0.016 0.020)
0.20 0.50 (0.0079 0.0197)
0.030 0.070 (0.0012 0.0028)
0.030 0.070 (0.0012 0.0028)
0.10 (0.0039)
0.070 0.330 (0.0028 0.0130)
0.026 0.052 (0.0010 0.0020)
1.486 1.498 (0.0585 0.0590)
1.504 1.512 (0.0592 0.0595)
1.514 1.522 (0.0596 0.0599)
1.614 1.622 (0.0635 0.0639)
0 0.022 (0 0.0009)
General Description
MECHANICAL
Bend limit
mm (in)
Out-of-roundness
mm (in)
mm (in)
Standard
0.03 (0.0012) US
mm (in) 0.05 (0.0020) US
0.25 (0.0098) US
Standard
0.03 (0.0012) US
mm (in) 0.05 (0.0020) US
0.25 (0.0098) US
Side clearance
mm (in) Standard
Oil clearance
mm (in) Standard
Standard
0.03 (0.0012) US
#1, #3
0.05 (0.0020) US
Bearing size
0.25 (0.0098) US
(Thickness at
center)
Standard
mm (in)
0.03 (0.0012) US
#2, #4, #5
0.05 (0.0020) US
0.25 (0.0098) US
Crank pin and
crank journal
Crankshaft
Main bearing
ME(H4DOTC)-4
0.035 (0.0014)
0.005 (0.0002) or less
51.750 (2.0374)
51.984 52.000 (2.0466 2.0472)
51.954 51.970 (2.0454 2.0461)
51.934 51.950 (2.0447 2.0453)
51.734 51.750 (2.0368 2.0374)
59.992 60.008 (2.3619 2.3625)
59.962 59.978 (2.3607 2.3613)
59.942 59.958 (2.3599 2.3605)
59.742 59.758 (2.3520 2.3527)
0.030 0.115 (0.0012 0.0045)
0.010 0.030 (0.00039 0.0012)
1.998 2.011 (0.0787 0.0792)
2.017 2.020 (0.0794 0.0795)
2.027 2.030 (0.0798 0.0799)
2.127 2.130 (0.0837 0.0839)
2.000 2.013 (0.0787 0.0793)
2.019 2.022 (0.0795 0.0796)
2.029 2.032 (0.0799 0.0800)
2.129 2.132 (0.0838 0.0839)
General Description
MECHANICAL
B: COMPONENT
1. TIMING BELT
(1)
(2)
T2
(3)
T1
(4)
(5)
T1
(9)
T5
T3
(6)
(12)
(8)
(7)
T5
T3
T4
(14)
T1
T1
T5
T4
(10)
(14)
(11)
T4
(17)
(13)
T1
(15)
(16)
T6
(18)
T1
ME-02010
(1)
(2)
(3)
(4)
(5)
(6)
Timing belt cover No. 2 (RH)

Timing belt guide
Crank sprocket
Timing belt cover No. 2 (LH)
Tensioner bracket
Automatic belt tension adjuster
ASSY
(7)
(8)
(9)
Belt idler
Exhaust cam sprocket (RH)
Intake cam sprocket (RH)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
Intake cam sprocket (LH)

Exhaust cam sprocket (LH)
Timing Belt
Belt idler No. 2
Belt idler
Timing belt cover (LH)
Front belt cover
Timing belt cover (RH)
Crank pulley
ME(H4DOTC)-5

T1: 5 (0.5, 3.6)
T2: 10 (1.0, 7.2)
T3: 25 (2.5, 18.1)
T4: 39 (4.0, 28.9)
T5: <Ref. to ME(H4DOTC)-51,
INSTALLATION, Cam
Sprocket.>
General Description
MECHANICAL

(1)
T4
T2
(2)
(6)
T2
T5
T6
(28)
(8)
T6
(9)
T2
T5
(29)
(13)
(4)
(7)
T3
(14)
(5)
(10)
(12)
(3)
T1
(32)
(30)
(31)
(11)
T2
T3
(9)
(23)
(8)
(24)
T2
(25)
(15)
(16)
(6)
(14)
(27)
T4
(19)
T5
T6
(26)
(21)
T6
(17)
(12)
(28)
(20)
(32)
(30)
(18)
(31)
T5
T3
(22)
(11)
T3
T1
T4
T4
ME-00799
ME(H4DOTC)-6
General Description
MECHANICAL
(1)
(2)
(3)
(4)
(5)
(6)
Rocker cover (RH)

Rocker cover gasket (RH)
Camshaft cap (Front RH)
Intake camshaft cap (Rear RH)
Intake camshaft (RH)
Oil flow control solenoid valve
(Intake)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
Exhaust camshaft cap (Rear RH)

Gasket
Oil return cover
Exhaust camshaft (RH)
Cylinder head bolt
Oil seal
Cylinder head (RH)
Cylinder head gasket
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
Cylinder head (LH)

Intake camshaft (LH)
Exhaust camshaft (LH)
Camshaft cap (Front LH)
Intake camshaft cap (Rear LH)
Exhaust camshaft cap (Rear LH)
Rocker cover gasket (LH)
Rocker cover (LH)
Oil filler cap
Gasket
Oil filler duct
O-ring
Oil pipe (LH)
Gasket
Oil pipe (RH)
ME(H4DOTC)-7
(30)
(31)
Stud bolt
(Exhaust)
(32)
Gasket

Head.>
T2:
T3:
T4:
T5:
T6:
8 (0.8, 5.9)
10 (1.0, 7.2)
6.4 (0.65, 4.7)
20 (2.0, 14.5)
29 (3.0, 21.4)
General Description
MECHANICAL
(11)
(1)
(4)
(5)
(6)
(7)
(8)
(9)
(3)
(2)
(11)
(4)
(5)
(6)
(7)
(8)
(9)
(12)
(4)
(10)
(6)
(12)
(7)
(8)
(4)
(9)
(10)
(6)
(7)
(8)
(9)
ME-00795
(1)
(2)
(3)
(4)
Exhaust valve
Intake valve
Cylinder head
Valve spring seat
(5)
(6)
(7)
(8)

Valve springs
Retainer
Retainer key
ME(H4DOTC)-8
(9)
(10)
(11)
(12)
Valve lifter
Intake valve guide
Exhaust valve guide
General Description
MECHANICAL
4. CYLINDER BLOCK
T2
T6
T2
T4
(1)
T5
(6)
T2
(7)
T4
(2)
(8)
(3)
T2
(5)
(4)
(10)
(9)
T2
T6
(10)
(14)
(11)
(4)
(3)
(10)
T4
(25)
T2
(4)
(3)
(24)
T8
(21)
(10)
T6
(12)
T4
(16)
(15)
(22)
T2
T5
T7
T2
(17)
T3
(13)
(23)
(20)
(19)
T1
T8
(18)
ME-02011
(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 strainer
Gasket
Oil pan
Drain plug
Metal gasket
Oil filter
Gasket
Water pump hose
Plug
Connector
ME(H4DOTC)-9

T1: 5 (0.5, 3.6)
T2: 6.4 (0.65, 4.7)
T3: 10 (1.0, 7.2)
T4: 25 (2.5, 18.1)
Block.>
T6: 70 (7.1, 51.6)
T7: First 12 (1.2, 8.7)
Second 12 (1.2, 8.7)
T8: 44 (4.5, 33)
General Description
MECHANICAL
(2)
T2
(8)
(1)
(7)
(3)
(4)
(10)
(5)
(11)
(8)
(6)
T1
(9)
(13)
(11)
(12)
(12)
(9)
T1
(11)
(6)
(11)
(14)
(8)
(5)
(4)
(3)
(10)
(8)
(7)
(17)
(16)
(15)
(16)
(15)
ME-02012
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Reinforcement
Drive plate
Top ring
Second ring
Oil ring
Piston
Piston pin
(8)
(9)
(10)
(11)
(12)
(13)
(14)
Snap ring
Connecting rod nut
Connecting rod
Connecting rod cap
Crankshaft
Woodruff key
ME(H4DOTC)-10
(15)
(16)
(17)
Crankshaft bearing #1, #3

Crankshaft bearing #2, #4
Crankshaft bearing #5

T1: 52 (5.3, 38.4)
T2: 72 (7.3, 53.1)
General Description
MECHANICAL
6. ENGINE MOUNTING
(1)
T1
T2
T1
T2
ME-02090
(1)

T1: 35 (3.6, 25.8)
T2: 85 (8.7, 62.7)
ME(H4DOTC)-11
General Description
MECHANICAL
7. LINEAR MOTION MOUNTING

T2
T2
(4)
(2)
T1
(3)
T1
(1)
T1
T1
ME-02091
(1)
(2)
(3)
Linear motion mounting

Linear motion mounting bracket
Dynamic damper
(4)
Bracket
ME(H4DOTC)-12

T1: 33 (3.4, 24.3)
T2: 30 (3.1, 22.1)
General Description
MECHANICAL
C: CAUTION
points.
cable from battery.
assembly.
making rechecks.
ready use.
with coolant or oil. Place a cover over fender, as required, for protection.
jacks, etc.
ME(H4DOTC)-13
General Description
MECHANICAL
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
498267600
DESCRIPTION
CYLINDER
HEAD TABLE
REMARKS
498457000
ENGINE STAND
ADAPTER RH
498457100
ENGINE STAND
ADAPTER LH
498497100
CRANKSHAFT
STOPPER
Used for stopping rotation of drive plate when

loosening/tightening crank pulley bolt.
ST-498267600
ST-498457000
ST-498457100
ST-498497100
ME(H4DOTC)-14
General Description
MECHANICAL
ILLUSTRATION
TOOL NUMBER
398744300
DESCRIPTION
PISTON GUIDE
REMARKS
Used for installing piston in cylinder.
498857100
VALVE OIL SEAL

GUIDE

guide oil seals.
499017100
PISTON PIN
GUIDE
499037100
CONNECTING
ROD BUSHING
REMOVER AND
INSTALLER

bushing.
ST-398744300
ST-498857100
ST-499017100
ST-499037100
ME(H4DOTC)-15
General Description
MECHANICAL
ILLUSTRATION
TOOL NUMBER
499097700
DESCRIPTION
PISTON PIN
REMOVER
ASSY
REMARKS
499977500
CAM
SPROCKET
WRENCH
Used for removing and installing the intake cam

sprocket and exhaust cam sprocket.
499587200
CRANKSHAFT
OIL SEAL
INSTALLER

(499597100).
499597100
CRANKSHAFT
ST-499097700
ST-499977500
ST-499587200
ST-499597100
ME(H4DOTC)-16
General Description
MECHANICAL
ILLUSTRATION
TOOL NUMBER
499718000
DESCRIPTION
VALVE SPRING
REMOVER
REMARKS
18251AA020
VALVE GUIDE
ADJUSTER
Used for installing intake and exhaust valve

guides.
499767200
VALVE GUIDE
REMOVER
499767400
VALVE GUIDE
REAMER
ST-499718000
ST18251AA020
ST-499767200
ST-499767400
ME(H4DOTC)-17
General Description
MECHANICAL
ILLUSTRATION
TOOL NUMBER
499817000
DESCRIPTION
ENGINE STAND
REMARKS
Stand used for engine disassembly and assembly.
Used with ENGINE STAND ADAPTER RH
(498457000) & LH (498457100).
499977400
CRANK PULLEY
WRENCH

499987500
CRANKSHAFT
SOCKET
499587100
OIL SEAL
INSTALLER
Used for installing oil pump oil seal.
ST-499817000
ST-499977400
ST-499987500
ST-499587100
ME(H4DOTC)-18
General Description
MECHANICAL
ILLUSTRATION
TOOL NUMBER
499587600
DESCRIPTION
OIL SEAL
INSTALLER
REMARKS
Used for installing camshaft oil seal for DOHC
engine.
18332AA000
OIL FILTER
WRENCH

18332AA010
OIL FILTER
WRENCH

ST-499587600
ST18332AA000
ST18332AA010
499597200
OIL SEAL GUIDE Used for installing camshaft oil seal for DOHC
engine.
Used with OIL SEAL INSTALLER (499587600)
ST-499597200
ME(H4DOTC)-19
General Description
MECHANICAL
ILLUSTRATION
TOOL NUMBER
498277200
DESCRIPTION
STOPPER SET
REMARKS
24082AA230
CARTRIDGE
22771AA030
SUBARU
SELECT MONITOR KIT

ST-498277200
ST24082AA230
ST22771AA030
2. GENERAL TOOL
TOOL NAME
Compression gauge
REMARKS
E: PROCEDURE
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 vehicle.
V-belt
Timing belt
Camshaft
Cylinder head
ME(H4DOTC)-20
Compression
MECHANICAL
2. Compression
A: INSPECTION
CAUTION:
switch to OFF.
4) Release the fuel pressure. <Ref. to
FU(H4DOTC)-40, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.>
5) Remove all the spark plugs.
<Ref. to IG(H4DOTC)-4, REMOVAL, Spark Plug.>
spark plug hole.
NOTE:
ME-00007
10) Perform at least two measurements per cylinder, and make sure that the values are correct.
Compression pressure (Throttle fully open):
Standard:
1,100 1,300 kPa (11.2 13.3 kg/cm2, 160
189 psi)
Difference between cylinders:
49 kPa (0.5 kgf/cm2, 7 psi) or less
ME(H4DOTC)-21
Idle Speed
MECHANICAL
3. Idle Speed
A: INSPECTION
properly.
not illuminate.
2) Idle the engine.
OFF.
connector.
6) Turn the ignition switch to ON and Subaru Select
Monitor switch to ON.
7) Select {Each System Check} in Main Menu.
8) Select {Engine} in Selection Menu.
9) Select {Current Data Display & Save} in Engine
Control System Diagnosis.
10) Select {Data Display} in Data Display Menu.
11) Start the engine, and read the engine idle
speed.
12) Check the idle speed when unloaded. (With
headlights, heater fan, rear defroster, radiator fan,
air conditioning, etc. OFF)
Idle speed [No load and gears in neutral]:
65050 rpm
13) Check the idle speed when loaded. (Turn the
air conditioning switch to ON and operate the
compressor for at least one minute before measurement.)
Idle speed [A/C ON, and gears in neutral]:
82550 rpm
NOTE:
<Ref. to EN(H4DOTC)(diag)-2, Basic Diagnostic
Procedure.>
ME(H4DOTC)-22
Ignition Timing
MECHANICAL
4. Ignition Timing
A: INSPECTION
1) Before checking the ignition timing, check the
following:
clogging, spark plugs are in good condition, and
hoses are connected properly.
not illuminate.
2) Idle the engine.
OFF.
connector.
idle speed.
143/650
system. Refer to Engine Control System. <Ref. to
EN(H4DOTC)(diag)-2, Basic Diagnostic Procedure.>
ME(H4DOTC)-23

MECHANICAL

A: INSPECTION
2) Idle the engine.
3) Disconnect the brake vacuum hose from intake
manifold, and then install the vacuum gauge.
4) Keep the engine at idle speed and read the vacuum gauge indication.
By observing the gauge needle movement, internal
condition of the engine can be diagnosed as described below.
ME-00801

66.7 kPa (500 mmHg, 19.70 inHg) or less
1. Needle motion is steady but lower than normal position. This Leakage around intake manifold gasket, or disconnected or
tendency becomes more evident as engine temperature rises.
damaged vacuum hose
2. Needle intermittently drops to the lower position than normal. Leakage around cylinder
3. Needle drops suddenly and intermittently from normal posiSticky valve
tion.
Defective ignition system or throttle chamber idle adjustment
range.
ME(H4DOTC)-24
Engine Oil Pressure

MECHANICAL

pressure switch. <Ref. to LU(H4DOTC)-16, INSTALLATION, Oil Pressure Switch.>
A: INSPECTION
2) Remove the oil pressure switch from engine cylinder block. <Ref. to LU(H4DOTC)-16, REMOVAL,
Oil Pressure Switch.>
block.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
IN-00203
5) Start the engine, and measure the oil pressure.
ME-00009
Oil pressure:
Standard:
98 kPa (1.0 kgf/cm2, 14 psi) or more (At 600
rpm)
588 kPa (6.0 kgf/cm2, 85 psi) or more (At
6,000 rpm)
CAUTION:
<Ref. to LU(H4DOTC)-22, INSPECTION, Engine
Lubrication System Trouble in General.>
If the oil pressure warning light is turned to
ON and oil pressure is within specification, replace the oil pressure switch. <Ref. to
LU(H4DOTC)-22, INSPECTION, Engine Lubrication System Trouble in General.>
NOTE:
The specified value is based on an engine oil temperature of 80C (176F).
ME(H4DOTC)-25
Fuel Pressure
MECHANICAL
7. Fuel Pressure
Fuel pressure:
Standard: 230 260 kPa (2.35 2.65 kgf/
cm2, 33 38 psi)
A: INSPECTION
WARNING:
Before removing the fuel pressure gauge, release the fuel pressure.
NOTE:
FU(H4DOTC)-40, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.>
filler cap.
4) Disconnect the fuel delivery hose and connect
ME-00802
NOTE:
to 0.2 kgf/cm2, 1 to 3 psi) higher than standard values during high-altitude operations.
FU-01122

Fuel pressure:
Standard: 284 314 kPa (2.9 3.2 kgf/cm2,
41 46 psi)
ME-00802

ME(H4DOTC)-26
Valve Clearance
MECHANICAL
8. Valve Clearance
NOTE:
Turn the crankshaft using a socket wrench.
A: INSPECTION
ME-00733
12) Measure the #1 cylinder intake valve and #3

cylinder exhaust valve clearance by using thickness gauge (A).
IN-00203

7) Remove a bolt which secures timing belt cover
(RH).
8) Loosen the remaining bolts which secure timing
belt cover (RH), then remove the timing belt cover.
(1) Remove the air cleaner case.
<Ref. to IN(H4DOTC)-8, REMOVAL, Air Cleaner Case.>
(2) Disconnect the connector from ignition coil.
(3) Remove the ignition coil.
(4) Place a suitable container under the vehicle.
(RH).
cover (RH).
(1) Disconnect the battery cable, and then remove the battery and battery carrier.
(2) Disconnect the connector from ignition coil.
(3) Remove the ignition coil.
(4) Place a suitable container under the vehicle.
(LH).
cover (LH).
11) Turn the crank pulley clockwise until arrow
mark on the cam sprocket is set to position shown
in the figure.
NOTE:
Insert the thickness gauge in as horizontal a direction as possible with respect to the valve lifter.
Measure the exhaust valve clearances while lifting-up the vehicle.
Valve clearance
Intake:
0.20+0.040.06mm (0.0079+0.00160.0024 in)
Exhaust:
0.350.05 mm (0.01380.0020 in)
If the measured value is not within specification,
take notes of the value in order to adjust the valve
clearance later on.
(A)
ME-00019

to ME(H4DOTC)-28, ADJUSTMENT, Valve Clearance.>
14) Further turn the crank pulley clockwise and
then measure the valve clearances again.
ME(H4DOTC)-27
Valve Clearance
MECHANICAL
(1) Set the arrow mark on cam sprocket to the

position shown in the figure, and measure the #2
cylinder exhaust valve and #3 cylinder intake
valve clearances.
B: ADJUSTMENT
CAUTION:
1) Measure all valve clearances. <Ref. to
ME(H4DOTC)-27, INSPECTION, Valve Clearance.>
NOTE:
Record each valve clearance after it has been
measured.
ME-00734

cylinder intake valve and #4 cylinder exhaust
valve clearances.
ME-00024
2) Remove the camshaft. <Ref. to ME(H4DOTC)53, REMOVAL, Camshaft.>

3) Remove the valve lifter.
4) Measure the thickness of valve lifter with a micrometer.
ME-00735

cylinder exhaust valve and #4 cylinder intake
valve clearances.
ME-00025
5) Select a valve lifter of suitable thickness based

on the measured valve clearance and valve lifter
thickness, by referring to the following table.
Unit: (mm)
ME-00736

Intake valve: S = (V + T) 0.20

Exhaust valve: S = (V + T) 0.35
S: Valve lifter thickness required
V: Measured valve clearance
T: Valve lifter thickness to be used
ME(H4DOTC)-28
Valve Clearance
MECHANICAL
Part number
13228 AB101
13228 AB111
13228 AB121
13228 AB131
13228 AB141
13228 AB151
13228 AB161
13228 AB171
13228 AB181
13228 AB191
13228 AB201
13228 AB211
13228 AB221
13228 AB231
13228 AB241
13228 AB251
13228 AB261
13228 AB271
13228 AB281
13228 AB291
13228 AB301
13228 AB311
13228 AB321
13228 AB331
13228 AB341
13228 AB351
13228 AB361
13228 AB371
13228 AB381
13228 AB391
13228 AB401
13228 AB411
13228 AB421
13228 AB431
13228 AB441
13228 AB451
13228 AB461
13228 AB471
13228 AB481
13228 AB491
13228 AB501
13228 AB511
13228 AB521
13228 AB531
13228 AB541
13228 AB551
13228 AB561
13228 AB571
13228 AB581
13228 AB591
13228 AB601
Thickness mm (in)
4.68 (0.1843)
4.69 (0.1846)
4.70 (0.1850)
4.71 (0.1854)
4.72 (0.1858)
4.73 (0.1862)
4.74 (0.1866)
4.75 (0.1870)
4.76 (0.1874)
4.77 (0.1878)
4.78 (0.1882)
4.79 (0.1886)
4.80 (0.1890)
4.81 (0.1894)
4.82 (0.1898)
4.83 (0.1902)
4.84 (0.1906)
4.85 (0.1909)
4.86 (0.1913)
4.87 (0.1917)
4.88 (0.1921)
4.89 (0.1925)
4.90 (0.1929)
4.91 (0.1933)
4.92 (0.1937)
4.93 (0.1941)
4.94 (0.1945)
4.95 (0.1949)
4.96 (0.1953)
4.97 (0.1957)
4.98 (0.1961)
4.99 (0.1965)
5.00 (0.1969)
5.01 (0.1972)
5.02 (0.1976)
5.03 (0.1980)
5.04 (0.1984)
5.05 (0.1988)
5.06 (0.1992)
5.07 (0.1996)
5.08 (0.2000)
5.09 (0.2004)
5.10 (0.2008)
5.11 (0.2012)
5.12 (0.2016)
5.13 (0.2020)
5.14 (0.2024)
5.15 (0.2028)
5.16 (0.2031)
5.17 (0.2035)
5.18 (0.2039)
Part number
13228 AB611
13228 AB621
13228 AB631
13228 AB641
13228 AB651
13228 AB661
13228 AB671
13228 AB681
13228 AB691
13228 AB701
13228 AB711
13228 AB721
13228 AB731
13228 AB741
13228 AB751
13228 AB761
13228 AB771
13228 AB781
13228 AB791
13228 AB801
13228 AB811
13228 AB821
13228 AB831
13228 AB841
13228 AB851
13228 AB861
13228 AB871
13228 AB881
13228 AB891
13228 AB901
13228 AB911
13228 AB921
13228 AB931
13228 AB941
13228 AB951
13228 AB961
13228 AB971
13228 AB981
13228 AB991
13228 AC001
13228 AC011
13228 AC021
13228 AC031
Thickness mm (in)
5.19 (0.2043)
5.20 (0.2047)
5.21 (0.2051)
5.22 (0.2055)
5.23 (0.2059)
5.24 (0.2063)
5.25 (0.2067)
5.26 (0.2071)
5.27 (0.2075)
4.38 (0.1724)
4.40 (0.1732)
4.42 (0.1740)
4.44 (0.1748)
4.46 (0.1756)
4.48 (0.1764)
4.50 (0.1771)
4.52 (0.1780)
4.54 (0.1787)
4.56 (0.1795)
4.58 (0.1803)
4.60 (0.1811)
4.62 (0.1819)
4.64 (0.1827)
4.66 (0.1835)
5.29 (0.2083)
5.31 (0.2091)
5.33 (0.2098)
5.35 (0.2106)
5.37 (0.2114)
5.39 (0.2122)
5.41 (0.2123)
5.43 (0.2138)
5.45 (0.2146)
5.47 (0.2154)
5.49 (0.2161)
5.51 (0.2169)
5.53 (0.2177)
5.55 (0.2185)
5.57 (0.2193)
5.59 (0.2201)
5.61 (0.2209)
5.63 (0.2217)
5.65 (0.2224)
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.
ME(H4DOTC)-29
Engine Assembly
MECHANICAL
9. Engine Assembly

compressor.
A: REMOVAL
2) Open the front hood fully and support with a front
food stay.
AC-20, Refrigerant Recovery Procedure.>
(1) Remove the fuse of fuel pump from main
fuse box.
ME-00803
FU-01122
(2) Start the engine, and run until stalls.

(3) After the engine stalls, crank it for 5 seconds
more.
11) Repair the air intake system.

(1) Remove the intercooler. (DOHC turbo model) <Ref. to IN(H4DOTC)-12, REMOVAL, Intercooler.>
(2) Remove the air cleaner element and air
cleaner case. <Ref. to IN(H4DOTC)-8, REMOVAL, Air Cleaner Case.>
12) Disconnect the following connectors and cables.
FU-01162
IN-00203

CO(H4DOTC)-19, REMOVAL, Radiator.>
Filler Tank.>
ME(H4DOTC)-30
FU-01163
Engine Assembly
MECHANICAL
(2) Engine ground terminals

(1) Loosen the lock bolt and slider bolt, and remove the front side belt. <Ref. to ME(H4DOTC)39, FRONT SIDE BELT, REMOVAL, V-belt.>
(2) Disconnect the power steering switch connector.
ME-00028
(3) Generator connector, terminal and A/C

compressor connector
(B)
(A)
ME-00035
(3) Remove the power steering pump from engine.
ME-00804
(A) A/C compressor connector

(B) Generator connector and terminal

ME-00809

side wheel apron.
15) Remove the linear motion mounting. <Ref. to
ME(H4DOTC)-37, REMOVAL, Linear Motion
Mounting.>
FU-01161

(3) Remove the hose between intake manifold
(A) and pressure regulator (B).
(A)
(B)
ME-00846
ME(H4DOTC)-31
Engine Assembly
MECHANICAL
18) Disconnect the oil flow control solenoid valve

connector and ground cable.
ME-00044
ME-00805
ME-02092
19) Remove the nuts which hold lower side of the

LU-00221
23) Disconnect the fuel delivery hose, return hose

and evaporation hose.
CAUTION:
Collect fuel from the hose into container.
ME-00040

ME-00045

wire ropes.
LU-00223

plate.
ME(H4DOTC)-32
LU-00222
Engine Assembly
MECHANICAL

CAUTION:
Doing this is very important because the transmission lowers for its own weight. This work is
also of great importance for facilitating reinstallation.

compartment.
NOTE:
B: INSTALLATION
1) Install the front cushion rubbers to engine.
Tightening torque:
35 Nm (3.6 kgf-m, 25.8 ft-lb)
2) Install the engine onto transmission.
Position the engine in engine compartment and
ME-00048
CAUTION:
Before moving the engine away from transmission, check to be sure no work has been overlooked.
26) Separation of engine and transmission.
(1) Remove the starter. <Ref. to SC(H4SO 2.0)6, REMOVAL, Starter.>
(2) Install the ST to converter case.
ST 498277200
STOPPER SET
NOTE:
panels with crank pulley, oil pressure gauge, etc.
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
ME-00050

ST
ME-00049

the transmission to engine.
LU-00222
ME-00050

ME(H4DOTC)-33
Engine Assembly
MECHANICAL
(1) Install the power steering pump.
Tightening torque:
T1: 50 Nm (5.1 kgf-m, 36.9 ft-lb)
T2: 58 Nm (5.9 kgf-m, 43 ft-lb)
Tightening torque:
20.1 Nm (2.05 kgf-m, 14.8 ft-lb)
T2
T1
ME-00037
LU-00224
7) Remove the ST from converter case.

NOTE:
Be careful not to drop the ST into the converter
case when removing the ST.
ST 498277200
STOPPER SET
by using ST.
CAUTION:
Be careful not to drop bolts into the torque converter clutch housing.
ST 499977400
CRANK PULLEY WRENCH
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
(2) Connect the power steering switch connector.
ME-00035
(3) Install the front side belt and adjust it. <Ref.
to ME(H4DOTC)-39, FRONT SIDE BELT, INSTALLATION, V-belt.>
13) Tighten the nuts which hold lower side of the
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
ME-00044
10) Install the linear motion mounting. <Ref. to

ME(H4DOTC)-37, INSTALLATION, Linear Motion
Mounting.>
ME-00040

Tightening torque:
85 Nm (8.7 kgf-m, 62.7 ft-lb)
ME(H4DOTC)-34
Engine Assembly
MECHANICAL
NOTE:
and locator are securely installed.
(1) Install the intercooler. (DOHC turbo model)

(2) Install the air cleaner element and air cleaner case. <Ref. to IN(H4DOTC)-8, INSTALLATION, Air Cleaner Case.>
NOTE:
Use new O-rings.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
LU-00223

Exhaust Pipe.>
16) Connect the oil flow control solenoid valve connector and ground cable of exhaust side.
ME-00803
ME-00805
ME-02092

18) Connect the following hoses.
(1) Fuel delivery hose, return hose and evaporation hose
(4) Pressure regulator hose
19) Connect the following connectors and terminals.
20) Install the air intake system.
22) Install the radiator. <Ref. to CO(H4DOTC)-20,

23) Install the coolant filler tank. (DOHC turbo model) <Ref. to CO(H4DOTC)-31, INSTALLATION,
Coolant Filler Tank.>
24) Install the window washer tank.
25) Install the battery to vehicle, and connect the
battery ground terminal.
27) Charge the A/C system with refrigerant.
<Ref. to AC-21, PROCEDURE, Refrigerant Charging Procedure.>
hood.
C: INSPECTION
1) Check pipes and hoses are connected firmly.
2) Check the engine coolant and ATF are at specified levels.
ME(H4DOTC)-35
Engine Mounting
MECHANICAL
10.Engine Mounting
A: REMOVAL
ME(H4DOTC)-30, REMOVAL, Engine Assembly.>
B: INSTALLATION
Tightening torque:
Engine mounting;
35 Nm (3.6 kgf-m, 25.8 ft-lb)
C: INSPECTION
Make sure that cracks or other damages do not exist.
ME(H4DOTC)-36
Linear Motion Mounting

MECHANICAL
11.Linear Motion Mounting
Tightening torque:
33 Nm (3.4 kgf-m, 24.3 ft-lb)
A: REMOVAL
ME-00853
Tightening torque:
30 Nm (3.1 kgf-m, 22.1 ft-lb)
ME-00852
4) Remove the speed nut (A), and remove the dynamic damper (B).
(A)
(B)
ME-00852
ME-02093
ME-00853
B: INSTALLATION
ME(H4DOTC)-37

MECHANICAL

A: PROCEDURE
1) After removing the engine from body, secure it in
the STs shown below.
RH
LH
ST3 499817000 ENGINE STAND
ST2
ST1
ST3
ME-00057
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(H4DOTC)-38
V-belt
MECHANICAL
13.V-belt
4) Remove the A/C belt tensioner.
A: REMOVAL
NOTE:
Perform the following procedures with the engine
installed to the body.
1. FRONT SIDE BELT

ME-00061
B: INSTALLATION
NOTE:
Wipe off any oil or water on the belt and pulley.
1. FRONT SIDE BELT
ME-00807

(B)
(C)
1) Install a V-belt (C), and tighten the slider bolt so

as to obtain the specified belt tension. <Ref. to
ME(H4DOTC)-40, INSPECTION, V-belt.>
Tightening torque:
Lock bolt (A):
25 Nm (2.5 kgf-m, 18.1 ft-lb)
Slider bolt (B):
8 Nm (0.8 kgf-m, 5.9 ft-lb)
(B)
(C)
(A)
ME-00059
2. REAR SIDE BELT
(A)

ME-00059
2. REAR SIDE BELT

1) Remove the A/C belt tensioner.
2) Install a V-belt, and tighten the slider bolt (B) so
<Ref. to ME(H4DOTC)-40, INSPECTION, V-belt.>
(B)
(A)
ME-00060
3) Remove the A/C belt.
ME(H4DOTC)-39
V-belt
MECHANICAL
Belt tension (without belt tension gauge)
Tightening torque:
Lock nut (A):
22.6 Nm (2.3 kgf-m, 16.6 ft-lb)
(A)
7 9 mm (0.276 0.354 in)
At inspection:
9 11 mm (0.354 0.433 in)
(B)
7.5 8.5 mm (0.295 0.335 in)
At inspection:
9.0 10.0 mm (0.354 0.394 in)
(B)
(A)
98 N (10 kgf, 22 lb)

ME-00060
P/S
GEN
(A) (B)
A/C
C: INSPECTION
1) Replace the belts, if crack, fraying or wear is
found.
and idler pulley installing position.
I/P
C/P
ME-00062
Belt tension (with belt tension gauge)

(A)
618 755 N (63 77 kgf, 139 170 lb)
At inspection:
490 640 N (50 65 kgf, 110 144 lb)
C/P
GEN
P/S
A/C
I/P
(B)
740 880 N (75 90 kgf, 166 198 lb)
At inspection:
350 450 N (36 46 kgf, 78 101 lb)
(A)
P/S
A/C
GEN
(B)
I/P
C/P
PM-00154
(A)
(B)
C/P
GEN
P/S
A/C
I/P
Front side belt

Rear side belt
Crank pulley
Generator
Idler pulley
ME(H4DOTC)-40
Crank pulley
Generator
Idler pulley
Crank Pulley
MECHANICAL
14.Crank Pulley
A: REMOVAL
REMOVAL, V-belt.>
ST 499977400
CRANK PULLEY WRENCH
Crank pulley bolt:

Part No. 12369AA011
in an angle 45 60.
NOTE:
the turning angle of the crank pulley bolt referring to
the gauge indicated on the timing belt cover.
4) Install the A/C belt tensioner.
ST
ME-00063
B: INSTALLATION
ST 499977400
CRANK PULLEY WRENCH
(1) Clean the crank shaft thread using compressed air.
and thread.
ME-00061
5) Install the V-belts. <Ref. to ME(H4DOTC)-39,

C: INSPECTION
1) Check the V-belt is not worn or otherwise damaged.
2) Check the tension of the belt. <Ref. to
ME(H4DOTC)-40, INSPECTION, V-belt.>
Tightening torque:
130 Nm (13.3 kgf-m, 95.9 ft-lb)
ST
ME-00063
3) Confirm that the tightening angle of the crank

pulley bolt is 45 or more. Perform the following
procedures when less than 45.
CAUTION:
If the tightening angle of crank pulley bolt is
less than 45, the bolt should be damaged. In
this case, the bolt must be replaced.
(1) Replace and clean the crank pulley bolts.
ME(H4DOTC)-41
Timing Belt Cover

MECHANICAL
15.Timing Belt Cover

A: REMOVAL
REMOVAL, V-belt.>
<Ref. to ME(H4DOTC)-41, REMOVAL, Crank Pulley.>
3) Remove the timing belt cover (LH) (A).
4) Remove the timing belt cover (RH) (B).
5) Remove the front timing belt cover (C).
(B)
(A)
(C)
ME-00064
B: INSTALLATION
1) Install the front timing belt cover (C).
Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
2) Install the timing belt cover (RH) (B).
Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
3) Install the timing belt cover (LH) (A).
Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
(B)
(A)
(C)
ME-00064
4) Install the crank pulley. <Ref. to ME(H4DOTC)41, INSTALLATION, Crank Pulley.>

C: INSPECTION
Check the cover for damage.
ME(H4DOTC)-42
Timing Belt
MECHANICAL
16.Timing Belt
(2) Using white paint, put alignment and/or arrow marks on the timing belts in relation to the
cam sprockets.
A: REMOVAL
1. TIMING BELT
REMOVAL, V-belt.>
2) Remove the crank pulley. <Ref. to
ME(H4DOTC)-41, REMOVAL, Crank Pulley.>
3) Remove the timing belt cover.
<Ref. to ME(H4DOTC)-42, REMOVAL, Timing Belt
Cover.>
4) Remove the timing belt guide.
ME-00070
ME-00065
5) If the alignment mark or arrow mark (which indicates rotation direction) on timing belt fade away,
put new marks before removing the timing belt as
shown in procedures below.
(1) Turn the crankshaft using ST, and align the
alignment marks on crank sprocket, intake cam
sprocket (LH), exhaust cam sprocket (LH), intake cam sprocket (RH) and exhaust cam
sprocket (RH) with notches of timing belt cover
and cylinder block.
ST 499987500
CRANKSHAFT SOCKET
ME-00071
Z1: 54.5 tooth length

Z2: 51 tooth length
Z3: 28 tooth length
Z1
Z3
Z2
Z3
ME-00072
6) Remove the belt idler (A).

(C)
(B)
ST
ME-00069
(A)
ME-00073
ME(H4DOTC)-43
Timing Belt
MECHANICAL
B: INSTALLATION
CAUTION:
After the timing belt has been removed, never
rotate the intake and exhaust cam sprocket. If
the cam sprocket is rotated, the intake and exhaust valve heads strike together and valve
stems are bent.
1. AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER
2. BELT IDLER AND AUTOMATIC BELT

TENSION ADJUSTER ASSEMBLY
1) Remove the belt idler (B) and (C).
(C)
(B)
(A)
ME-00074
1) Preparation for installation of automatic belt tension adjuster assembly.

CAUTION:
(1,000 kgf, 2,205 lb).
Do not release the 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 165 N (16.8 kgf, 37.1 lb) or more until the adjuster rod is aligned with the stopper pin
hole in the cylinder.
ME-00075

ME-00077
(3) With a 2 mm (0.08 in) dia. stopper pin or a

2 mm (0.08 in) (nominal) dia. hex wrench inserted into the stopper pin hole in cylinder, secure the adjuster rod.
ME-00076
ME-00078
ME(H4DOTC)-44
Timing Belt
MECHANICAL
2) Install the automatic belt tension adjuster assembly.
(1) Align the mark (A) on crank sprocket with

the mark on oil pump cover at cylinder block.
Tightening torque:
39 Nm (4.0 kgf-m, 28.9 ft-lb)
(A)
ME-00081
ME-00079
(2) Align single line mark (A) on the exhaust

cam sprocket (RH) with notch (B) on timing belt
cover.
Tightening torque:
39 Nm (4.0 kgf-m, 28.9 ft-lb)
(A)
(B)
ME-00082
ME-00075
4) Install the belt idlers.
(3) Align single line mark (A) on the intake cam

sprocket (RH) with notch (B) on timing belt cover. (Ensure double lines (C) on intake and exhaust cam sprockets are aligned.)
(B)
Tightening torque:
39 Nm (4.0 kgf-m, 28.9 ft-lb)
(A)
(C)
ME-00083
ME-00080
2. TIMING BELT
1) Preparation for installation of automatic belt tension adjuster assembly. <Ref. to ME(H4DOTC)-44,
AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER, INSTALLATION,
Timing Belt.>
2) Crankshaft and cam sprocket alignment
ME(H4DOTC)-45
Timing Belt
MECHANICAL
(4) Align single line mark (A) on exhaust cam

sprocket (LH) with notch (B) on timing belt cover
by turning the sprocket counterclockwise (as
viewed from front of engine).
(B)
(6) Ensure that the cam and crank sprockets

are positioned properly.
CAUTION:
Intake and exhaust camshafts for this DOHC
engine can be independently rotated with the
timing belts removed. As can be seen from the
figure, if the intake and exhaust valves are lifted
simultaneously, their heads will interfere with
each other, resulting in bent valves.
(A)
(A)
ME-00084
(5) Align single line mark (A) on intake cam

sprocket (LH) with notch (B) on timing belt cover
by turning the sprocket clockwise (as viewed
from front of engine).
Ensure double lines (C) on intake and exhaust
cam sprockets are aligned.
(B)
(A)
(C)
(B)
ME-00086
ME-00085
(A) Intake camshaft

(B) Exhaust camshaft
When the timing belts are not installed, four

camshafts are held at the zero-lift position,
where all cams on camshafts do not push the
intake and exhaust valves down. (Under this
condition, all valves remain unlifted.)
When the camshafts are rotated to install the
timing belts, #2 intake and #4 exhaust cam of
camshafts (LH) are held to push their corresponding valves down. (Under this condition,
these valves are held lifted.) Camshafts (RH)
are held so that their cams do not push valves
down.
Camshafts (LH) must be rotated from the zero-lift position to the position where the timing
belt is to be installed with the smallest possible
angle, in order to prevent mutual interference of
intake and exhaust valve heads.
ME(H4DOTC)-46
Timing Belt
MECHANICAL
Do not allow the 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.
(A)
(A)
(B)
(A)
(A)
(B)
ME-00314
(A) Revolving direction

(B) Timing belt installation position
ME(H4DOTC)-47
Timing Belt
MECHANICAL
3) Installation of timing belt:

Align the alignment mark on the timing belt with marks on the sprockets in the alphabetical order shown in
the figure. While aligning marks, position the timing belt properly.
CAUTION:
Disengagement of more than one timing belt tooth may result in interference between valve and
piston.
Ensure the belts rotating direction is correct.
(1)
(2)
(4)
(3)
(5)
(D)
(6)
(B)
(A)
RH-IN
LH-IN
RH-EX
LH-EX
(E)
(1)
(2)
(3)
Arrow mark
Timing belt
28 tooth length
(7)
(4)
(5)
(6)
(C)
54.5 tooth length

51 tooth length
28 tooth length
4) Install the belt idlers.

Tightening torque:
39 Nm (4.0 kgf-m, 28.9 ft-lb)
NOTE:
Make sure that the marks on the timing belt and
sprockets are aligned.
(7)
Install it in the end
6) Install the timing belt guide.

(1) Temporarily tighten the bolts.
(2) Check and adjust the clearance between
timing belt and timing belt guide.
Clearance:
1.00.5 mm (0.0390.020 in)
ME-00091
ME-00090
5) After ensuring that the marks on the timing belt

and sprockets are aligned, remove the stopper pin
from tensioner adjuster.
ME-00089
(3) Tighten the bolt.
ME(H4DOTC)-48
Timing Belt
MECHANICAL
Tightening torque:
10 Nm (1.0 kgf-m, 7.2 ft-lb)
ME-00095

<Ref. to ME(H4DOTC)-42, INSTALLATION, Timing Belt Cover.>
<Ref. to ME(H4DOTC)-41, INSTALLATION, Crank
Pulley.>
NOTE:
Slight trace of oil at rods oil seal does not indicate
a problem.
2) Check that the adjuster rod does not move when
a pressure of 165 N (16.8 kgf, 37.1 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 165 N (16.8 kgf, 37.1 lb), check it using the following procedures:
(1) Slowly press the adjuster rod down to the
end surface of the cylinder. Repeat this operation two to three times.
(2) With the adjuster rod moved all the way up,
apply a pressure of 165 N (16.8 kgf, 37.1 lb) to it.
Check the 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:
Be careful not to let oil, grease or engine
coolant contact the belt. Remove quickly and
thoroughly if this happens.
Do not bend the timing belt sharply.
CAUTION:
(1,000 kgf, 2,205 lb).
4) Measure the amount of rod protrusion beyond
the body. If it is not within specifications, replace
with a new one.
In radial diameter h:
Amount of rod protrusion H:

5.70.5 mm (0.2240.020 in)
C: INSPECTION
1. TIMING BELT
1) Check the timing belt teeth for breaks, cracks
and wear. If any fault is found, replace the timing
belt.
2) Check the condition of the backside of timing
belt. If cracks are found, replace the timing belt.
ME-00100
ME-00099
2. AUTOMATIC BELT TENSION ADJUSTER

1) Visually check the oil seals for leaks, and rod
ends for abnormal wear and scratches. If necessary, replace the automatic belt tension adjuster
assembly.
3. BELT TENSION PULLEY

1) Check the mating surfaces of timing belt and
contact point of adjuster rod for abnormal wear or
scratches. Replace the belt tension pulley if faulty.
2) Check the belt tension pulley for smooth rotation. Replace if noise or excessive play occurs.
3) Check the belt tension pulley for grease leakage.
ME(H4DOTC)-49
Timing Belt
MECHANICAL
4. BELT IDLER
1) Check the belt idler for smooth rotation. Replace
if noise or excessive play occurs.
2) Check the outer contacting surfaces of idler pulley for abnormal wear and scratches.
3) Check the belt idler for grease leakage.
ME(H4DOTC)-50
Cam Sprocket
MECHANICAL
17.Cam Sprocket
C: INSPECTION
A: REMOVAL

and scratches.
sprocket and key.
3) Check the cam sprocket protrusion used for sensor for damage and contamination of foreign matter.

REMOVAL, V-belt.>
Cover.>
<Ref. to ME(H4DOTC)-43, REMOVAL, Timing
Belt.>
5) Remove the cam sprocket. To lock the camshaft, use ST.
ST 499977500
CAM SPROCKET WRENCH
ME-00838
B: INSTALLATION
1) Install the cam sprocket. To lock the camshaft,
use ST.
Tightening torque:
Tighten to 29.5 Nm (3.0 kgf-m, 21.8 ft-lb) of
torque, and then tighten further by 45
ME-00838
2) Install the timing belt. <Ref. to ME(H4DOTC)-44,

INSTALLATION, Timing Belt.>
Pulley.>
ME(H4DOTC)-51
Crank Sprocket
MECHANICAL
18.Crank Sprocket
C: INSPECTION
A: REMOVAL

wear and scratches.
sprocket and key.
3) Check the crank sprocket protrusion used for
sensor for damage and contamination of foreign
matter.

REMOVAL, V-belt.>
Cover.>
Belt.>
5) Remove the cam sprocket.
<Ref. to ME(H4DOTC)-51, REMOVAL, Cam
Sprocket.>
ME-00103
B: INSTALLATION
ME-00103
2) Install the cam sprocket.

<Ref. to ME(H4DOTC)-51, INSTALLATION, Cam
Sprocket.>
3) Install the timing belt.
<Ref. to ME(H4DOTC)-44, INSTALLATION, Timing Belt.>
ME(H4DOTC)-52
Camshaft
MECHANICAL
19.Camshaft
10) Remove the timing belt cover No. 2 (RH).
A: REMOVAL
REMOVAL, V-belt.>
Cover.>
4) Remove the timing belt. <Ref. to ME(H4DOTC)43, REMOVAL, Timing Belt.>
5) Remove the cam sprocket. <Ref. to
ME(H4DOTC)-51, REMOVAL, Cam Sprocket.>
6) Remove the crank sprocket. <Ref. to
ME(H4DOTC)-52, REMOVAL, Crank Sprocket.>
7) Disconnect the oil flow control solenoid valve assembly connector.
ME-00107

12) Remove the oil level gauge guide. (LH side)
13) Remove the rocker cover and gasket.
14) Remove the oil pipe.
ME-00712
ME-00808
15) Remove the camshaft position sensor on exhaust side.
FU-01186
ME-00105
9) Remove the timing belt cover No. 2 (LH).
16) Loosen the oil flow control solenoid valve assembly and intake camshaft cap bolts equally, a little at a time in alphabetical sequence shown in the
figure.
(A)
(B)
(E)
(C)
(F)
(D)
ME-00106
ME-00771
ME(H4DOTC)-53
Camshaft
MECHANICAL
17) Loosen the exhaust camshaft cap bolts equally, a little at a time in alphabetical sequence shown
in the figure.
Exhaust camshaft (LH):

Rotate 45 counterclockwise.
A
(a)
77.5
(b)
11
(A)
(B)
(E)
(C)
(F)
(D)
ME-00772
18) Remove the oil flow control solenoid valve assembly, intake camshaft cap and camshaft.
19) Remove the exhaust camshaft caps and camshaft.
B
(b)
11
77.5
(a)
NOTE:
Arrange camshaft caps in order so that they can be
installed in their original positions.
20) Similarly, remove the camshafts (RH) and related parts.
ME-00111
B: INSTALLATION
1) Camshaft installation:
Apply engine oil to the cylinder head at camshaft
bearing location before installing the camshaft. Install the camshaft so that each valve is close to or in
contact with base circle of cam lobe.
NOTE:
When the camshafts are positioned as shown in
the figure, camshafts need to be rotated at a minimum to align with the timing belt during installation.
Camshaft (RH) need not be rotated when set at
the position shown in the figure.
Intake camshaft (LH):
Rotate 80 clockwise.
A
B
(a)
(b)
Cylinder head (LH)

Cylinder head (RH)
Intake camshaft
Exhaust camshaft
2) Camshaft cap and oil flow control solenoid valve

assembly installation:
(1) Apply small amount of liquid gasket to the
cap mating surface.
NOTE:
Do not apply liquid gasket excessively. Otherwise,
the excessive liquid gasket may come out and flow
toward oil seal, resulting in oil leaks.
Liquid gasket:
equivalent
ME-00773
(2) Apply engine oil to the cap bearing surface,

and install the cap on camshaft as shown by
identification mark.
ME(H4DOTC)-54
Camshaft
MECHANICAL
(3) Gradually tighten the camshaft cap and oil

control valve assembly in at least two stages in
alphabetical sequence shown in the figure, and
then tighten to the specified torque.
Tightening torque:
T1: 10 Nm (1.0 kgf-m, 7.2 ft-lb)
T2: 20 Nm (2.0 kgf-m, 14.5 ft-lb)
(G)
5) Rocker cover installation:

(1) Install the gasket on rocker cover. Install the
peripheral gasket and ignition coil gasket.
(2) Apply liquid gasket to the designated point
of cylinder head.
Liquid gasket:
equivalent
(L)
(C)
T2
T1
(E)
(F)
(A)
(B)
(K)
T1
(J)
T2
(H)
(D)
(I)
ME-00839
(4) After tightening the camshaft cap, ensure

the camshaft rotates only slightly while holding it
at base circle.
3) Install the camshaft position sensor on exhaust
side.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
ME-00776
FU-01186
4) Camshaft oil seal installation:

Apply grease to the new oil seal lips and press onto
the front end of camshaft by using ST1 and ST2.
NOTE:
Use a new oil seal.
(3) Install the rocker cover on cylinder head.

Ensure the gasket is properly positioned during
installation.
(4) Tighten the rocker cover tightening bolt in alphabetical sequence shown in the figure, and
then tighten to the specified torque.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
(C),(K)
(H)
(E)
(B),(J)
(A),(I)
(G)
(D),(L)
ST1
ST2
ME-00116
ME(H4DOTC)-55
(F)
ME-00777
Camshaft
MECHANICAL
6) Install the oil pipe.
11) Install the timing belt cover No. 2 (LH).
Tightening torque:
29 Nm (3.0 kgf-m, 21.4 ft-lb)
Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
ME-00712
7) Connect the oil flow control solenoid valve connector.
ME-00106

Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
ME-00808
8) Install the spark plug cord.

9) Similarly, install the parts on right-hand side.
10) Install the timing belt cover No. 2 (RH).
Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
ME-00107
ME-00105

Sprocket.>
Sprocket.>
15) Install the timing belt. <Ref. to ME(H4DOTC)44, INSTALLATION, Timing Belt.>
Pulley.>
ME(H4DOTC)-56
Camshaft
MECHANICAL
C: INSPECTION
1) Measure the bend, and repair or replace if necessary.
Service limit:
0.020 mm (0.00079 in)
(6) Measure the widest point of the plastigauge

on each journal. If 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)
ME-00118

3) Measure the outside diameter of camshaft journal. If the journal diameter is not within specification, check the oil clearance.
Camshaft journal
Front
Center, rear
37.946 37.963
29.946 29.963
(1.4939 1.4946) (1.1790 1.1796)
Standard value
mm (in)
4) Measurement of the camshaft journal oil clearance:

(1) Clean the bearing caps and camshaft journals.
(2) Place the camshafts on cylinder head.
(Without installing the valve rocker.)
(3) Place a plastigauge across each of the camshaft journals.
(4) Gradually tighten the cap in at least two
stages in alphabetical sequence shown in the
figure, and then tighten to the specified torque.
Do not turn the camshaft.
ME-00119
(7) Completely remove the plastigauge.

5) Check the cam face condition, and remove the
minor faults by grinding with oil stone. Measure the
cam height H. If it exceeds the limit or has partial
wear, replace it.
Cam height H:
Standard
Intake
45.85 45.95 mm (1.805 1.809 in)
Exhaust
45.75 45.85 mm (1.801 1.805 in)
37.0 mm (1.457 in)
Tightening torque:
T1: 10 Nm (1.0 kgf-m, 7.2 ft-lb)
T2: 20 Nm (2.0 kgf-m, 14.5 ft-lb)
(A)
T2
(E)
(C)
(F)
(D)
T1
(B)
ME-00774
(5) Remove the bearing caps.
ME(H4DOTC)-57
ME-00120
Camshaft
MECHANICAL
6) Measure the side clearance of camshaft with dial

gauge. If the clearance exceeds the limit or has
partial wear, replace the caps and cylinder head as
a set. If necessary, replace the camshaft.
Standard:
0.068 0.116 mm (0.0027 0.0047 in)
ME-00121
ME(H4DOTC)-58
Cylinder Head
MECHANICAL
20.Cylinder Head
A: REMOVAL
CAUTION:
12) Similarly, remove the cylinder head (RH).

REMOVAL, V-belt.>
Cover.>
Belt.>
Sprocket.>
7) Remove the bolt which installs the A/C compressor bracket on cylinder head.
8) Remove the camshaft. <Ref. to ME(H4DOTC)53, REMOVAL, Camshaft.>
sequence shown in the figure.
Leave the bolts (A) and (D) engaged by three or
four threads to prevent the cylinder head from falling.
(D)
(B)
(F)
(E)
B: INSTALLATION
block.
CAUTION:
of cylinder head and cylinder block.
bolt threads.
(2) Tighten all bolts to 29 Nm (3.0 kgf-m, 21.4
ft-lb) in alphabetical sequence.
(3) Retighten all bolts to 69 Nm (7.0 kgf-m, 51
ft-lb) in alphabetical sequence.
(4) Back off all bolts by 180 in the reverse order of installation, and back them off again by
180.
sequence.
sequence.
CAUTION:
Do not tighten the bolts more than 45.
(8) Further tighten the bolts (A) and (B) by 40
45.
(A)
CAUTION:
Ensure the total re-tightening angle [in the
former two steps], do not exceed 90.
(C)
ME-00122
(C)
(A)
(F)
(E)
(B)
(D)

Remove the bolts (A) and (D) to remove cylinder
head.
(D)
(F)
(A)
ME-00123
(B)
(E)
(C)
ME-00122
3) Install the camshaft. <Ref. to ME(H4DOTC)-54,

4) Install the A/C compressor bracket on cylinder
head.
<Ref. to FU(H4DOTC)-15, INSTALLATION, Intake
Manifold.>
ME(H4DOTC)-59
Cylinder Head
MECHANICAL

Sprocket.>
Pulley.>
C: DISASSEMBLY
2) Compress the valve spring and remove the
valve spring retainer key. Remove each valve and
valve spring.
ST2 499718000 VALVE SPRING REMOVER
NOTE:
CAUTION:
seals.
ST2
ST1
ME-00124
ME(H4DOTC)-60
Cylinder Head
MECHANICAL
D: ASSEMBLY
(11)
(1)
(4)
(5)
(6)
(7)
(8)
(9)
(3)
(2)
(11)
(4)
(5)
(6)
(7)
(8)
(9)
(12)
(4)
(10)
(6)
(12)
(7)
(8)
(4)
(9)
(10)
(6)
(7)
(8)
(9)
ME-00795
(1)
(2)
(3)
(4)
Exhaust valve
Intake valve
Cylinder head
Valve spring seat
(5)
(6)
(7)
(8)

Valve spring
Retainer
Retainer key
ME(H4DOTC)-61
(9)
(10)
(11)
(12)
Valve lifter
Intake valve guide
Exhaust valve guide
Cylinder Head
MECHANICAL

NOTE:
When inserting the valve into valve guide, use special care not to damage the oil seal lip.
(2) Set the cylinder head on ST1.
(3) Install the valve spring and retainer using
ST2.
ST2 499718000 VALVE SPRING REMOVER
NOTE:
Uneven torque for the cylinder head nuts can
cause warping. When reinstalling, pay special attention to the torque so as to tighten evenly.
(A)
NOTE:
Be sure to install the valve spring with their closecoiled end facing the seat on the cylinder head.
(B)
ME-00126
2. VALVE SEAT
ST2
ST1
ME-00124

lightly with a wooden hammer for better seating.
2) Apply oil to the surfaces of the valve lifter.
3) Install the valve lifter.
Valve seat width W:

Intake
Standard
0.6 1.4 mm (0.024 0.055 in)
Exhaust
Standard
1.2 1.8 mm (0.047 0.071 in)
E: INSPECTION
1. CYLINDER HEAD
1) Make sure that cracks or other damages do not

exist. In addition to visual inspection, inspect important areas using liquid penetrant tester.
2) Measure the warping of the cylinder head surface that mates with crankcase using a straight
edge (A) and thickness gauge (B).
If the warping exceeds the limit, regrind the surface
with a surface grinder.
Warping limit:
0.035 mm (0.0014 in)
Grinding limit:
0.3 mm (0.012 in)
127.5 mm (5.02 in)
ME-00127
3. VALVE GUIDE
the outer diameter of valve stem and inner diameter of valve guide respectively with a micrometer.
stem:
Standard
Intake
0.030 0.057 mm (0.0012 0.0022 in)
Exhaust
0.040 0.067 mm (0.0016 0.0026 in)
ME(H4DOTC)-62
Cylinder Head
MECHANICAL
2) If the clearance between valve guide and stem

exceeds the standard value, replace the valve
guide or valve itself whichever shows greater
amount of wear or has abnormality such as
scratch. See the following procedure for valve
guide replacement.
ST1
ST2
ST1
ST2

6.000 6.012 mm (0.2362 0.2367 in)
Intake
5.955 5.970 mm (0.2344 0.2350 in)
Exhaust
5.945 5.960 mm (0.2341 0.2346 in)
guides fit the holes in ST1.
(2) Insert the ST2 into valve guide and press it
ST2 499767200 VALVE GUIDE REMOVER
ST2
ST1
ME-00128

ST 18251AA020 VALVE GUIDE ADJUSTER
499767200 VALVE GUIDE REMOVER

18251AA020 VALVE GUIDE ADJUSTER
ME-00130

15.8 16.2 mm (0.622 0.638 in)
reamer slowly clockwise pushing it lightly. Bring
the reamer back while rotating it clockwise. After
reaming, clean the valve guide to remove chips.
ST 499767400
VALVE GUIDE REAMER
NOTE:
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 chip, use a new
reamer or remedy the reamer.
guide.

1) Inspect the flange and stem of valve, and replace them if damaged, worn, deformed, or if H is
exceed the standard value or if they have partial
wear.
ST
H:
ME-00757

cylinder head.
guide. Press-in until the valve guide upper end is
Intake (A)
Standard
1.0 1.4 mm (0.039 0.055 in)
Exhaust (B)
Standard
1.3 1.7 mm (0.051 0.067 in)
ME(H4DOTC)-63
Cylinder Head
MECHANICAL

SEAL

Intake (A)
104.4 mm (4.110 in)
Exhaust (B)
104.65 mm (4.1201 in)
Replace the oil seal with a new one, if the lip is

damaged or spring is out of place, or when the surfaces of intake valve and valve seat are reconditioned or intake valve guide is replaced.
1) Place the cylinder head on ST1.
2) Press-fit the oil seal to the specified dimension
indicated in the figure using ST2.
ST2 498857100 VALVE OIL SEAL GUIDE
(A)
NOTE:
Apply engine oil to oil seal before force-fitting.
Differentiate between the intake valve oil seal
and exhaust valve oil seal by noting their difference
in color.
Color of rubber part:
Intake [Gray]
Exhaust [Green]
(B)
ST2
ME-00758

seat surface, and lap the valve and seat surface.
Install a new intake valve oil seal after lapping.
ME-00133
5. VALVE SPRINGS
7. VALVE LIFTER
1) Check the valve lifter visually.
2) Measure the outer diameter of valve lifter.
Outer diameter:
34.959 34.975 mm (1.3763 1.3770 in)
Free length
mm (in) 44.67 (1.759)

206 236 (21.0 24.1,
Set
Tension/spring
46.3 53.1)/36.0 (1.417)
height
485 537 (21.0 24.1, 109
N (kgf, lb)/mm (in) Lift
121) /26.0 (1.024)
Squareness
2.5, 2.0 mm (0.079 in)
ME-00134
ME-00132
ME(H4DOTC)-64
Cylinder Head
MECHANICAL
3) Measure the inner diameter of valve lifter mating

part on cylinder head.
Inner diameter:
34.994 35.016 mm (1.3777 1.3786 in)
ME-00135
NOTE:
If difference between outer diameter of valve lifter
and inner diameter of valve lifter mating part is over
the standard or has partial wear in inner surface,
replace the cylinder head.
Standard:
0.019 0.057 mm (0.0007 0.0022 in)
ME(H4DOTC)-65
Cylinder Block
MECHANICAL
21.Cylinder Block
10) Remove the drive plate.

To lock crankshaft, use ST.
ST 498497100
CRANKSHAFT STOPPER
A: REMOVAL
NOTE:
Before conducting this procedure, drain engine oil
completely.
REMOVAL, V-belt.>
Cover.>
Belt.>
Sprocket.>
<Ref. to ME(H4DOTC)-52, REMOVAL, Crank
Sprocket.>
8) Remove the generator and A/C compressor with
their brackets.
9) Remove the cylinder head.
<Ref. to ME(H4DOTC)-59, REMOVAL, Cylinder
Head.>
ST 498497100
CRANKSHAFT STOPPER
ST
ME-00778
ST
ME-00136
11) Remove the oil separator cover.

12) Remove the oil pump by using flat tip screwdriver.
CAUTION:
ME-00138
13) Remove the water by-pass pipe for heater.

14) Remove the oil filter.
15) Removal of oil pan:
(2) Remove the bolts which secure oil pan to
cylinder block.
(3) Insert a oil pan cutter blade between cylinder block-to-oil pan clearance and remove the
oil pan. Do not use a screwdriver or similar tools
in place of oil pan cutter.
16) Remove the oil strainer stay.
19) Remove the water pipe.
ME(H4DOTC)-66
Cylinder Block
MECHANICAL
(2)
(1)
(3)
(4)
(6)
(4)
(3)
(5)
(4)
(2)
(3)
(1)
(4)
(3)
(1)
(2)
ME-00139
(1)
(2)
Service hole plug

Gasket
(3)
(4)
Snap ring
Piston pin

hole plugs using a hexagon wrench [14 mm].
(5)
(6)
Service hole cover

O-ring
#2 cylinders.
ME-00140
ME-00141
23) Draw out the piston pins from #1 and #2 pistons

using ST.
ST 499097700
PISTON PIN REMOVER
ME(H4DOTC)-67
Cylinder Block
MECHANICAL
NOTE:
ST
ME-00142
24) Similarly remove the piston pins from #3 and #4

pistons.
25) Remove the bolts which connect cylinder block
on the side of #2 and #4 cylinders.
26) Back off the bolts which connect cylinder block
on the side of #1 and #3 cylinders two or three
turns.
27) Place the cylinder block to face the #1 and #3
cylinder side upward, and remove cylinder block
connecting bolts.
28) Separate the cylinder block (LH) and (RH).
NOTE:
the connecting rod to fall and damage the cylinder
block.
(5)
(1)
(4)
(2)
(4)
(3)
(1)
(5)
ME-00143
(1)
(2)
Cylinder block
Rear oil seal
(3)
(4)
Crankshaft
Crankshaft bearing

(5)
Piston
NOTE:
NOTE:
Do not confuse the combination of crankshaft bearings.
Press the bearing at the end opposite to locking lip.
ME(H4DOTC)-68
Cylinder Block
MECHANICAL
B: INSTALLATION
(4)
(1)
(3)
(2)
(3)
ME-00144
(1)
(2)
Crankshaft bearing
Crankshaft
(3)
Cylinder block
1) Remove oil on the mating surface of bearing and

2) Position the crankshaft on the #2 and #4 cylinder
block.
3) Apply liquid gasket to the mating surface of #1
and #3 cylinder block, and position it on #2 and #4
cylinder block.
(4)
Rear oil seal
4) Apply a coat of engine oil to washers and bolt

threads.
bolts on LH side (A D) in alphabetical sequence.
Tightening torque:
10 Nm (1.0 kgf-m, 7.4 ft-lb)
Liquid gasket:
equivalent
NOTE:
Do not allow liquid gasket to run over to O-ring
grooves, oil passages, bearing grooves, etc.
(A)
(D)
(B)
(C)
ME-00840
ME-00145
ME(H4DOTC)-69
Cylinder Block
MECHANICAL

bolts on RH side (E J) in alphabetical sequence.
9) Further tighten the LH side bolts (A D) to 90

Tightening torque:
10 Nm (1.0 kgf-m, 7.4 ft-lb)
(A)
(D)
(G)
(E)
(J)
(B)
(C)
ME-00840
(I)
(H)
(F)
ME-02359
10) Further tighten the RH side bolts (E J) to 90

7) Further tighten the LH side bolts (A D) in alphabetical sequence.

Tightening torque:
(A), (C): 20 Nm (2.0 kgf-m, 14.8 ft-lb)
(B), (D): 15 Nm (1.5 kgf-m, 10.8 ft-lb)
(G)
(E)
(I)
(F)
(J)
(H)
(A)
ME-02359
(D)
11) Tighten the 8 mm and 6 mm cylinder block connecting bolts on LH side (A H) in alphabetical sequence.
(B)
(C)
ME-00840
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) Further tighten the RH side bolts (E J) in alphabetical sequence.

Tightening torque:
(E), (F), (G), (I): 20 Nm (2.0 kgf-m, 14.8 ft-lb)
(H), (J): 18 Nm (1.8 kgf-m, 13.3 ft-lb)
(G)
(I)
(E)
(J)
(G)
(D)
(H)
(F)
ME-02359
ME(H4DOTC)-70
(C)
(E)
(H)
(A)
(B)
(F)
ME-00147
Cylinder Block
MECHANICAL
ST1 499597100 CRANKSHAFT OIL SEAL
GUIDE
ST2 499587200 CRANKSHAFT OIL SEAL INSTALLER
(B)
16) Align the upper rail spin stopper (E) to the side
hole (D) on the piston.
(D)
(E)
(A)
ST2
(F)
(G)
ME-00843
17) Position the expander gap at 180 on the reverse side of (C) that shown (F) in the figure.
ST1
ME-00148
(A) Rear oil seal

(B) Flywheel attaching bolt
(F)
13) Position the top ring gap at (A) or (B) in the figure.
14) Position the second ring gap at 180 on the reverse side of the top ring gap.
ME-02088
18) Position the lower rail gap at 120 on counterclockwise of (C) that shown (G) in the figure.
(A)
(B)
ME-00718
(G)
(C)
120
25
(C)
ME-02087
ME-02089
CAUTION:
skirt area.
ME(H4DOTC)-71
Cylinder Block
MECHANICAL
NOTE:
Use new snap rings.
#3
#1
#4
(A)
#2
ME-00154
(A) Front side

(5)
(4)
(1)
(5)
(3)
(4)
(3)
(2)
(2)
(1)
ME-00155
(1)
(2)
(3)
Piston
Piston pin
Snap ring
(4)
(5)
Gasket
Service hole plug
20) Installation of piston:

(2) Using the ST1, turn the crankshaft so that
#1 and #2 connecting rods are set at bottom
dead center.
ST1 499987500 CRANKSHAFT SOCKET

T: 70 (7.1, 51.6)
(3) Apply a coat of engine oil to the pistons and

cylinders and insert pistons in their cylinders using ST2.
ST2 398744300 PISTON GUIDE
ST1
ST2
ME-00157
ME(H4DOTC)-72
Cylinder Block
MECHANICAL
NOTE:
Piston front mark faces towards the front of engine.
(4) Apply liquid gasket around the service hole

plug.
Liquid gasket:
equivalent
(A)
ME-00722
(A) Front mark
21) Installation of piston pin:

(1) Apply a coat of engine oil to ST3 before insertion, and then insert it into the service hole to
align piston pin hole with connecting rod small
end.
ST3 499017100 PISTON PIN GUIDE
ST1
ME-00160
(5) Install the service hole plug and gasket.

NOTE:
Use a new gasket.
ST3
ME-00140
ME-00158

(3) Install the snap ring.
NOTE:
Use new snap rings.
ME-00159
ME(H4DOTC)-73
Cylinder Block
MECHANICAL
T2
(5)
T1
(6)
(3)
(4)
(7)
(2)
(1)
(3)
(2)
(1)
ME-00161
(1)
(2)
(3)
(4)
Piston
Piston pin
Snap ring
Gasket
(5)
(6)
(7)
Service hole plug

Service hole cover
O-ring

#4 cylinder side upward. Following the same
procedures as used for #1 and #2 cylinders, install the pistons and piston pins.

T1: 6.4 (0.65, 4.7)
T2: 70 (7.1, 51.6)
Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
24) Install the oil strainer and O-ring.
Tightening torque:
10 Nm (1.0 kgf-m, 7.2 ft-lb)
25) Install the oil strainer stay.
26) Apply liquid gasket to mating surfaces and install the oil pan.
27) Apply liquid gasket to mating surfaces and install the oil separator cover.
Liquid gasket:
equivalent
NOTE:
Install them within 20 min. from applying liquid gasket.
ME-00162
Liquid gasket:
equivalent
ME(H4DOTC)-74
Cylinder Block
MECHANICAL
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
(2) Apply liquid gasket to the matching surface

of oil pump.
Liquid gasket:
equivalent
ME-00163
(A)
28) Install the drive plate.

ST 498497100
CRANKSHAFT STOPPER
Tightening torque:
72 Nm (7.3 kgf-m, 53.1 ft-lb)
ME-00165
(A) O-ring
(3) Apply a coat of engine oil to the inside of oil

seal.
ST
ME-00136
29) Installation of oil pump:

(1) Install the front oil seal by using ST.
ST 499587100
OIL SEAL INSTALLER
NOTE:
Use a new front oil seal.
ME-00312
(4) Install the oil pump on cylinder block. Be

careful not to damage the oil seal during installation.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
CAUTION:
Do not forget to install the O-ring and seal
when installing the oil pump.
Align the flat surface of oil pumps inner rotor
with crankshaft before installation.
30) Install the water pump and gasket.
ME-00164
Tightening torque:
First: 12 Nm (1.2 kgf-m, 8.7 ft-lb)
Second: 12 Nm (1.2 kgf-m, 8.7 ft-lb)
ME(H4DOTC)-75
Cylinder Block
MECHANICAL
CAUTION:
Be sure to use a new gasket.
When installing the water pump, tighten the
bolts in two stages in alphabetical sequence as
(F)
(E)
(A)
(D)
(C)
(B)
ME-02094
31) Install the water by-pass pipe for heater.

32) Install the oil filter.
33) Install the water by-pass pipe between oil cooler and water pump.
NOTE:
Always use new O-rings.
35) Install the cylinder head.
<Ref. to ME(H4DOTC)-59, INSTALLATION, Cylinder Head.>
36) Install the oil level gauge guide. (LH side)
Sprocket.>
Sprocket.>
Pulley.>
43) Install the generator and A/C compressor
brackets on cylinder head.
<Ref. to FU(H4DOTC)-15, INSTALLATION, Intake
Manifold.>
ME(H4DOTC)-76
Cylinder Block
MECHANICAL
C: DISASSEMBLY
(1)
(2)
(2)
(5)
(4)
(3)
(6)
ME-00168
(1)
(2)
Connecting rod cap

(3)
(4)
Top ring
Second ring

NOTE:
rod cap and bearing in order to prevent confusion.
3) Remove the piston rings using a piston ring expander.
NOTE:
Arrange the removed piston rings in proper order to
prevent confusion.
ME(H4DOTC)-77
(5)
(6)
Oil ring
Snap ring
Cylinder Block
MECHANICAL
D: ASSEMBLY
(3)
T
(1)
(1)
(2)
(4)
(5)
(8)
(6)
(7)
ME-00169
(1)
(2)
(3)
(4)

Connecting rod
Connecting rod cap
Oil ring
(5)
(6)
(7)
(8)
Second ring
Top ring
Snap ring
Side mark

bearings. Install the connecting rod bearings on
connecting rods and connecting rod caps.
2) Install the connecting rod on crankshaft.
NOTE:
Position each connecting rod with the side marked
facing forward.
3) Install the connecting rod cap.
Ensure the arrow mark on connecting rod cap facing front during installation.
CAUTION:
4) Install the oil ring spacer, upper rail and lower rail
in this order by hand. Then install the second ring
and top ring with a piston ring expander.
ME(H4DOTC)-78

T: 45 (4.6, 33)
Cylinder Block
MECHANICAL
E: INSPECTION
Standard diameter:
A: 92.005 92.015 mm (3.6222 3.6226 in)
B: 91.995 92.005 mm (3.6219 3.6222 in)
1. CYLINDER BLOCK
3) Inspect the crankcase surface that mates with
cylinder head for warping by using a straight edge,
and correct by grinding if necessary.
Warping limit:
0.025 mm (0.00098 in)
Grinding limit:
0.1 mm (0.004 in)
(B)
#3

#2
NOTE:
#1
#4
(F)
#5

201.0 mm (7.91 in)
(A)
(D)
(E) (C)
ME-00170
(A)
(B)
(C)
(D)
(E)
(F)
Main journal size mark

Cylinder block (RH) (LH) combination mark

NOTE:
Taper:
Standard
0.015 mm (0.0006 in)
ME(H4DOTC)-79
Cylinder Block
MECHANICAL
Out-of-roundness:
Standard
0.010 mm (0.0004 in)
(A)
Piston outer diameter:

Standard
A: 92.005 92.015 mm (3.6222 3.6226
in)
B: 91.995 92.005 mm (3.6219 3.6222
in)
92.245 92.265 mm (3.6317 3.6467 in)
92.495 92.515 mm (3.6415 3.6423 in)
(B)
H1
H2
H3
H
H4
ME-00172

piston.
ME-00171
(A)
(B)
H1:
H2:
H3:
H4:

Thrust direction
10 mm (0.39 in)
45 mm (1.77 in)
80 mm (3.15 in)
115 mm (4.53 in)

NOTE:
40.0 mm (1.57 in)
NOTE:
Standard
0.010 0.010 mm (0.00039 0.00039 in)
6) Boring and honing:
(1) If one of the values of taper, out-of-roundness, or cylinder-to-piston clearance exceeds
the specified limit or is out of standard, or if there
is any damage on the cylinder wall, rebore it to
use an oversize piston.
CAUTION:
(2) If the cylinder inner diameter exceeds
92.515 mm (3.6423 in) after boring and honing,
replace the crankcase.
NOTE:
rise. Thus, pay attention to this when measuring
the cylinder diameter.
ME(H4DOTC)-80
Cylinder Block
MECHANICAL
4. PISTON RING

cracks, and wear and the piston ring grooves for
each cylinder. <Ref. to ME(H4DOTC)-79, CYLINDER AND PISTON, INSPECTION, Cylinder
Block.> If any of the clearances is out of specification, replace the piston or bore the cylinder to use
an oversize piston.
into the piston pin hole with your thumb at 20C
(68F). Replace if defective.
1) If the piston ring is broken, damaged or worn, or

CAUTION:
Marks are displayed on the end of top and
second rings. When installing the rings to the
piston, face those marks upward.
and lower rail. When installing on piston, be
careful of each rails direction.
Standard clearance between piston pin and

hole in piston:
Standard
0.004 0.008 mm (0.0002 0.0003 in)
(A)
(B)
(C)
(A)
(B)
ME-00173
(C)
ME-00789
(A) Upper rail

(B) Expander
(C) Lower rail
ME-00174
4) Check the snap ring installation groove on the

piston for burr (A). If necessary, remove burr from
Top ring
(A)
Piston ring
gap
Second ring
Oil ring rail
ME-00175

cracks and wear.
ME(H4DOTC)-81
Standard
mm (in)
Outer circle side: 0.20 0.25
(0.0079 0.0098)
Inner circle side: 0.20 0.30
(0.0079 0.014)
0.40 0.50
(0.016 0.020)
0.20 0.50
(0.0079 0.0197)
Cylinder Block
MECHANICAL
NOTE:
Difference between outer and inner perimeters of
top ring should be within 0.05 mm (0.0020 in).
Limit of bend or twist per 100 mm (3.94 in) in

length:
0.10 mm (0.0039 in)
(A)
(B)
ME-00177

NOTE:
Before measuring the clearance, clean the piston
ring groove and piston ring.
Clearance
between
piston ring
and piston
ring groove
Top ring
Second ring
(A)
Standard
mm (in)
0.030 0.070
(0.0012 0.0028)
0.030 0.070
(0.0012 0.0028)
(B)
ME-00179
(A) Thickness gauge

(B) Connecting rod

clearance). If side clearance exceeds the limit or
has partial wear, replace the connecting rod.
Standard
0.070 0.330 mm (0.0028 0.0130 in)
ME-00178
5. CONNECTING ROD
aligner. Replace the connecting rod if the bend or
twist exceeds the limit.
ME-00180

ME(H4DOTC)-82
Cylinder Block
MECHANICAL

Standard
0.026 0.052 mm (0.0010 0.0020 in)
ST
499037100
Unit: mm (in)
Bearings
Standard
0.03
(0.0012)
undersize
0.05
(0.0020)
undersize
0.25
(0.0098)
undersize
Bearing size
1.486 1.498
(0.0585 0.0590)
51.984 52.000
(2.0466 2.0472)
1.504 1.512
(0.0592 0.0595)
51.954 51.970
(2.0454 2.0461)
1.514 1.522
(0.0596 0.0599)
51.934 51.950
(2.0447 2.0453)
1.614 1.622
(0.0635 0.0639)
51.734 51.750
(2.0368 2.0374)
Outer diameter of
crank pin

end.
Standard
0 0.022 mm (0 0.0009 in)
ST
ME-00182
(3) Make two 3 mm (0.12 in) holes in bushing.


BEARING
cracks using liquid penetrant tester. Replace if defective.
2) Measure the bend of crankshaft. If it exceeds the
limit, repair or replace it.
NOTE:
the crankshaft on these bearings, and then measure the crankshaft bend using a dial gauge.
Crankshaft bend limit:
0.035 mm (0.0014 in)
ME-00181
ME-00183
ME-00174

with ST and press.

ME(H4DOTC)-83
Cylinder Block
MECHANICAL
Crank pin and crank journal:

Out-of-roundness
0.005 mm (0.0002 in) or less
Cylindricality
0.006 mm (0.0002 in)
51.750 mm (2.0374 in)
ME-00184
Unit: mm (in)
Journal O.D.
Standard
0.03 (0.0012)
undersize
0.05 (0.0020)
undersize
0.25 (0.0098)
undersize
Bearing size
Journal O.D.
Bearing size
Journal O.D.
Bearing size
Journal O.D.
Bearing size
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
2.000 2.013
(0.0787 0.0792)
(0.0787 0.0793)
59.962 59.978
59.962 59.978
(2.3607 2.3613)
(2.3607 2.3613)
2.017 2.020
2.019 2.022
(0.0794 0.0795)
(0.0795 0.0796)
59.942 59.958
59.942 59.958
(2.3599 2.3605)
(2.3599 2.3605)
2.027 2.030
2.029 2.032
(0.0798 0.0799)
(0.0799 0.0800)
59.742 59.758
59.742 59.758
(2.3520 2.3527)
(2.3520 2.3527)
2.127 2.130
2.129 2.132
(0.0837 0.0839)
(0.0838 0.0839)
O.D. : Outer Diameter
ME(H4DOTC)-84
Crank pin diameter

51.984 52.000
(2.0466 2.0472)
1.486 1.498
(0.0585 0.0590)
51.954 51.970
(2.0454 2.0461)
1.504 1.512
(0.0592 0.0595)
51.934 51.950
(2.0447 2.0453)
1.514 1.522
(0.0596 0.0599)
51.734 51.750
(2.0368 2.0374)
1.614 1.622
(0.0635 0.0639)
Cylinder Block
MECHANICAL
4) Measure the thrust clearance of crankshaft at

center bearing. If clearance exceeds the limit, replace the bearing.
Standard
0.030 0.115 mm (0.0012 0.0045 in)
ME-00313

of flaking, seizure, melting, and wear.
Standard
0.010 0.030 mm (0.00039 0.0012 in)
ME(H4DOTC)-85
Intake and Exhaust Valve

MECHANICAL
22.Intake and Exhaust Valve

A: SPECIFICATION
Refer to Cylinder Head for removal and installation procedures of intake and exhaust valves. <Ref.
to ME(H4DOTC)-59, REMOVAL, Cylinder Head.>
<Ref. to ME(H4DOTC)-59, INSTALLATION, Cylinder Head.>
ME(H4DOTC)-86
Piston
MECHANICAL
23.Piston
A: SPECIFICATION
Refer to Cylinder Block for removal and installation procedures of pistons. <Ref. to ME(H4DOTC)66, REMOVAL, Cylinder Block.> <Ref. to
ME(H4DOTC)-69,
INSTALLATION,
Cylinder
Block.>
ME(H4DOTC)-87
Connecting Rod
MECHANICAL
24.Connecting Rod
A: SPECIFICATION
Refer to Cylinder Block for removal and installation procedures of connecting rod. <Ref. to
ME(H4DOTC)-66, REMOVAL, Cylinder Block.>
<Ref. to ME(H4DOTC)-69, INSTALLATION, Cylinder Block.>
ME(H4DOTC)-88
Crankshaft
MECHANICAL
25.Crankshaft
A: SPECIFICATION
Refer to Cylinder Block for removal and installation procedures of crankshaft. <Ref. to
ME(H4DOTC)-66, REMOVAL, Cylinder Block.>
<Ref. to ME(H4DOTC)-69, INSTALLATION, Cylinder Block.>
ME(H4DOTC)-89

MECHANICAL

A: INSPECTION
NOTE:
RANK shown in the chart refers to the possibility of the cause of trouble in order (Very often to Rarely)
A Very often
B Sometimes
C Rarely
Symptom

not occur.
Problem parts, etc.

Starter
Possible cause

Defective inhibitor switch or neutral switch
Defective starter
Battery
Run-down battery
Friction
Seized camshaft
Immobilizer system <Ref. to IM(diag)-2, Basic Diagnostic Procedure.>
Starter
Defective starter
Engine control system <Ref. to EN(H4DOTC)(diag)-2, Basic Diagnostic Procedure.>
Fuel line
Belt
Trouble
Defective timing
Compression
ME(H4DOTC)-90
RANK
B
C
C
B
A
A
B
C
C
C
A
C
A
A
B
B
B
C
C
C
C
C
B
C
B
B

MECHANICAL
Symptom

combustion.
Problem parts, etc.

Possible cause
Intake system
Fuel line
Clogged fuel line
Belt
Trouble
Defective timing
Compression
Intake system
Fuel line
Clogged fuel line
Belt
Trouble
Defective timing
Compression
ME(H4DOTC)-91
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

MECHANICAL
Symptom
stall
Problem parts, etc.

Possible cause
Intake system
Defective PCV valve
Fuel line
Clogged fuel line
Belt
Defective timing
Compression
Lubrication system
Cooling System
Over-heating
Other
ME(H4DOTC)-92
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

MECHANICAL
Symptom
poor acceleration
4. Surging
Problem parts, etc.

Possible cause
Intake system
Defective PCV valve
Fuel line
Clogged fuel line
Belt
Defective timing
Compression
Lubrication system
Cooling System
Over-heating
Over-cooling
Other
Intake system
Defective PCV valve
Fuel line
Clogged fuel line
Belt
Defective timing
Compression
Cooling System
Over-heating
Other
ME(H4DOTC)-93
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

MECHANICAL
Symptom
idle.

system
8. Knocking
Problem parts, etc.

Possible cause
Intake system
Other
Cooling System
Over-heating
Other
Intake system
Defective PCV valve
Belt
Defective timing
Compression
Lubrication system
Cooling System
Over-cooling
Other
Intake system
Belt
Defective timing
Compression
Cooling System
Over-heating
Intake system
Defective PCV valve
Compression
Lubrication system
Defective oil filter O-ring
ME(H4DOTC)-94
RANK
A
A
A
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

MECHANICAL
Symptom
Problem parts, etc.
Possible cause
10. Excessive fuel consump- Engine control system <Ref. to EN(H4DOTC)(diag)-2, Basic Diagnostic Procedure.>
tion
Intake system
Belt
Defective timing
Compression
Lubrication system
Cooling System
Over-cooling
ME(H4DOTC)-95
RANK
A
A
B
B
C
C
B
C
C
B
B
C
C
Engine Noise
MECHANICAL
27.Engine Noise
A: INSPECTION
Type of sound
High-pitched clank

1,000 to 2,000 rpm

and engine is warm
Squeaky sound
Rubbing sound
engine
a dry cloth
Hissing sound
Timing belt noise
Valve tappet noise
Condition
Possible cause
Worn valve rocker
speed increases.
Worn camshaft
Broken valve spring
Worn crankshaft main bearing
Worn connecting rod bearing (large end)
Loose flywheel mounting bolts
Improper gasoline
(NOTE*)
(NOTE*)


Loose drive belt

Loss of compression

Loose timing belt
Belt contacting case/adjacent part
NOTE*:
Therefore, carry out the clear memory mode <Ref. to EN(H4DOTC)(diag)-30, OPERATION, Clear Memory Mode.> and inspection mode <Ref. to EN(H4DOTC)(diag)-28, PROCEDURE, Inspection Mode.> after connecting the fuel injector connector.
ME(H4DOTC)-96
EXHAUST
EX(H4DOTC)
1.
2.
3.
4.
5.
6.
Page
Center Exhaust Pipe ...................................................................................6
Joint Pipe ..................................................................................................10
Rear Exhaust Pipe ....................................................................................11
Muffler .......................................................................................................12
General Description
EXHAUST
A: COMPONENT
1. FRONT EXHAUST PIPE
T1
(2)
(3)
T1
T2
(4)
(1)
T3
EX-00248
(1)
(2)
Front exhaust pipe ASSY

Gasket
(3)
(4)
Turbocharger joint pipe

Front exhaust pipe cover
EX(H4DOTC)-2

T1: 35 (3.6, 26.0)
T2: 30 (3.1, 22.1)
T3: 7.5 (0.76, 5.5)
General Description
EXHAUST
2. CENTER AND REAR EXHAUST PIPE, AND MUFFLER
(15)
(15)
(19)
(18)
(15)
(21)
(18)
(15)
(15)
(17)
(13)
(16)
T6
(20)
(12)
(14)
(10)
T5
(1)
T7
(4)
T8
(7)
(22)
(3)
(2)
T2
(11)
T4
(6)
(8)
T5
T1
(9)
T5
T1
(5)
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Gasket
Center exhaust pipe (Front)
Bracket
Gasket
Center pipe upper cover (Rear)
Clamp
cover
(10)
(11)
Rear oxygen sensor

(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
T3
Gasket
Rear exhaust pipe
Chamber
Cushion rubber
Spring
Bolt
Gasket
Muffler (RH)
Self-locking nut
Muffler (LH)
Center exhaust pipe (Rear)
EX(H4DOTC)-3
EX-02005

T1: 13 (1.3, 9.6)
T2: 18 (1.8, 13.3)
T3: 23 (2.3, 17.0)
T4: 30 (3.1, 22.1)
T5: 35 (3.6, 26.0)
T6: 48 (4.9, 35.4)
T7: <Ref. to FU(H4DOTC)-33,
INSTALLATION, Front Oxygen
(A/F) Sensor.>
T8: <Ref. to FU(H4DOTC)-34,
INSTALLATION, Rear Oxygen
Sensor.>
General Description
EXHAUST
B: CAUTION
points.
cable from battery.
EX(H4DOTC)-4
Front Exhaust Pipe

EXHAUST
2) Install the front exhaust pipe assembly to turbocharger joint pipe.
A: REMOVAL
3) Remove the front exhaust pipe cover.
assembly onto turbocharger joint pipe.
Tightening torque:
35 Nm (3.6 kgf-m, 26.0 ft-lb)
EX-00201
EX-00201
5) While holding the front exhaust pipe assembly,

remove the nuts which hold front exhaust pipe assembly to cylinder head exhaust port.
3) Install the front exhaust pipe cover.

C: INSPECTION
1) Check the connections and welds for exhaust
leaks.
2) Check for holes or rust.
EX-00202
6) Remove the front exhaust pipe assembly.
B: INSTALLATION
NOTE:
Use a new gasket.
1) Install the front exhaust pipe assembly.
Tightening torque:
30 Nm (3.1 kgf-m, 22.1 ft-lb)
EX-00202
EX(H4DOTC)-5
Center Exhaust Pipe

EXHAUST
3. Center Exhaust Pipe
12) Remove the turbocharger cover.
A: REMOVAL
5) Remove the intercooler bracket.
(B)
(A)
EX-00249

(B) Turbocharger cover
13) Separate the center exhaust pipe from turbocharger.

EX-00203

8) Remove the universal joint bolts and then remove the universal joint.
CAUTION:
Scribe alignment marks on the universal joint
so that it can be reassembled at the original
serration.
EX-00204
14) Disconnect the connector from front oxygen (A/

F) sensor.
EX-00008

10) Remove the linear motion mounting. <Ref. to
Mounting.>
EX-00205

sensor.
EX-00206
EX(H4DOTC)-6
Center Exhaust Pipe

EXHAUST
17) Separate the center exhaust pipe from rear exhaust pipe.
3) Connect the center exhaust pipe to turbocharger.

Tightening torque:
35 Nm (3.6 kgf-m, 26.0 ft-lb)
EX-00207

pipe bracket to transmission.
EX-00204
4) Install the center exhaust pipe to rear exhaust

pipe.
Tightening torque:
35 Nm (3.6 kgf-m, 26.0 ft-lb)
EX-00208
19) Remove the intercooler bracket.

CAUTION:
Be careful not to pull down the center exhaust
pipe.
EX-00207
EX-00209
B: INSTALLATION
NOTE:
Use a new gasket.
1) Install the center exhaust pipe and temporarily
tighten the bolt which holds center exhaust pipe to
hanger bracket.
2) Temporarily tighten the bolt which holds center
exhaust pipe to transmission.
EX(H4DOTC)-7
EX-00206
Center Exhaust Pipe

EXHAUST
6) Tighten the bolt which holds center exhaust pipe

bracket to transmission.

sensor.
Tightening torque:
30 Nm (3.1 kgf-m, 22.1 ft-lb)
EX-00205
EX-00208
7) Tighten the bolt which holds center exhaust pipe

to hanger bracket.
Tightening torque:
35 Nm (3.6 kgf-m, 26.0 ft-lb)
EX-00209

9) Install the turbocharger cover.
10) Install the linear motion mounting bracket.
Tightening torque:
T1: 7.4 Nm (0.75 kgf-m, 5.4 ft-lb)
T2: 40 Nm (4.1 kgf-m, 29.5 ft-lb)
T1
Tightening torque:
24 Nm (2.4 kgf-m, 17.4 ft-lb)
CAUTION:
Make sure the universal joint bolts are tightened through the shaft serration notches.
Excessively large tightening torque of universal joint bolts may lead to heavy steering
wheel operation.
Standard clearance between gearbox and DOJ:
T1
(A)

14) Install the universal joint.
(1) Align the bolt hole on the long yoke side of
universal joint with the cutout at the serrated
section of shaft end, and then insert the universal joint.
(2) Align the bolt hole on the short yoke side of
universal joint with the cutout at the serrated
section of gearbox assembly. Lower the universal joint completely.
(3) Temporarily tighten the bolt of short yoke
side. Raise the universal joint to make sure the
bolt is properly passing through the cutout at the
serrated section.
(4) Tighten the long yoke side bolt, and also
tighten the short yoke side bolt.
(B)
T1
T1
T2
EX-00250

(B) Turbocharger cover
EX-00008
11) Install the linear motion mounting. <Ref. to

Mounting.>

EX(H4DOTC)-8
Center Exhaust Pipe

EXHAUST
17) Install the intercooler bracket.
EX-00203

C: INSPECTION
leaks.
EX(H4DOTC)-9
Joint Pipe
EXHAUST
4. Joint Pipe
C: INSPECTION
A: REMOVAL

leaks.

IN-00203

5) Remove the front exhaust pipe cover.
6) Remove the nuts which hold front exhaust manifold to turbocharger joint pipe.
EX-00201

8) Remove
the
turbocharger.
<Ref.
to
IN(H4DOTC)-14, REMOVAL, Turbocharger.>
9) Remove the joint pipe from the lower side of vehicle.
B: INSTALLATION
Tightening torque:
T: 35 Nm (3.6 kgf-m, 26.0 ft-lb)
T
EX-02019
EX(H4DOTC)-10
Rear Exhaust Pipe

EXHAUST
Tightening torque:
35 Nm (3.6 kgf-m, 26.0 ft-lb)
A: REMOVAL
2) Separate the rear exhaust pipe from center exhaust pipe.
EX-00207
C: INSPECTION
EX-00207
3) Separate the rear exhaust pipe from both mufflers.

CAUTION:
pipe.

leaks.
2) Check the rear exhaust pipe for holes or rust.
3) Check the cushion rubber for wear or crack.
EX-00210
B: INSTALLATION
NOTE:
Use a new gasket.
1) Install the rear exhaust pipe to both mufflers.
Tightening torque:
48 Nm (4.9 kgf-m, 35.4 ft-lb)
EX-00210

pipe.
EX(H4DOTC)-11
Muffler
EXHAUST
6. Muffler
C: INSPECTION
A: REMOVAL

leaks.
2) Check the mufflers for holes or rust.
3) Check the cushion rubber for wear or crack.
1) Separate the muffler (RH) from rear exhaust

pipe.
EX-00210
2) Remove the cushion rubbers, and detach the

muffler.
CAUTION:
Be careful not to drop the muffler during removal.
NOTE:
To facilitate removal, apply a coat of spray type lubricant to the mating area of cushion rubbers in advance.
EX-00211
3) Perform the same procedure for muffler (LH).
B: INSTALLATION
NOTE:
Always use a new gasket and self-locking nuts.
Tightening torque:
48 Nm (4.9 kgf-m, 35.4 ft-lb)
EX-00210
EX(H4DOTC)-12
COOLING
CO(H4DOTC)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Page
Engine Coolant..........................................................................................13
Water Pump ..............................................................................................15
Thermostat ................................................................................................17
Radiator.....................................................................................................19
Radiator Cap .............................................................................................23
Reservoir Tank..........................................................................................30
Coolant Filler Tank ....................................................................................31
General Description
COOLING
A: SPECIFICATION
Cooling system
Type
Water pump
Thermostat
Radiator fan
Radiator
2 (US qt, Imp qt)

Approx. 7.3 (7.7, 6.4)
Discharge amount
2 (US gal, Imp gal)/min
Discharge perforPump speed Discharge
mance I
pressure
Discharge amount
mance II
pressure
Discharge amount
mance III
pressure
Impeller diameter
mm (in)
Pump pulley diameter
mm (in)
Clearance between
Standard
mm (in)
impeller and case
Type
Fully opens
Valve lift
mm (in)
Valve bore
mm (in)
Main fan
W
Motor input
Sub fan
W
Main
fan
Fan diameter /
Blades
Sub fan
Type
Width Height Thickness
Core dimensions
mm (in)
Pressure range in
which cap valve is
open
Capacity
760 rpm 2.9 kPa (0.3 mAq)

85C (185F)
100 (26.4, 22.0)
3,000 rpm 49.0 kPa (5.0 mAq)
85C (185F)
200 (52.8, 44.0)
6,000 rpm 225.4 kPa (23.0 mAq)
85C (185F)
76 (2.99)
8
60 (2.36)
0.5 1.5 (0.020 0.059)
Wax pellet type
76 80C (169 176F)
91C (196F)
9.0 (0.354) or more
35 (1.38)
90
90
300 mm (11.8 in) /4
300 mm (11.8 in) /5
Down flow
687.4 340 16 (27.06 13.39 0.63)
Coolant filler tank side

kPa (kg/cm2, psi)
Above: 10815
(1.10.15, 162)
Below: 1.0 4.9
(0.01 0.05, 0.1 0.7)
Radiator side
kPa (kg/cm2, psi)
Above only: 13714.7

(1.400.15, 202.1)
Fins
Reservoir
tank
20 (5.3, 4.4)
Corrugated fin type

2 (US qt, Imp qt)
CO(H4DOTC)-2
0.45 (0.48, 0.40)
General Description
COOLING
Vehicle speed
19 km/h (12 MPH) or less
20 69 km/h
(12 43 MPH)
70 105 km/h
(43 65 MPH)
106 km/h (66 MPH) or more
A/C compressor load
OFF
Low
High
OFF
Low
High
OFF
Low
High
OFF
Low
High

96 99C
95C (203F) or less
100C (212F) or more
(205 210F)
fan
fan
fan
OFF
Low-Speed
High-Speed
Low-Speed
Low-Speed
High-Speed
High-Speed
High-Speed
High-Speed
OFF
Low-Speed
High-Speed
High-Speed
High-Speed
High-Speed
High-Speed
High-Speed
High-Speed
OFF
Low-Speed
High-Speed
OFF
Low-Speed
High-Speed
Low-Speed
High-Speed
High-Speed
OFF
OFF
High-Speed
OFF
Low-Speed
High-Speed
OFF
Low-Speed
High-Speed
CO(H4DOTC)-3
General Description
COOLING
B: COMPONENT
1. WATER PUMP
T2
(5)
(8)
(4)
T2
T1
T1
(3)
(7)
(6)
(2)
T2
(1)
CO-00002
(1)
(2)
(3)
(4)
Thermostat cover
Gasket
Thermostat
Water pump ASSY
(5)
(6)
(7)
(8)
Gasket
Heater by-pass hose
Coolant filler by-pass hose
Water by-pass pipe
CO(H4DOTC)-4

T1: First 12 (1.2, 8.7)
Second 12 (1.2, 8.7)
T2: 12 (1.2, 8.7)
General Description
COOLING
(27)
(26)
(25)
(24)
(5)
(5)
(6)
T3
T3
(5)
(10)
(8)
(7)
T2
(5)
(29)
(11)
T2
T4
(9)
T1
(12)
(13)
(4)
(3)
(17)
(15)
(2)
T3
T1
(14)
(15)
(18)
(5)
B
(16)
T3
(30)
(15)
T3
B
C
(21)
(19)
(23)
(22)
(1)
(28)
(5)
C
(15)
(20)
CO-02004
CO(H4DOTC)-5
General Description
COOLING
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)

Radiator
Clamp
Radiator inlet hose
Overflow hose A
Overflow pipe
Radiator sub fan ASSY
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
Radiator main fan ASSY

ATF hose clamp
ATF inlet hose A
ATF outlet hose A
ATF pipe
ATF inlet hose B
ATF outlet hose B
Radiator drain plug
O-ring
Engine coolant filler tank
Radiator cap (Engine coolant filler
tank cap)
C: CAUTION
points.
cable from battery.
CO(H4DOTC)-6
(26)
(27)
(28)
(29)
(30)
Engine overflow hose

Engine air breather hose
Overflow hose B
Heat shield cover

T1: 3.4 (0.35, 2.5)
T2: 4.4 (0.45, 3.3)
T3: 7.5 (0.76, 5.5)
T4: 18 (1.8, 13.0)
General Description
COOLING
D: PREPARATION TOOL
ILLUSTRATION
TOOL NUMBER
499977400
DESCRIPTION
CRANK PULLEY
WRENCH
REMARKS
Used for stopping crank pulley when loosening and tightening crank pulley bolts.
499977500
CAM SPROCKET
WRENCH
Used for removing and installing the intake

and exhaust camshaft sprocket.
ST-499977400
ST-499977500
CO(H4DOTC)-7
Radiator Fan System

COOLING

A: WIRING DIAGRAM
SBF-1
SBF-7
No.3
IGNITION
SWITCH
No.2
No.26
No.22
MAIN FUSE BOX (M/B)
C:
F35
E:
F36
E3
B7
C11
B: B143
C10
E7
E6
MAIN
FAN
RELAY 1
THROUGH JOINT
CONNECTOR
GL
B360
23
LR
2
F109
MAIN
FAN
RELAY 2
SUB
FAN
RELAY
A/C RELAY HOLDER

F27
21
22
BW
YG
RL
THROUGH JOINT
CONNECTOR
F16
F108
B361
B25
16
E
M
B24
4
B
F17
MAIN FAN
MOTOR
RL
20 RW
GB
1
10
B135
ECM
SUB FAN MOTOR

F16
B361
F17
1 2 3
4 5 6
7 8 9 10 11 12 13 14
F27
B360
F108
F109
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
1 2 3 4
5 6 7 8
9 10 11 12 13 14 15 16 17 18
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
1
2 4 5
3
2 1
10
8 9 11
12
B135
B: B143
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
C:
F35
1 2
3 4 5
6 7 8 9 10 11 12
E:
F36
1 2
4 5
3
7
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
18 19
20 21
22
23
24 25
26
27
28 29
13
14 16 17
15
6
7
30
31
CO-00298
CO(H4DOTC)-8
Radiator Fan System

COOLING
B: INSPECTION
TROUBLE SYMPTOMS:
Radiator main and sub fan do not rotate under the above conditions.
Step
Check
sub fan rotate at low speed?
Monitor.
NOTE:
this order.
EN(H4DOTC)(diag)-31, Compulsory Valve
Operation Check Mode.>
sub fan rotate at high speed?
Monitor.
Yes
Go to step 2.
No
Go to step 3.
Radiator fan system is normal.
Go to step 27.
NOTE:
this order.
LAY.
2) Remove the sub fan relay from A/C relay
holder.
LAY.
CO(H4DOTC)-9
Go to step 5.
Go to step 6.
Radiator Fan System

COOLING
10
11
12
13
Step
CHECK FUSE.
CHECK FUSE.
relay terminals.
Terminals
No. 20 No. 21:
1) Connect the terminals No. 22 and No. 23 of
sub fan relay to battery.
relay terminals.
Terminals
No. 20 No. 21:
CHECK HARNESS BETWEEN SUB FAN RELAY TERMINAL AND SUB FAN MOTOR
CONNECTOR.
1) Disconnect the connector from sub fan
motor.
between sub fan relay terminal and sub fan
motor connector.
(F16) No. 2 (F27) No. 21:
CHECK HARNESS BETWEEN SUB FAN MOTOR CONNECTOR AND MAIN FAN RELAY 2
CONNECTOR.
holder.
between sub fan motor connector and main fan
relay 2 connector.
(F16) No. 1 (F27) No. 5:
CHECK POOR CONTACT.
Check the poor contact in sub fan motor connector.
CHECK SUB FAN MOTOR.
Connect the battery positive (+) terminal to terminal No. 2 of sub fan motor, and the ground (
) terminal to terminal No. 1.
Measure the resistance of main fan relay 2.
Terminals
No. 2 No. 5:
Check
Yes
Replace the fuse.
No
Repair the power
supply line.
Replace the fuse.
Repair the power

supply line.

M?
Go to step 8.
Replace the sub

fan relay.

?
Go to step 9.
Replace the sub

fan relay.

?
Go to step 10.
Repair the open

circuit of harness
between sub fan
relay terminal and
sub fan motor connector.

?
Go to step 11.
Repair the open

harness between
sub fan motor connector and main
fan relay 2 connector.
Is there poor contact in sub fan Repair the poor

motor connector?
contact in sub fan
motor connector.
Go to step 13.

?
CO(H4DOTC)-10
Go to step 14.
Go to step 12.
Replace the sub

fan motor.
Replace the main

fan relay 2.
Radiator Fan System

COOLING
14
15
16
17
18
19
20
21
22
Step
motor.
(F17) No. 2 (F27) No. 2:
CHECK MAIN FAN MOTOR AND GROUND
CIRCUIT.
motor connector and chassis ground.
CHECK POOR CONTACT.
Check poor contact in main fan motor connector.
CHECK MAIN FAN MOTOR.
Connect the battery positive (+) terminal to terminal No. 2 of main fan motor, and the ground
CHECK HARNESS BETWEEN SUB FAN RELAY AND ECM.
relay terminal and ECM connector.
(B135) No. 25 (F27) No. 22:
CHECK POOR CONTACT.

holder.
fan relay 1 switch.
1) Connect the terminal of main fan relay 1
coil side terminal to battery.
motor.
(F17) No. 2 (F36) No. 6:
Check
?
Yes
Go to step 15.
No
Repair the open
circuit of harness
between main fan
relay 2 terminal
and main fan
motor connector.
Is the resistance less than5 ? Go to step 16.
Repair the open

circuit in harness
between main fan
motor connector
and chassis
ground.
Go to step 17.
Is there poor contact in main

fan motor connector?
Does the main fan rotate?

?
Repair the poor

contact in main fan
motor connector.
Go to step 18.
Replace the main
fan motor.
Go to step 19.

connector?
contact in ECM
connector.
Repair the open

circuit in harness
between sub fan
relay terminal and
ECM.
Check the DTC.

Repair the trouble
cause. <Ref. to
EN(H4DOTC)(diag
)-27, Read Diagnostic Trouble
Code (DTC).>
Replace the main
fan relay 1.

M?
Go to step 21.

?
Go to step 22.
Replace the main

fan relay 1.

?
Go to step 23.
Repair the open

circuit of harness
between main fan
relay 1 terminal
and main fan
motor connector.
CO(H4DOTC)-11
Radiator Fan System

COOLING
23
24
25
26
27
28
29
30
31
Step
RELAY 1 AND ECM.
(B135) No. 24 (B143) No. 7:
RELAY 2 AND ECM.
(B135) No. 24 (F27) No. 3:
CHECK FUSE.
2) Remove the fuse No. 2 and No. 26.
CHECK POOR CONTACT.
Check the sub fan rotates when both fans do
not rotate at high speed under the step 2.
CHECK GROUND CIRCUIT OF MAIN FAN
RELAY 2.
holder.
CHECK POWER SUPPLY TO MAIN FAN RELAY 2.
2) Measure the voltage between main fan
2) Remove the main fan relay 2.
Terminals
(F27) No. 4 (F27) No. 5:
No. 3 of main fan relay 2.
Terminals
(F27) No. 4 (F27) No. 5:
Check
?
Yes
Go to step 24.
No
Repair the open
circuit of harness
between main fan
relay 1 terminal
and ECM.

?
Go to step 25.
Repair the open

circuit of harness
between main fan
relay 2 terminal
and ECM.
Replace the fuse.
Go to step 26.

connector?
contact in ECM
connector.
Go to step 20.
Repair the power

supply circuit for
main fuse box.
Go to step 28.

?
Go to step 29.
Repair the open

circuit in harness
between main fan
relay 2 and chassis ground.
Repair the power

supply line.

M?
Go to step 31.
Replace the main

fan relay 2.

?
Go to step 23.
Replace the main

fan relay 2.
CO(H4DOTC)-12
Engine Coolant
COOLING
3. Engine Coolant
A: REPLACEMENT
into container.
NOTE:
Remove the coolant filler tank cap so that engine
coolant will drain faster.
4) Warm up the engine completely for more than

5) If the engine coolant level drops in coolant filler
tank, add engine coolant to filler neck position.
level.
7) Attach the coolant filler tank cap and reservoir
tank cap properly.
CO-00248

2) Fill engine coolant into coolant filler tank up to
the filler neck position.
CAUTION:
Do not confuse the cap of coolant filler tank and
cap of radiator.
NOTE:
When pouring the engine coolant, the radiator
side cap must not be removed.
FULL level.
FULL
FULL
LOW
LOW
CO-00010
CO(H4DOTC)-13
Engine Coolant
COOLING
B: INSPECTION
Specific gravity
of coolant

[Example]
If the coolant temperature is 25C (77F) and its
specific gravity is 1.054, the concentration is 45%
20C (4F) (point C).
Concentration
of coolant
1.100
1.090

[Example]
only.
1.080
C
1.060
60%
1.070
B
50%
(1.054)
1.050
40%
1.040
1.030
Freezing
temperature
30%
1.020
1.000
20%
25 C
(77 F)
1.010
of coolant
3
(3.2,
2.6)
10%
0
10 20 30 40 50
-40 -30 -20 -10
(-40) (-22) (-4) (14) (32) (50) (68) (86) (104) (122)
CO-00237
2
(2.1,
1.8)
1
(1.1,
0.9)
0
45%
A
35%
40%
30%
25%
20%
10% 15%
10
20
30
40
50
CO-00012
CO(H4DOTC)-14
Water Pump
COOLING
4. Water Pump
A: REMOVAL
2) Remove the radiator. <Ref. to CO(H4DOTC)-19,
REMOVAL, Radiator.>
REMOVAL, V-belt.>
4) Remove the timing belt. <Ref. to ME(H4DOTC)43, REMOVAL, Timing Belt.>
5) Remove the automatic belt tension adjuster (A).
6) Remove the belt idler (B).
7) Remove the belt idler No. 2 (C).
CO-00021
B: INSTALLATION
1) Install the water pump onto cylinder block (LH).
NOTE:
When installing the water pump, tighten the bolts
in two stages in alphabetical sequence as shown in
the figure.
(A)
(B)
(C)
CO-00023
8) Remove the camshaft position sensor. <Ref. to

FU(H4DOTC)-25, REMOVAL, Camshaft Position
Sensor.>
9) Remove the cam sprocket (LH) using ST. <Ref.
to ME(H4DOTC)-51, REMOVAL, Cam Sprocket.>
Tightening torque:
First:
12 Nm (1.2 kgf-m, 8.7 ft-lb)
Second:
12 Nm (1.2 kgf-m, 8.7 ft-lb)
(F)
(E)
(A)
(D)
(C)
(B)
ME-02094
2) Install the hose to water pump.

3) Install the belt cover No. 2 (LH).
CO-00025
Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
11) Remove the belt cover No. 2 (LH).
CO-00024
CO-00024
12) Disconnect the hose from water pump.
CO(H4DOTC)-15
Water Pump
COOLING
C: INSPECTION
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)

2) Check the water pump pulley for abnormalities.
3) Make sure the impeller is not deformed or damaged.
4) Inspect the clearance between impeller and
pump case.
Clearance between impeller and pump case:
Standard value
0.5 1.5 mm (0.020 0.059 in)
CO-00025
5) Install the cam sprocket (LH) using ST. <Ref. to

ME(H4DOTC)-51, INSTALLATION, Cam Sprocket.>
6) Install the camshaft position sensor. <Ref. to
FU(H4DOTC)-25, INSTALLATION, Camshaft Position Sensor.>
7) Install the belt idler No. 2 (C).
8) Install the belt idler (B).
9) Install the automatic belt tension adjuster (A)
which has a tension rod held by a pin. <Ref. to
ME(H4DOTC)-44, AUTOMATIC BELT TENSION
ADJUSTER ASSEMBLY AND BELT IDLER, INSTALLATION, Timing Belt.>
CO-00293
5) After water pump installation, check the pulley

shaft for engine coolant leaks and noise. If leaks or
noise are noted, replace the water pump assembly.
Tightening torque:
39 Nm (4.0 kgf-m, 28.9 ft-lb)
(A)
(B)
(C)
CO-00023
10) Install the timing belt. <Ref. to ME(H4DOTC)45, TIMING BELT, INSTALLATION, Timing Belt.>
12) Install the radiator. <Ref. to CO(H4DOTC)-20,
CO(H4DOTC)-16
Thermostat
COOLING
5. Thermostat
6) Remove the thermostat cover, and then remove

the gasket and thermostat.
A: REMOVAL
<Ref. to CO(H4DOTC)-13, DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>
(C)
(B)
CO-00248
5) Disconnect the radiator outlet hose from the

thermostat cover.
(A)
CO-00154
(A) Thermostat cover

(B) Gasket
(C) Thermostat
B: INSTALLATION
1) Install the gasket to thermostat, and install the
thermostat and gasket to water pump as a unit.
Then, install the thermostat cover.
CO-00249
NOTE:
When reinstalling the thermostat, use a new gasket.
The thermostat must be installed with the jiggle
pin facing upward.
CO(H4DOTC)-17
Thermostat
COOLING
Tightening torque:
12 Nm (1.2 kgf-m, 8.7 ft-lb)
Valve lift:
(A)
(B)
CO-00033
(D)
(A) Thermometer
(B) Thermostat
T
(C)
(B)
(A)
CO-00155
(A)
(B)
(C)
(D)
Thermostat cover
Gasket
Thermostat
Jiggle pin

cover.
5) Fill with engine coolant. <Ref. to CO(H4DOTC)13, FILLING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>
C: INSPECTION
Inspection method
During the test, agitate the water for even temperature distribution. The measurement should be to
the specification.
76 80C (169 176F)
Fully opens:
91C (196F)
CO(H4DOTC)-18
Radiator
COOLING
6. Radiator
8) Disconnect the connectors of radiator main fan

motor (A) and sub fan motor (B).
A: REMOVAL
WARNING:
The radiator is pressurized. Wait until engine
cools down before working on the radiator.
(A)
CO-00251
(B)
IN-00203

CO-00252
9) Disconnect the ATF cooler hoses from ATF

pipes.
Plug the ATF pipe to prevent ATF leaks.
CO-00250

<Ref. to CO(H4DOTC)-13, DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>
CO-00253
CO-00249

12) Remove the air intake duct. <Ref.
CO(H4DOTC)-19
to
Radiator
COOLING
14) Remove the reservoir tank. <Ref. to

CO(H4DOTC)-30, REMOVAL, Reservoir Tank.>
15) Disconnect the radiator inlet hose (A) from radiator.
16) Remove the hood stay holder (B).
B: INSTALLATION
the radiator lower bracket.
(A)
(B)
CO-00041
CO-00255
17) Disconnect the two coolant filler tank hoses

from radiator.

NOTE:
the bolts.
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
CO-00256
CO-00040
4) Connect the two coolant filler tank hoses to radiator.
CO-00040
19) While lifting the radiator up, slide it to the left.

CO-00256
5) Connect the radiator inlet hose (A).
CO(H4DOTC)-20
Radiator
COOLING
13) Connect the connectors to radiator main fan

motor (A) and sub fan motor (B).
6) Install the hood stay holder (B).

(A)
(A)
(B)
CO-00255
CO-00251
7) Install
the
reservoir
tank.
<Ref.
to
CO(H4DOTC)-30, INSTALLATION, Reservoir
Tank.>
9) Install the air intake duct.
<Ref. to IN(H4DOTC)-9, INSTALLATION, Air Intake Duct.>
11) Connect the ATF cooler hoses.
(B)
CO-00252
CO-00253

CO-00250

CO-00249
IN-00203

CO(H4DOTC)-21
Radiator
COOLING
C: INSPECTION
1) Remove the coolant filler tank cap and fill engine
coolant to coolant filler tank, then attach the tester
to radiator in place of cap.
CO-00257

Engine coolant leaks at or around radiator.
CAUTION:
Inspection must be carried out at the side of
coolant filler tank, not at the side of radiator.
Be careful not to deform the filler neck of
coolant filler tank when installing or removing
the tester.
CO(H4DOTC)-22
Radiator Cap
COOLING
7. Radiator Cap
A: INSPECTION
CO-00044

Coolant filler tank side
Standard pressure:
93 123 kPa (0.95 1.25 kg/cm2, 14 18
psi)
83 kPa (0.85 kg/cm2, 12 psi)
Radiator side
Standard pressure:
122 152 kPa (1.24 1.55 kg/cm2, 18
22 psi)
112 kPa (1.14 kg/cm2, 16 psi)
CAUTION:
Be sure to remove foreign matter and rust
from the cap in advance. Otherwise, results of
pressure test will be incorrect.
Not to confuse the cap of coolant filler tank
and cap of radiator.
CO(H4DOTC)-23

COOLING

Motor

main fan motor assembly.
A: REMOVAL
CO-00258
IN-00203

5) Disconnect the main fan motor connector (A).

12) Remove the over flow pipe.
14) Remove the mounting bolts from radiator main
fan motor assembly.
(A)
CO-00251
CO-00259

(A)
CO-00250
7) Drain the coolant about 1 2 (1.06 US qt, 0.88

Imp qt). <Ref. to CO(H4DOTC)-13, DRAINING OF
ENGINE COOLANT, REPLACEMENT, Engine
Coolant.>
(B)
CO-00255
17) Remove the radiator main fan motor assembly

from vehicle.
CO(H4DOTC)-24

COOLING
B: INSTALLATION
12) Connect the main fan motor connector (A).
1) Install the radiator main fan motor assembly to

vehicle.
2) Connect the radiator inlet hose (A) to radiator.
(A)
(A)
CO-00251

(B)
CO-00255
4) Install the mounting bolts of radiator main fan

motor assembly.
IN-00203
CO-00259
5) Install
the
reservoir
tank.
<Ref.
to
Tank.>
6) Install the over flow pipe.
10) Attach the ATF hose to the clip of radiator main
fan motor assembly.
11) Install the heat shield cover to radiator.

CO-00250
CO(H4DOTC)-25

COOLING
C: DISASSEMBLY
D: ASSEMBLY
1) Remove the clip which holds fan motor connector onto shroud.
2) Remove the nut which holds fan itself onto fan

Tightening torque:
4.4 Nm (0.45 kgf-m, 3.3 ft-lb)
CO-00050
CO-00102
3) Remove the bolts which hold fan motor onto

shroud.
Tightening torque:
3.4 Nm (0.35 kgf-m, 2.5 ft-lb)
CO-00050
CO(H4DOTC)-26
CO-00102

COOLING

Motor
14) Remove the mounting bolts of radiator sub fan

motor assembly.
A: REMOVAL
CO-00292

IN-00203
(A)

5) Disconnect the sub fan motor connector (B).
(B)
(B)
CO-00255
17) Remove the radiator sub fan motor assembly

from vehicle.
CO-00252
B: INSTALLATION
1) Install the radiator sub fan motor assembly to vehicle.
2) Connect the radiator inlet hose (A) to radiator.
(A)
CO-00250
7) Drain the coolant about 1 2 (1.06 US qt, 0.88

Coolant.>
sub fan motor assembly.
12) Remove the over flow pipe.
CO(H4DOTC)-27
(B)
CO-00255

COOLING
4) Install the mounting bolts of radiator sub fan motor assembly.
IN-00203
CO-00292
5) Install
the
reservoir
tank.
<Ref.
to
Tank.>
6) Install the over flow pipe.
10) Attach the ATF hose to the clip of radiator sub
fan motor assembly.
11) Install the heat shield cover to radiator.

C: DISASSEMBLY
1) Remove the clip which holds fan motor connector onto shroud.
CO-00097
CO-00250
12) Connect the sub fan motor connector (B).
3) Remove the bolts which hold fan motor onto

shroud.
(B)
CO-00252

CO(H4DOTC)-28
CO-00050

COOLING
D: ASSEMBLY
Tightening torque:
4.4 Nm (0.45 kgf-m, 3.3 ft-lb)
CO-00050
Tightening torque:
3.4 Nm (0.35 kgf-m, 2.5 ft-lb)
CO-00097
CO(H4DOTC)-29
Reservoir Tank
COOLING
10.Reservoir Tank
A: REMOVAL
2) Disconnect the over flow hose (A).
3) Pull out the reservoir tank to the arrow direction
while pushing the claw (B).
(B)
(A)
CO-00263
B: INSTALLATION
C: INSPECTION
FULL and LOW.
CO(H4DOTC)-30
Coolant Filler Tank

COOLING
11.Coolant Filler Tank

A: REMOVAL
WARNING:
2) Drain the coolant about 3.0 2 (3.2 US qt, 2.6
Coolant.>
3) Disconnect the engine coolant hoses from coolant filler tank.
4) Remove the bolts which install the coolant filler
tank.
5) Disconnect the engine coolant hose which connects the under side of coolant filler tank.
CO-00264
B: INSTALLATION
Tightening torque:
16 Nm (1.6 kgf-m, 11.8 ft-lb)
CO-00264
2) Fill with engine coolant. <Ref. to CO(H4DOTC)13, FILLING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>
CO(H4DOTC)-31

COOLING

A: INSPECTION
Trouble
Over-heating
Over-cooling
Engine coolant
leaks
Noise
Possible cause
Corrective action
b. Loose timing belt
Repair or replace timing belt tensioner.
c. Oil on drive belt
Replace.
d. Malfunction of thermostat
Replace.
e. Malfunction of water pump
Replace.
f. Clogged engine coolant passage
Clean.
Inspect and repair the ignition control system. <Ref. to
g. Improper ignition timing
EN(H4DOTC)(diag)-2, PROCEDURE, Basic Diagnostic
Procedure.>
h. Clogged or leaking radiator
i. Improper engine oil in engine coolant
Inspect and repair the fuel injection system. <Ref. to
j. Air/fuel mixture ratio too lean
EN(H4DOTC)(diag)-2, PROCEDURE, Basic Diagnostic
Procedure.>
k. Excessive back pressure in exhaust system
Clean or replace.
l. Insufficient clearance between piston and cylinder Adjust or replace.
m. Slipping clutch
Repair or replace.
n. Dragging brake
Adjustment.
o. Defective radiator fan
sensor or radiator motor and replace there.
Replace.
a. Loosened or damaged connecting units on hoses Repair or replace.
Replace.
Repair or replace.
e. Damaged or cracked cylinder head and crankcase Repair or replace.
Repair or replace.
Repair or replace.
a. Defective drive belt
Replace.
Replace.
Replace water pump.
Replace water pump.
CO(H4DOTC)-32
LUBRICATION
LU(H4DOTC)
1.
2.
3.
4.
5.
6.
7.
8.
9.
Page
Engine Oil....................................................................................................8
Oil Pump .....................................................................................................9
Oil Pipe......................................................................................................17
Engine Lubrication System Trouble in General.........................................22
General Description
LUBRICATION
A: SPECIFICATION
Lubrication method
Pump type
Inner rotor
Outer rotor
Tip clearance between inner and outer rotors
Side clearance between inner rotor and pump case
Case clearance between outer
Standard value
rotor and pump case
Discharge
pressure
600 rpm
Discharge
Performance at
80C (176F)
Discharge
6,000 rpm pressure
Discharge
mm (in)
mm (in)
mm (in)
Forced lubrication
Trochoid type
9
10
78 12 (3.07 0.47)
0.04 0.14 (0.0016 0.0055)
0.02 0.07 (0.0008 0.0028)
mm (in)
0.10 0.175 (0.0039 0.0069)
Number of teeth
Oil pump
Relief valve working pressure
kPa (kg/cm2, psi)
98 (1.0, 14)
6.5 (6.9, 5.7) or more
kPa (kg/cm2, psi)

kPa (kg/cm
2,
588 (6.0, 85)

59.0 (62.3, 51.9) or more
588 (6.0, 85)
psi)
Filter type
Filtration area
Oil filter

cm2
800 (124)
470 (72.9)
kPa (kg/cm2, psi)

Outer diameter
68 mm (2.68 in)
mm (in)
Outer diameter
65 mm (2.56 in)

Oil pressure
switch
Outer diameter
68 mm (2.68 in)
(sq in)
Outer diameter
65 mm (2.56 in)
160 (1.63, 23.2)

68 65 (2.68 2.56)
65 74.4 (2.56 2.93)
M 20 1.5
12 V 3.4 W or less

Type
Working voltage wattage
Proof pressure
kPa (kg/cm2, psi)
14.7 (0.15, 2.1)
(kg/cm2,
981 (10, 142) or more
kPa
psi)
2 (US qt, Imp qt)
Recommended oil
API classification
SL or 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 SL or
SJ or SH grade, you may use SG grade.)
SAE (1)
( C) -30 -20 -15
( F) -22 -4 5
4.0 (4.2, 3.5)
0
32
15
59
30 40
86 104
10W-30
5W-30
LU-00206
LU(H4DOTC)-2
General Description
LUBRICATION
B: COMPONENT
(13)
T6
(26)
T3
(14)
(15)
(12)
T3
(11)
(28)
(27)
T5
T7
(16)
(17)
T3
(10)
(9)
(18)
T4
T2
(8)
(6)
(23)
(19)
(20)
(7)
(21)
(22)
T4
(5)
(4)
(2)
T1
T1
(3)
(1)
(24)
T5
(25)
T5
LU-02022
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
Plug
Gasket
Relief valve spring
Relief valve
Oil seal
Oil pump case
Inner rotor
Outer rotor
Oil pump cover
Oil filter
O-ring
Oil pump ASSY
Oil pressure switch
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
Oil filler duct

O-ring
Rocker cover
Baffle plate
O-ring
Oil strainer
Gasket
Oil pan
Oil level gauge
Metal gasket
Drain plug
Oil filler cap
LU(H4DOTC)-3
(27)
(28)
Plug
Connector

T1: 5 (0.5, 3.6)
T2: 5.4 (0.55, 4.0)
T3: 6.4 (0.65, 4.7)
T4: 10 (1.0, 7.0)
T5: 44 (4.5, 32.5)
T6: 25 (2.5, 18.1)
T7: 70 (7.1, 51.6)
General Description
LUBRICATION
C: CAUTION

points.
cable from battery.
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
499977400
DESCRIPTION
CRANK PULLEY
WRENCH
REMARKS
removing and tightening crank pulley bolt.
499587100
OIL SEAL
INSTALLER
Used for installing oil seal into oil pump.
18332AA000
OIL FILTER
WRENCH

ST-499977400
ST-499587100
ST18332AA000
LU(H4DOTC)-4
General Description
LUBRICATION
ILLUSTRATION
TOOL NUMBER
18332AA010
DESCRIPTION
OIL FILTER
WRENCH
ST18332AA010
LU(H4DOTC)-5
REMARKS
Oil Pressure System

LUBRICATION

A: WIRING DIAGRAM
B72
IGNITION
SWITCH
BATTERY
No.5
SBF-7
3
A3
A4
SBF-1
OIL PRESSURE
WARNING LIGHT
COMBINATION
METER
i10
A15
A:
17
i3
31
B38
B21
E2
E11
E
OIL PRESSURE
SWITCH
B21
B72
1 2 3
4 5 6
A:
i10
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
B38
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
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 45
46 47
48 49 50 51 52 53 54
LU-00241
LU(H4DOTC)-6
Oil Pressure System

LUBRICATION
B: INSPECTION
1
Step
Check
Does the warning light illumi1)Turn the ignition switch to ON (engine OFF). nate?
2)Check the warning light of combination
meter.
Yes
Go to step 2.

2)Disconnect the connector from oil pressure
switch.
4)Measure the voltage of harness between oil
?
2)Remove the combination meter.
3)Measure the resistance of combination
meter.
Terminals
No. 4 No. 15:
No. 3 No. 15:
Replace the oil

pressure switch.
LU(H4DOTC)-7

pressure switch.
No
Repair or replace
the combination
Combination
Meter System.>
Go to step 3.
Repair or replace
the combination
Combination
Meter System.>
Engine Oil
LUBRICATION
3. Engine Oil

engine oil.
A: INSPECTION
orientated.
4) Remove it again and check the engine oil level. If
the engine oil level is below L line, add oil to bring
the level up to F line.
the level.
6) Just after driving or while the engine is warm, engine oil level show in the range between F line
and notch mark. This is caused by thermal expansion of the engine oil.
NOTE:
(A)
NOTE:
Use a new metal gasket.
Tightening torque:
44 Nm (4.5 kgf-m, 32.5 ft-lb)
LU-00219
point on level gauge. Make sure that the vehicle is
Recommended oil:
<Ref. to LU(H4DOTC)-2, SPECIFICATION,
(B)
(C)
(E)
(D)
LU-00213
(A)
(B)
(C)
(D)
(E)
Oil level gauge

Upper level
Lower level
Engine oil capacity:

Upper level
4.0 2 (4.2 US qt, 3.5 Imp qt)
Lower level
3.0 2 (3.2 US qt, 2.6 Imp qt)
level gauge.
(A)
(B)
B: REPLACEMENT
engine oil.
plug.
(C)
(E)
(D)
LU-00213
(A)
(B)
(C)
(D)
(E)
LU-00219
LU(H4DOTC)-8
Oil level gauge

Upper level
Lower level
Oil Pump
LUBRICATION
4. Oil Pump
9) Remove the crank pulley by using ST. <Ref. to

A: REMOVAL
LU-00012
IN-00203
10) Remove the water pump. <Ref.

CO(H4DOTC)-15, REMOVAL, Water Pump.>
11) Remove the timing belt guide.
to

5) Remove the radiator. <Ref. to CO(H4DOTC)-19,
REMOVAL, Radiator.>
LU-00013
LU-00046

REMOVAL, V-belt.>
8) Remove the rear side V-belt tensioner.
LU-00014
13) Remove the bolts which hold oil pump onto cylinder block.
LU-00011
LU-00015
14) Remove the oil pump by using flat bladed

screwdriver.
LU(H4DOTC)-9
Oil Pump
LUBRICATION
CAUTION:
Be careful not to scratch mating surfaces of
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
T
LU-00016
B: INSTALLATION
LU-00019
C: DISASSEMBLY

Perform the following.
1) Apply liquid gasket to the matching surfaces of
oil pump.
Remove the screws which secure oil pump cover

and then disassemble oil pump. Inscribe alignment
marks on the inner and outer rotors so that they can
be replaced in their original positions during reassembly.
Liquid gasket:
equivalent
CAUTION:
Before disassembling the oil pump, remove the
relief valve.
(E)
(D)
(B)
(C)
(A)
LU-00017
(A)
2) Replace the O-ring (A) with a new one.

3) Apply a coat of engine oil to the inside of oil seal.
(I)
(F)
(G)
(H)
LU-00020
ME-00312
4) Position the oil pump, aligning the notched area

with crankshaft, and push the oil pump straight.
CAUTION:
Make sure the oil seal lip is not folded.
Be careful not to scratch oil seal when installing oil pump on cylinder block.
5) Install the oil pump.
(A)
(B)
(C)
(D)
(E)
(F)
(G)
(H)
(I)
LU(H4DOTC)-10
Oil seal
Pump case
Inner rotor
Outer rotor
Pump cover
Relief valve
Relief valve spring
Plug
Gasket
Oil Pump
LUBRICATION
D: ASSEMBLY
E: INSPECTION
1) Install the front oil seal by using ST.

ST 499587100
OIL SEAL INSTALLER
1. TIP CLEARANCE
NOTE:
Use a new oil seal.

exceeds the standard value, replace the rotors as a
matched set.
Tip clearance:
Standard value
0.04 0.14 mm (0.0016 0.0055 in)
ST
LU-00021
2) Apply a coat of engine oil to the inner and outer

rotors.
3) Install the inner and outer rotors in their original
positions.
4) Install the oil relief valve and relief valve spring
and plug.
NOTE:
Use a new gasket.
LU-00023
2. CASE CLEARANCE
Measure the clearance between outer rotor and oil
pump rotor housing. If the clearance exceeds the
standard value, replace the oil pump case.
Case clearance:
Standard value
0.10 0.175 mm (0.0039 0.0069 in)
Tightening torque:
T1: 5.4 Nm (0.55 kgf-m, 4.0 ft-lb)
T2: 44 Nm (4.5 kgf-m, 32.5 ft-lb)
T1
LU-00024
T2
LU-00022
LU(H4DOTC)-11
Oil Pump
LUBRICATION
3. SIDE CLEARANCE
Measure the clearance between oil pump inner rotor and pump cover. If the clearance exceeds the
standard value, replace the rotor or pump body.
Side clearance:
Standard value
0.02 0.07 mm (0.0008 0.0028 in)
LU-00025
4. OIL RELIEF VALVE

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
73.7 mm (2.902 in)
Installed length
54.7 mm (2.154 in)
Load when installed
93.1 N (9.49 kgf, 20.88 lb)
5. OIL PUMP CASE

Check the oil pump case for worn shaft hole,
clogged oil passage, worn rotor chamber, cracks
and other faults.
6. OIL SEAL
Check the oil seal lips for deformation, hardening,
wear, etc. and replace if defective.
LU(H4DOTC)-12

LUBRICATION
A: REMOVAL
CO-00040

wire ropes.
IN-00203
5) Disconnect the connector from mass airflow

sensor.
6) Remove the air intake boot and air cleaner upper
cover.
LU-00222
LU-00220
7) Remove the intercooler.

CAUTION:
When lifting up the vehicle, raise up wire ropes
at the same time.
14) Drain engine oil.
15) Remove the front exhaust pipe.
<Ref. to EX(H4DOTC)-5, REMOVAL, Front Exhaust Pipe.>
LU-02023
LU-00221

17) Remove the bolts which install oil pan on cylinder block with the engine raised up.
18) Insert the oil pan cutter blade into the clearance
between cylinder block and oil pan.
CAUTION:
of oil pan cutter.
LU(H4DOTC)-13

LUBRICATION

Liquid gasket:
equivalent
(D)
(C)
(B)
LU-00034
4) Tighten the bolts which install oil pan onto engine block.
(A)
Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
LU-00189
(D)
(A)
(B)
(C)
(D)
Oil pan
Oil strainer
Baffle plate
Cylinder block
B: INSTALLATION
CAUTION:
Before installing the oil pan, wipe clean the oil
pan and the mating face of engine block.
(C)
(B)
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
2) Install the oil strainer onto baffle plate.
(A)
NOTE:
Tightening torque:
10 Nm (1.0 kgf-m, 7.2 ft-lb)
LU-00189
(A)
(B)
(C)
(D)
Oil pan
Oil strainer
Baffle plate
Cylinder block
5) Lower the engine onto front crossmember.

6) Tighten the nuts which hold front cushion rubber
onto front crossmember.
LU(H4DOTC)-14

LUBRICATION
13) Install the radiator upper brackets.
Tightening torque:
83 Nm (8.5 kgf-m, 61 ft-lb)
CO-00040
LU-02023
7) Install the front exhaust pipe.

<Ref. to EX(H4DOTC)-5, INSTALLATION, Front
Exhaust Pipe.> <Ref. to EX(H4SO 2.0)-8, INSTALLATION, Front Exhaust Pipe.>

15) Install the air intake boot and air cleaner upper
cover.
16) Connect the connector to mass air flow sensor.
CAUTION:
When lowing the vehicle, lower the lift-up device and wire ropes at the same time.
LU-00220

LU-00222

Tightening torque:
T1: 50 Nm (5.1 kgf-m, 36.9 ft-lb)
T2: 58 Nm (5.9 kgf-m, 42.8 ft-lb)
IN-00203
20) Fill engine oil. <Ref. to LU(H4DOTC)-8, INSPECTION, Engine Oil.>
C: INSPECTION
Visually check that the oil pan, oil strainer, oil
strainer stay and baffle plate are not damaged.
T2
T1
LU-00224
12) Install the linear motion mounting.

<Ref. to ME(H4DOTC)-37, INSTALLATION, Linear
Motion Mounting.>
LU(H4DOTC)-15
Oil Pressure Switch

LUBRICATION
2) Install the oil pressure switch onto engine block.
A: REMOVAL
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)

2) Remove the generator from bracket.
<Ref. to SC(H4SO 2.0)-14, REMOVAL, Generator.>
LU-00037
3) Connect the terminal to oil pressure switch.
LU-00036
LU-00036
LU-00037
4) Install the generator to bracket.

<Ref. to SC(H4SO 2.0)-14, INSTALLATION, Generator.>
B: INSTALLATION
C: INSPECTION

threads.
Make sure oil does not leak or seep from where the
oil pressure switch is installed.
Liquid gasket:
equivalent
LU-00038
LU(H4DOTC)-16
Oil Pipe
LUBRICATION
7. Oil Pipe
8) Remove the oil inlet pipe from the turbocharger.
A: REMOVAL
CAUTION:
the figure when loosing the oil inlet pipe flare
while loosening the nut.

(a)
IN-00203

4) Remove the intercooler bracket RH.
5) Remove the linear motion mount. <Ref. to
Mounting.>
6) Remove the linear motion mount bracket.
LU-02510
(A)
LU-02512
(B)
IN-00251
(A) Linear motion mount bracket

7) Remove the turbocharger upper cover.
(B)
(A)
9) Remove the intake manifold. <Ref. to

FU(H4DOTC)-13, REMOVAL, Intake Manifold.>
10) Remove the radiator main fan and radiator sub
fan. <Ref. to CO(H4DOTC)-24, REMOVAL, Radiator Main Fan and Fan Motor.> <Ref. to
CO(H4DOTC)-27, REMOVAL, Radiator Sub Fan
and Fan Motor.>
11) Remove the V-belts. <Ref. to ME(H4DOTC)39, REMOVAL, V-belt.>
ME(H4DOTC)-42, REMOVAL, Timing Belt Cover.>
14) Remove
the
timing
belt.
<Ref.
to
ME(H4DOTC)-43, REMOVAL, Timing Belt.>
15) Remove the cam sprocket LH. <Ref. to
ME(H4DOTC)-51, REMOVAL, Cam Sprocket.>
EX-00249

(B) Turbocharger upper cover
LU(H4DOTC)-17
Oil Pipe
LUBRICATION
B: INSTALLATION
16) Remove the belt cover No. 2 LH.
1) Inspect the union screw with filter. <Ref. to

LU(H4DOTC)-20, INSPECTING UNION SCREW
WITH FILTER, INSPECTION, Oil Pipe.>
2) Install the oil pipe.
NOTE:
Make sure not to mix up the union screws with filter and without filter as their installation positions
are different.
Use a new gasket.
CO-00024
17) Remove the oil pipe.
Tightening torque:
T1: 8 Nm (0.8 kgf-m, 5.9 ft-lb)
T2: 29 Nm (3.0 kgf-m, 21.4 ft-lb)
(B)
(D)
(B)
(A)
(C)
T1
T2
(D)
(D)
T2
(A)
(C)
(D)
(B)
(C)
(B)
T2
(D)
(C)
(D)
(A)
(A)
(D)
(D)
LU-02517
T2
(A)
(B)
(C)
(D)
Union screw with filter (with protrusion)

Union screw without filter (without protrusion)
Oil pipe
Gasket
(A)
(B)
(C)
(D)
LU-02519

Oil pipe
Gasket
3) Install the belt cover No. 2 LH.

Tightening torque:
5 Nm (0.5 kgf-m, 3.7 ft-lb)
CO-00024
LU(H4DOTC)-18
Oil Pipe
LUBRICATION
4) Install the cam sprocket LH. <Ref. to

ME(H4DOTC)-51, INSTALLATION, Cam Sprocket.>
5) Install the timing belt. <Ref. to ME(H4DOTC)-45,
TIMING BELT, INSTALLATION, Timing Belt.>
6) Install the timing belt cover. <Ref. to
ME(H4DOTC)-42, INSTALLATION, Timing Belt
Cover.>
9) Install the radiator main fan and the radiator sub
fan. <Ref. to CO(H4DOTC)-25, INSTALLATION,
Radiator Main Fan and Fan Motor.> <Ref. to
CO(H4DOTC)-27, INSTALLATION, Radiator Sub
Fan and Fan Motor.>
10) Install the intake manifold. <Ref. to
FU(H4DOTC)-15, INSTALLATION, Intake Manifold.>
11) Temporarily tighten the bolts and flare nut
which secure the oil inlet pipe to the turbocharger.
Tightening torque:
T1: 16 Nm (1.6 kgf-m, 11.8 ft-lb)
T2: 20 Nm (2.0 kgf-m, 14.8 ft-lb)
T1
T2
LU-02513
13) Tighten the bolts which hold the oil inlet pipe
stay to the turbocharger.
Tightening torque:
5 Nm (0.5 kgf-m, 3.7 ft-lb)
NOTE:
Use a new gasket.
LU-02514
14) Install the turbocharger upper cover.

Tightening torque:
7.5 Nm (0.8 kgf-m, 5.5 ft-lb)
LU-02512
12) Tighten the union screws and flare nut which

secure the oil inlet pipe to the turbocharger.
(B)
(A)
CAUTION:
the figure when tightening the oil inlet pipe flare
while tightening the nut.
EX-00249

(B) Turbocharger upper cover
(a)
LU-02510
LU(H4DOTC)-19
Oil Pipe
LUBRICATION
15) Install the linear motion mount bracket.
C: INSPECTION
1. INSPECTING UNION SCREW WITH FILTER
(A)
Check the filter part of union screw for clogging or

damage, and if defective, replace the union screw
with filter with a new part.
(B)
(D)
(B)
(A)
(C)
IN-00251
(D)

16) Install the linear motion mount. <Ref. to

ME(H4DOTC)-37, INSTALLATION, Linear Motion
Mounting.>
17) Install the intercooler bracket RH.
19) Connect the ground cable to battery.
(B)
(C)
(D)
(A)
(D)
LU-02517
IN-00203
(A)
(B)
(C)
(D)

Oil pipe
Gasket
2. OTHER INSPECTIONS
1) Check that the oil pipe and union screw have no
deformation, cracks and other damages.
2) Check that there are no oil leaks or oil oozing
from the oil pipe attachment section.
LU(H4DOTC)-20
Engine Oil Filter

LUBRICATION

A: REMOVAL
3) Remove the oil filter using STs.
LU-00227
B: INSTALLATION
1) Clean the oil filter installation surface on cylinder
block or oil cooler.
2) Obtain a new oil filter and apply a thin coat of engine oil to seal rubber.
3) Install the oil filter, turning it by hand, being careful not to damage seal rubber.
4) Tighten more after the seal rubber contacts oil
cooler.
NOTE:
In case of oil filter in diameter 68 mm (2.68 in),
tighten by approx. one turn.
In case of oil filter in diameter 65 mm (2.56 in),
tighten by approx. 2/3 to 3/4 turn.
Over-tightening may cause oil leak.
C: INSPECTION
1) After installing the oil filter, run the engine and
make sure that no oil is leaking around seal rubber.
NOTE:
2) Check the engine oil level.
<Ref. to LU(H4DOTC)-8, INSPECTION, Engine
Oil.>
LU(H4DOTC)-21
Engine Lubrication System Trouble in General

LUBRICATION
9. Engine Lubrication System Trouble in General

A: INSPECTION
Symptom

on.

not come on.

momentarily.
Possible cause
Cracked
failure
2) Low oil pressure
Clogged oil passage
pump rotor and gear
3) No oil pressure
3) Low oil pressure
LU(H4DOTC)-22
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).
SP(H4DOTC)
1.
Page
General Description
A: SPECIFICATION
Specifications for Turbo model is included in
SP(H4SO 2.0) section. <Ref. to SP(H4SO 2.0)-2,
SP(H4DOTC)-2
IGNITION
IG(H4DOTC)
1.
2.
3.
Page
Spark Plug...................................................................................................4
General Description
IGNITION
A: SPECIFICATION
Item
Model
Ignition system
Manufacturer
Manufacturer and type
Spark plug gap
Electrode

ASSY
Spark plug
mm
mm (in)
Specification
FK0186
Independent ignition coil
Diamond Electric
NGK: ILFR6B
14, 1.25, 26.5
0.7 0.8 (0.028 0.031)
Iridium
B: COMPONENT
T2
T1
(2)
(1)
T1
(1)
(2)
T2
IG-00098
(1)
(2)

T1: 21 (2.1, 15.2)
T2: 16 (1.6, 11.7)
Spark plug
IG(H4DOTC)-2
General Description
IGNITION
C: CAUTION
goggle and protective shoes during operation.
points.
cable from battery.
IG(H4DOTC)-3
Spark Plug
IGNITION
2. Spark Plug
2. LH SIDE
A: REMOVAL

CAUTION:
Spark plug:
<Ref. to IG(H4DOTC)-2, SPECIFICATION,
NOTE:
Turn the #4 ignition coil by 180 to remove it.
1. RH SIDE
IG-00093
B: INSTALLATION
1. RH SIDE
IN-00203

Case.>
NOTE:
Turn the #3 ignition coil by 180 to remove it.

Tightening torque (Spark plug):
21 Nm (2.1 kgf-m, 15.2 ft-lb)
Tightening torque (Ignition coil):
16 Nm (1.6 kgf-m, 11.7 ft-lb)
NOTE:
The above torque should only be applied to new
should be reduced by approximately 1/3 of the
specified torque in order to avoid over-stressing.
2. LH SIDE
21 Nm (2.1 kgf-m, 15.2 ft-lb)
IG-00092

16 Nm (1.6 kgf-m, 11.7 ft-lb)
NOTE:
The above torque should only be applied to new
IG(H4DOTC)-4
Spark Plug
IGNITION
C: INSPECTION
3) Oil fouled:
guides and stems.
(E)
(C)
(B)
(D)
(A)
IG-02010
IG-00013
(A)
(B)
(C)
(D)
(E)
Spark plug gap

Crack
Damage
Damaged gasket
1) Normal:
4) Overheating:
overheating. Moreover, the appearance results
from incorrect ignition timing, loose spark plugs,
wrong selection of fuel, etc.
IG-00014
IG-00011
2) Carbon fouled:
cleaner, etc.
IG-00012
IG(H4DOTC)-5
Spark Plug
IGNITION
D: ADJUSTMENT
Clean the spark plugs using a wire brush.
Clean and remove the carbon or oxide deposits.
But do not wear away ceramic insulator.
If deposits are too stubborn, replace the plugs.
After cleaning the spark plugs, measurement the
spark plug gap using a gap gauge.
NOTE:
Do not use a plug cleaner because the spark plugs
are applied with iridium tip.
Spark plug gap: L
0.7 0.8 mm (0.028 0.031 in)
IG-02035
IG(H4DOTC)-6

IGNITION

A: REMOVAL
Direct ignition type has been adopted. Refer to
Spark Plug for removal procedure. <Ref. to
IG(H4DOTC)-4, REMOVAL, Spark Plug.>
B: INSTALLATION
Tightening torque:
16 Nm (1.6 kgf-m, 11.7 ft-lb)
C: INSPECTION
For inspection procedure, refer to Diagnostics for
Engine Starting Failure. <Ref. to EN(H4DOTC)(diag)-48, IGNITION CONTROL SYSTEM, Diagnostics for Engine Starting Failure.>
IG(H4DOTC)-7

IGNITION
IG(H4DOTC)-8
SC(H4DOTC)
1.
Page
General Description
A: SPECIFICATION
Specifications for Turbo model is included in
SC(H4SO 2.0) section. <Ref. to SC(H4SO 2.0)-2,
SC(H4DOTC)-2
EN(H4DOTC)(diag)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Page
Inspection Mode........................................................................................28


A: PROCEDURE
1. ENGINE
Step
Check
<Ref. to EN(H4DOTC)(diag)-3, CHECK, Check
List for Interview.>
CHECK ILLUMINATION OF MALFUNCTION Does malfunction indicator

INDICATOR LIGHT.
light illuminate?
CHECK INDICATION OF DTC ON SCREEN. Is DTC displayed on the Sub1) Turn the ignition switch to OFF.
aru Select Monitor?
link connector.
PERFORM THE DIAGNOSIS.

Is DTC displayed on the Subaru Select Monitor?
1) Perform clear memory mode. <Ref. to
EN(H4DOTC)(diag)-30, Clear Memory Mode.>
EN(H4DOTC)(diag)-28, Inspection Mode.>
EN(H4DOTC)(diag)-2
Yes
Go to step 2.
No
Inspection using
Diagnostics for
Engine Starting
Failure. <Ref. to
EN(H4DOTC)(diag
)-42, Diagnostics
Go to step 3.
Inspection using
EN(H4DOTC)(diag
)-202, General
Diagnostic Table.>
Record the DTC. Repair the related
cause. <Ref. to
NOTE:
EN(H4DOTC)(diag If DTC is not
)-55, List of Diag- shown on display
nostic Trouble
although the malCode (DTC).> Go function indicator
to step 4.
light
illuminates,
perform the diagnostics for malfunction indicator
light circuit or combination
meter.
<Ref.
to
EN(H4DOTC)(diag)-33, Malfunction
Indicator
Light.>
Check on DiagFinish the diagnonostic Chart with sis.
<Ref. to
EN(H4DOTC)(diag
)-60, Diagnostic
Procedure with


A: CHECK
1. CHECK LIST No. 1
NOTE:
Customers name
Date of sale
Date of repair
V.I.N.
Weather
Engine No.
Fuel brand
Fine
Cloudy
Rainy
Snowy
Various/Others:
C (F)
Place
Engine temperature
Engine speed
Vehicle speed
Driving conditions
Headlight
Blower
A/C compressor
Radiator fan
Front wiper
Rear wiper
km
miles
Odometer reading
Hot
Warm
Cool
Cold
Highway
Suburbs
Inner city
Uphill
Downhill
Rough road
Others:
Cold
Warming-up
After warming-up
Any temperature
Others:
rpm
km/h (MPH)
Not affected
At starting
While idling
At racing
While accelerating
While cruising
While decelerating
ON / OFF
ON / OFF
ON / OFF
ON / OFF
ON / OFF
ON / OFF
Rear defogger
Audio
Car phone
EN(H4DOTC)(diag)-3
ON / OFF
ON / OFF
ON / OFF

2. CHECK LIST No. 2

NOTE:
ABS warning light
b) Fuel level
What:
What:
What:
Where:
From where:
What kind:
From where:
What kind:
Rough idling
Poor acceleration
Back fire
After fire
Does not shift.
EN(H4DOTC)(diag)-4
General Description

point to the body when measuring voltage and resistance inside the passenger compartment.
A: CAUTION
CAUTION:
All airbag system wiring harnesses and connectors are colored yellow. Do not use the electrical test equipment on these circuits.
The fuel injector and other part will be damaged.
engine is running.
sensor and the ECM, be sure to turn the ignition
switch to OFF.
CAUTION:
NOTE:
Immobilizer system must be registered when installing the ECM of the model with immobilizer. For
doing so, all ignition keys and ID cards should be
prepared. Refer to REGISTRATION MANUAL
FOR IMMOBILIZER.
7) Connectors to each sensor in the engine compartment and the harness connectors on the engine side and body side are all designed to be
(A)
EN-00069
(A) Stud bolt
9) Use engine grounding terminal or engine proper

as the grounding point to the body when measuring
FU-01170

not drop them.
CAUTION:
under the steering column, inside of the instrument panel lower trim panel.)
matching.
special attention to the three items above mentioned.
the operation of the ECM.
EN(H4DOTC)(diag)-5
General Description

three causes.
perform the ABS memory clearance procedure of
self-diagnosis function.
B: INSPECTION
items which might affect engine problems:
1. BATTERY
electrolyte.
proper grounding.
2. ENGINE GROUND
Make sure the engine grounding terminal is properly connected to the engine.
FU-01170
3. SELF-DIAGNOSIS FUNCTION
When detecting a malfunction by self-diagnosis
function on ECM, malfunction indicator light illuminates and malfunction occurrence is displayed.
Calling the self-diagnosis result is performed by
Subaru Select Monitor.
EN(H4DOTC)(diag)-6
General Description
C: PREPARATION TOOL
ILLUSTRATION
TOOL NUMBER
24082AA230
DESCRIPTION
CARTRIDGE
REMARKS
22771AA030
SUBARU SELECT
MONITOR KIT

ST24082AA230
ST22771AA030
EN(H4DOTC)(diag)-7


A: LOCATION
1. ENGINE
Control module
(4)
(2)
(3)
(1)
EN-02451
(1)
(2)

(3)
Test mode connector
(4)
Data link connector
(1)
EN-01147
(2)
EN-01966
(4)
(3)
EN-02476
EN(H4DOTC)(diag)-8
EN-02477

Sensor
(5)
(8)
(1)
(7)
(6)
(5)
(3)
(2)
(4)
(6)
EN-01926
(1)
(2)
(3)
(4)
(5)
(6)

Knock sensor
EN(H4DOTC)(diag)-9
(7)
(8)


(1)
(2)
EN-01927
EN-00295
(4)
(3)
EN-01928
EN-02169
(5)
(6)
EN-01798
EN-01929
(7)
(8)
EN-01930
EN(H4DOTC)(diag)-10
EN-02089

(2)
(3)
(1)
(4)
EN-01931
(1)
(2)

(3)
Rear oxygen sensor
(4)
(3)
(1)
(2)
(4)
EN-01932
EN(H4DOTC)(diag)-11
EN-01933

(4)
(3)
(1)
(4)
(2)
(3)
(5)
(5)
EN-01934
(1)
(2)
(3)

Ignition coil
(4)
Intake oil flow control solenoid

valve
EN(H4DOTC)(diag)-12
(5)
Exhaust oil flow control solenoid

valve

(3)
(2)
(1)
EN-01935
EN-01936
(5)
(4)
EN-01937
(1)
(8) (7) (6)
EN-01938
(2)
(9)
(5) (4)
(3)
EN-01898
(1)
(2)
(3)
Inhibitor switch
Fuel pump
Main relay
(4)
(5)
(6)
Fuel pump relay

EN(H4DOTC)(diag)-13
(7)
(8)
(9)

Starter

(2)
EN-02093
EN-00178
(3)
(6)
(8)
(4)
(7)
(5)
EN-02094
(9)
EN-02096
EN(H4DOTC)(diag)-14
EN-02095


To B135
To B134
7 6 5 4 3
17 16 15 14 13 12 11
27 26 25 24 23 22 21
34 33
32 31
2 1
10 9 8
20 19 18
30 29 28
To B136
7 6 5 4 3
2 1
19 18 17 16 15 14 13 12 11 10 9 8
27 26
25 24
23 22 21 20
35 34
33 32
31 30 29 28
6 5
4 3 2 1
16 15 14 13 12 11 10 9 8 7
27 26 25 24 23 22 21 20 19 18 17
30 29 28
35 34 33 32 31
To B137
7 6 5 4 3 2 1
17 16 15 14 13 12 11 10 9 8
25 24
23 22 21 20 19 18
31 30
29 28
27 26
EN-01812
Description
Connector
No.
Terminal No.
B135
B135
B135
B137
B137
Signal (V)
Note
10
22
31
25
31
Ignition SW ON
(engine OFF)
0
0
0
0
0
Engine ON
(idling)
7 +7
0
0
0 0.9
0
Waveform
B136
35
B134
Waveform
B134
Waveform
B135
0 13
Waveform
B136
14
1.0 1.4
1.0 1.4
B136
35
B136
B136
B136
23
32
31
0
0
0.3 4.5
0
0
B136
13
0.3 4.6
0.3 4.6
Signal (+)
Crankshaft posi- Signal ()
tion sensor Shield
Signal
Rear oxyShield
gen senGND
sor
(sensor)
Front oxy- Signal 1
gen (A/F)
sensor
Signal 2
heater
Rear oxygen sensor
heater signal
Engine
Signal
coolant
temperaGND
ture sen(sensor)
sor
Signal
Air flow
Shield
sensor
GND
sensor signal
Starter switch
B134
32
0 or 10 13
0 or 13 14
Waveform
B137
B137
17
Ignition switch
B137
14
B137
0
ON: 13 14
OFF: 0
13 14
ON: 0
OFF: 13 14
Cranking: 8 14
A/C switch
0
ON: 10 13
OFF: 0
10 13
ON: 0
OFF: 10 13
EN(H4DOTC)(diag)-15

Connector
No.
Terminal No.
Sensor power supply

#1
#2
Ignition
control
#3
#4
#1
Fuel injec- #2
tor
#3
#4
Fuel pump Signal 1
control unit Signal 2
B137
B136
B136
B135
B135
B135
B136
B135
B135
B135
B135
B136
B136
B136
B136
B137
B135
15
25
33
19
5
6
16
18
17
16
16
6
5
4
3
28
27
A/C relay control
B135
33
B135
25
B135
24
B134
Description
Test mode connector
Signal
Knock
sensor
Shield
Control module power
supply
Radiator fan relay 1

control
Radiator fan relay 2
control
Malfunction indicator
light
Engine speed output
Purge control solenoid
valve
Signal
Manifold
Power
absolute
supply
pressure
GND
sensor
(sensor)
Blower fan 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 communication
line
GND (injector)
GND (sensor)
GND (power supply)
Signal (V)
Note
Ignition SW ON
(engine OFF)
10 13
2.8
0
10 13
10 13
10 13
5
0
0
0
0
10 13
10 13
10 13
10 13
10 13
0 or 5
ON: 0.5 or less
OFF: 10 13
ON: 0.5 or less
OFF: 10 13
ON: 0.5 or less
OFF: 10 13
Engine ON
(idling)
13 14
2.8
0
13 14
13 14
13 14
5
13 14
13 14
13 14
13 14
1 14
1 14
1 14
1 14
13 14
0 or 5
ON: 0.5 or less
OFF: 13 14
ON: 0.5 or less
OFF: 13 14
ON: 0.5 or less
OFF: 13 14
17
B134
23
B134
14
B136
22
ON: 1 or less
OFF: 10 13
1.7 2.4
0 13 or more
ON: 1 or less
OFF: 13 14
1.1 1.6
B136
16
B136
35
B137
13
ON: 0
OFF: 10 13
B137
10
10 13
ON: 0
OFF: 13 14
ON: 0
OFF: 13 14
B134
33
2.8 3.2
2.8 3.2
B134
26
2.4 2.7
2.4 2.7
B134
25
B137
20
B137
B136
B135
B135
B135
B137
B137
7
35
12
4
1
1
2
Less than 1 More

than 4
0
0
0
0
0
0
0
Less than 1 More

than 4
0
0
0
0
0
0
0
EN(H4DOTC)(diag)-16
When connected: 0
Ignition switch OFF: 10 13
Waveform
Waveform
Waveform
Waveform
Waveform
Waveform
Waveform
Waveform
Waveform
Model with A/C

Light ON: 1 or less
Light OFF: 10 14
Waveform
Waveform
With manual A/C model only

Description
Terminal No.
B134
Signal (V)
Ignition SW ON
(engine OFF)
Engine ON
(idling)
Note
B134
B135
0 or 5
0 or 5
Waveform
B135
0 or 5
0 or 5
Waveform
Main
B136
18
0.64 0.72
Fully open: 3.96
Sub
B136
29
1.51 1.58
Fully open: 4.17
B136
16
B136
35
B137
Duty waveform
Duty waveform
B137
Duty waveform
Duty waveform
B137
10 13
13 14
B135
35
19
ON: 0
OFF: 13 14
ON: 13 14
OFF: 0

to ON: ON
B134
ON: 0
OFF: 10 13
ON: 10 13
OFF: 0
B134
29
B134
18
ON: 10 13
OFF: 0
ON: 13 14
OFF: 0
B134
28
B134
21
ON: 10 13
OFF: 0
ON: 13 14
OFF: 0
B134
31
B134
20
ON: 10 13
OFF: 0
ON: 13 14
OFF: 0
B134
30
B135
B135
20
28
0
0
7 +7
0
Waveform
B135
30
B135
B135
21
29
0
0
7 +7
0
Waveform
B135
30
GND (Front oxygen (A/

F) sensor heater 1)
GND (Front oxygen (A/
F) sensor heater 2)
Intake camshaft position sensor (LH)
Intake camshaft position sensor (RH)
Electronic
throttle
control
Connector
No.
Power
supply
GND
(sensor)
Electronic throttle control motor (+)
Electronic throttle control motor ()
Electronic throttle control motor power supply
Electronic throttle control motor relay
Intake
Signal (+)
AVCS
solenoid
Signal ()
(LH)
Intake
Signal (+)
AVCS
solenoid
Signal ()
(RH)
Exhaust
Signal (+)
AVCS
solenoid
Signal ()
(LH)
Exhaust
Signal (+)
AVCS
solenoid
Signal ()
(RH)
Exhaust
Signal (+)
camshaft
Signal ()
position
sensor
Shield
(LH)
Exhaust
Signal (+)
camshaft
Signal ()
position
sensor
Shield
(RH)
0.64 0.72
(After engine is
warmed-up.)
1.51 1.58
(After engine is
warmed-up.)
EN(H4DOTC)(diag)-17
Fully closed: 0.6 Fully open:

3.96
Fully closed: 1.48 Fully open:
4.17

Description
Connector
No.
Terminal No.
Main
B136
17
B136
Accelerator position
sensor
Signal (V)
Ignition SW ON
(engine OFF)
Fully closed: 1
Fully open: 3.3
Engine ON
(idling)
Fully closed: 1
Fully open: 3.3
Note
15
B136
34
Sub
B136
28
Shield
Power
supply
GND
(sensor)
B137
Fully closed: 1
Fully open: 3.3
0
Fully closed: 1
Fully open: 3.3
0
B136
16
B136
35
B135
32
ON: 0
OFF: 10 13
ON: 0
OFF: 10 13
5
depressed: 0
released: 10 13
When brake pedal is
depressed: 0
When brake pedal is
released: 10 13
When brake pedal is
depressed: 10 13
When brake pedal is
released: 0
When operating RES/
ACC: 2.5 3.5
When operating SET/
COAST: 0.5 1.5
ON: 0
OFF: 5
ON: 0
OFF: 13 14
ON: 0
OFF: 13 14
5
depressed: 0
released: 13 14
When brake pedal is
depressed: 0
When brake pedal is
released: 13 14
When brake pedal is
depressed: 13 14
When brake pedal is
released: 0
When operating RES/
ACC: 2.5 3.5
When operating SET/
COAST: 0.5 1.5
ON: 0
OFF: 5
Power
supply
GND
(sensor)
Starter relay
A/C middle pressure
switch
Clear memory switch
B136
30
B137
24
Clutch switch
B134
Brake switch 1
B136
Brake switch 2
B136
Cruise control command switch
B136
11
Cruise control main

switch
B136
EN(H4DOTC)(diag)-18
ON: Cranking
When connected: 0


Remarks
Engine load
Specification
1.2 2.9 (%): Idling
4.7 12.8 (%): 2,500 rpm racing
Gear position is in neutral.
A/C is turned off.
Turn all accessory switches to OFF.
EN(H4DOTC)(diag)-19
Data Link Connector


A: NOTE
CAUTION:
Do not connect any scan tools other than Subaru Select Monitor, because the circuit for the Subaru
Select Monitor may be damaged.
9 10 11 12 13 14 15 16
EN-00037
Terminal No.
1
2
3
4
5
6
7
8
Remarks
Power supply
Empty
Empty
Empty
Empty
Line end check signal 1
Empty
Empty
Terminal No.
9
10
11
12
13
14
15
16
Remarks
Empty
Empty
Ground
Ground
Empty
Empty
Empty
EN(H4DOTC)(diag)-20


A: OPERATION
CAUTION:

EN(H4DOTC)(diag)-7, PREPARATION TOOL,
(A)
EN-00040
(A) Power switch

EN-00038

Monitor.
<Ref. to EN(H4DOTC)(diag)-7, PREPARATION


information about how to indicate DTC. <Ref. to
EN(H4DOTC)(diag)-27, Read Diagnostic Trouble
Code (DTC).>

EN(H4DOTC)(diag)-27, Read Diagnostic Trouble
Code (DTC).>
EN-00039

connector.
portion of the instrument panel (on the drivers
side).
EN-02097

connector.
EN(H4DOTC)(diag)-21


3) Press the [YES] key after the information of engine type was displayed.
4) On the Engine Diagnosis screen, select the {Current Data Display/Save}, and then press the [YES] key.
5) On the Data Display Menu screen, select the {Data Display} and press the [YES] key.
Remarks
Display
Unit
of measure
C
%
%
mmHg
Note (at idling)

A/F correction 1
A/F learning 1
Coolant Temp.
A/F Correction #1
A/F Learning #1
Engine speed signal
Engine Speed
rpm

Battery voltage
Primary supercharged pressure control signal
Fuel pump duty ratio
AVCS advance angle amount RH
AVCS advance angle amount LH
Oil flow control solenoid valve duty RH (AVCS)
Oil flow control solenoid valve duty LH (AVCS)
Oil flow control solenoid valve current RH
Oil flow control solenoid valve current LH
A/F sensor current value 1
km/h
deg
C
g/s
%
V
V
V
ms
deg
%
%
%
%
%
deg
deg
%
%
mA
mA
mA
ohm
27 35 mA

A/F correction 3
Throttle motor duty
Sub accelerator sensor voltage
Main accelerator sensor voltage
Vehicle Speed
Ignition Timing
Intake Air Temp.
Mass Air Flow
Rear O2 Sensor
Battery Voltage
Air Flow Sensor Voltage
Knock Correction
Primary Control
ALT Duty
Fuel Pump Duty
VVT Adv. Ang. Amount R
VVT Adv. Ang. Amount L
OCV Duty R
OCV Duty L
OCV Current R
OCV Current L
A/F Sensor #1 Current
A/F Sensor #1
A/F Correction #3
Throttle Motor Duty
Sub-throttle Sensor
Atmospheric Pressure
80 100C
10 +10%
15 +15%
220 275 mmHg
630 770 rpm (Agree
0 km/h (at parking)
10 15 deg
20 50C
2.1 3.1 g/s
2.0 2.4%
0 1.0 V
12 15 V
1.0 1.7 V
1.2 2.2 ms
0.0 deg
0.0%
0.0%
0 25%
0 100%
30 40%
5 deg
5 deg
0 20%
0 20%
40 100 mA
40 100 mA
20 20 mA
%
%
V
V
V
V
V
mmHg
mmHg
1.0
0.00%
5%
12 15 V
1.5 V
0.6 V
1.1 V
1.0 V
Intake manifold absolute

pressure Atmospheric
pressure
EN(H4DOTC)(diag)-22

Remarks
Display

Estimated cumulative driving distance
Exhaust AVCS retard angle amount RH
Exhaust AVCS retard angle amount LH
Exhaust oil flow control solenoid valve duty ratio RH
Exhaust oil flow control solenoid valve duty ratio LH
Exhaust oil flow control solenoid valve current value RH
Exhaust oil flow control solenoid valve current value LH
Memorized Cruise
Speed
Estimated Cumulative
Driving Distance
Exh. VVT Retard Ang. R
Exh. VVT Retard Ang. L
Exh. OCV Duty R
Exh. OCV Duty L
Exh. OCV Current R
Exh. OCV Current L
Unit
of measure
Note (at idling)
km/h
km
deg
deg
%
%
mA
mA
5 deg
5 deg
0 20%
0 20%
40 100 mA
40 100 mA
NOTE:
EN(H4DOTC)(diag)-23


5) On the OBD Menu screen, select the {Current Data Display/Save}, and then press the [YES] key.
6) On the Data Display Menu screen, select the {Data Display} and press the [YES] key.
Description
Test of catalyst
Test of EGR system
Display
MI (MIL)
Misfire monitoring
Catalyst Diagnosis
Heated catalyst
Oxygen sensor
O2 Heater Diagnosis
EGR system
Unit of measure
ON or OFF
no support
complete or incomplete
no support
no support
no support
no support
no support
no support
NOTE:
EN(H4DOTC)(diag)-24


4) On the Engine Diagnosis screen, select the {Current Data Display/Save}, and then press the [YES] key.
5) On the Data Display screen, select the {Data & LED Display} and press the [YES] key.
Remarks
Display
Message
ON or OFF
Test mode signal
Test Mode Signal
ON or OFF
Clear memory signal
Clear Memory Terminal
ON or OFF
ON or OFF
Idle switch signal
Idle Switch Signal
ON or OFF
Ignition Switch
ON or OFF
P/S Switch
ON or OFF
Handle SW
LHD or RHD
Starter Switch
ON or OFF
A/C Switch
ON or OFF
Rear O2 Rich Signal
ON or OFF
Knocking Signal
ON or OFF
ON or OFF
ON or OFF
ON or OFF
Blower Fan Switch
ON or OFF
Light Switch
ON or OFF

Knocking signal
signal
Windshield wiper switch signal Wiper SW
ON or OFF

signal
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
AT fuel cut signal
ON or OFF
Fuel Cut
EN(H4DOTC)(diag)-25
LED ON requirements
When test mode connector is
connected.
When clear memory connector is connected.
entered.
entered.
to ON.
entered.
input.
input.
When camshaft position sensor signal is input.
turned to ON.
turned to ON.
turned to ON.
is turned to ON.
in function.
function.
function.
signal is input.
input.

Remarks
Display
Message
Torque down output signal
Torque Down Output
ON or OFF
Torque down demand signal
Request Torque Down
ON or OFF
ON or OFF
ETC Motor Relay
ON or OFF
Clutch Switch
ON or OFF
Stop Light Switch
ON or OFF
SET/COAST Switch
ON or OFF
RESUME/ACCEL Switch
ON or OFF
Brake switch signal
Brake Switch
ON or OFF
Main switch signal
Main Switch
ON or OFF
Cancel Switch
ON or OFF
Body Int. Unit Data
ON or OFF
ON or OFF

motor relay signal
LED ON requirements
When torque down output signal is input.
When torque down demand
signal is input.
to ON.
ON.
turned to ON.
turned to ON.
ON.
ON.
to ON.
entered.
entered.
NOTE:
EN(H4DOTC)(diag)-26

9. Read Diagnostic Trouble

Code (DTC)
A: OPERATION
MODE)
key.
NOTE:
SUBARU SELECT MONITOR OPERATION
MANUAL.
For details concerning DTCs, refer to the List of
Diagnostic Trouble Code (DTC). <Ref. to
EN(H4DOTC)(diag)-55, List of Diagnostic Trouble
Code (DTC).>

MODE)
key.
NOTE:
MANUAL.
EN(H4DOTC)(diag)-55, List of Diagnostic Trouble
Code (DTC).>
EN(H4DOTC)(diag)-27
Inspection Mode
10.Inspection Mode
A: PROCEDURE
1) After clearing the memory, check for any remaining

unresolved
trouble
data.
<Ref.
to
2) Idle the engine.

MODE
1) Check battery voltage is more than 12 V and fuel
remains half [20 to 40 2 (5.3 to 10.6 US gal, 4.4 to
8.8 Imp gal)].
WARNING:
brakes are applied.
wheels.
and the vehicle.
EN-00038

Monitor.
EN-00039

(A)
(A)
EN-01983
(B)
EN-00041
(A) Rigid rack

(B) Free rollers
EN(H4DOTC)(diag)-28
Inspection Mode


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 function.
EN-02097
CAUTION:
(A)
EN-00040
(A) Power switch

key.
NOTE:
MANUAL.
<Ref. to EN(H4DOTC)(diag)-55, List of Diagnostic
EN(H4DOTC)(diag)-29
Clear Memory Mode


A: OPERATION
MODE)
key.
switch to OFF and then Subaru Select Monitor to
OFF.
NOTE:
MANUAL.

MODE)
key.
NOTE:
MANUAL.
EN(H4DOTC)(diag)-30


Check Mode

A: OPERATION
EN-02097
EN-00038

Monitor.
CAUTION:
(A)
EN-00040
(A) Power switch

EN-00039

(A)
EN-01983

key.
the [YES] key.
11) On the System Operation Check Mode
screen, select the {Actuator ON/OFF Operation}
and press the [YES] key.
12) On the Actuator ON/OFF Operation screen,
select the desired compulsory actuator and press
the [YES] key.
screen.
EN(H4DOTC)(diag)-31


table.
Description
Compulsory fuel pump relay operation
check
Compulsory radiator fan relay operation
check
Compulsory air conditioning relay operation check
Compulsory purge control solenoid
valve operation check
Compulsory wastegate control solenoid valve operation check
Display
Fuel Pump
Radiator Fan
Relay
A/C Compressor
Relay
CPC Solenoid
NOTE:
Display
EGR Solenoid
ASV Solenoid
FICD Solenoid
Pressure Switching Solenoid
PCV Solenoid
AAI Solenoid
Vcut Solenoid

MANUAL.
EN(H4DOTC)(diag)-32


A: PROCEDURE
1. Activation of malfunction indicator light. <Ref. to EN(H4DOTC)(diag)-34, ACTIVATION OF MALFUNCTION INDICATOR
2. Check that the malfunction indicator light does not come on. <Ref. to EN(H4DOTC)(diag)-35, MALFUNCTION INDICATOR
3. Check that the malfunction indicator light does not go off. <Ref. to EN(H4DOTC)(diag)-37, MALFUNCTION INDICATOR LIGHT
DOES NOT GO OFF., Malfunction Indicator Light.>
4. Check that the malfunction indicator light does not blink. <Ref. to EN(H4DOTC)(diag)-38, MALFUNCTION INDICATOR LIGHT
5. Check that the malfunction indicator light remains blinking. <Ref. to EN(H4DOTC)(diag)-40, MALFUNCTION INDICATOR
EN(H4DOTC)(diag)-33

INDICATOR LIGHT

(1)
NOTE:
EN(H4DOTC)(diag)-35, MALFUNCTION INDICATOR LIGHT DOES NOT COME ON, Malfunction
Indicator Light.>
(2)
(4)
(3)
EN-01681
(1)
(2)
(3)
(4)
(A)
ON
OFF
Ignition switch ON
1 second
EN-01984
the emission control system is malfunctioning.
(1)
(3)
(4)
(2)
(3)
(4)
(5)
(6)
EN-01679
(1)
(2)
(3)
(4)
(5)
(6)
No trouble
Trouble occurs
ON
OFF
Ignition switch ON
Engine start

EN(H4DOTC)(diag)-34


DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B72
IGNITION
SWITCH
BATTERY
SBF-7
No.5
6
SBF-1
3
4
16
COMBINATION
METER
8
i3
i10
17
B38
ECM
B134
i10
B72
B38
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
1 2 3
4 5 6
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
B134
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
EN-01939
EN(H4DOTC)(diag)-35

Step
CHECK POOR CONTACT.
Check for poor connection when shaking or
pulling ECM connector and harness.

combination meter.
(B134) No. 17 (i10) No. 16:
Check
Yes
Go to step 4.

light illuminate?
Repair the poor

contact in ECM
connector.
connected?
<Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
Go to step 5.
?
CHECK POOR CONTACT.

16, Combination
Meter.>
EN(H4DOTC)(diag)-36
No
Go to step 2.
Go to step 3.

connector.

NOTE:
the following:
Open circuit in
harness between
Poor contact in
coupling connector
Go to step 6.

necessary.
NOTE:
Blown out fuse
Open or short
circuit in harness
between fuse and
battery terminal
Poor contact in


DIAGNOSIS:
TROUBLE SYMPTOM:
Monitor display.
WIRING DIAGRAM:
B72
IGNITION
SWITCH
BATTERY
SBF-7
No.5
6
SBF-1
3
4
16
COMBINATION
METER
8
i3
i10
17
B38
ECM
B134
i10
B72
B38
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
1 2 3
4 5 6
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
B134
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
EN-01939
Step
Check
light illuminate?
EN(H4DOTC)(diag)-37
Yes
Repair the short
circuit in harness
ECM connector.
No
Replace the ECM.
<Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>


DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
IGNITION
SWITCH
B72
BATTERY
SBF-7
No.5
6
SBF-1
3
4
16
COMBINATION
METER
B75
B76
i3
8
B38
*
*
A17
D15
B138
A: B134
B75
B76
B72
1
2
1
2
1 2 3
4 5 6
C19
i10
C: B136
D: B137
2
10
20
30
ECM
A: B134
1
8 9
18 19
28 29
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
C:
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
i10
B38
B138
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
1 2 3 4
5 6 7 8
D: B137
5 6
14 15 16
25 26 27
33 34 35
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
EN-02401
EN(H4DOTC)(diag)-38

Step
OFF)
Check
light illuminate?


light illuminate?

CONNECTOR AND ECU.
between test mode connector and ECM.
(B76) No. 1 (B136) No. 19:

?
CHECK POOR CONTACT.

Is the poor contact in ECM

connector?

ECM and test mode connector.
(B137) No. 15 (B75) No. 1:
CHECK POOR CONTACT.

?

connector?
EN(H4DOTC)(diag)-39
Yes
Go to step 2.
No
to
EN(H4DOTC)(diag
)-35, MALFUNCTION INDICATOR LIGHT
DOES NOT
COME ON, Malfunction Indicator
Light.>
combination meter
and ECM connector.
Go to step 4.
Repair the poor

contact in ECM
connector.
Go to step 6.
Repair the poor

contact in ECM
connector.
NOTE:
the following:
Open circuit in
harness between
test mode connector and ECM
Poor contact in
joint connector
Go to step 5.
Repair the open

circuit in harness
between ECM and
Replace the ECM.
<Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>


DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
IGNITION
SWITCH
B72
BATTERY
SBF-7
No.5
6
SBF-1
3
4
16
COMBINATION
METER
8
B38
B75
B76
*
*
B138
D15
A17
A: B134
1
2
B76
B72
1
2
1 2 3
4 5 6
C19
i10
B75
i3
C: B136
D: B137
2
10
20
30
ECM
A: B134
1
8 9
18 19
28 29
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
C:
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
i10
B38
B138
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
1 2 3 4
5 6 7 8
D: B137
5 6
14 15 16
25 26 27
33 34 35
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
EN-02401
EN(H4DOTC)(diag)-40

Step
1) Disconnect the test mode connectors
Check
Yes
light blink?

MINAL.
EN(H4DOTC)(diag)-41
No
System is in good
order.
NOTE:
Malfunction indicator light blinks at a
cycle of 3 Hz when
test mode connector is connected.
Repair the short
Replace the ECM.
circuit in harness <Ref. to
between ECM and FU(H4DOTC)-35,
test mode connec- Engine Control
tor.
Module (ECM).>


A: PROCEDURE
2. Inspection of starter motor circuit. <Ref. to EN(H4DOTC)(diag)-43, STARTER MOTOR CIRCUIT, Diagnostics for Engine Starting Failure.>
3. Inspection of ECM power supply and ground line. <Ref. to EN(H4DOTC)(diag)-46, CHECK POWER SUPPLY AND GROUND
4. Inspection of ignition control system. <Ref. to EN(H4DOTC)(diag)-48, IGNITION CONTROL SYSTEM, Diagnostics for Engine
Starting Failure.>
5. Inspection of fuel pump circuit. <Ref. to EN(H4DOTC)(diag)-51, FUEL PUMP CIRCUIT, Diagnostics for Engine Starting Failure.>
6. Inspection of fuel injector circuit. <Ref. to EN(H4DOTC)(diag)-53, FUEL INJECTOR CIRCUIT, Diagnostics for Engine Starting
Failure.>
EN(H4DOTC)(diag)-42


CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4DOTC)(diag)30, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4DOTC)(diag)-28, PROCEDURE, Inspection Mode.>.
WIRING DIAGRAM:
BATTERY
No.21
SBF-7
2
B72
14
16
SBF-1
IGNITION
SWITCH
STARTER RELAY
STARTER MOTOR
13
15
B225
D8
B32
B14
B: B135
D: B137
ECM
B225
B: B135
1
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
1
8 9
20 21
28 29
3
2
10 11 12 13
22 23
30 31
4 5 6
7
14 15 16 17 18 19
24 25
26 27
32 33
34 35
D: B137
3 4
1
2
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
B72
1 2 3
4 5 6
EN-02402
EN(H4DOTC)(diag)-43

1
2
Step
Check
CHECK DTC.
EN(H4DOTC)(diag)-27,
Yes
Go to step 2.

List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(H4DOTC)(diag
)-55, List of Diagnostic Trouble
Code (DTC).>
TOR.
motor.
ground.
NOTE:
Set the selector lever in the P or N range.
MOTOR.
?
starter motor.
ground.
switch.

switch.
switch terminals while turning the ignition
Terminals
No. 2 No. 3:

?
EN(H4DOTC)(diag)-44
No
Go to step 3.
Repair the poor
contact in ECM
connector.
Go to step 5.
Check the starter

motor. <Ref. to
SC(H4SO 2.0)-6,
Starter.>
Repair the open

circuit of ground
cable.
Go to step 6.

necessary.
Blown out
fuse
Open circuit
in harness
between ignition switch and
battery
Go to step 7.

10
11
Step
relay connector and chassis ground while turning the ignition switch to START position.
relay terminals.
Terminals
No. 13 No. 14:
2) Connect the starter relay connector.
between ECM and starter relay connector.
(B135) No. 32 (B225) No. 15:
CHECK INPUT VOLTAGE FOR STARTER
MOTOR.
4) Measure the voltage between starter motor
and engine ground.
CHECK HARNESS BETWEEN IGNITION
SWITCH AND ECM.
switch and ECM.
between ignition switch and ECM connector.
(B137) No. 8 (B72) No. 2:
Check
Yes
No
Repair the open or
between starter
relay and ignition
switch.

?
Go to step 9.
Replace the
starter relay.

?
Go to step 10.
Repair the open

circuit in harness
between ECM and
starter relay.
Repair the open or

between starter
relay and starter.

?
Repair the open

circuit between
ignition switch and
ECM.
EN(H4DOTC)(diag)-45
Check engine control module (ECM)

power supply and
ground line. <Ref.
to
EN(H4DOTC)(diag
)-46, CHECK
POWER SUPPLY
AND GROUND
LINE OF ENGINE
CONTROL MODULE (ECM), Diagnostics for Engine
Starting Failure.>

CAUTION:
WIRING DIAGRAM:
MAIN RELAY
TO FRONT OXYGEN(A/F) SENSOR
3
5
SBF-6
SBF-8
6
4
No.13
1
2
B72
B47
IGNITION
SWITCH
BATTERY
No.12
SBF-7
3
D16
B5
B6
B19
D14
SBF-1
B134
B:
B135
D:
B137
ECM
A6
A7
B1
B4
D7
B12
D1
D2
D3
A:
37
34
12
36
35
54
B21
E2
B72
B47
1 2 3
4 5 6
1
3
5
2
4
6
A: B134
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B: B135
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
32 33
34 35
28 29 30 31
D: B137
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
28 29
30 31
26 27
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
EN-02403
EN(H4DOTC)(diag)-46

Step
CHECK MAIN RELAY.
No. 1 and No. 2.
terminals.
Terminals
No. 3 No. 5:
No. 4 No. 6:
and chassis ground.
1) Connect the main relay connector.
Check
?
Yes
Go to step 2.
No
Replace the main
relay.

?
Go to step 3.
Repair the open

circuit in harness
between ECM
connector and
engine grounding
terminal.
Repair the open or

Repair the open or

Repair the open or


control system.
<Ref. to
EN(H4DOTC)(diag
)-48, IGNITION
CONTROL SYSTEM, Diagnostics
Repair the open or

between ECM
connector and
EN(H4DOTC)(diag)-47


CAUTION:
WIRING DIAGRAM:
15
16
ECM
17
18
B135
IGNITION
SWITCH
SBF-1
No.12
SBF-7
3
6
B72
16
15
14
13
49
B21
E2
E34
3
E33
3
E32
3
E31
E
E
IGNITION COIL
No.1
E31
B21
E32
E33
E34
1
2
3
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
IGNITION COIL
No.2
IGNITION COIL
No.3
B72
B135
1 2 3
4 5 6
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
IGNITION COIL
No.4
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
EN-02404
EN(H4DOTC)(diag)-48

Step
CHECK SPARK PLUG CONDITION.
1) Remove the spark plug. <Ref. to
IG(H4DOTC)-4, REMOVAL, Spark Plug.>
2) Check the spark plug condition. <Ref. to
IG(H4DOTC)-5, INSPECTION, Spark Plug.>
INSPECTION FOR SPARK OF IGNITION
SYSTEM.
1) Connect the spark plug to ignition coil.
FU(H4DOTC)-40, RELEASING OF FUEL
engine.
4) While the throttle valve is opening fully,
crank the engine to check that spark occurs at
each cylinder.
CHECK POWER SUPPLY CIRCUIT FOR IGNITION COIL & IGNITOR ASSY.
& ignitor ASSY.
engine ground.
Check
Yes
Is the spark plugs status OK? Go to step 2.
Does spark occur at each cylinder?

system. <Ref. to
EN(H4DOTC)(diag
)-51, FUEL PUMP
Starting Failure.>
?
ground.
Go to step 5.
TOR.
& ignitor ASSY.
connector.
(B135) No. 15 (E34) No. 1:
(B135) No. 16 (E33) No. 1:
(B135) No. 17 (E32) No. 1:
(B135) No. 18 (E31) No. 1:
Go to step 6.
EN(H4DOTC)(diag)-49
No
Replace the spark
plug.

NOTE:
the following:
Open circuit in
harness between
ignition coil & ignitor ASSY, and ignition switch
connector
Poor contact in
coupling connector
NOTE:
the following:
Open circuit in
harness between
grounding terminal
NOTE:
the following:
Open circuit in
harness between
ECM and ignition
coil & ignitor ASSY
connector
Poor contact in
coupling connector

Step
CHECK POOR CONTACT.
Check
M?
Yes
Go to step 7.
No
Repair the ground
ECM and ignition
coil & ignitor ASSY
connector.

connector?
Repair the poor

contact in ECM
connector.

ASSY.
EN(H4DOTC)(diag)-50


CAUTION:
WIRING DIAGRAM:
BATTERY
No.31
1
FUEL PUMP
RELAY
B362
7
4
B98
10
R2
FUEL PUMP
CONTROL UNIT
9
8
7
6
R122
6
5
R2
D28
B27
5
6
B98
FUEL
PUMP
ECM
R58
B: B135
D: B137
B362
1 2
3
4
5
7 8
6
B98
R58
R122
1
2 3
4 5 6 7 8
1 2
3 4
5 6
3 4
1 2
5 6 7 8 9 10
B:
B135
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
D: B137
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
28 29
30 31
26 27
EN-01944
EN(H4DOTC)(diag)-51

Step
PUMP.
Make sure that fuel pump is in operation for 2
ON.
Check
operating sound?
NOTE:
Mode for procedures. <Ref. to
EN(H4DOTC)(diag)-52
Yes
Check the fuel
injector circuit.
<Ref. to
EN(H4DOTC)(diag
)-53, FUEL INJECTOR CIRCUIT,
Diagnostics for
Engine Starting
Failure.>
No
Display DTC.
<Ref. to
EN(H4DOTC)(diag
)-27, OPERATION, Read Diagnostic Trouble
Code (DTC).>


CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H4DOTC)(diag)-30, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H4DOTC)(diag)-28,
PROCEDURE, Inspection Mode.>.
WIRING DIAGRAM:
MAIN RELAY
5
3
BATTERY
SBF-8
6
4
2
1
D7
ECM
34
C3
C4
D: B137
44
43
48
42
C5
C6
C: B136
45
B47
B21
E2
2
1
E17
2
1
E6
2
1
E16
2
1
E5
#1
#2
#3
#4
FUEL INJECTORS
E5
E6
E16
E17
1 2
C:
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B21
5 6
14 15 16
25 26 27
33 34 35
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 45
46 47
48 49 50 51 52 53 54
B47
1
3
5
2
4
6
D:
B137
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
28 29
30 31
26 27
EN-01945
EN(H4DOTC)(diag)-53

Step
Check
CHECK OPERATION OF EACH FUEL INJEC- Does the fuel pump produce
TOR.
operating sound?
While cranking the engine, check that each
fuel injector emits operating sound. Use a
sound scope or attach a screwdriver to the
injector for this check.
INJECTOR.
Yes
No
Check the fuel
Go to step 2.
pressure. <Ref. to
ME(H4DOTC)-26,
INSPECTION,
Fuel Pressure.>
Go to step 3.

NOTE:
the following:
Open circuit in
harness between
main relay and fuel
injector connector
Poor contact in
Poor contact in
coupling connector
Poor contact in

(B136) No. 6 (E5) No. 1:
(B136) No. 5 (E16) No. 1:
(B136) No. 4 (E6) No. 1:
(B136) No. 3 (E17) No. 1:

?

injector terminals.
Terminals
No. 1 No. 2:
CHECK POOR CONTACT.

M?
Go to step 5.
Go to step 6.
Replace the faulty

fuel injector.

connector?
Repair the poor

contact in ECM
connector.
Inspection using
EN(H4DOTC)(diag
)-202, INSPECTION, General
Diagnostic Table.>
EN(H4DOTC)(diag)-54
Go to step 4.
NOTE:
the following:
Open circuit in
harness between
ECM and fuel
injector connector
Poor contact in
coupling connector
Repair the ground
ECM and fuel
injector connector.


A: LIST
DTC
P0031
Item
(Bank 1 Sensor 1)
P0032

(Bank 1 Sensor 1)
P0037

(Bank 1 Sensor 2)
P0038

(Bank 1 Sensor 2)
P0102
Mass or Volume Air Flow Circuit

Low Input
P0103

High Input
P0107
P0108
Intake Air Pressure Sensor Circuit

High Input
P0112

Input
P0113

Input
P0117
P0118
P0122

P0123

P0131
O2 Sensor Circuit Low Voltage

(Bank 1 Sensor 1)
P0132

(Bank 1 Sensor 1)
P0134

P0137
O2 Sensor Circuit Low Voltage

(Bank 1 Sensor 2)
Note
<Ref. to EN(H4DOTC)(diag)-60, DTC P0031 HO2S HEATER CONTROL
<Ref. to EN(H4DOTC)(diag)-69, DTC P0102 MASS OR VOLUME AIR
FLOW CIRCUIT LOW INPUT, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
<Ref. to EN(H4DOTC)(diag)-72, DTC P0103 MASS OR VOLUME AIR
FLOW CIRCUIT HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
<Ref. to EN(H4DOTC)(diag)-74, DTC P0107 MANIFOLD ABSOLUTE
<Ref. to EN(H4DOTC)(diag)-76, DTC P0108 MANIFOLD ABSOLUTE
<Ref. to EN(H4DOTC)(diag)-78, DTC P0112 INTAKE AIR TEMPERATURE
Code (DTC).>
<Ref. to EN(H4DOTC)(diag)-80, DTC P0113 INTAKE AIR TEMPERATURE
Code (DTC).>
<Ref. to EN(H4DOTC)(diag)-83, DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to EN(H4DOTC)(diag)-85, DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to EN(H4DOTC)(diag)-88, DTC P0122 THROTTLE/PEDAL POSITION
SENSOR/SWITCH A CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4DOTC)(diag)-90, DTC P0123 THROTTLE/PEDAL POSITION
SENSOR/SWITCH A CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4DOTC)(diag)-92, DTC P0131 O2 SENSOR CIRCUIT LOW
<Ref. to EN(H4DOTC)(diag)-94, DTC P0132 O2 SENSOR CIRCUIT HIGH
<Ref. to EN(H4DOTC)(diag)-96, DTC P0134 O2 SENSOR CIRCUIT NO
<Ref. to EN(H4DOTC)(diag)-98, DTC P0137 O2 SENSOR CIRCUIT LOW
EN(H4DOTC)(diag)-55

DTC
P0138
P0171
P0172
P0222
P0223
P0230
P0245
P0246
P0261
P0264
P0267
P0270
P0327
P0328
P0335
P0340
P0345
P0350
P0365
P0390
P0458
Item
(Bank 1 Sensor 2)
Note
<Ref. to EN(H4DOTC)(diag)-101, DTC P0138 O2 SENSOR CIRCUIT HIGH
<Ref. to EN(H4DOTC)(diag)-103, DTC P0171 SYSTEM TOO LEAN (BANK
<Ref. to EN(H4DOTC)(diag)-104, DTC P0172 SYSTEM TOO RICH (BANK
<Ref. to EN(H4DOTC)(diag)-107, DTC P0222 THROTTLE/PEDAL POSISwitch B Circuit Low Input
TION SENSOR/SWITCH B CIRCUIT LOW, Diagnostic Procedure with
<Ref. to EN(H4DOTC)(diag)-109, DTC P0223 THROTTLE/PEDAL POSISwitch B Circuit High Input
TION SENSOR/SWITCH B CIRCUIT HIGH, Diagnostic Procedure with
Fuel Pump Primary Circuit
<Ref. to EN(H4DOTC)(diag)-111, DTC P0230 FUEL PUMP PRIMARY CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Turbo/Super Charger Wastegate
<Ref. to EN(H4DOTC)(diag)-114, DTC P0245 TURBO/SUPER CHARGER
Solenoid A Low
WASTEGATE SOLENOID A LOW, Diagnostic Procedure with Diagnostic
Turbo/Super Charger Wastegate
<Ref. to EN(H4DOTC)(diag)-116, DTC P0246 TURBO/SUPER CHARGER
Solenoid A High
WASTEGATE SOLENOID A HIGH, Diagnostic Procedure with Diagnostic
Cylinder 1 Injector Circuit Low
<Ref. to EN(H4DOTC)(diag)-118, DTC P0261 CYLINDER 1 INJECTOR
<Ref. to EN(H4DOTC)(diag)-122, DTC P0327 KNOCK SENSOR 1 CIRCUIT
LOW (BANK 1 OR SINGLE SENSOR), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Knock Sensor 1 Circuit High Input <Ref. to EN(H4DOTC)(diag)-124, DTC P0328 KNOCK SENSOR 1 CIRCUIT
HIGH (BANK 1 OR SINGLE SENSOR), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Crankshaft Position Sensor A Cir- <Ref. to EN(H4DOTC)(diag)-126, DTC P0335 CRANKSHAFT POSITION
cuit
(DTC).>
Camshaft Position Sensor A Cir- <Ref. to EN(H4DOTC)(diag)-128, DTC P0340 CAMSHAFT POSITION SENcuit (Bank 1or Single Sensor)
SOR A CIRCUIT (BANK 1 OR SINGLE SENSOR), Diagnostic Procedure
Camshaft Position Sensor A Cir- <Ref. to EN(H4DOTC)(diag)-130, DTC P0345 CAMSHAFT POSITION SENcuit (Bank 2)
SOR A CIRCUIT (BANK 2), Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
Ignition Coil Primary/Secondary
<Ref. to EN(H4DOTC)(diag)-132, DTC P0350 IGNITION COIL PRIMARY/
Circuit
SECONDARY CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
Camshaft Position Sensor B Cir- <Ref. to EN(H4DOTC)(diag)-135, DTC P0365 CAMSHAFT POSITION SENcuit (Bank 1)
SOR B CIRCUIT (BANK 1), Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
Camshaft Position Sensor B Cir- <Ref. to EN(H4DOTC)(diag)-137, DTC P0390 CAMSHAFT POSITION SENcuit (Bank 2)
SOR B CIRCUIT (BANK 2), Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
Evaporative Emission Control Sys- <Ref. to EN(H4DOTC)(diag)-139, DTC P0458 EVAPORATIVE EMISSION
tem Purge Control Valve Circuit
Low
EN(H4DOTC)(diag)-56

DTC
P0459
P0500
Item
Evaporative Emission Control System Purge Control Valve Circuit
High
P0512
P0513
P0519

(Fail-Safe)
P0562
System Voltage Low
P0563
System Voltage High
P0600
P0604

P0605

Memory (ROM) Error
P0607
P0638
Throttle Actuator Control Range/

Performance (Bank 1)
P0700

Request)
P0851
P0852
P1110
Atmospheric Pressure Sensor Circuit Malfunction (Low Input)
P1111
Atmospheric Pressure Sensor Circuit Malfunction (High Input)
P1160
P1518
P1560
P1570
Antenna
P1571
Note
<Ref. to EN(H4DOTC)(diag)-141, DTC P0459 EVAPORATIVE EMISSION
<Ref. to EN(H4DOTC)(diag)-143, DTC P0500 VEHICLE SPEED SENSOR,
<Ref. to EN(H4DOTC)(diag)-144, DTC P0512 STARTER REQUEST CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4DOTC)(diag)-146, DTC P0519 IDLE CONTROL SYSTEM
PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to EN(H4DOTC)(diag)-147, DTC P0562 SYSTEM VOLTAGE LOW,
<Ref. to EN(H4DOTC)(diag)-149, DTC P0563 SYSTEM VOLTAGE HIGH,
<Ref. to EN(H4DOTC)(diag)-151, DTC P0600 SERIAL COMMUNICATION
<Ref. to EN(H4DOTC)(diag)-151, DTC P0604 INTERNAL CONTROL MODULE RANDOM ACCESS MEMORY (RAM) ERROR, Diagnostic Procedure
<Ref. to EN(H4DOTC)(diag)-151, DTC P0605 INTERNAL CONTROL MODULE READ ONLY MEMORY (ROM) ERROR, Diagnostic Procedure with
<Ref. to EN(H4DOTC)(diag)-152, DTC P0607 CONTROL MODULE PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4DOTC)(diag)-154, DTC P0638 THROTTLE ACTUATOR
<Ref. to EN(H4DOTC)(diag)-154, DTC P0700 TRANSMISSION CONTROL
Code (DTC).>
<Ref. to EN(H4DOTC)(diag)-154, DTC P0851 PARK/NEUTRAL SWITCH
(DTC).>
<Ref. to EN(H4DOTC)(diag)-154, DTC P0852 PARK/NEUTRAL SWITCH
(DTC).>
<Ref. to EN(H4DOTC)(diag)-155, DTC P1110 ATMOSPHERIC PRESSURE
SENSOR CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Procedure
<Ref. to EN(H4DOTC)(diag)-155, DTC P1111 ATMOSPHERIC PRESSURE
SENSOR CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Procedure
<Ref. to EN(H4DOTC)(diag)-155, DTC P1160 RETURN SPRING FAILURE,
<Ref. to EN(H4DOTC)(diag)-156, DTC P1518 STARTER SWITCH CIRCUIT
<Ref. to EN(H4DOTC)(diag)-158, DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
EN(H4DOTC)(diag)-57

DTC
P1572
P1574
P1576
P1577
P1578
P2088
P2089
P2090
P2091
P2092
P2093
P2094
P2095
P2101
P2102
P2103
P2109
P2122
P2123
P2127
Item
IMM Circuit Failure (Except
Antenna Circuit)
Note
(DTC).>
Meter Failure
OCV Solenoid Valve Signal A Cir- <Ref. to EN(H4DOTC)(diag)-160, DTC P2088 INTAKE CAMSHAFT POSIcuit Open (Bank 1)
TION ACTUATOR CONTROL CIRCUIT LOW (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
OCV Solenoid Valve Signal A Cir- <Ref. to EN(H4DOTC)(diag)-162, DTC P2089 INTAKE CAMSHAFT POSIcuit Short (Bank 1)
TION ACTUATOR CONTROL CIRCUIT HIGH (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
OCV Solenoid Valve Signal B Cir- <Ref. to EN(H4DOTC)(diag)-164, DTC P2090 EXHAUST CAMSHAFT
cuit Open (Bank 1)
POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 1), Diagnostic
cuit Short (Bank 1)
POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 1), Diagnostic
OCV Solenoid Valve Signal A Cir- <Ref. to EN(H4DOTC)(diag)-168, DTC P2092 INTAKE CAMSHAFT POSIcuit Open (Bank 2)
TION ACTUATOR CONTROL CIRCUIT LOW (BANK 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
OCV Solenoid Valve Signal A Cir- <Ref. to EN(H4DOTC)(diag)-170, DTC P2093 INTAKE CAMSHAFT POSIcuit Short (Bank 2)
TION ACTUATOR CONTROL CIRCUIT HIGH (BANK 2), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
cuit Open (Bank 2)
POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 2), Diagnostic
cuit Short (Bank 2)
POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 2), Diagnostic
Throttle Actuator Control Motor Cir- <Ref. to EN(H4DOTC)(diag)-176, DTC P2101 THROTTLE ACTUATOR
cuit Range/Performance
cuit Low
cuit High
<Ref. to EN(H4DOTC)(diag)-184, DTC P2109 THROTTLE/PEDAL POSIMinimum Stop Performance
TION SENSOR A MINIMUM STOP PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H4DOTC)(diag)-185, DTC P2122 THROTTLE/PEDAL POSISwitch D Circuit Low Input
TION SENSOR/SWITCH D CIRCUIT LOW INPUT, Diagnostic Procedure
<Ref. to EN(H4DOTC)(diag)-188, DTC P2123 THROTTLE/PEDAL POSISwitch D Circuit High Input
TION SENSOR/SWITCH D CIRCUIT HIGH INPUT, Diagnostic Procedure
<Ref. to EN(H4DOTC)(diag)-190, DTC P2127 THROTTLE/PEDAL POSISwitch E Circuit Low Input
TION SENSOR/SWITCH E CIRCUIT LOW INPUT, Diagnostic Procedure
EN(H4DOTC)(diag)-58

DTC
P2128
Item
P2135

P2138

Note
<Ref. to EN(H4DOTC)(diag)-193, DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT HIGH INPUT, Diagnostic Procedure
<Ref. to EN(H4DOTC)(diag)-195, DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH A / B VOLTAGE CORRELATION, Diagnostic
<Ref. to EN(H4DOTC)(diag)-198, DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH D / E VOLTAGE CORRELATION, Diagnostic
EN(H4DOTC)(diag)-59


A: DTC P0031 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 1)
Detect as soon as the malfunction occurs.
CAUTION:
WIRING DIAGRAM:
B18
BATTERY
MAIN RELAY
1 2
3 4
SBF-6
5
3
6
4
B47
3
1
3
5
FRONT OXYGEN
(A/F) SENSOR
2
4
6
B18
2
B21
4
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
A25
A: B134
1
8 9
18 19
28 29
ECM
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
A6
A7
B21
54
A: B134
A33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
A26
B47
A2
A3
2
1
F2
E
EN-01946
EN(H4DOTC)(diag)-60

Step
Check
Yes
CHECK POWER SUPPLY TO FRONT OXY- Is the voltage more than 10 V? Go to step 2.
GEN (A/F) SENSOR.
(A/F) sensor.
CHECK HARNESS BETWEEN FRONT OXYGEN (A/F) SENSOR AND ECM.

3) Measure the resistance between front oxygen (A/F) sensor connector and ECM.
(B18) No. 4 (B134) No. 2:
(B18) No. 4 (B134) No. 3:
CHECK HARNESS BETWEEN FRONT OXYGEN (A/F) SENSOR AND ECM.
Terminals
No. 3 No. 4:
No
Repair the power
supply line.
NOTE:
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
Repair the open
circuit in harness
between ECM and
front oxygen (A/F)
sensor.

?
Go to step 3.

M?
Go to step 4.
Repair the ground

ECM and front
Is the resistance 2.4 ?
Repair the poor

contact in ECM
connector.
Replace the front

FU(H4DOTC)-33,
Front Oxygen (A/
F) Sensor.>
EN(H4DOTC)(diag)-61

B: DTC P0032 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 1)

CAUTION:
WIRING DIAGRAM:
B18
BATTERY
MAIN RELAY
1 2
3 4
SBF-6
5
3
6
4
B47
3
1
3
5
FRONT OXYGEN
(A/F) SENSOR
2
4
6
B18
2
B21
4
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
A25
A: B134
1
8 9
18 19
28 29
ECM
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
A6
A7
B21
54
A: B134
A33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
A26
B47
A2
A3
2
1
F2
E
EN-01946
EN(H4DOTC)(diag)-62

Step
Check
?
CHECK VOLTAGE BETWEEN ECM AND
and chassis ground.
EN(H4DOTC)(diag)-63
Yes
Go to step 2.
No
Repair the open
circuit in harness
between ECM
connector and
chassis ground.
Repair the battery Repair the poor

short circuit in harcontact in ECM
ness between
connector.
ECM and front

C: DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 2)

CAUTION:
WIRING DIAGRAM:
BATTERY
MAIN RELAY
B19
5
3
T5
2
4
6
B83
T6
1 2 3 4
5 6 7 8
2 1
4 3
2
1
B47
2
4
B19
2
6
4
1
3
B47
1
3
5
REAR
OXYGEN SENSOR
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
2
4
T6
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
1
3
T5
B19
B: B135
*
*
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
32 33
34 35
28 29 30 31
D31
C35
B2
D25
B83
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B: B135
D:
ECM
35
C: B136
B137
B21
D: B137
E2
B4
B1
5 6
14 15 16
25 26 27
33 34 35
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
28 29
30 31
26 27
E
EN-01947
EN(H4DOTC)(diag)-64

Step
Check
?
Yes
Go to step 2.

REAR OXYGEN SENSOR.
sensor.
REAR OXYGEN SENSOR.
(T6) No. 1 (+) Chassis ground ():
Go to step 3.

M?
No
NOTE:
the following:
Open circuit in
harness between
ECM and engine
ground cable
Poor contact in
ECM connector
Poor contact in
coupling connector
Repair the ground
ECM and rear oxygen sensor connector.
Does the resistance change by Repair the poor

connector.
connector?
Go to step 4.
Repair the power

supply line.
EN(H4DOTC)(diag)-65
NOTE:
the following:
Open circuit in
harness between
main relay and
Poor contact in
Poor contact in
coupling connector

Step
Check
?
2) Measure the resistance between rear oxygen sensor connector terminals.
Terminals
No. 1 No. 2:
EN(H4DOTC)(diag)-66
Yes
No
tor.
<Ref. to
FU(H4DOTC)-34,
NOTE:
In this case, repair Rear Oxygen Sensor.>
the following:
Open circuit in
harness between
Poor contact in
Poor contact in
ECM connector
Poor contact in
coupling connector

D: DTC P0038 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 2)

CAUTION:
WIRING DIAGRAM:
BATTERY
MAIN RELAY
B19
5
3
T5
2
4
6
B83
T6
1 2 3 4
5 6 7 8
2 1
4 3
2
1
B47
2
4
B19
2
6
4
1
3
B47
1
3
5
REAR
OXYGEN SENSOR
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
2
4
T6
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
1
3
T5
B19
B: B135
*
*
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
32 33
34 35
28 29 30 31
D31
C35
B2
D25
B83
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B: B135
D:
ECM
35
C: B136
B137
B21
D: B137
E2
B4
B1
5 6
14 15 16
25 26 27
33 34 35
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
28 29
30 31
26 27
E
EN-01947
EN(H4DOTC)(diag)-67

Step
Check
?
Yes
Go to step 2.
No
NOTE:
the following:
Open circuit in
harness between
ECM and engine
ground cable
Poor contact in
ECM connector
Poor contact in
coupling connector
Is the voltage more than 10 V? Repair the battery Repair the poor
short circuit in har- connection in ECM
REAR OXYGEN SENSOR.
ness between
connector.
Measure the voltage between ECM and chasECM and rear oxysis ground.
gen sensor.
EN(H4DOTC)(diag)-68

E: DTC P0102 MASS OR VOLUME AIR FLOW CIRCUIT LOW INPUT

TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
5
3
BATTERY
SBF-8
6
4
2
1
B47
MASS AIR FLOW AND
SENSOR
2
31
3
23
13
5
32
B3
*
*
35
B83
E
B136
ECM
B3
1 2 3 4 5
B47
1
3
5
2
4
6
B83
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
1 2 3 4
5 6 7 8
EN-01948
EN(H4DOTC)(diag)-69

Step
Check
SELECT MONITOR.
link connector.
NOTE:
READ CURRENT DATA SHOWN ON DISPLAY
FOR
ENGINE.
<Ref.
to
EN(H4DOTC)(diag)-21, Subaru Select Monitor.>

FLOW SENSOR.
flow sensor.
(B136) No. 23 (B3) No. 3:
(B136) No. 31 (B3) No. 2:
(B136) No. 35 (B3) No. 5:
Yes
No
Even if the malGo to step 2.
function indicator
light illuminates,
the circuit has
of the connector or
harness may be
the cause. Repair
air flow sensor.
NOTE:
the following:
Open or ground
Poor contact in
Go to step 3.

Select Monitor?

?
EN(H4DOTC)(diag)-70
Repair the poor

contact in ECM
connector.
Go to step 4.
Go to step 5.
Replace and
check it again
because of ECM
malfunction possibility.
Repair the open
circuit between
mass air flow sensor and main relay.
Repair the open

circuit between
ECM and mass air

Step
CHECK POOR CONTACT.
connector.
Check
M?
Yes
Go to step 6.
No
Repair the ground
short circuit
between ECM and

Repair the poor

contact in mass air
Replace the mass

air flow and intake
air temperature
sensor. <Ref. to
FU(H4DOTC)-28,
Mass Air Flow and
EN(H4DOTC)(diag)-71

F: DTC P0103 MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT

TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
5
3
BATTERY
SBF-8
6
4
2
1
B47
MASS AIR FLOW AND
SENSOR
2
31
3
23
13
5
32
B3
*
*
35
B83
E
B136
ECM
B3
1 2 3 4 5
B47
1
3
5
2
4
6
B83
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
1 2 3 4
5 6 7 8
EN-01948
EN(H4DOTC)(diag)-72

Step
Check
SELECT MONITOR.
link connector.
NOTE:
FOR
ENGINE.
<Ref.
to
?
sensor connector.
(B3) No. 2 (B136) No. 31:
EN(H4DOTC)(diag)-73
Yes
light illuminates,
the circuit has
this time.
No
Go to step 2.

ECM connector.
Replace the mass

air flow sensor.
<Ref. to
FU(H4DOTC)-28,
Mass Air Flow and
Repair the open

circuit in harness
between mass air
connector.

G: DTC P0107 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE

CIRCUIT LOW INPUT
CAUTION:
WIRING DIAGRAM:
1
3
2
MANIFOLD ABSOLUTE
PRESSURE SENSOR
E21
19
20
7
E2
B21
*
*
35
16
22
B83
B136 ECM
E21
B83
1 2 3
1 2 3 4
5 6 7 8
B136
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
EN-01949
Step
Check
Yes
and chassis ground.
EN(H4DOTC)(diag)-74
No
Go to step 2.

Step
and chassis ground.
2) Disconnect the connector from the manifold
engine ground.
sensor connector.
(B136) No. 35 (E21) No. 1:
manifold absolute pressure sensor connector
and engine ground.
CHECK POOR CONTACT.
Check
shaking the harness and connector of ECM while monitoring the value with voltage
meter?
Is the voltage less than 0.7 V?
Yes
Repair the poor
contact in ECM
connector.
Go to step 4.
No
Replace the ECM.
<Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
Replace the ECM.
<Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
Repair the open
circuit in harness
between ECM and
manifold absolute
pressure sensor
connector.

?
Go to step 6.
Repair the open

circuit in harness
between ECM and
manifold absolute
pressure sensor
connector.

M?
Go to step 7.
Repair the ground

connector.

connector?
Repair the poor

connector.

to FU(H4DOTC)28, Mass Air Flow
and Intake Air
EN(H4DOTC)(diag)-75

H: DTC P0108 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE

CIRCUIT HIGH INPUT
CAUTION:
WIRING DIAGRAM:
1
3
2
MANIFOLD ABSOLUTE
PRESSURE SENSOR
E21
19
20
7
E2
B21
*
*
35
16
22
B83
B136 ECM
E21
B83
1 2 3
1 2 3 4
5 6 7 8
B136
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
EN-01949
Step
Check
Yes
and chassis ground.
EN(H4DOTC)(diag)-76
No
Go to step 2.

Step
and chassis ground.
and chassis ground.
engine ground.
sensor connector.
(B136) No. 22 (E21) No. 2:
connector.
(B136) No. 35 (E21) No. 1:
CHECK POOR CONTACT.
Check
shaking the harness and connector of ECM while monitoring the value with voltage
meter?
Is the voltage more than 4.5 V?
Yes
Repair the poor
contact in ECM
connector.
Go to step 4.
No
Replace the ECM.
<Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
Replace the ECM.
<Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
Repair the open
circuit in harness
between ECM and
manifold absolute
pressure sensor
connector.

?
Go to step 6.
Repair the open

circuit in harness
between ECM and
manifold absolute
pressure sensor
connector.

?
Go to step 7.
Repair the open

circuit in harness
between ECM and
manifold absolute
pressure sensor
connector.

connector?
Repair the poor

connector.

to FU(H4DOTC)29, Manifold Absolute Pressure Sensor.>
EN(H4DOTC)(diag)-77

I:
DTC P0112 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT LOW

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
5
3
BATTERY
SBF-8
6
4
2
1
B47
MASS AIR FLOW AND
SENSOR
2
31
3
23
13
5
32
B3
*
*
35
B83
E
B136
ECM
B3
1 2 3 4 5
B47
1
3
5
2
4
6
B83
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
1 2 3 4
5 6 7 8
EN-01948
EN(H4DOTC)(diag)-78

Step
CHECK CURRENT DATA.
Check
Yes
Is intake air temperature more Go to step 2.
than 55C (131F)?
NOTE:
FOR
ENGINE.
<Ref.
to
Is the value less than 36C

(33F)?
2) Disconnect the connector mass air flow and
NOTE:
FOR
ENGINE.
<Ref.
to
EN(H4DOTC)(diag)-79
Replace the mass

air flow and intake
air temperature
sensor. <Ref. to
FU(H4DOTC)-28,
Mass Air Flow and
No
Repair the poor
contact.
NOTE:
the following:
Poor contact in
mass air flow and
Poor contact in
ECM
Poor contact in
joint connector
Repair the ground
mass air flow and
ECM connector.

J: DTC P0113 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT HIGH

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
5
3
BATTERY
SBF-8
6
4
2
1
B47
MASS AIR FLOW AND
SENSOR
2
31
3
23
13
5
32
B3
*
*
35
B83
E
B136
ECM
B3
1 2 3 4 5
B47
1
3
5
2
4
6
B83
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
1 2 3 4
5 6 7 8
EN-01948
EN(H4DOTC)(diag)-80

Step
CHECK CURRENT DATA.
NOTE:
FOR
ENGINE.
<Ref.
to
Check
Yes
Is the value less than 36C ( Go to step 2.
33F)?
No
Repair the poor
contact.
NOTE:
the following:
Poor contact in
mass air flow and
Poor contact in
ECM
Poor contact in
joint connector
mass air flow and
ECM connector.

and engine ground.
and engine ground.
and engine ground.
EN(H4DOTC)(diag)-81

mass air flow and
ECM connector.
Go to step 5.

NOTE:
the following:
Open circuit in
ness between
mass air flow and
ECM connector
Poor contact in
mass air flow and
Poor contact in
ECM
Poor contact in
joint connector

Step
Check
?
between mass air flow and intake air temperature sensor and engine ground.
EN(H4DOTC)(diag)-82
Yes
Replace the mass
air flow and intake
air temperature
sensor. <Ref. to
FU(H4DOTC)-28,
Mass Air Flow and
No
NOTE:
the following:
Open circuit in
ness between
mass air flow and
ECM connector
Poor contact in
mass air flow and
Poor contact in
ECM
Poor contact in
joint connector

K: DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW

TROUBLE SYMPTOM:
Hard to start
Erroneous idling
CAUTION:
WIRING DIAGRAM:
E8
ENGINE
COOLANT
TEMPERATURE
SENSOR
1 2
2
1
B83
E8
1 2 3 4
5 6 7 8
8
19
E2
B21
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
*
*
14
35
B83
B136 ECM
EN-01950
EN(H4DOTC)(diag)-83

Step
CHECK CURRENT DATA.
NOTE:
FOR
ENGINE.
<Ref.
to

ECM CONNECTOR.
Check
Yes
Is engine coolant temperature Go to step 2.
No
Repair the poor
contact.
NOTE:
the following:
Poor contact in
engine coolant
temperature sensor
Poor contact in
ECM
Poor contact in
coupling connector
Poor contact in
joint connector
Is engine coolant temperature Replace the
Repair the ground
engine coolant
sor. <Ref. to
engine coolant
FU(H4DOTC)-23, temperature senEngine Coolant
sor.>
NOTE:
FOR
ENGINE.
<Ref.
to
EN(H4DOTC)(diag)-84

L: DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH

TROUBLE SYMPTOM:
Hard to start
Erroneous idling
CAUTION:
WIRING DIAGRAM:
E8
ENGINE
COOLANT
TEMPERATURE
SENSOR
1 2
2
1
B83
E8
1 2 3 4
5 6 7 8
8
19
E2
B21
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
*
*
14
35
B83
B136 ECM
EN-01950
EN(H4DOTC)(diag)-85

Step
CHECK CURRENT DATA.
NOTE:
FOR
ENGINE.
<Ref.
to
Check
Yes
No
Repair the poor
contact.
NOTE:
the following:
Poor contact in
engine coolant
temperature sensor
Poor contact in
ECM
Poor contact in
coupling connector
Poor contact in
joint connector
ECM and engine

ECM CONNECTOR.
ground.
ECM CONNECTOR.
ground.
ECM CONNECTOR.
ground.
EN(H4DOTC)(diag)-86

ECM and engine
Go to step 5.

NOTE:
the following:
Open circuit in
harness between
ECM and engine
Poor contact in
engine coolant
Poor contact in
ECM connector
Poor contact in
coupling connector
Poor contact in
joint connector

Step
ECM CONNECTOR.
Check
?
EN(H4DOTC)(diag)-87
Yes
Replace the
engine coolant
FU(H4DOTC)-23,
Engine Coolant
No
NOTE:
the following:
Open circuit in
harness between
ECM and engine
Poor contact in
engine coolant
Poor contact in
ECM connector
Poor contact in
coupling connector
Poor contact in
joint connector

M: DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT

LOW
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
WIRING DIAGRAM:
BATTERY
SBF-8
7
5
6
8
ELECTRONIC
THROTTLE
CONTROL RELAY
MAIN RELAY
D6
B35
B362
B: B135
D: B137
ECM
C29
C18
D4
D5
C35
C16
B1
B4
D1
D2
D3
C: B136
*
*
B84
*
*
B138
7
3
B122
E2
4
6
1
2
3
5
E1
39
38
19
20
35
36
37
B21
16
15
B20
E57
ELECTRONIC
THROTTLE
CONTROL
B20
B362
1 2
1
5
9
13
3
4
5
7 8
6
2
3
10 11 12 13
22 23
30 31
2
6
10
14
B21
3
7
11
15
4
8
12
16
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 45
46 47
48 49 50 51 52 53 54
B: B135
1
8 9
20 21
28 29
4 5 6
7
14 15 16 17 18 19
24 25
26 27
32 33
34 35
C: B136
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
B84
E57
B122
1 2 3 4 5 6
B138
1 2 3 4
5 6 7 8
D: B137
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
EN-01951
EN(H4DOTC)(diag)-88

Step
CHECK POOR CONTACT.
Check the poor contact in connector between
Check
Yes
No
Go to step 3.


(B136) No. 16 (E57) No. 5:
(B136) No. 18 (E57) No. 6:
THROTTLE CONTROL.

?
Go to step 4.
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.

M?
Go to step 5.
Go to step 6.

harness.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective.
<Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
Repair the poor
?
trol connector.
Replace the ECM
Replace the elec- if defective.
tronic throttle con- <Ref. to
trol if defective.
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
EN(H4DOTC)(diag)-89

N: DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT

HIGH
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
WIRING DIAGRAM:
BATTERY
SBF-8
7
5
6
8
ELECTRONIC
THROTTLE
CONTROL RELAY
MAIN RELAY
D6
B35
B362
B: B135
D: B137
ECM
C29
C18
D4
D5
C35
C16
B1
B4
D1
D2
D3
C: B136
*
*
B84
*
*
B138
7
3
B122
E2
4
6
1
2
3
5
E1
39
38
19
20
35
36
37
B21
16
15
B20
E57
ELECTRONIC
THROTTLE
CONTROL
B20
B362
1 2
1
5
9
13
3
4
5
7 8
6
2
3
10 11 12 13
22 23
30 31
2
6
10
14
B21
3
7
11
15
4
8
12
16
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 45
46 47
48 49 50 51 52 53 54
B: B135
1
8 9
20 21
28 29
4 5 6
7
14 15 16 17 18 19
24 25
26 27
32 33
34 35
C: B136
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
B84
E57
B122
1 2 3 4 5 6
B138
1 2 3 4
5 6 7 8
D: B137
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
EN-01951
EN(H4DOTC)(diag)-90

Step
CHECK POOR CONTACT.
Check
V?
Yes
Go to step 2.

(B136) No. 18 (E57) No. 6:
(B136) No. 35 (E57) No. 3:
3) Check the voltage change by shaking the
harness and connector of ECM and engine
harness connector while monitoring the value
with voltage meter.
(B136) No. 18 (B136) No. 16:

?
Go to step 4.
Go to step 5.

M?
Repair the poor

Repair the short
Repair the elecpower supply.

EN(H4DOTC)(diag)-91
No
Go to step 3.
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.
Repair the battery

ECM connector
and electronic
throttle control
connector.

O: DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1)

CAUTION:
WIRING DIAGRAM:
B18
BATTERY
MAIN RELAY
1 2
3 4
SBF-6
5
3
6
4
B47
3
1
3
5
FRONT OXYGEN
(A/F) SENSOR
2
4
6
B18
2
B21
4
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
A25
A: B134
1
8 9
18 19
28 29
ECM
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
A6
A7
B21
54
A: B134
A33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
A26
B47
A2
A3
2
1
F2
E
EN-01946
EN(H4DOTC)(diag)-92

Step
ECM connectors.
(B134) No. 26 (B134) No. 33:
Check
M?
Yes
Go to step 2.
No
Repair the ground
ECM and front

M?
Replace the front

FU(H4DOTC)-33,
Front Oxygen (A/
F) Sensor.>
Repair harness
short in harness
between ECM and
front oxygen (A/F)
sensor connector.
EN(H4DOTC)(diag)-93

P: DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1)

CAUTION:
WIRING DIAGRAM:
B18
BATTERY
MAIN RELAY
1 2
3 4
SBF-6
5
3
6
4
B47
3
1
3
5
FRONT OXYGEN
(A/F) SENSOR
2
4
6
B18
2
B21
4
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
A25
A: B134
1
8 9
18 19
28 29
ECM
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
A6
A7
B21
54
A: B134
A33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
A26
B47
A2
A3
2
1
F2
E
EN-01946
EN(H4DOTC)(diag)-94

Step
Check
(A/F) sensor.
EN(H4DOTC)(diag)-95
Yes
Replace the front
FU(H4DOTC)-33,
Front Oxygen (A/
F) Sensor.>
No
Repair the battery
ECM and front

Q: DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 1)

CAUTION:
WIRING DIAGRAM:
B18
BATTERY
MAIN RELAY
1 2
3 4
SBF-6
5
3
6
4
B47
3
1
3
5
FRONT OXYGEN
(A/F) SENSOR
2
4
6
B18
2
B21
4
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
A25
A: B134
1
8 9
18 19
28 29
ECM
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
A6
A7
B21
54
A: B134
A33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
A26
B47
A2
A3
2
1
F2
E
EN-01946
EN(H4DOTC)(diag)-96

Step
connector.
(B134) No. 26 (B18) No. 1:
(B134) No. 33 (B18) No. 2:
Check
?
EN(H4DOTC)(diag)-97
Yes
Replace the front
FU(H4DOTC)-33,
Front Oxygen (A/
F) Sensor.>
No
Repair the open
circuit in harness
between ECM and
front oxygen (A/F)
sensor connector.

R: DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2)

CAUTION:
WIRING DIAGRAM:
BATTERY
MAIN RELAY
B19
5
3
T5
2
4
6
B83
T6
1 2 3 4
5 6 7 8
2 1
4 3
2
1
B47
2
4
B19
2
6
4
1
3
B47
1
3
5
REAR
OXYGEN SENSOR
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
2
4
T6
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
1
3
T5
B19
B: B135
*
*
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
D31
C35
B2
D25
B83
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B: B135
D:
ECM
35
C: B136
B137
B21
D: B137
E2
B4
B1
5 6
14 15 16
25 26 27
33 34 35
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
28 29
30 31
26 27
E
EN-01947
EN(H4DOTC)(diag)-98

Step
Check

Does the value fluctuate?
the engine speed at 2,000 rpm to 3,000 rpm for
2 minutes.
NOTE:
FOR
ENGINE.
<Ref.
to
Read the data of rear oxygen sensor signal

?
rear oxygen sensor.
(B137) No. 25 (T6) No. 4:
CHECK HARNESS BETWEEN REAR OXY- Is the voltage more than 0.2 V?
sensor.
EN(H4DOTC)(diag)-99
Yes
No
Inspect the DTC
Go to step 2.
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
Code (DTC).>
Go to step 6.
Go to step 3.
Go to step 4.
Repair the open

circuit in harness
between ECM and
Replace the rear

oxygen sensor.
<Ref. to
FU(H4DOTC)-34,
Rear Oxygen Sensor.>
Replace the rear

oxygen sensor.
<Ref. to
FU(H4DOTC)-34,
Go to step 5.

NOTE:
the following:
Open circuit in
harness between
Poor contact in
Poor contact in
ECM connector

Step
Check
Yes
Is there a fault in exhaust sys- Repair or replace
tem?
the faulty part.
NOTE:
sensor
EN(H4DOTC)(diag)-100
No
Replace the rear
oxygen sensor.
<Ref. to
FU(H4DOTC)-34,

S: DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2)

CAUTION:
WIRING DIAGRAM:
BATTERY
MAIN RELAY
B19
5
3
T5
2
4
6
B83
T6
1 2 3 4
5 6 7 8
2 1
4 3
2
1
B47
2
4
B19
2
6
4
1
3
B47
1
3
5
REAR
OXYGEN SENSOR
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
2
4
T6
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
1
3
T5
B19
B: B135
*
*
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
32 33
34 35
28 29 30 31
D31
C35
B2
D25
B83
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B: B135
D:
ECM
35
C: B136
B137
B21
D: B137
E2
B4
B1
5 6
14 15 16
25 26 27
33 34 35
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
28 29
30 31
26 27
E
EN-01947

Step
Check

Does the value fluctuate?
the engine speed at 2,000 rpm to 3,000 rpm for
two minutes.
NOTE:
FOR
ENGINE.
<Ref.
to
Read the data of rear oxygen sensor signal

?
rear oxygen sensor.
(B137) No. 25 (T6) No. 4:
CHECK HARNESS BETWEEN REAR OXY- Is the voltage more than 0.2 V?
sensor.
Yes
No
Inspect the DTC
Go to step 2.
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
Code (DTC).>
Go to step 6.
Go to step 3.
Go to step 4.
Repair the open

circuit in harness
between ECM and
Replace the rear

oxygen sensor.
<Ref. to
FU(H4DOTC)-34,
Replace the rear

oxygen sensor.
<Ref. to
FU(H4DOTC)-34,
Go to step 5.

NOTE:
the following:
Open circuit in
harness between
Poor contact in
Poor contact in
ECM connector

Step
Check
Yes
Is there a fault in exhaust sys- Repair or replace
tem?
the faulty part.
NOTE:
sensor
No
Replace the rear
oxygen sensor.
<Ref. to
FU(H4DOTC)-34,
T: DTC P0171 SYSTEM TOO LEAN (BANK 1)

NOTE:
For diagnostic procedure, refer to DTC P0172. <Ref. to EN(H4DOTC)(diag)-104, DTC P0172 SYSTEM TOO

U: DTC P0172 SYSTEM TOO RICH (BANK 1)

TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
Step

Warning:
Place NO FIRE signs near the working
area.
pump relay.
(4) After the engine stalls, crank it for 5 more
seconds.
7) Disconnect the fuel delivery hose from fuel
filter, and connect the fuel pressure gauge.
10)Measure the fuel pressure while disconnecting pressure regulator vacuum hose from
intake manifold.
Check
on exhaust system?
disconnection of hoses on air
intake system?
kPa (2.9 3.2 kg/cm2, 41
46 psi)?
Warning:
NOTE:
If fuel pressure does not increase, squeeze the
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.

Fuel pressure is
too high:
Clogged fuel
return line or
bent hose
Fuel pressure is
too low:
Improper fuel
pump discharge
Clogged fuel
supply line

Step
Check
Yes
kPa (2.1 2.4 kg/cm2, 30
34 psi)?
Warning:
NOTE:
If out of specification as measured at this
step, check or replace pressure regulator and
pressure regulator vacuum hose.
CHECK ENGINE COOLANT TEMPERATURE Is engine coolant temperature Go to step 6.

SENSOR.
1) Start the engine and warm-up completely.
NOTE:
FOR
ENGINE.
<Ref.
to
CHECK MASS AIR FLOW AND INTAKE AIR
TEMPERATURE SENSOR.
coolant temperature is greater than 60C
(140F).
2) Place the shift lever in neutral position.
Select Monitor.
Is the measured value within

Go to step 7.
the following?
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)
NOTE:
FOR
ENGINE.
<Ref.
to
No
Fuel pressure is
too high:
Clogged fuel
return line or
bent hose
Fuel pressure is
too low:
Improper fuel
pump discharge
Clogged fuel
supply line
Replace the
engine coolant
FU(H4DOTC)-23,
Engine Coolant
Replace the mass

air flow and intake
air temperature
sensor. <Ref. to
FU(H4DOTC)-28,
Mass Air Flow and

Step
CHECK MASS AIR FLOW AND INTAKE AIR
TEMPERATURE SENSOR.
(140F).
2) Place the shift lever in neutral position.
5) Open the hood.
6) Measure the ambient temperature.
Select Monitor.
Check
Subtract the ambient temperature from intake air temperature, and is the value from
10C (14F) to 50C (122F)?
NOTE:
FOR
ENGINE.
<Ref.
to
Yes
Replace the ECM.
<Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
No
Check mass air
flow and intake air
FU(H4DOTC)-28,
Mass Air Flow and

V: DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT

LOW
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
WIRING DIAGRAM:
BATTERY
SBF-8
7
5
6
8
ELECTRONIC
THROTTLE
CONTROL RELAY
MAIN RELAY
D6
B35
B362
B: B135
D: B137
ECM
C29
C18
D4
D5
C35
C16
B1
B4
D1
D2
D3
C: B136
*
*
B84
*
*
B138
7
3
B122
E2
4
6
1
2
3
5
E1
39
38
19
20
35
36
37
B21
16
15
B20
E57
ELECTRONIC
THROTTLE
CONTROL
B20
B362
1 2
1
5
9
13
3
4
5
7 8
6
2
3
10 11 12 13
22 23
30 31
2
6
10
14
B21
3
7
11
15
4
8
12
16
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 45
46 47
48 49 50 51 52 53 54
B: B135
1
8 9
20 21
28 29
4 5 6
7
14 15 16 17 18 19
24 25
26 27
32 33
34 35
C: B136
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
B84
E57
B122
1 2 3 4 5 6
B138
1 2 3 4
5 6 7 8
D: B137
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
EN-01951

Step
Check
Yes
CHECK POOR CONTACT.
Repair the poor
contact.
(B136) No. 16 (E57) No. 5:
(B136) No. 29 (E57) No. 4:

?
Go to step 4.

M?
Go to step 5.
Go to step 6.
No
Go to step 3.
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.

harness.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective.
<Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
Repair the poor
?
trol connector.
Replace the ECM
Replace the elec- if defective.
tronic throttle con- <Ref. to
trol if defective.
FU(H4DOTC)-35,
Engine Control
Module (ECM).>

W: DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT

HIGH
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
WIRING DIAGRAM:
BATTERY
SBF-8
7
5
6
8
ELECTRONIC
THROTTLE
CONTROL RELAY
MAIN RELAY
D6
B35
B362
B: B135
D: B137
ECM
C29
C18
D4
D5
C35
C16
B1
B4
D1
D2
D3
C: B136
*
*
B84
*
*
B138
7
3
B122
E2
4
6
1
2
3
5
E1
39
38
19
20
35
36
37
B21
16
15
B20
E57
ELECTRONIC
THROTTLE
CONTROL
B20
B362
1 2
1
5
9
13
3
4
5
7 8
6
2
3
10 11 12 13
22 23
30 31
2
6
10
14
B21
3
7
11
15
4
8
12
16
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 45
46 47
48 49 50 51 52 53 54
B: B135
1
8 9
20 21
28 29
4 5 6
7
14 15 16 17 18 19
24 25
26 27
32 33
34 35
C: B136
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
B84
E57
B122
1 2 3 4 5 6
B138
1 2 3 4
5 6 7 8
D: B137
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
EN-01951

Step
CHECK POOR CONTACT.
Check
V?
Yes
Go to step 2.

(B136) No. 35 (E57) No. 3:
(B136) No. 29 (E57) No. 4:
terminals.
(B136) No. 29 (B136) No. 16:

?
Go to step 4.
Go to step 5.

M?
Repair the poor

Sensor power supcontact. Repair the ply circuit may be
electronic throttle shorted.
control.

No
Go to step 3.
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.
Repair the battery

ECM connector
and electronic
throttle control
connector.

X: DTC P0230 FUEL PUMP PRIMARY CIRCUIT

CAUTION:
WIRING DIAGRAM:
BATTERY
No.31
1
FUEL PUMP
RELAY
B362
7
4
B98
10
R2
FUEL PUMP
CONTROL UNIT
9
8
7
6
R122
6
5
R2
D28
B27
5
6
B98
FUEL
PUMP
ECM
R58
B: B135
D: B137
B362
1 2
3
4
5
7 8
6
B98
R58
R122
1
2 3
4 5 6 7 8
1 2
3 4
5 6
3 4
1 2
5 6 7 8 9 10
B:
B135
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
D: B137
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
28 29
30 31
26 27
EN-01944

Step
Check
Yes
CHECK POWER SUPPLY CIRCUIT TO FUEL Is the voltage more than 10 V? Go to step 2.
PUMP CONTROL UNIT.
2) Disconnect the connector from fuel pump
control unit.
4) Measure the voltage between fuel pump
control unit and chassis ground.
CHECK GROUND CIRCUIT OF FUEL PUMP Is the resistance less than 5

CONTROL UNIT.
?
between fuel pump control unit and chassis
ground.
Go to step 3.

CONTROL UNIT AND FUEL PUMP CONNECTOR.
between fuel pump control unit and fuel pump
connector.
(R122) No. 7 (R58) No. 5:
(R122) No. 6 (R58) No. 6:
fuel pump control unit and chassis ground.

?
Go to step 4.

M?
Go to step 5.
No
Repair the power
supply circuit.
NOTE:
the following:
Open or ground
pump relay and
fuel pump control
unit
Poor contact in
fuel pump control
unit connector
Poor contact in
fuel pump relay
connector
NOTE:
the following:
Open circuit
between fuel pump
control unit and
chassis ground
Poor contact in
fuel pump control
unit connector
Repair the open
circuit between
fuel pump control
unit and fuel
pump.
Repair the ground

short circuit
between fuel pump
control unit and
fuel pump.

Step
Check
CONTROL UNIT AND ECM CONNECTOR.
?
between fuel pump control unit and ECM connector.
(R122) No. 9 (B137) No. 28:
(R122) No. 8 (B135) No. 27:
Yes
Go to step 6.

CHECK POOR CONTACT.
Check poor contact in ECM and fuel pump
control unit connector.
Go to step 7.

M?
No
NOTE:
the following:
Open circuit
between fuel pump
control unit and
ECM
Poor contact in
fuel pump control
unit and ECM connector
Repair the ground
short circuit
between fuel pump
control unit and
ECM.

Repair the poor
Go to step 8.
and fuel pump control unit con- contact in ECM
nector?
and fuel pump
control unit.
CHECK EXPERIENCE OF RUNNING OUT OF Did the vehicle experience run- Finish the diagno- Replace the fuel
pump control unit.
FUEL.
ning out of fuel?
sis.
<Ref. to
NOTE:
DTC record may FU(H4DOTC)-39,
be conducted as a Fuel Pump Control
result of fuel pump Unit.>
idling while running
out of fuel.

Y: DTC P0245 TURBO/SUPER CHARGER WASTEGATE SOLENOID A LOW

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
5
3
BATTERY
SBF-5
B47
6
4
1
3
5
2
1
2
4
6
B47
B134
1
8 9
18 19
28 29
B134
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
ECM
E64
32
1 2
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
48
40
B21
E2
2
1
E64
E
WASTEGATE
CONTROL SOLENOID
VALVE
EN-01952

Step
chassis ground.
Check
Yes
light illuminates,
the circuit has
this time.
CHECK HARNESS BETWEEN WASTEGATE Is the resistance more than 1 Go to step 3.
CONTROL SOLENOID VALVE AND ECM
M?
CONNECTOR.
2) Disconnect the connectors from wastegate
control solenoid valve and ECM.
between wastegate control solenoid valve connector and engine ground.
CHECK HARNESS BETWEEN WASTEGATE Is the resistance less than 1
Go to step 4.
CONTROL SOLENOID VALVE AND ECM
?
CONNECTOR.
wastegate control solenoid valve of harness
connector and ECM.
(B134) No. 32 (E64) No. 1:
CHECK WASTEGATE CONTROL SOLENOID VALVE.

1) Remove the wastegate control solenoid
valve.
2) Measure the resistance between wastegate
Terminals
No. 1 No. 2:
CHECK POWER SUPPLY TO WASTEGATE
CONTROL SOLENOID VALVE.
2) Measure the voltage between wastegate
control solenoid valve and engine ground.
CHECK POOR CONTACT.
Check poor contact in wastegate control solenoid valve connector.
Go to step 5.
Is there poor contact in waste- Repair the poor

gate control solenoid valve
contact in wasteconnector?
gate control solenoid valve
connector.
No
Go to step 2.
Repair the ground

ECM and wastegate control solenoid valve
connector.
Repair the open

circuit in harness
between ECM and
wastegate control
solenoid valve
connector.
NOTE:
the following:
Open circuit in
harness between
ECM and wastegate control solenoid valve
connector
Replace the
wastegate control
solenoid valve.
<Ref. to
FU(H4DOTC)-32,
Wastegate Control Solenoid
Valve.>
Repair the open
circuit in harness
between main
relay and wastegate control solenoid valve
connector.
Replace the ECM.
<Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>

Z: DTC P0246 TURBO/SUPER CHARGER WASTEGATE SOLENOID A HIGH

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
5
3
BATTERY
SBF-5
B47
6
4
1
3
5
2
1
2
4
6
B47
B134
1
8 9
18 19
28 29
B134
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
ECM
E64
32
1 2
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
48
40
B21
E2
2
1
E64
E
WASTEGATE
CONTROL SOLENOID
VALVE
EN-01952

Step
chassis ground.
CHECK POOR CONTACT.
Check
Yes

connector?
Replace the ECM.

<Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
CHECK HARNESS BETWEEN WASTEGATE Is the voltage more than 10 V? Repair the battery Go to step 4.
short circuit in harCONTROL SOLENOID VALVE AND ECM
ness between
CONNECTOR.
ECM and waste1) Turn the ignition switch to OFF.
gate control sole2) Disconnect the connector from wastegate
noid valve
connector. After
repair, replace the
ECM. <Ref. to
chassis ground.
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
CHECK WASTEGATE CONTROL SOLEIs the resistance less than 1
Replace the
Go to step 5.
NOID VALVE.
?
wastegate control
solenoid valve and
2) Measure the resistance between wastegate
ECM. <Ref. to
FU(H4DOTC)-32,
Terminals
Wastegate ConNo. 1 No. 2:
trol Solenoid
Valve.> <Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
CHECK POOR CONTACT.
Repair the poor
Replace the ECM.
connector?
contact in ECM
<Ref. to
connector.
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
Repair the poor

contact in ECM
connector.
No
Go to step 2.

AA:DTC P0261 CYLINDER 1 INJECTOR CIRCUIT LOW

NOTE:
For the diagnostic procedure, refer to DTC P0270. <Ref. to EN(H4DOTC)(diag)-119, DTC P0270 CYLINDER 4 INJECTOR CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
AB:DTC P0264 CYLINDER 2 INJECTOR CIRCUIT LOW

NOTE:
AC:DTC P0267 CYLINDER 3 INJECTOR CIRCUIT LOW

NOTE:

AD:DTC P0270 CYLINDER 4 INJECTOR CIRCUIT LOW

TROUBLE SYMPTOM:
Engine stalls.
Erroneous idling
Rough driving
CAUTION:

WIRING DIAGRAM:
MAIN RELAY
5
3
BATTERY
SBF-8
6
4
2
1
D7
ECM
34
C3
C4
D: B137
44
43
48
42
C5
C6
C: B136
45
B47
B21
E2
2
1
E17
2
1
E6
2
1
E16
2
1
E5
#1
#2
#3
#4
FUEL INJECTORS
E5
E6
E16
E17
1 2
C:
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B21
5 6
14 15 16
25 26 27
33 34 35
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 45
46 47
48 49 50 51 52 53 54
B47
1
3
5
2
4
6
D:
B137
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
28 29
30 31
26 27
EN-01945

Step
Check
Yes

12 ?
Terminals
No. 1 No. 2:
1) Connect the connector to the fuel injector.

?
Repair the poor

contact in fuel
injector and ECM
connector.
No
NOTE:
the following:
Open circuit in
harness between
main relay and fuel
injector connector
on faulty cylinders
Poor contact in
coupling connector
Poor contact in
Poor contact in
cylinders
Replace the faulty
fuel injector and
ECM. <Ref. to
FU(H4DOTC)-30,
Fuel Injector.>
NOTE:
the following:
Open circuit in
harness between
ECM and fuel
injector connector
Poor contact in
coupling connector
Repair ground
open circuit in
ECM.

AE:DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW (BANK 1 OR SINGLE SENSOR)

TROUBLE SYMPTOM:
Knocking occurs.
CAUTION:
WIRING DIAGRAM:
KNOCK
SENSOR
E14
1 2
E14
B20
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
13
E1
B136
B20
5 6
14 15 16
25 26 27
33 34 35
33
25
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B136
ECM
EN-01953

Step
Check
700 k?
Yes
Go to step 2.
CHECK KNOCK SENSOR.

sor.
Terminals
Go to step 3.

INSTALLATION.
No
NOTE:
the followingin this
case, repair the following:
Open circuit in
harness between
knock sensor and
ECM connector
Poor contact in
Poor contact in
coupling connector
NOTE:
the followingin this
case, repair the following:
Poor contact in
Poor contact in
coupling connector
sensor. <Ref. to
FU(H4DOTC)-26, securely.
Knock Sensor.>

AF:DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH (BANK 1 OR SINGLE SENSOR)

TROUBLE SYMPTOM:
Knocking occurs.
CAUTION:
WIRING DIAGRAM:
KNOCK
SENSOR
E14
1 2
E14
B20
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
13
E1
B136
B20
5 6
14 15 16
25 26 27
33 34 35
33
25
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B136
ECM
EN-01953

Step
CHECK KNOCK SENSOR.
Terminals
Check
Yes
k?
No
Go to step 3.

k?
sensor. <Ref. to
FU(H4DOTC)-26,
Knock Sensor.>
Repair the ground

connector.

sensor.
chassis ground.

light illuminates,
the circuit has
remains.)
NOTE:
the following:
Poor contact in
Poor contact in
ECM connector
Poor contact in
coupling connector
NOTE:
are
shielded. Repair
harness covered
with shield.
Repair the poor
contact in ECM
connector.

AG:DTC P0335 CRANKSHAFT POSITION SENSOR A CIRCUIT

TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
WIRING DIAGRAM:
2
1
CRANKSHAFT
POSITION
SENSOR
E10
E10
1 2
E1
8
7
B20
B20
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
B135
22
10
31
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
B135 ECM
EN-01954

Step
Check

NECTOR.
2) Disconnect the connector from the crankshaft position sensor.
and engine ground.
(E10) No. 1 (B135) No. 10:
(E10) No. 2 (B135) No. 22:
CHECK HARNESS BETWEEN CRANKIs the resistance more than 1

SHAFT POSITION SENSOR AND ECM CON- M?
NECTOR.
engine ground.
Yes
No
Inspect the DTC
Go to step 2.
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
Code (DTC).>
Go to step 3.
NOTE:
the following:
Open circuit in
harness between
ECM connector
Poor contact in
ECM connector
Poor contact in
coupling connector
Go to step 4.
Repair the ground
ECM connector.
NOTE:
are
shielded. Repair
the ground short
circuit in harness
together
with
shield.
securely.
Repair the poor
sor connector.
FU(H4DOTC)-24,
Terminals
tion Sensor.>

AH:DTC P0340 CAMSHAFT POSITION SENSOR A CIRCUIT (BANK 1 OR SINGLE SENSOR)

TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
5
3
BATTERY
SBF-8
6
4
INTAKE
CAMSHAFT
POSITION
SENSOR RH
2
3
INTAKE
CAMSHAFT
POSITION
SENSOR LH
B47
2
3
2
1
E35
E36
48
E2
19
B21
E1
E1
2
1
B20
B20
*
*
B8
B9
C35
B83
B : B135
ECM
C : B136
B21
B47
E36
B:
B20
E35
1
3
5
2
4
6
1 2 3
B83
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
B135
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
C:
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
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 45
46 47
48 49 50 51 52 53 54
1 2 3 4
5 6 7 8
EN-02405

Step
Check
Yes
No
Inspect the DTC
Go to step 2.
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
Code (DTC).>
CHECK POWER SUPPLY OF CAMSHAFT
short circuit
POSITION SENSOR.
between main
relay connector
and camshaft
position sensor.
position sensor
3) Measure the voltage between camshaft
connector.
Repair the open or
ground short cirPOSITION SENSOR.
cuit between main
relay connector
and camshaft
position sensor
connector.
CHECK HARNESS BETWEEN CAMSHAFT Is the resistance less than 1
Go to step 5.
Repair the open
POSITION SENSOR CONNECTOR AND
?
circuit between
ECM.
camshaft position
sensor and ECM.
3) Measure the resistance between camshaft
position sensor connector and ECM.
(E36) No. 2 (B135) No. 9:
(E36) No. 3 (B136) No. 35:
CHECK HARNESS BETWEEN CAMSHAFT Is the resistance more than 1 Go to step 6.
Repair the ground
M?
short circuit
ECM.
between camshaft
Measure the resistance between camshaft
position sensor
and ECM.
securely.
Is there any abnormality in
Replace the cam- Go to step 8.
Check waveform of camshaft position sensor. waveform?
shaft position sen<Ref. to EN(H4DOTC)(diag)-15, Engine Consor. <Ref. to
trol Module (ECM) I/O Signal.>
FU(H4DOTC)-24,
CHECK POOR CONTACT.
Repair the poor
Replace the ECM.
connector?
contact in ECM
<Ref. to
connector.
FU(H4DOTC)-35,
Engine Control
Module (ECM).>

AI: DTC P0345 CAMSHAFT POSITION SENSOR A CIRCUIT (BANK 2)

TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
5
3
BATTERY
SBF-8
6
4
INTAKE
CAMSHAFT
POSITION
SENSOR RH
2
3
INTAKE
CAMSHAFT
POSITION
SENSOR LH
B47
2
3
2
1
E35
E36
48
E2
19
B21
E1
E1
2
1
B20
B20
*
*
B8
B9
C35
B83
B : B135
ECM
C : B136
B21
B47
E36
B:
B20
E35
1
3
5
2
4
6
1 2 3
B83
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
B135
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
C:
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
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 45
46 47
48 49 50 51 52 53 54
1 2 3 4
5 6 7 8
EN-02405

Step
Check
Yes
No
Inspect the DTC
Go to step 2.
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
Code (DTC).>
short circuit
POSITION SENSOR.
between main
relay connector
and camshaft
position sensor.
position sensor
connector.
Repair the open or
ground short cirPOSITION SENSOR.
cuit between main
relay connector
and camshaft
position sensor
connector.
Go to step 5.
Repair the open
?
circuit between
ECM.
camshaft position
sensor and ECM.
(E35) No. 2 (B135) No. 8:
(E35) No. 3 (B136) No. 35:
Repair the ground
M?
short circuit
ECM.
between camshaft
position sensor
and ECM.
securely.
shaft position sen<Ref. to EN(H4DOTC)(diag)-15, Engine Consor. <Ref. to
trol Module (ECM) I/O Signal.>
FU(H4DOTC)-25,
Camshaft Position
Sensor.>
CHECK POOR CONTACT.
Repair the poor
Replace the ECM.
connector?
contact in ECM
<Ref. to
connector.
FU(H4DOTC)-35,
Engine Control
Module (ECM).>

AJ:DTC P0350 IGNITION COIL PRIMARY/SECONDARY CIRCUIT

TROUBLE SYMPTOM:
Engine stalls.
CAUTION:

WIRING DIAGRAM:
15
16
ECM
17
18
B135
IGNITION
SWITCH
SBF-1
No.12
SBF-7
3
6
B72
16
15
14
13
49
B21
E2
E34
3
E33
3
E32
3
E31
E
E
IGNITION COIL
No.1
E31
B21
E32
E33
E34
1
2
3
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
IGNITION COIL
No.2
IGNITION COIL
No.3
B72
B135
1 2 3
4 5 6
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
IGNITION COIL
No.4
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
EN-02404

Step
Check
Yes
& ignitor ASSY.
engine ground.
CHECK HARNESS OF ECM AND IGNITION Is the resistance less than 5
COIL & IGNITOR ASSY GROUND CIRCUIT. ?
ground.
Go to step 3.
TOR.
& ignitor ASSY.
connector.
(B135) No. 18 (E31) No. 1:
(B135) No. 17 (E32) No. 1:
(B135) No. 16 (E33) No. 1:
(B135) No. 15 (E34) No. 1:
Go to step 4.
CHECK HARNESS BETWEEN ECM AND IG- Is the resistance more than 1
NITION COIL & IGNITOR ASSY CONNECM?
TOR.
engine ground.
No
NOTE:
the following:
Open circuit in
harness between
ignition coil & ignitor ASSY and ignition switch
connector
Poor contact in
coupling connector
NOTE:
the following:
Open circuit in
harness between
grounding terminal
Poor contact in
coupling connector
Repair the harness and connectorrepair the
harness and connector.
NOTE:
the following:
Open circuit in
harness between
ECM and ignition
coil & ignitor ASSY
connector
Poor contact in
coupling connector
Repair the poor
Repair the harcontact in terminal. ness and connectorrepair the
harness and connector.

AK:DTC P0365 CAMSHAFT POSITION SENSOR B CIRCUIT (BANK 1)

TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
WIRING DIAGRAM:
EXHAUST
CAMSHAFT
POSITION
SENSOR RH
EXHAUST
CAMSHAFT
POSITION
SENSOR LH
E62
E65
2
1
2
1
1 2
E62
E65
B20
1
5
9
13
3
7
11
15
4
8
12
16
9
10
11
12
E1
2
6
10
14
B20
B135
21
29
30
20
28
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
32 33
34 35
28 29 30 31
B135
ECM
EN-01956

Step
position sensor.
and ECM.
(E62) No. 1 (B135) No. 29:
(E62) No. 2 (B135) No. 21:
Check
?

engine ground.

M?
Yes
Go to step 2.
Go to step 3.
No
NOTE:
the following:
Open circuit in
harness between
camshaft position
sensor and ECM
connector
Poor contact in
ECM connector
Poor contact in
coupling connector
Repair the ground
camshaft position
sensor and ECM
connector.
NOTE:
are
shielded. Repair
the ground short
circuit in harness
together
with
shield.
securely.
Repair the poor
sor connector.
FU(H4DOTC)-25,
Terminals
Camshaft Position
No. 1 No. 2:
Sensor.>

AL:DTC P0390 CAMSHAFT POSITION SENSOR B CIRCUIT (BANK 2)

TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
WIRING DIAGRAM:
EXHAUST
CAMSHAFT
POSITION
SENSOR RH
EXHAUST
CAMSHAFT
POSITION
SENSOR LH
E62
E65
2
1
2
1
1 2
E62
E65
B20
1
5
9
13
3
7
11
15
4
8
12
16
9
10
11
12
E1
2
6
10
14
B20
B135
21
29
30
20
28
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
32 33
34 35
28 29 30 31
B135
ECM
EN-01956

Step
position sensor.
and ECM.
(E65) No. 1 (B135) No. 28:
(E65) No. 2 (B135) No. 20:
Check
?

engine ground.

M?
Yes
Go to step 2.
Go to step 3.
No
NOTE:
the following:
Open circuit in
harness between
camshaft position
sensor and ECM
connector
Poor contact in
ECM connector
Poor contact in
coupling connector
Repair the ground
camshaft position
sensor and ECM
connector.
NOTE:
are
shielded. Repair
the ground short
circuit in harness
together
with
shield.
securely.
Repair the poor
sor connector.
FU(H4DOTC)-25,
Terminals
Camshaft Position
No. 1 No. 2:
Sensor.>

AM:DTC P0458 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE

CIRCUIT LOW
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
5
3
B47
BATTERY
SBF-8
1
3
5
6
4
2
4
6
2
1
B47
B134
ECM
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
14
B134
1
8 9
18 19
28 29
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
E4
1 2
48
41
B21
E2
1
2
E4
E
PURGE CONTROL
SOLENOID VALVE
EN-01957

Step
chassis ground.
Check
Yes
light illuminates,
the circuit has
this time.
NECTOR.
Go to step 4.
NECTOR.
ECM and purge control solenoid valve of harness connector.
(B134) No. 14 (E4) No. 2:

VALVE.
Terminals
No. 1 No. 2:
CHECK POOR CONTACT.
valve connector.
Go to step 5.
No
Go to step 2.
Repair the ground

ECM and purge
control solenoid
valve connector.
Repair the open

circuit in harness
between ECM and
NOTE:
the following:
Open circuit in
harness between
ECM and purge
control solenoid
valve connector
Poor contact in
coupling connector
Replace the purge
control solenoid
valve. <Ref. to
EC(H4DOTC)-6,
Purge Control
Solenoid Valve.>
Repair the open

circuit in harness
between main
relay and purge
control solenoid
valve connector.

tor?
control solenoid
valve connector.
Replace the ECM.

<Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>

AN:DTC P0459 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE

CIRCUIT HIGH
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
MAIN RELAY
5
3
B47
BATTERY
SBF-8
1
3
5
6
4
2
4
6
2
1
B47
B134
ECM
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
14
B134
1
8 9
18 19
28 29
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
E4
1 2
48
41
B21
E2
1
2
E4
E
PURGE CONTROL
SOLENOID VALVE
EN-01957

Step
drivers side).
Check
Does the purge control solenoid valve operate?

VALVE.
35 ?
Terminals
No. 1 No. 2:
CHECK HARNESS BETWEEN PURGE CON- Is the voltage less than 1 V?
TROL SOLENOID VALVE AND ECM CONNECTOR.
chassis ground.
CHECK POOR CONTACT.

connector?
Yes
Go to step 2.
Go to step 3.
Go to step 4.
Repair the poor

contact in ECM
connector.
No
light illuminates,
the circuit has
this time. In this
case, repair the
poor contact in
ECM connector.
Replace the purge
control solenoid
valve. <Ref. to
EC(H4DOTC)-6,
Purge Control
Solenoid Valve.>
Repair the battery

ECM and purge
control solenoid
valve connector.
After repair,
replace the ECM.
<Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
Replace the ECM.
<Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>

AO:DTC P0500 VEHICLE SPEED SENSOR

CAUTION:
Step
CHECK DTC OF ABS.
Check DTC of ABS.
Check
Yes
No
the DTC. <Ref. to
ABS(diag)-39, List

AP:DTC P0512 STARTER REQUEST CIRCUIT

TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
BATTERY
No.21
SBF-7
2
14
16
B72
SBF-1
3
IGNITION
SWITCH
STARTER RELAY
STARTER MOTOR
13
15
B225
D8
B32
B14
B: B135
D: B137
ECM
B225
B: B135
1
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
1
8 9
20 21
28 29
3
2
10 11 12 13
22 23
30 31
4 5 6
7
14 15 16 17 18 19
24 25
26 27
32 33
34 35
D: B137
3 4
1
2
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
B72
1 2 3
4 5 6
EN-02402

Step
CHECK HARNESS BETWEEN IGNITION
SWITCH AND ECM.
chassis ground.
Check
Yes
No
Is the voltage more than 10 V? Repair the battery Repair the poor
short circuit in harcontact in ECM.
ness between ignition switch and
ECM.

AQ:DTC P0519 IDLE CONTROL SYSTEM PERFORMANCE

TROUBLE SYMPTOM:
Fuel is cut according to fail-safe function.
CAUTION:
Step

throttle body
body gasket
Check

system?

control?
Yes
No
vant DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(H4DOTC)(diag
Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0519.
and leaks.
Remove foreign
matters from the
electronic throttle
control.

P2101.

AR:DTC P0562 SYSTEM VOLTAGE LOW

Detect in case of low power supply voltage of ECM.
TROUBLE SYMPTOM:
Charge indicator light illuminates.
CAUTION:
WIRING DIAGRAM:
GENERATOR
SBF-1
MAIN RELAY
5
3
BATTERY
SBF-8
6
4
2
1
5
6
B47
B135
ECM
B135
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
32 33
34 35
28 29 30 31
B47
1
3
5
2
4
6
EN-01958

Step
CHECK BATTERY.
2) Measure battery voltage and specific gravity of electrolyte.
CHECK GENERATOR.
2) Run the engine at idle after warming up.
3) Measure the voltage between generator B
Terminals
Generator B terminal (+) Chassis
ground ():
CHECK GENERATOR.
1) Run the engine at 5,000 rpm.
Terminals
ground ():
CHECK BATTERY TERMINAL.
2) Check the installation of positive and negative terminals of battery.
1) Run the engine at idle.
CHECK POOR CONTACT IN CONNECTORS.
Check the poor contact in connectors between
generator, battery and ECM.
CHECK ECM.
2) Erase the memory. <Ref. to
4) Read the DTC. <Ref. to
EN(H4DOTC)(diag)-27, Read Diagnostic Trouble Code (DTC).>
Check if the same DTC is displayed.
CHECK ANY OTHER DTC IS DISPLAYED.
Check if any other DTC is displayed.
Check
Is the voltage more than 12 V
and the gravity more than
1.26?
Yes
Go to step 2.
No
Charge or replace
the battery.

V?
Go to step 3.
Repair the generator. <Ref. to

SC(H4SO 2.0)-14,
Generator.>

V?
Go to step 4.

SC(H4SO 2.0)-14,
Generator.>
Are the positive and negative

battery terminals clamped
tightly?
Go to step 5.
Tighten the clamp

of terminal.

V?
Go to step 6.
Repair the harness connectors

between battery,
main relay and
ECM.
Is there poor contact in connectors between generator,

battery and ECM?
Is the same DTC displayed?
Repair the poor

contact.
Go to step 7.
Replace the generator.
Go to step 8.
Perform the diagnosis of DTC displayed.
Temporary poor
contact occurs.

AS:DTC P0563 SYSTEM VOLTAGE HIGH

Detect in case of high power supply voltage of ECM.
TROUBLE SYMPTOM:
Charge indicator light illuminates.
CAUTION:
WIRING DIAGRAM:
GENERATOR
SBF-1
MAIN RELAY
5
3
BATTERY
SBF-8
6
4
2
1
5
6
B47
B135
ECM
B135
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
32 33
34 35
28 29 30 31
B47
1
3
5
2
4
6
EN-01958

Step
CHECK BATTERY.
2) Measure battery voltage and specific gravity of electrolyte.
CHECK GENERATOR.
Terminals
ground ():
CHECK GENERATOR.
1) Run the engine at 5,000 rpm.
Terminals
ground ():
2) Check the installation of positive and negative terminals of battery.
Check the poor contact in connectors between
generator, battery and ECM.
CHECK ECM.
4) Read the DTC. <Ref. to
EN(H4DOTC)(diag)-27, Read Diagnostic Trouble Code (DTC).>
Check if the same DTC is displayed.
CHECK ANY OTHER DTC IS DISPLAYED.
Check if any other DTC is displayed.
Check
Is the voltage more than 12 V
and the gravity more than
1.26?
Yes
Go to step 2.
No
Replace the battery.
Is the voltage more than 16.2

V?
Go to step 3.

SC(H4SO 2.0)-14,
Generator.>

V?
Go to step 4.

SC(H4SO 2.0)-14,
Generator.>

tightly?
Go to step 5.
Tighten the clamp

of terminal.

V?
Go to step 6.
Repair the harness connectors

between battery,
main relay and
ECM.
Is there poor contact in connectors between generator,

battery and ECM?
Repair the poor

contact.
Go to step 7.
Replace the generator.
Go to step 8.
Perform the diagnosis of DTC displayed.
Temporary poor
contact occurs.

AT:DTC P0600 SERIAL COMMUNICATION LINK

NOTE:
For the diagnostic procedure, refer to LAN system.
AU:DTC P0604 INTERNAL CONTROL MODULE RANDOM ACCESS MEMORY

(RAM) ERROR
NOTE:
For the diagnostic procedure, refer to DTC P0607. <Ref. to EN(H4DOTC)(diag)-152, DTC P0607 CONTROL
MODULE PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
AV:DTC P0605 INTERNAL CONTROL MODULE READ ONLY MEMORY (ROM)

ERROR
NOTE:
For the diagnostic procedure, refer to DTC P0607. <Ref. to EN(H4DOTC)(diag)-152, DTC P0607 CONTROL

AW:DTC P0607 CONTROL MODULE PERFORMANCE

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:

WIRING DIAGRAM:
MAIN RELAY
3
5
SBF-6
SBF-8
6
4
No.13
1
2
B72
B47
IGNITION
SWITCH
BATTERY
No.12
SBF-7
3
D16
B5
B6
B19
D14
SBF-1
B134
B:
B135
D:
B137
ECM
A6
A7
B1
B4
D7
B12
D1
D2
D3
A:
37
34
12
36
35
54
B21
E2
B72
B47
1 2 3
4 5 6
1
3
5
2
4
6
A: B134
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B: B135
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
32 33
34 35
28 29 30 31
D: B137
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
28 29
30 31
26 27
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
EN-02403

Step
Check
and chassis ground.
Yes
Go to step 2.
No
Repair the open or
Go to step 3.
Repair the open or

Repair the poor

Further tighten the
contact in ECM
minal.
Replace the ECM
if defective.
<Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
AX:DTC P0638 THROTTLE ACTUATOR CONTROL RANGE/PERFORMANCE

(BANK 1)
NOTE:
For diagnostic procedure, refer to DTC P2101. <Ref. to EN(H4DOTC)(diag)-176, DTC P2101 THROTTLE
AY:DTC P0700 TRANSMISSION CONTROL SYSTEM (MIL REQUEST)

NOTE:
AZ:DTC P0851 PARK/NEUTRAL SWITCH INPUT CIRCUIT LOW

NOTE:
BA:DTC P0852 PARK/NEUTRAL SWITCH INPUT CIRCUIT HIGH

NOTE:

BB:DTC P1110 ATMOSPHERIC PRESSURE SENSOR CIRCUIT MALFUNCTION

(LOW INPUT)
CAUTION:
Step
Check
Yes
No
Is DTC P1110 displayed on the Replace the ECM. Temporary poor
<Ref. to
contact occurs.
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
NOTE:
Atmospheric pressure sensor is built
in ECM.
BC:DTC P1111 ATMOSPHERIC PRESSURE SENSOR CIRCUIT MALFUNCTION

(HIGH INPUT)
CAUTION:
Step
Check
Yes
No
Is DTC P1111 displayed on the Replace the ECM. Temporary poor
contact occurs.
<Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
NOTE:
Atmospheric pressure sensor is built
in ECM.
BD:DTC P1160 RETURN SPRING FAILURE

NOTE:

BE:DTC P1518 STARTER SWITCH CIRCUIT LOW INPUT

TROUBLE SYMPTOM:
CAUTION:
WIRING DIAGRAM:
BATTERY
No.21
SBF-7
2
14
16
B72
SBF-1
3
IGNITION
SWITCH
STARTER RELAY
STARTER MOTOR
13
15
B225
D8
B32
B14
B: B135
D: B137
ECM
B225
B: B135
1
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
1
8 9
20 21
28 29
3
2
10 11 12 13
22 23
30 31
4 5 6
7
14 15 16 17 18 19
24 25
26 27
32 33
34 35
D: B137
3 4
1
2
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
B72
1 2 3
4 5 6
EN-02402

Step
Check
CHECK HARNESS BETWEEN STARTER

RELAY AND ECM.
1) Disconnect the connectors from starter
relay and ECM.

M?
Yes
Inspect the DTC
Code (DTC).
<Ref. to
EN(H4DOTC)(diag
Code (DTC).>
Repair the ground
short circuit
between starter
motor and ECM.
No
Go to step 2.
Repair the poor

contact in ECM
connector.

BF:DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION

CAUTION:
WIRING DIAGRAM:
MAIN RELAY
3
5
SBF-6
SBF-8
6
4
No.13
1
2
B72
B47
IGNITION
SWITCH
BATTERY
No.12
SBF-7
3
D16
B5
B6
B19
D14
SBF-1
B134
B:
B135
D:
B137
ECM
A6
A7
B1
B4
D7
B12
D1
D2
D3
A:
37
34
12
36
35
54
B21
E2
B72
B47
1 2 3
4 5 6
1
3
5
2
4
6
A: B134
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B: B135
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
32 33
34 35
28 29 30 31
D: B137
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
28 29
30 31
26 27
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
EN-02403

Step
chassis ground.
CHECK FUSE No. 13
Check
Yes
contact in ECM
connector.
No
Go to step 2.

?

ECM connector
Replace the fuse.

NOTE:
the following:
Open circuit in
harness between
ECM and battery
Poor contact in
ECM connector
Poor contact in
battery terminal

BG:DTC P2088 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT

LOW (BANK 1)
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
B134 ECM
1
8 9
18 19
28 29
28
18
B134
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
23
24
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B21
E38
E2
1 2
1
2
E38
OIL FLOW CONTROL

SOLENOID VALVE RH
EN-01960

Step
Check
CHECK HARNESS BETWEEN ECM AND OIL Is the resistance less than 1
FLOW CONTROL SOLENOID VALVE.
?
2) Disconnect the connector from ECM and oil
oil flow control solenoid valve.
(B134) No. 18 (E38) No. 1:
(B134) No. 28 (E38) No. 2:
CHECK OIL FLOW CONTROL SOLENOID

VALVE.
1) Disconnect the oil flow control solenoid
valve connector.
2) Measure the resistance between oil flow
Terminals
No. 1 No. 2:
Yes
Go to step 2.
No
Repair the open
circuit in harness
between ECM and
oil flow control
solenoid valve
connector.
NOTE:
the following:
Open circuit in
harness between
ECM and oil flow
control solenoid
valve connector
Poor contact in
coupling connector
Repair the poor
Replace the oil
contact in ECM
flow control soleand oil flow connoid valve. <Ref.
trol solenoid valve. to ME(H4DOTC)53, Camshaft.>

BH:DTC P2089 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT

HIGH (BANK 1)
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
B134 ECM
1
8 9
18 19
28 29
28
18
B134
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
23
24
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B21
E38
E2
1 2
1
2
E38
OIL FLOW CONTROL

SOLENOID VALVE RH
EN-01960

Step
Check
CHECK HARNESS BETWEEN ECM AND OIL Is the resistance more than 1
M?
VALVE.
valve connector.
Terminals
No. 1 No. 2:
Yes
Go to step 2.
No
Repair the short
circuit between
ECM and oil flow
control solenoid
valve connector.
Repair the poor

contact in ECM
and oil flow control solenoid valve.
Replace the oil

flow control solenoid valve. <Ref.
to ME(H4DOTC)53, Camshaft.>

BI: DTC P2090 EXHAUST CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 1)
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
B134 ECM
1
8 9
18 19
28 29
30
20
B134
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
25
26
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B21
E63
E2
1 2
1
2
E63
OIL FLOW CONTROL

SOLENOID VALVE RH
EN-01961

Step
Check
?
(B134) No. 20 (E63) No. 1:
(B134) No. 30 (E63) No. 2:

VALVE.
valve connector.
Terminals
No. 1 No. 2:
Yes
Go to step 2.
No
Repair the open
circuit in harness
between ECM and
oil flow control
solenoid valve
connector.
NOTE:
the following:
Open circuit in
harness between
ECM and oil flow
control solenoid
valve connector
Poor contact in
coupling connector
Repair the poor
Replace the oil
contact in ECM

BJ:DTC P2091 EXHAUST CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 1)
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
B134 ECM
1
8 9
18 19
28 29
30
20
B134
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
25
26
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B21
E63
E2
1 2
1
2
E63
OIL FLOW CONTROL

SOLENOID VALVE RH
EN-01961

Step
Check
M?
VALVE.
valve connector.
Terminals
No. 1 No. 2:
Yes
Go to step 2.
No
Repair the short
circuit between
ECM and oil flow
control solenoid
valve connector.
Repair the poor

contact in ECM
Replace the oil


BK:DTC P2092 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT

LOW (BANK 2)
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
B134
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
29
19
B134 ECM
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
27
28
E37
1 2
B21
E2
1
2
E37
OIL FLOW CONTROL

SOLENOID VALVE LH
EN-01962

Step
Check
?
(B134) No. 19 (E37) No. 1:
(B134) No. 29 (E37) No. 2:

VALVE.
valve connector.
Terminals
No. 1 No. 2:
Yes
Go to step 2.
No
Repair the open
circuit in harness
between ECM and
oil flow control
solenoid valve
connector.
NOTE:
the following:
Open circuit in
harness between
ECM and oil flow
control solenoid
valve connector
Poor contact in
coupling connector
Repair the poor
Replace the oil
contact in ECM

BL:DTC P2093 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT

HIGH (BANK 2)
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
B134
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
29
19
B134 ECM
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
27
28
E37
1 2
B21
E2
1
2
E37
OIL FLOW CONTROL

SOLENOID VALVE LH
EN-01962

Step
Check
M?
VALVE.
valve connector.
Terminals
No. 1 No. 2:
Yes
Go to step 2.
No
Repair the short
circuit between
ECM and oil flow
control solenoid
valve connector.
Repair the poor

contact in ECM
Replace the oil


BM:DTC P2094 EXHAUST CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT LOW (BANK 2)
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
B134
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
31
21
B134 ECM
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
29
30
E66
1 2
B21
E2
1
2
E66
OIL FLOW CONTROL

SOLENOID VALVE LH
EN-01963

Step
Check
?
(B134) No. 21 (E66) No. 1:
(B134) No. 31 (E66) No. 2:

VALVE.
valve connector.
Terminals
No. 1 No. 2:
Yes
Go to step 2.
No
Repair the open
circuit in harness
between ECM and
oil flow control
solenoid valve
connector.
NOTE:
the following:
Open circuit in
harness between
ECM and oil flow
control solenoid
valve connector
Poor contact in
coupling connector
Repair the poor
Replace the oil
contact in ECM

BN:DTC P2095 EXHAUST CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT HIGH (BANK 2)
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
WIRING DIAGRAM:
B134
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
31
21
B134 ECM
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
29
30
E66
1 2
B21
E2
1
2
E66
OIL FLOW CONTROL

SOLENOID VALVE LH
EN-01963

Step
Check
M?
VALVE.
valve connector.
Terminals
No. 1 No. 2:
Yes
Go to step 2.
No
Repair the short
circuit between
ECM and oil flow
control solenoid
valve connector.
Repair the poor

contact in ECM
Replace the oil


BO:DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/

PERFORMANCE
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
WIRING DIAGRAM:
BATTERY
SBF-8
7
5
6
8
ELECTRONIC
THROTTLE
CONTROL RELAY
MAIN RELAY
D6
B35
B362
B: B135
D: B137
ECM
C29
C18
D4
D5
C35
C16
B1
B4
D1
D2
D3
C: B136
*
*
B84
*
*
B138
7
3
B122
E2
4
6
1
2
3
5
E1
39
38
19
20
35
36
37
B21
16
15
B20
E57
ELECTRONIC
THROTTLE
CONTROL
B20
B362
1 2
1
5
9
13
3
4
5
7 8
6
2
3
10 11 12 13
22 23
30 31
2
6
10
14
B21
3
7
11
15
4
8
12
16
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 45
46 47
48 49 50 51 52 53 54
B: B135
1
8 9
20 21
28 29
4 5 6
7
14 15 16 17 18 19
24 25
26 27
32 33
34 35
C: B136
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
B84
E57
B122
1 2 3 4 5 6
B138
1 2 3 4
5 6 7 8
D: B137
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
EN-01951

Step
No. 6 of electronic throttle control relay.
Terminals
No. 7 No. 8:
ground.
ground.
ground.
(B135) No. 35 (B362) No. 6:
(B137) No. 6 (B362) No. 8:
(B136) No. 18 (+) (B136) No. 35 ():
Check
?
Yes
Go to step 2.
No
Repair the open or


harness between

M?
Go to step 5.
Repair the ground


?
Go to step 6.
Repair the open

circuit in harness
between ECM and
electronic throttle
control relay.
Go to step 9.

10
11
Step
(B136) No. 29 (+) (B136) No. 35 ():
CHECK POOR CONTACT.
(B136) No. 16 (E57) No. 5:
Check
Yes
No
Go to step 9.
Repair the poor

contact.
Go to step 13.

?
Go to step 10.
Repair the open

circuit of harness
connector.

M?
Go to step 11.
Repair the ground

Go to step 12.
Go to step 14.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective.
<Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
Repair the poor
contact in ECM
connector.
Replace the ECM
if defective.
<Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
Go to step 16.
Go to step 15.
Go to step 16.
Repair the poor

contact.
Go to step 20.
12

?
13

CHECK POOR CONTACT.
14
15

16
17
18
19
20
21
Step
(B136) No. 35 (E57) No. 3:
(B136) No. 18 (E57) No. 6:
(B136) No. 29 (E57) No. 4:
Check
?
Yes
Go to step 17.
No
Repair the open
circuit of harness
connector.

?
Go to step 18.

2) Remove the ECM.
(B136) No. 18 (B136) No. 35:
(B136) No. 29 (B136) No. 35:
2) Connect the connectors except of the electric control throttle relay.
Go to step 19.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective.
<Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
Repair the short
circuit in harness
between ECM
connector and
electronic throttle
control connector.

M?
Go to step 20.
Repair the short

circuit to sensor
power supply.
Go to step 21.
Go to step 22.
Repair the poor

Repair the poor
contact in ECM
connector.

22
23
24
25
26
27
28
Step
(B137) No. 5 (E57) No. 2:
(B137) No. 4 (E57) No. 1:
(E57) No. 2 (E57) No. 1:
Terminals
No. 1 No. 2:
Check the valve returns to the specified position when releasing fingers.
Check
?
Yes
Go to step 23.
No
Repair the open
circuit of harness
connector.
Go to step 24.

harness between

M?
Go to step 25.
Repair the short

circuit of harness.

M?
Go to step 26.
Repair the short

circuit of harness.

?
Go to step 27.
Repair the open

circuit of harness.

?
Go to step 28.

specified position? Standard
value: 3 mm (0.12 in) from fully
closed position
Repair the poor

trol.
Replace the ECM
if defective.
<Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>

BP:DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW

TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
WIRING DIAGRAM:
BATTERY
SBF-8
7
5
6
8
ELECTRONIC
THROTTLE
CONTROL RELAY
MAIN RELAY
D6
B35
B362
B: B135
D: B137
ECM
C29
C18
D4
D5
C35
C16
B1
B4
D1
D2
D3
C: B136
*
*
B84
*
*
B138
7
3
B122
E2
4
6
1
2
3
5
E1
39
38
19
20
35
36
37
B21
16
15
B20
E57
ELECTRONIC
THROTTLE
CONTROL
B20
B362
1 2
1
5
9
13
3
4
5
7 8
6
3
2
10 11 12 13
22 23
30 31
2
6
10
14
B21
3
7
11
15
4
8
12
16
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 45
46 47
48 49 50 51 52 53 54
B: B135
1
8 9
20 21
28 29
4 5 6
7
14 15 16 17 18 19
24 25
26 27
32 33
34 35
C: B136
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
B84
E57
B122
1 2 3 4 5 6
B138
1 2 3 4
5 6 7 8
D: B137
3 4
1
2
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
EN-01951

Step
No. 6 of electronic throttle control relay.
Terminals
(B362) No. 7 (B362) No. 8:
ground.
ground.
ground.
(B135) No. 35 (B362) No. 6:
(B137) No. 6 (B362) No. 8:
Check
?
Yes
Go to step 2.
No
Repair the open or


harness between

M?
Go to step 5.
Repair the ground


?
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective.
<Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
Repair the open

circuit in harness
between ECM and
electronic throttle
control relay.

BQ:DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH

WIRING DIAGRAM:
BATTERY
SBF-8
7
5
6
8
ELECTRONIC
THROTTLE
CONTROL RELAY
MAIN RELAY
D6
B35
B362
B: B135
D: B137
ECM
C29
C18
D4
D5
C35
C16
B1
B4
D1
D2
D3
C: B136
*
*
B84
*
*
B138
7
3
B122
E2
4
6
1
2
3
5
E1
39
38
19
20
35
36
37
B21
16
15
B20
E57
ELECTRONIC
THROTTLE
CONTROL
B20
B362
1 2
1
5
9
13
3
4
5
7 8
6
2
3
10 11 12 13
22 23
30 31
2
6
10
14
B21
3
7
11
15
4
8
12
16
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 45
46 47
48 49 50 51 52 53 54
B: B135
1
8 9
20 21
28 29
4 5 6
7
14 15 16 17 18 19
24 25
26 27
32 33
34 35
C: B136
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
B84
E57
B122
1 2 3 4 5 6
B138
1 2 3 4
5 6 7 8
D: B137
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
30 31
26 27
28 29
EN-01951

Step
Terminals
No. 7 No. 8:
RELAY.
ground.
Check
M?
Yes
Go to step 2.
No
Go to step 3.

harness between

M?
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective.
<Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
Repair the ground

BR:DTC P2109 THROTTLE/PEDAL POSITION SENSOR A MINIMUM STOP

PERFORMANCE
NOTE:

BS:DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT

LOW INPUT
TROUBLE SYMPTOM:
Erroneous idling
WIRING DIAGRAM:
MAIN
SUB
B315
ACCELERATOR
POSITION
SENSOR
B21
1 2 3 4 5 6
B315
B122
4
7
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 45
46 47
48 49 50 51 52 53 54
*
*
B83
C35
C28
C16
C34
C17
C15
B83
B122
1 2 3 4
5 6 7 8
ECM
C: B136
C:
B136
D2
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
D:
E2
5 6
14 15 16
25 26 27
33 34 35
B137
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
28 29
30 31
26 27
B21
36
D1
D: B137
EN-01964

Step
Check
Yes
SOR OUTPUT.
CHECK POOR CONTACT.
Repair the poor
contact.
(B136) No. 17 (B315) No. 5:
(B136) No. 15 (B315) No. 3:
position sensor connector and chassis ground.
sensor.
Terminals
No. 3 No. 4:
sensor.
Terminals
No. 5 No. 4:
pedal.
No
Go to step 3.
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.

?
Go to step 4.

M?
Go to step 5.

harness.
Go to step 6.

k?
Go to step 7.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective.
<Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
sensor.

k?
Go to step 8.

sensor.

Step
Check
SOR.
k?
sensor.
Terminals
No. 5 No. 4:
Yes
No
Repair the poor
erator position
connector.
sensor.
Replace the ECM
if defective. <Ref.
to FU(H4DOTC)35, Engine Control Module
(ECM).>

BT:DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT

HIGH INPUT
TROUBLE SYMPTOM:
Erroneous idling
WIRING DIAGRAM:
MAIN
SUB
B315
ACCELERATOR
POSITION
SENSOR
B21
1 2 3 4 5 6
B315
B122
4
7
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 45
46 47
48 49 50 51 52 53 54
*
*
B83
C35
C28
C16
C34
C17
C15
B83
B122
1 2 3 4
5 6 7 8
ECM
C: B136
C:
B136
D2
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
D:
E2
5 6
14 15 16
25 26 27
33 34 35
B137
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
28 29
30 31
26 27
B21
36
D1
D: B137
EN-01964

Step
Check
Yes
SOR OUTPUT.
CHECK POOR CONTACT.
Repair the poor
contact.
(B136) No. 34 (B315) No. 4:
2) Measure the resistance between accelerator position sensor connector and chassis
ground.

?
Go to step 4.

?
Go to step 5.
M?
3) Measure the resistance between ECM connector terminals.
(B136) No. 17 (B136) No. 15:
(B136) No. 17 (B136) No. 16:
Go to step 6.
No
Go to step 3.
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
(ECM).>
Repair the battery
ECM connector
and accelerator
position sensor
connector.
Repair the poor

Repair the short
sor connector.

BU:DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT

LOW INPUT
TROUBLE SYMPTOM:
Erroneous idling
WIRING DIAGRAM:
MAIN
SUB
B315
ACCELERATOR
POSITION
SENSOR
B21
1 2 3 4 5 6
B315
B122
4
7
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 45
46 47
48 49 50 51 52 53 54
*
*
B83
C35
C28
C16
C34
C17
C15
B83
B122
1 2 3 4
5 6 7 8
ECM
C: B136
C:
B136
D2
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
D:
E2
5 6
14 15 16
25 26 27
33 34 35
B137
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
28 29
30 31
26 27
B21
36
D1
D: B137
EN-01964

Step
CHECK POOR CONTACT.
Check
Yes
No
Go to step 3.
Repair the poor

contact.

(B136) No. 28 (B315) No. 2:
(B136) No. 16 (B315) No. 1:

?
Go to step 4.
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.

M?
Go to step 5.

harness.
Go to step 6.

k?
Go to step 7.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective.
<Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
sensor.

k?
Go to step 8.

sensor.
Terminals
No. 1 No. 6:
Terminals
No. 2 No. 6:

sensor.

Step
Check
SOR.
k?
Terminals
No. 2 No. 6:
depressed.
Yes
No
Repair the poor
erator position
connector.
sensor.
Replace the ECM
if defective.
<Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>

BV:DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT

HIGH INPUT
TROUBLE SYMPTOM:
Erroneous idling
WIRING DIAGRAM:
MAIN
SUB
B315
ACCELERATOR
POSITION
SENSOR
B21
1 2 3 4 5 6
B315
B122
4
7
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 45
46 47
48 49 50 51 52 53 54
*
*
B83
C35
C28
C16
C34
C17
C15
B83
B122
1 2 3 4
5 6 7 8
ECM
C: B136
C:
B136
D2
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
D:
E2
5 6
14 15 16
25 26 27
33 34 35
B137
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
28 29
30 31
26 27
B21
36
D1
D: B137
EN-01964

Step
CHECK POOR CONTACT.
Check
Yes
No
Go to step 3.
Repair the poor

contact.

(B136) No. 35 (B315) No. 6:
ground.

?
Go to step 4.
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.

?
Go to step 5.
M?
(B137) No. 28 (B137) No. 15:
(B137) No. 28 (B137) No. 16:
Go to step 6.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective.
<Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
Repair the battery
ECM connector
and accelerator
position sensor
connector.
Repair the poor

Repair the short
sor connector.

BW:DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH A / B

VOLTAGE CORRELATION
TROUBLE SYMPTOM:
Erroneous idling
WIRING DIAGRAM:
BATTERY
SBF-8
7
5
6
8
ELECTRONIC
THROTTLE
CONTROL RELAY
MAIN RELAY
D6
B35
B362
B: B135
D: B137
ECM
C29
C18
D4
D5
C35
C16
B1
B4
D1
D2
D3
C: B136
*
*
B84
*
*
B138
7
3
B122
E2
4
6
1
2
3
5
E1
39
38
19
20
35
36
37
B21
16
15
B20
E57
ELECTRONIC
THROTTLE
CONTROL
B20
B362
1 2
1
5
9
13
3
4
5
7 8
6
2
3
10 11 12 13
22 23
30 31
2
6
10
14
B21
3
7
11
15
4
8
12
16
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 45
46 47
48 49 50 51 52 53 54
B: B135
1
8 9
20 21
28 29
4 5 6
7
14 15 16 17 18 19
24 25
26 27
32 33
34 35
C: B136
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
B84
E57
B122
1 2 3 4 5 6
B138
1 2 3 4
5 6 7 8
D: B137
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
EN-01951

Step
(B136) No. 18 (+) (B136) No. 35 ():
terminals.
(B136) No. 29 (+) (B136) No. 35 ():
CHECK POOR CONTACT.
(B136) No. 16 (E57) No. 5:
Check
Yes
No
Go to step 4.
Go to step 4.
Repair the poor

contact.
Go to step 14.

?
Go to step 5.
Repair the open

circuit of harness
connector.

M?
Go to step 6.
Repair the ground

Go to step 7.

V?
Go to step 9.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective.
<Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
Repair the poor
contact in ECM
connector.
Replace the ECM
if defective.
<Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
Go to step 11.

V?
Go to step 10.
Go to step 11.

?


10
11
12
13
14
15
16
Step
CHECK POOR CONTACT.
Check
Yes
Repair the poor
contact.

(B136) No. 35 (E57) No. 3:
(B136) No. 18 (E57) No. 6:
(B136) No. 29 (E57) No. 4:

?
Go to step 12.

?
Go to step 13.

(B136) No. 18 (B136) No. 35:
(B136) No. 29 (B136) No. 35:
(E57) No. 6 (E57) No. 4:
Go to step 14.
Go to step 15.
Repair the short

circuit in harness
between ECM
connector and
electronic throttle
control connector.

M?
Go to step 16.
Repair the short

circuit to sensor
power supply.

M?
Repair the poor

Repair the short
contact in ECM
circuit of harness.
connector.
Replace the ECM
if defective.
<Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
No
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective.
<Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
Repair the battery
ECM connector
and electronic
throttle control
connector.

BX:DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH D / E

VOLTAGE CORRELATION
TROUBLE SYMPTOM:
Erroneous idling
WIRING DIAGRAM:
MAIN
SUB
B315
ACCELERATOR
POSITION
SENSOR
B21
1 2 3 4 5 6
B315
B122
4
7
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 45
46 47
48 49 50 51 52 53 54
*
*
B83
C35
C28
C16
C34
C17
C15
B83
B122
1 2 3 4
5 6 7 8
ECM
C: B136
C:
B136
D2
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
D:
E2
5 6
14 15 16
25 26 27
33 34 35
B137
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
28 29
30 31
26 27
B21
36
D1
D: B137
EN-01964

Step
CHECK POOR CONTACT.
(B136) No. 17 (B315) No. 5:
(B136) No. 15 (B315) No. 3:
(B136) No. 28 (B315) No. 2:
(B136) No. 16 (B315) No. 1:
sensor.
Terminals
No. 3 No. 4:
sensor.
Terminals
No. 1 No. 6:
pedal.
Terminals
No. 5 No. 4:
Check
Yes
No
Go to step 3.
Repair the poor

contact.
Go to step 12.

?
Go to step 4.
Repair the open

circuit of harness
connector.

M?
Go to step 5.
Repair the ground

Go to step 6.

k?
Go to step 7.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective.
<Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
sensor.

k?
Go to step 8.

sensor.

k?
Go to step 9.

sensor.

10
11
12
13
14
15
16
Step
pedal.
Terminals
No. 2 No. 6:
Terminals
No. 5 No. 4:
Terminals
No. 2 No. 6:
CHECK POOR CONTACT.
(B136) No. 34 (B315) No. 4:
(B136) No. 35 (B315) No. 6:
ground.
Check
k?
Yes
Go to step 10.
No
sensor.

k?
Go to step 11.

sensor.

k?
Go to step 12.

sensor.
Go to step 14.
Repair the poor

contact.
Go to step 18.

?
Go to step 15.
Repair the open

circuit of harness
connector.

?
Go to step 16.
Go to step 17.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective.
<Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
Repair the battery
ECM connector
and accelerator
position sensor
connector.

17
18
Step
(B136) No. 17 (B136) No. 15:
(B136) No. 17 (B136) No. 16:
(B136) No. 28 (B136) No. 15:
(B136) No. 28 (B136) No. 16:
(B315) No. 5 (B315) No. 2:
Check
M?
Yes
Go to step 18.
No
Repair the short
circuit to sensor
power supply.

M?
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
(ECM).>
Repair the short

circuit in harness
between ECM
connector and


A: INSPECTION
1. ENGINE
NOTE:
Malfunction of parts other than those listed is also possible. <Ref. to ME(H4DOTC)-90, Engine Trouble in
General.>
Symptom
2. Rough idling
5. Engine stalls or engine sags or hesitates at

acceleration.
6.Surge
Problem parts
10) Oxygen sensor
4) Mass air flow sensor
7) Throttle position sensor

Symptom
7. Spark knock
Problem parts
4) Knock sensor
*4: Check fuel injector, fuel pressure regulator and fuel filter.

ENGINE SECTION 3

of SUBARU vehicles.
FU(H6DO)
EMISSION CONTROL
EC(H6DO)
INTAKE (INDUCTION)
IN(H6DO)
MECHANICAL
ME(H6DO)
EXHAUST
EX(H6DO)
COOLING
CO(H6DO)
LUBRICATION
LU(H6DO)
SP(H6DO)
IGNITION
IG(H6DO)
SC(H6DO)
EN(H6DO)(diag)

approval.
G2320GE4
FU(H6DO)
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
Throttle Body.............................................................................................11
Intake Manifold..........................................................................................12
Knock Sensor............................................................................................21
EGR Valve ................................................................................................25
Fuel Injector ..............................................................................................26
Variable Valve Lift Diagnosis Oil Pressure Switch ....................................28
Oil Temperature Sensor............................................................................29
Main Relay ................................................................................................35
Fuel Pump Relay.......................................................................................36
Fuel Pump Control Unit.............................................................................38
Fuel ...........................................................................................................39
Fuel Tank ..................................................................................................40
Fuel Filler Pipe ..........................................................................................46
Fuel Pump.................................................................................................48
Fuel Filter ..................................................................................................52
Fuel Bypass Valve ....................................................................................53
General Description
A: SPECIFICATION
Fuel tank
Fuel pump

Discharge
Fuel filter
64 2(16.9 US gal, 14.1 Imp gal)

Under rear seat
Impeller
Capacity
Location
Type
550 850 kPa (5.61 8.67 kg/cm2, 79.8 123.3 psi)

125 2 (33 US gal, 27.5 Imp gal)/h or more
[12 V at 300 kPa (3.06 kg/cm2, 43.5 psi)]
In-tank type
FU(H6DO)-2
General Description
B: COMPONENT
1. INTAKE MANIFOLD
T5
T3
(16)
(9)
T4
T4
(10)
T5
(18)
(17)
T6
T6
(15)
T5
(6)
(5)
T3
(7)
T5
T4
(17)
(9)
(8)
T4
(10)
(3)
T5
(1)
(2)
T3
(11)
(4)
(14)
(2)
(13)
T5
(14)
T2
T1
T2
T2
T2
(14)
(13)
(14)
T2
(12)
T1
FU-02107
FU(H6DO)-3
General Description
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Intake manifold
O-ring
Manifold pressure sensor
Filter
Hose
Hose
Nipple
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
Plug
Fuel pipe ASSY
Hose
Clamp
EGR valve (Except for KA model)
Gasket (Except for KA model)
Gasket (Except for KA model)
EGR pipe (Except for KA model)

T1: 1.5 (0.15, 1.1)
T2: 5 (0.5, 3.6)
T3: 6.4 (0.65, 4.7)
T4: 17 (1.7, 12.5)
T5: 19 (1.9, 13.7)
T6: 25 (2.5, 18.1)
2. FUEL INJECTOR
T
(6)
(5)
(4)
T
(3)
(1)
(2)
(5)
(4)
(3)
(2)
FU-02108
(1)
(2)
(3)
Fuel injector pipe LH

Insulator
Fuel injector
(4)
(5)
(6)
Injection rubber
O-ring
Fuel injector pipe RH
FU(H6DO)-4

T: 19 (1.9, 14)
General Description
(2)
(1)
FU-02109
(1)
(2)

T: 8 (0.8, 5.8)
O-ring
Throttle body
FU(H6DO)-5
General Description
T4
T4
(2)
T1
(3)
T2
T1
(4)
(6)
(1)
T1
(5)
T3
(8)
(7)
T2
FU-02110
(1)
(2)
(3)
(4)
(5)

Knock sensor RH
Knock sensor LH
Camshaft position sensor RH
Camshaft position sensor LH
(6)
Variable valve lift diagnosis oil

pressure switch RH
(7)

pressure switch LH
(8)
Oil temperature sensor
FU(H6DO)-6

T1: 6.4 (0.65, 4.7)
T2: 17 (1.7, 12.5)
T3: 18 (1.8, 13.3)
T4: 25 (2.5, 18)
General Description
5. FUEL TANK
T1
(19)
(17)
(18)
(15)
(16)
(8)
T1
(17)
(14)
(7)
(15)
(10)
(12)
(9)
(11)
(1)
(13)
(22)
T4
(6)
(22)
(5)
(20)
(3)
(2)
T4
(21)
T4
(4)
T3
T3
T3
T3
(23)
(24)
(25)
T3
T2
T2
T3
FU-01080
FU(H6DO)-7
General Description
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
Fuel tank
Fuel tank band RH
Fuel tank band LH
Delivery tube
Return tube
Jet pump tube
Fuel pump ASSY
Fuel pump gasket
Fuel level sensor
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)

Fuel filler hose
Clamp
Vent hose
Clip
Stopper RH
Stopper LH
FU(H6DO)-8
(22)
(23)
(24)
(25)
Retainer
Heat shield cover

T1: 4.4 (0.45, 3.3)
T2: 9.0 (0.92, 6.6)
T3: 17.5 (1.78, 12.9)
T4: 33 (3.4, 25)
General Description
6. FUEL LINE
T1
(1)
(28)
(18)
(26)
(23)
(25)
(27)
(15)
(17)
(19)
(1)
(20)
(22)
(14)
(13)
(24)
(21)
T2
(1)
(16)
(1)
(1) (22)
(34)
(11)
(29)
(10)
T2
(12)
T3
T2
(1)
(1) (1)
(4)
(3)
T2
B
(2) (1)
(5)
(33)
(1)
(9)
(32)
(1)
(6)
(30)
(31)
T2
T2
(8)
(7)
FU-02182
FU(H6DO)-9
General Description
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
Clip
Fuel return hose
Evaporation hose
Fuel bypass valve
Bracket
Bracket
Fuel pipe ASSY
Clamp
Canister
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)

Purge hose A
Purge hose B
Two-way valve
Connector
Filler pipe packing
Filler ring
C: CAUTION
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
Filler cap
Tether
Clip
Fuel hose
Purge hose C
Connector
Purge pipe

T1: 4.4 (0.45, 3.2)
T2: 7.5 (0.76, 5.53)
T3: 8.3 (0.85, 6.1)

points.
cable from battery.
D: PREPARATION TOOL
ILLUSTRATION
TOOL NUMBER
24082AA230
DESCRIPTION
CARTRIDGE
REMARKS
22771AA030
SUBARU SELECT
MONITOR KIT

ST24082AA230
ST22771AA030
FU(H6DO)-10
Throttle Body
2. Throttle Body
A: REMOVAL
IN-00203

IN(H6DO)-7, REMOVAL, Air Intake Chamber.>
sensor.
FU-02111

throttle body.
6) Remove the bolts (B) which secure throttle body
to intake manifold.
(A)
(B)
(B)
(A)
FU-02112
B: INSTALLATION
NOTE:
Use a new O-ring.
Tightening torque:
8 Nm (0.8 kgf-m, 5.8 ft-lb)
FU(H6DO)-11
Intake Manifold
3. Intake Manifold
8) Disconnect the PCV hose.
A: REMOVAL
<Ref. to FU(H6DO)-39, RELEASING OF FUEL
filler cap.
EC-02021
IN-00203

chamber. <Ref. to IN(H6DO)-5, REMOVAL, Air
Cleaner Case.> <Ref. to IN(H6DO)-7, REMOVAL,
Air Intake Chamber.>
6) Disconnect the connector (A) and (B).
FU-02115
10) Disconnect the fuel hoses from fuel pipe.
(A)
FU-02116
(B)
FU-02113
11) Remove the EGR pipe from EGR valve. (Except for KA model)
CAUTION:
Be careful not to drop gaskets.
FU-02114
FU-00547
12) Disconnect the connector from EGR valve. (Except for KA model)
FU(H6DO)-12
Intake Manifold
LH side
FU-02117
14) Remove the bolts, which hold fuel injector pipe

LH onto cylinder head.
FU-02121
RH side
FU-02122
FU-02118
B: INSTALLATION
NOTE:
Use a new O-ring.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
RH side
FU-02119
16) Remove the bolts, which hold fuel injector pipe

RH onto cylinder head.
FU-02122
FU-02120
17) Remove bolts which hold intake manifold onto

cylinder heads.
FU(H6DO)-13
Intake Manifold
Tightening torque:
19 Nm (1.9 kgf-m, 14 ft-lb)
LH side
FU-02121
2) Install the bolts, which hold fuel injector pipe RH

onto cylinder head.
Tightening torque:
19 Nm (1.9 kgf-m, 14 ft-lb)
Tightening torque:
19 Nm (1.9 kgf-m, 14 ft-lb)
FU-02118
FU-02120
FU-02117
6) Connect the connector to EGR valve. (Except for

KA model)
7) Install the EGR pipe to EGR valve. (Except for
KA model)
Tightening torque:
19 Nm (1.9 kgf-m, 14 ft-lb)
NOTE:
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
FU-02119
4) Install the bolts which hold fuel injector pipe LH

onto cylinder head.
FU-00547
FU(H6DO)-14
Intake Manifold
12) Connect the connector (A) and (B).
8) Connect the fuel hoses to fuel pipe.
(A)
(B)
FU-02116
FU-02113
13) Install the air cleaner case and air intake chamber. <Ref. to IN(H6DO)-6, INSTALLATION, Air
Cleaner Case.> <Ref. to IN(H6DO)-7, INSTALLATION, Air Intake Chamber.>
FU-02115
10) Connect the PCV hose.
IN-00203
C: DISASSEMBLY
EC-02021
11) Connect the engine coolant hoses to throttle

body.
1) Remove the throttle body. <Ref. to FU(H6DO)11, REMOVAL, Throttle Body.>

2) Remove the EGR valve. <Ref. to FU(H6DO)-25,
REMOVAL, EGR Valve.>
FU-02123
FU-02114
4) Remove the manifold absolute pressure sensor.

<Ref. to FU(H6DO)-23, REMOVAL, Manifold Absolute Pressure Sensor.>
5) Remove the purge control solenoid valve. <Ref.
to EC(H6DO)-7, REMOVAL, Purge Control Solenoid Valve.>
FU(H6DO)-15
Intake Manifold

to fuel hose, and then disconnect the pipe from fuel
hose.
D: ASSEMBLY
NOTE:
Liquid gasket:
1) Tighten the bolts which install fuel pipes on intake manifold.
Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
FU-02124
7) Remove the bolts which install fuel pipes on intake manifold.
FU-02125
FU-02125
FU-02126
2) Connect the fuel injector pipe to fuel hose, and

tighten the clamp screw.
FU-02126
Tightening torque:
1.5 Nm (0.15 kgf-m, 1.1 ft-lb)
FU-02124
3) Install the purge control solenoid valve. <Ref. to

EC(H6DO)-7, INSTALLATION, Purge Control Solenoid Valve.>
4) Install the manifold absolute pressure sensor.
<Ref. to FU(H6DO)-23, INSTALLATION, Manifold
Absolute Pressure Sensor.>
FU(H6DO)-16
Intake Manifold
5) Connect the pressure regulator vacuum hose to

intake manifold.
FU-02123
6) Install the EGR valve. <Ref. to FU(H6DO)-25,

INSTALLATION, EGR Valve.>
7) Install the throttle body to intake manifold. <Ref.
to FU(H6DO)-11, INSTALLATION, Throttle Body.>
E: INSPECTION
FU(H6DO)-17


Sensor
A: REMOVAL
IN-00203
3) Disconnect the connector from engine coolant

temperature sensor.
FU-00572
B: INSTALLATION
Tightening torque:
16 Nm (1.6 kgf-m, 12 ft-lb)
FU-00572
FU(H6DO)-18

B: INSTALLATION
A: REMOVAL

Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
IN-00203

FU-02127
FU-02128
FU(H6DO)-19
FU-02128


A: REMOVAL
7) Remove the camshaft position sensor RH in the

same procedure as LH.
B: INSTALLATION
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
Fuel pipe protector
19 Nm (1.9 kgf-m, 14 ft-lb)
IN-00203
3) Remove the generator harness from fuel pipe

protector LH.
FU-02117
5) Disconnect the connector from camshaft position sensor LH.
FU-02129
6) Remove the camshaft position sensor LH.
FU-02130
FU(H6DO)-20
Knock Sensor
7. Knock Sensor
3) Install the intake manifold. <Ref. to FU(H6DO)13, INSTALLATION, Intake Manifold.>

A: REMOVAL
IN-00203

IN-00203

<Ref. to FU(H6DO)-12, REMOVAL, Intake Manifold.>
FU-00577
B: INSTALLATION
Tightening torque:
25 Nm (2.5 kgf-m, 18 ft-lb)
NOTE:
For the knock sensors installation angle, refer to
the figure below.
30
10
45
(A)
FU-00578
(A) Front side
FU(H6DO)-21


A: SPECIFICATION
body.
procedure. <Ref. to FU(H6DO)-11, REMOVAL,
Throttle Body.> <Ref. to FU(H6DO)-11, INSTALLATION, Throttle Body.>
FU(H6DO)-22


Sensor
A: REMOVAL
IN-00203
3) Disconnect the connector from manifold absolute pressure sensor (A), and remove the filter assembly (B) from intake manifold.
(A)
(B)
FU-02131

B: INSTALLATION
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
FU(H6DO)-23

10.Mass Air Flow and Intake Air

Temperature Sensor
A: REMOVAL
IN-00203

IN-02009
FU-02132
B: INSTALLATION
Tightening torque:
1.0 Nm (0.10 kgf-m, 0.74 ft-lb)
FU(H6DO)-24
EGR Valve
11.EGR Valve
B: INSTALLATION
A: REMOVAL
Install in the reverse of removal.
NOTE:
Model except for KA is equipped with EGR valve.
NOTE:
Replace the old gaskets with new ones.
Tightening torque:
EGR valve
19 Nm (1.9 kgf-m, 14 ft-lb)
EGR pipe
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
IN-00203

4) Remove the starter. <Ref. to SC(H6DO)-6, REMOVAL, Starter.>
5) Remove the EGR pipe from the EGR valve and
cylinder head.
FU-02133
FU(H6DO)-25
FU-02133
Fuel Injector
12.Fuel Injector

A: REMOVAL
1. RH SIDE
filler cap.
FU-02120

injector pipe.
2. LH SIDE
IN-00203
5) Remove the air cleaner case. <Ref.

IN(H6DO)-5, REMOVAL, Air Cleaner Case.>
to

filler cap.
5) Remove the generator harness from fuel pipe
protector LH.
FU-02119
FU-02117
FU-02134
8) Remove the engine harness from fuel injector

pipe RH.
FU-02135
8) Remove the engine harness from fuel injector

pipe LH.
FU(H6DO)-26
Fuel Injector

2. LH SIDE
NOTE:
Use new O-rings.
Tightening torque:
19 Nm (1.9 kgf-m, 13.7 ft-lb)
FU-02118

injector pipe.
B: INSTALLATION
1. RH SIDE
FU-02118
Tightening torque:
19 Nm (1.9 kgf-m, 13.7 ft-lb)

NOTE:
Use new O-rings.
Tightening torque:
19 Nm (1.9 kgf-m, 13.7 ft-lb)
FU-02117
FU-02120
Tightening torque:
19 Nm (1.9 kgf-m, 13.7 ft-lb)
FU-02119
FU(H6DO)-27
Variable Valve Lift Diagnosis Oil Pressure Switch

13.Variable Valve Lift Diagnosis

Oil Pressure Switch
A: REMOVAL
B: INSTALLATION
NOTE:
Apply liquid gasket to the thread of variable valve
lift diagnosis oil pressure switch.
Liquid gasket:
equivalent
Tightening torque:
17 Nm (1.7 kgf-m, 12.5 ft-lb)1
IN-00203

4) Disconnect the connector from variable valve lift
diagnosis oil pressure switch.
5) Remove the variable valve lift diagnosis oil pressure switch.
LH side
FU-02136
RH side
FU-02137
FU(H6DO)-28
Oil Temperature Sensor

14.Oil Temperature Sensor

A: REMOVAL
IN-00203

4) Disconnect the connector from oil temperature
sensor.
5) Remove the oil temperature sensor.
FU-02138
B: INSTALLATION
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
FU(H6DO)-29

LH side
A: REMOVAL
FU-02141
RH side
IN-00203

4) Disconnect the connector of front oxygen (A/F)
sensor.
LH side
FU-02142
B: INSTALLATION
removal easier.
FU-02139
RH side
SS-30 JET LUBE
CAUTION:
Tightening torque:
21 Nm (2.1 kgf-m, 15.2 ft-lb)
LH side
FU-02140
one minute or more.
CAUTION:
FU(H6DO)-30
FU-02141

RH side
FU-02142

sensor.
LH side
FU-02139
RH side
FU-02140

IN-00203
FU(H6DO)-31
Rear Oxygen Sensor

LH side
A: REMOVAL
FU-02145
RH side
IN-00203

LH side
FU-02146
B: INSTALLATION
FU-02143
RH side
SS-30 JET LUBE
CAUTION:
Tightening torque:
21 Nm (2.1 kgf-m, 15.2 ft-lb)
LH side
FU-02144

minute or more.
CAUTION:
FU(H6DO)-32
FU-02145
Rear Oxygen Sensor

RH side
FU-02146

LH side
FU-02143
RH side
FU-02144

IN-00203
FU(H6DO)-33

B: INSTALLATION
A: REMOVAL
IN-00203

Trim.>
CAUTION:
When replacing the ECM, immobilizer system
must be registered. For doing so, all ignition
keys and ID cards should be prepared. Refer to
REGISTRATION MANUAL FOR IMMOBILIZER.
Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
FU-02090
5) Remove the nuts (A) which hold ECM to bracket.

(B)
(A)
(A)
FU-02091
7) Disconnect the ECM connectors, and take out

the ECM.
FU(H6DO)-34
Main Relay
18.Main Relay
A: REMOVAL
IN-00203

(A)
FU-02092
FU-02093
B: INSTALLATION
FU(H6DO)-35
Fuel Pump Relay

19.Fuel Pump Relay

A: REMOVAL
IN-00203

(A)
FU-02092
FU-02094
B: INSTALLATION
FU(H6DO)-36


Relay
A: REMOVAL
IN-00203

(A)
FU-02092
4) Disconnect the connector from electronic throttle

control relay.
FU-02095
B: INSTALLATION
FU(H6DO)-37
Fuel Pump Control Unit

21.Fuel Pump Control Unit

A: REMOVAL
IN-00203

3) Remove the fuel pump control unit.
Wagon model
FU-02159
Sedan model
FU-02160
4) Disconnect the connector from fuel pump control

unit.
B: INSTALLATION
FU(H6DO)-38
Fuel
22.Fuel

the drain plugs from fuel tank to drain the fuel from
fuel tank.
A: PROCEDURE
WARNING:
box.
FU-01123

NOTE:
Use a new gasket.
FU-01122
2) Start the engine and run until it stalls.

2. DRAINING FUEL
WARNING:
Tightening torque:
26 Nm (2.65 kgf-m, 19.2 ft-lb)
NOTE:
Use a new nut.
Tightening torque:
Nut
9.0 Nm (0.92 kgf-m, 6.6 ft-lb)
Bolt
17.5 Nm (1.78 kgf-m, 12.9 ft-lb)
IN-00203
filler cap.
FU(H6DO)-39
Fuel Tank
23.Fuel Tank

A: REMOVAL
WARNING:
3) Drain fuel from fuel tank.
<Ref. to FU(H6DO)-39, DRAINING FUEL, PROCEDURE, Fuel.>
(A)
(A)
(B)
FU-01126

sensor.
9) Disconnect the quick connector from the fuel delivery (B) and return hose (C). <Ref. to FU(H6DO)54, REMOVAL, Fuel Delivery, Return and Evaporation Lines.>
(A)
(A)
(A)
(B)
(C)
(B)
FU-01124
FU-01127

11) Remove the bolts which secure the rear brake
FU-01125
FU(H6DO)-40
FU-01128
Fuel Tank


cable clamp.
FU-00462

<Ref. to EX(H6DO)-8, REMOVAL, Rear Exhaust
Pipe.>
speed sensor.
FU-01130
FU-01131

CAUTION:
(2) Remove the bolt which installs rear shock
absorber to rear suspension arm.
FU-01129
FU-01132
FU(H6DO)-41
Fuel Tank
(3) Remove the bolts which secure rear suspension assembly to body.
23) Support the fuel tank with transmission jack, remove the bolts from fuel tank bands, and dismount
WARNING:
FU-01133
FU-01137
B: INSTALLATION
of fuel tank band.
FU-01134
WARNING:

from bracket.
FU-01137
(A)
FU-01135
22) Loosen the clamp, and disconnect the fuel filler

(A)
(B)
FU-01136
FU(H6DO)-42
Fuel Tank

clamp.
Tightening torque:
T1: 125 Nm (12.7 kgf-m, 92.2 ft-lb)
T2: 65 Nm (6.2 kgf-m, 48 ft-lb)
T3: 175 Nm (17.8 kgf-m, 129 ft-lb)
(A)
T1
T1
(B)
T1
T1
FU-01136
FU-01150
(2)
(1)
(3)
L/2
T3
T2
T2
T3
FU-00104
FU-01138
(1) Hose
(2) Clip or clamp
(3) Pipe
(3) Tighten the bolts which install rear shock absorber to rear suspension arm. <Ref. to RS-11,
INSTALLATION, Rear Arm.>

Tightening torque:
62 Nm (6.3 kgf-m, 46 ft-lb)
(A)
FU-01135
FU-01132
Tightening torque:
33 Nm (3.4 kgf-m, 25 ft-lb)
CAUTION:
then tighten the bolts which secure rear suspension assembly to body.
FU(H6DO)-43
Fuel Tank
Tightening torque:
33 Nm (3.4 kgf-m, 25 ft-lb)
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
FU-01130
Tightening torque:
32 Nm (3.3 kgf-m, 23.9 ft-lb)
FU-01128

18) Connect the quick connector of the fuel delivery
(B) and return hose (C). <Ref. to FU(H6DO)-55, INSTALLATION, Fuel Delivery, Return and Evaporation Lines.>
NOTE:
return side.
FU-01131
(A)
(C)
(B)
FU-01127

sensor.
FU-01129

10) Install the rear exhaust pipe. <Ref. to
EX(H6DO)-8, INSTALLATION, Rear Exhaust
Pipe.>
FU(H6DO)-44
(A)
(A)
(B)
(A) Bolt
(B) Grommet
FU-01126
Fuel Tank
FU-01125
(A)
(A)
(B)
FU-01124
(A) Bolt
(B) Grommet

C: INSPECTION
1) Check that the fuel tank is not holed, cracked, or
otherwise damaged.
FU(H6DO)-45
Fuel Filler Pipe

24.Fuel Filler Pipe

the drain plug from fuel tank to drain the fuel from
fuel tank.
A: REMOVAL
WARNING:
FU-01123

NOTE:
Use a new gasket.
IN-00203
cap.
3) Remove the screws which secure packing.
Tightening torque:
26 Nm (2.65 kgf-m, 19.2 ft-lb)
10) Remove the bolts which hold fuel filler pipe
FU-00095

FU-01139

(A)
(B)
FU-00096
FU-01136

vehicle.
FU(H6DO)-46
Fuel Filler Pipe

B: INSTALLATION
2) Set the fuel saucer (A) with rubber packing (C),
side of apron.
5) Tighten the bolts which hold fuel filler pipe bracket on the body.
Tightening torque:
7.5 Nm (0.75 kgf-m, 5.4 ft-lb)
NOTE:
(A)
FU-01139
(B)
(C)
FU-00103

clamp.
(A)
(B)
FU-00096

FU-01136
(2)
(1)
(3)
L/2
IN-00203
FU-00104
(1) Hose
(2) Clip or clamp
(3) Pipe
FU(H6DO)-47
Fuel Pump
25.Fuel Pump
7) Remove the nuts which install fuel pump assembly onto fuel tank.
A: REMOVAL
WARNING:
NOTE:
level sensor.
2) Drain the fuel. <Ref. to FU(H6DO)-39, DRAINING FUEL, PROCEDURE, Fuel.>
(A)
(B)
(C)
(A)
FU-01140
(A) Delivery hose

(B) Return hose
(C) Jet pump hose
B: INSTALLATION
NOTE:
Use a new gasket.
Tightening torque:
4.4 Nm (0.45 kgf-m, 3.3 ft-lb)
(A)
1
(B)
FU-01124

5
7
2
FU-01141
C: INSPECTION
FU-01125
6) Disconnect the quick connector, and then disconnect the fuel delivery hose, return hose and jet
pump hose. <Ref. to FU(H6DO)-54, REMOVAL,

of fuel pump, and apply the battery power supply to
WARNING:
possible.
FU(H6DO)-48
Fuel Pump

non-load condition.
2 1
4 3
6 5
FU-01330
FU(H6DO)-49
Fuel Level Sensor


A: REMOVAL
WARNING:
NOTE:
FU(H6DO)-48, REMOVAL, Fuel Pump.>
FU-01142
B: INSTALLATION
FU(H6DO)-50

6) Remove the nuts and bolts which install fuel sub

level sensor on fuel tank.
A: REMOVAL
WARNING:
1) Drain the fuel. <Ref. to FU(H6DO)-39, DRAINING FUEL, PROCEDURE, Fuel.>
(C)
(A)
(B)
FU-01144
(A) Jet pump hose

(B) Delivery hose
(C) Return hose
B: INSTALLATION
(A)

(A)
(B)
FU-01126

sensor.
NOTE:
Use a new gasket.
Tightening torque:
4.4 Nm (0.45 kgf-m, 3.3 ft-lb)
3
1
5
6
2
4
FU-01143
FU-01145
5) Disconnect the quick connector, and then disconnect the fuel delivery hose, return hose and jet
pump hose. <Ref. to FU(H6DO)-54, REMOVAL,
FU-01146
FU(H6DO)-51
Fuel Filter
28.Fuel Filter
A: SPECIFICATION
<Ref. to FU(H6DO)-48, REMOVAL, Fuel Pump.>
<Ref. to FU(H6DO)-48, INSTALLATION, Fuel
Pump.>
FU(H6DO)-52
Fuel Bypass Valve

29.Fuel Bypass Valve

A: REMOVAL
2) Disconnect the pressure regulator vacuum
hose.
3) Disconnect the fuel delivery line and return line
from fuel bypass valve.
4) Remove the fuel bypass valve from vehicle
body.
(A)
(B)
(C)
(B)
T
T
T
FU-02180
(A) Pressure regulator vacuum hose

(B) Fuel delivery line
(C) Fuel return line
B: INSTALLATION
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.53 ft-lb)
FU(H6DO)-53


A: REMOVAL
2) Release the fuel pressure. <Ref. to FU(H6DO)-39, RELEASING OF FUEL PRESSURE, PROCEDURE,
Fuel.>
FU-02181

(A) (B)

covered with dust.
plastic bag, etc.
FU-02148

(B) Evaporation hose

8) Remove the fuel tank. <Ref. to FU(H6DO)-40,
REMOVAL, Fuel Tank.>
FU-01333
(3) Hold the connector and push retainer down.

(4) Pull out the connector from retainer.
FU(H6DO)-54

CAUTION:
securely.
CAUTION:
(B)
(C)
(A)
FU-00124
(A)
(A) Connector
(B) Retainer
(C) Pipe
(B)
(C)
FU-00127
B: INSTALLATION
(A) Connector
(B) Retainer
(C) Pipe

CAUTION:

2: 2.51.5 mm (0.0980.059 in)
(A)
L: 22.52.5 mm (0.8860.098 in)

(B)
(1)
(2)
(3)
Type A
FU-00125
L
(A) Seal surface

(B) Pipe
Type B
(1) Set the new retainer to connector.

FU-00128
(1) Pipe
(2) Clamp
(3) Hose
(A)
(B)
(C)
FU-00126

to the pipe by approx. 15 mm (0.59 in) from the
hose end.
Fuel return hose:
L = 22.52.5 mm (0.8850.098 in)
L = 17.52.5 mm (0.6890.098 in)
(A) Connector
(B) Retainer
(C) Pipe
FU(H6DO)-55

CAUTION:
(2)
(1)
(3)
L/2
L
FU-00129
(1) Hose
(2) Clip
(3) Pipe
C: INSPECTION
1) Make sure that there are no crack on the fuel
FU(H6DO)-56


A: INSPECTION
1)
Corrective action
Defective terminal contact
Trouble in electromagnetic or electronic circuit parts

2)
Decline of fuel pump function
3)
Clogged dust or water in the fuel filter
4)
Clogged or bent fuel pipe or hose
5)
Air mixed in the fuel system
6)
Clogged or bent air breather tube or pipe
7)
Damaged diaphragm of pressure regulator
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

1)
pipe
2)
Defective packing air tightness on the fuel saucer
3)
Cracked fuel separator
4)
Inoperative fuel pump modulator or circuit
1)
Defective operation of fuel level sensor
2)
Defective operation of fuel meter
3)
Defective body integrated unit
5. Noise
1)
Large operation noise or vibration of fuel pump

securely.
Replace.
Retighten.
Replace.
Replace.
Replace.
tube.
Retighten.
Replace separator.
Replace.
Replace.
Replace.
Replace.
Replace.
NOTE:
When water condensation is noticed in the fuel filter, drain water from both the fuel filter and fuel tank or
use a water removing agent in the fuel tank.
FU(H6DO)-57

FU(H6DO)-58
EMISSION CONTROL
EC(H6DO)
1.
2.
3.
4.
5.
6.
7.
8.
Page
EGR Valve ..................................................................................................5
Canister.......................................................................................................6
Two-way Valve............................................................................................8
PCV Valve...................................................................................................9
General Description
A: CAUTION
points.
cable from battery.
EC(H6DO)-2


A: REMOVAL
The front and rear catalytic converters are integrated into front exhaust pipe as one unit; therefore, refer to Front Exhaust Pipe for removal procedure.
<Ref. to EX(H6DO)-5, REMOVAL, Front Exhaust
Pipe.>
(A)
(B)
EC-02018
(A) Front catalytic converter

(B) Rear catalytic converter
B: INSTALLATION
The front and rear catalytic converters are integrated into front exhaust pipe as one unit; therefore, refer to Front Exhaust Pipe for installation
procedure. <Ref. to EX(H6DO)-6, INSTALLATION,
Front Exhaust Pipe.>
(A)
(B)
EC-02018

C: INSPECTION
EC(H6DO)-3


A: REMOVAL
The front and rear catalytic converters are integrated into front exhaust pipe as one unit; therefore, refer to Front Exhaust Pipe for removal procedure.
Pipe.>
(A)
(B)
EC-02018

B: INSTALLATION
The front and rear catalytic converters are integrated into front exhaust pipe as one unit; therefore, refer to Front Exhaust Pipe for installation
procedure. <Ref. to EX(H6DO)-6, INSTALLATION,
(A)
(B)
EC-02018

C: INSPECTION
EC(H6DO)-4
EGR Valve
4. EGR Valve
A: SPECIFICATION
Refer to EGR valve for removal and installation.
<Ref. to FU(H6DO)-25, EGR Valve.>
EC(H6DO)-5
Canister
5. Canister
Tightening torque:
8.3 Nm (0.85 kgf-m, 6.1 ft-lb)
A: REMOVAL
3) Remove the mud guard LH.
4) Remove the protector. (Sedan model)
(B)
(B)
(A)
(A)
(B)
(B)
EC-02027
C: INSPECTION
cracked or loose.
EC-02027
B: INSTALLATION
NOTE:
EC(H6DO)-6


A: REMOVAL
NOTE:

(B)
(A)
EC-02020
IN-00203

4) Disconnect the connector and hoses of purge
control solenoid valve, and then remove the purge
(A) To fuel pipe (Evaporation line)

(B) To intake manifold
C: INSPECTION
EC-02019
B: INSTALLATION
Tightening torque:
19 Nm (1.9 kgf-m, 14.0 ft-lb)
EC-02019
EC(H6DO)-7
Two-way Valve
7. Two-way Valve
A: REMOVAL
valve.
from body.
EC-00221
B: INSTALLATION
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
C: INSPECTION
EC(H6DO)-8
PCV Valve
8. PCV Valve
A: REMOVAL
1) Disconnect the PCV hose.
EC-02021
2) Remove the PCV valve from rocker cover.
EC-02022
B: INSTALLATION
NOTE:
valve.
Liquid gasket:
Tightening torque:
25 Nm (2.5 kgf-m, 18 ft-lb)
EC(H6DO)-9
PCV Valve
EC(H6DO)-10
INTAKE (INDUCTION)
IN(H6DO)
1.
2.
3.
4.
5.
6.
Page
Air Cleaner Case.........................................................................................5
Air Intake Chamber .....................................................................................7
Air Intake Duct.............................................................................................8
Resonator Chamber....................................................................................9
General Description
INTAKE (INDUCTION)
A: COMPONENT
T2
T2
(14)
(14)
(13)
(13)
T3
(11)
(15)
(10)
T3
(12)
T3
(16)
(9)
(9)
T5
(18)
(8)
(7)
T4
(4)
(17)
(3)
T1
(2)
(6)
(6)
(1)
(5)
(5)
IN-02008
IN(H6DO)-2
General Description
INTAKE (INDUCTION)
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Air intake duct

Clip
Resonator chamber
Spacer
Cushion
Air cleaner element
Clip
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
Clamp
Intake duct
Clamp
Cushion
Spacer
Air intake chamber
Clamp
Cushion
B: CAUTION
points.
cable from battery.
IN(H6DO)-3
(18)

T1: 6.0 (0.6, 4.4)
T2: 6.4 (0.65, 4.7)
T3: 3.0 (0.3, 2.2)
T4: 7.5 (0.76, 5.5)
T5: 1.0 (0.10, 0.7)
Air Cleaner Element

INTAKE (INDUCTION)
B: INSTALLATION
A: REMOVAL

NOTE:
case.
IN-00203

IN-00207
C: INSPECTION
IN-02009
3) Remove the clip (A) from the upper side of air

cleaner case.
(A)
IN-02010
4) Pull the air cleaner case (rear) to the rearward of

vehicle, and then remove the air cleaner element.
NOTE:
Be careful that the power steering hose is secured
to the under side of air cleaner case (rear).
IN(H6DO)-4
Air Cleaner Case

INTAKE (INDUCTION)
3. Air Cleaner Case
6) Remove the air cleaner case (rear) and air

cleaner element.
A: REMOVAL
IN-00206
IN-00203
7) Remove the bolt (A) and nut (B) which hold air
cleaner case on the body.
2) Remove the air intake duct. <Ref. to IN(H6DO)8, REMOVAL, Air Intake Duct.>
(B)
(A)
IN-00208

IN-02009
4) Loosen the clamp (A) which connects air cleaner

case to intake duct.
5) Remove the clip (B) from the upper side of air
cleaner case.
(B)
(A)
IN-02011
IN(H6DO)-5
Air Cleaner Case

INTAKE (INDUCTION)
B: INSTALLATION
Tightening torque:
Bolt (A): 6.0 Nm (0.6 kgf-m, 4.4 ft-lb)
Nut (B): 7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
(B)
(A)
IN-00208
NOTE:
case.
IN-00207
C: INSPECTION
Check for cracks or loose connection.
IN(H6DO)-6
Air Intake Chamber

INTAKE (INDUCTION)
4. Air Intake Chamber

A: REMOVAL
2) Loosen the clamp (A) which connects air intake
chamber to throttle body.
3) Loosen the clamp (B) which connects intake
duct to air intake chamber.
4) Remove the bolt (C) which secures air intake
chamber to the stay.
(A)
(B)
(C)
(C)
IN-02012
5) Disconnect one part of blow-by hose, and remove the air intake chamber.
B: INSTALLATION
Tightening torque:
Clamp (A), (B)
3.0 Nm (0.3 kgf-m, 2.2 ft-lb)
Bolt (C)
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
(A)
(B)
(C)
(C)
IN-02012
C: INSPECTION
chamber.
IN(H6DO)-7
Air Intake Duct

INTAKE (INDUCTION)
5. Air Intake Duct

A: REMOVAL
1) Remove the clips which install air intake duct on
the front side of body.
IN-02013
B: INSTALLATION
C: INSPECTION
duct.
IN(H6DO)-8
Resonator Chamber
INTAKE (INDUCTION)
A: REMOVAL
with air cleaner case. <Ref. to IN(H6DO)-5, REMOVAL, Air Cleaner Case.>
B: INSTALLATION
Refer to Air Cleaner Case for installation procedure because the resonator chamber forms a single unit with air cleaner case. <Ref. to IN(H6DO)-6,
INSTALLATION, Air Cleaner Case.>
C: INSPECTION
IN(H6DO)-9
Resonator Chamber
INTAKE (INDUCTION)
IN(H6DO)-10
MECHANICAL
ME(H6DO)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
Page
Compression .............................................................................................23
Idle Speed .................................................................................................24
Ignition Timing...........................................................................................25
Fuel Pressure............................................................................................28
Valve Clearance........................................................................................29
V-belt.........................................................................................................34
Engine Assembly ......................................................................................35
Engine Mounting .......................................................................................41
Crank Pulley..............................................................................................43
Front Chain Cover.....................................................................................44
Timing Chain Assembly ............................................................................46
Cam Sprocket ...........................................................................................51
Crank Sprocket .........................................................................................52
Rear Chain Cover .....................................................................................53
Camshaft...................................................................................................55
Cylinder Head ...........................................................................................59
Cylinder Block ...........................................................................................64
Oil Flow Control Solenoid Valve................................................................79
Oil Switching Solenoid Valve ....................................................................80
ATF Warmer Cock ....................................................................................81
Engine Noise.............................................................................................89
General Description
MECHANICAL
A: SPECIFICATION
Bore Stroke
mm (in)
cm3
Displacement
Compression ratio
Compression pressure
(350 rpm and fully open throttle):
Engine
2,999 (183)
10.7
kPa (kg/cm2, psi)

Open
Close
Open
Close
Open
Close
Min.
advance
Intake valve timing
Max.
retard

Valve clearance
(cu in)

Chain driven, double overhead camshaft,
4-valve/cylinder
89.2 80 (3.512 3.150)
mm (in)
0.350.05 (0.01380.020)
rpm
Ignition order
Ignition timing

BTDC 47
ABDC 23
ATDC 3
ABDC 73
BBDC 60
ATDC 6
0.20+0.04 -0.06 (0.0079+0.0016-0.0024)
Intake
Exhaust
Idling speed [P or N range]
1,275 1,471 (13.0 15.0, 185 213)
No
load
A/C
ON
BTDC/rpm
65050
77050
1 6 3 2 5 4
158/650
NOTE:
OS: Oversize US: undersize
Standard
Standard
HIGH
Standard
Intake
LOW1
Standard
Cam lobe height
mm (in)
LOW2
Standard
Exhaust
Standard
HIGH
Standard
Intake
LOW1
Standard
Cam base circle diammm (in)
eter
LOW2
Standard
Exhaust
Standard
Front:
Standard
Journal O.D.
mm (in)
Except for front
Standard
Oil clearance
mm (in) Standard
Flatness
mm (in) Standard
Inner diameter of valve lifter hole
mm (in)
Standard height
mm (in)
Refacing angle
Intake
Standard
Contacting width
mm (in)
Exhaust
Standard
Inside diameter
mm (in)
mm (in)
Side clearance
Camshaft
Cylinder
head
Valve seat
Valve guide
mm (in)
Intake
Exhaust
ME(H6DO)-2
0.075 0.135 (0.0030 0.0053)

0.030 0.090 (0.0012 0.0035)
42.09 42.19 (1.6571 1.6610)
38.14 38.24 (1.5016 1.5055)
34.94 35.04 (1.3756 1.3795)
41.65 41.75 (1.6398 1.6437)
32.00 (1.2598)
31.84 (1.2535)
31.84 (1.2535)
32.00 (1.2598)
37.946 37.963 (1.4939 1.4946)
25.946 25.963 (1.0215 1.0222)
0.037 0.072 (0.0015 0.0028)
0.02 (0.0008)
32.994 33.016 (1.2990 1.2998)
1240.05 (4.880.0020)
90
1.0 (0.039)
1.5 (0.059)
5.500 5.512 (0.2165 0.2170)
11.4 11.8 (0.449 0.465)
General Description
MECHANICAL
Head edge thickness
Valve
mm (in)
Intake
Exhaust
Stem outer diameter
mm (in)
Stem oil clearance
Intake
Exhaust
Overall length
mm (in)
Standard
Standard
Intake
Exhaust
Standard
Standard
Intake
Exhaust
Outer diameter of valve lifter

Free length
mm (in)
mm (in)
Inner
Outer
Intake
Exhaust
Valve spring
Squareness
Inner
Outer
Intake
Exhaust
Standard height
Cylinder
block
Piston
Piston pin
Piston ring
Connecting
rod
mm (in)
A
Cylinder inner diameter
B
Cylindricality
mm (in) Standard
Out-of-roundness
mm (in) Standard
Piston clearance
mm (in) Standard
A
Standard
B
Outer diameter
mm (in)
0.25 (0.0098) OS
0.50 (0.0197) OS
Inner diameter of piston pin hole
Standard
Outer diameter
mm (in) Standard
Standard clearance between piston and piston pin
Standard
mm (in)
Top ring
Standard
Ring closed gap
mm (in) Second ring
Standard
Oil ring
Standard
Top ring
Standard
Ring groove gap
mm (in) Second ring
Standard
Oil ring
Standard
Stanmm (in)
dard
Side clearance of large end

Oil clearance
Bearing of
large end
Bushing of
small end
Bearing size
1.0 (0.039)
1.2 (0.047)
5.455 5.470 (0.2148 0.2145)
5.455 5.460 (0.2148 0.2150)
0.030 0.057 (0.0012 0.0022)
0.040 0.067 (0.0016 0.0026)
99.7 (3.925)
105.2 (4.142)
32.959 32.975 (1.2976 1.2982)
39.55 (1.5571)
41.18 (1.6213)
46.32 (1.8236)
2.5, 1.7 mm (0.067 in)
2.5, 1.8 mm (0.071 in)
2.5, 2.0 mm (0.079 in)
202 (7.95)
89.205 89.215 (3.5120 3.5124)
89.195 89.205 (3.5116 3.5120)
0.030 (0.0012)
0.010 (0.0004)
0.010 0.010 (0.0004 0.0004)
89.205 89.215 (3.5120 3.5124)
89.195 89.205 (3.5116 3.5120)
89.445 89.465 (3.5215 3.5222)
89.695 89.715 (3.5313 3.5321)
22.000 22.006 (0.8661 0.8664)
21.994 22.000 (0.8659 0.8661)
0.004 0.008 (0.0002 0.0003)
0.20 0.35 (0.0079 0.0138)
0.35 0.50 (0.0138 0.0197)
0.20 0.60 (0.0079 0.0236)
0.040 0.080 (0.0016 0.0031)
0.030 0.070 (0.0012 0.0028)
0.045 0.125 (0.0018 0.0049)
mm (in) Standard
0.070 0.330 (0.0028 0.0130)
mm (in) Standard
Standard
0.03 (0.0012) US
mm (in)
0.05 (0.0020) US
0.25 (0.0098) US
0.016 0.043 (0.0006 0.0017)

1.490 1.506 (0.0587 0.0593)
1.509 1.513 (0.0594 0.0596)
1.519 1.523 (0.0598 0.0600)
1.619 1.623 (0.0637 0.0639)
Clearance between piston pin and bushing
mm (in) Standard
ME(H6DO)-3
0 0.022 (0 0.0009)
General Description
MECHANICAL
Out-of-roundness
mm (in)
Cylindricality
mm (in)
Standard
0.03 (0.0012) US
mm (in)
0.05 (0.0020) US
0.25 (0.0098) US
Standard
0.03 (0.0012) US
#1, #3,
#5, #7
0.05 (0.0020) US
0.25 (0.0098) US
mm (in)
Standard
0.03 (0.0012) US
#2, #4,
#6
0.05 (0.0020) US
0.25 (0.0098) US
Thrust clearance
mm (in) Standard
Oil clearance
mm (in) Standard
Standard
0.03 (0.0012) US
#1, #3,
#5, #7
0.05 (0.0020) US
0.25 (0.0098) US
Bearing size
mm (in)
Standard
0.03 (0.0012) US
#2, #4,
#6
0.05 (0.0020) US
0.25 (0.0098) US
Crank pin and crank journal
Crankshaft
Main bearing
ME(H6DO)-4
0.005 (0.0002)
0.006 (0.0002)
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)
63.992 64.008 (2.5194 2.5200)
63.962 63.978 (2.5182 2.5188)
63.942 63.958 (2.5174 2.5180)
63.742 63.758 (2.5095 2.5102)
63.992 64.008 (2.5194 2.5200)
63.962 63.978 (2.5182 2.5188)
63.942 63.958 (2.5174 2.5180)
63.742 63.758 (2.5095 2.5102)
0.030 0.115 (0.0012 0.0045)
0.010 0.030 (0.0004 0.0012)
1.992 2.005 (0.0784 0.0789)
2.011 2.014 (0.0792 0.0793)
2.021 2.024 (0.0796 0.0797)
2.121 2.124 (0.0835 0.0836)
1.996 2.009 (0.0786 0.0791)
2.015 2.018 (0.0793 0.0794)
2.025 2.028 (0.0797 0.0798)
2.125 2.128 (0.0837 0.0838)
General Description
MECHANICAL
B: COMPONENT
1. V-BELT
(5)
(6)
(4)
(3)
T2
(2)
T3
T3
(7)
(8)
T1
(9)
T4
(1)
ME-02020
(1)
(2)
(3)
(4)
(5)
V-belt
Collector cover bracket
Belt tension adjuster ASSY
Power steering pump bracket
Generator
(6)
(7)
(8)
(9)
Generator plate
A/C compressor stay
Idler pulley
Idler pulley cover
ME(H6DO)-5

T1: 6.4 (0.65, 4.7)
T2: 20 (2.0, 14)
T3: 25 (2.5, 18)
T4: 33 (3.4, 25)
General Description
MECHANICAL
2. TIMING CHAIN COVER
T3
(8)
T3
T2
T3
(7)
(4)
T2
T3
T3
T1
(1)
(2)
(6)
(5)
(3)
T2
T2
T4
ME-02021
(1)
(2)
(3)
(4)
Crank pulley cover

O-ring
Crank pulley
Sealing washer
(5)
(6)
(7)
(8)
Oil seal
Front chain cover
Rear chain cover
Water pump gasket

T1: <Ref. to ME(H6DO)-43, Crank
Pulley.>
T2: <Ref. to ME(H6DO)-44, Front
Chain Cover.>
T3: <Ref. to ME(H6DO)-53, Rear
Chain Cover.>
T4: 6.4 (0.65, 4.7)
ME(H6DO)-6
General Description
MECHANICAL
3. TIMING CHAIN
(4)
(3)
(9)
(1)
(8)
T1
(2)
T6
(5)
(6)
T4
(11)
T2
(12)
T4
(17)
(10)
(13)
(24)
T3
(7)
(22)
(19)
(18)
T4
(25)
(14)
(23)
T1
T4
(22)
(24)
(20)
(16)
T4
(15)
T1
T5
T3
(21)
ME-02022
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
Crank sprocket
Oil relief case
Inner rotor
Outer rotor
Chain guide (CTR)
Intake cam sprocket (RH)
Exhaust cam sprocket (RH)
Chain guide (RH: between cams)
Timing chain (RH)
Chain guide (RH)
Chain tensioner lever (RH)
Chain tensioner (RH)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
Chain tensioner lever (LH)

Chain tensioner (LH)
Water pump
O-ring
Chain guide (LH)
Chain guide (LH: between cams)
Timing chain (LH)
Intake cam sprocket (LH)
Exhaust cam sprocket (LH)
Idler sprocket plate
Idler sprocket (lower)
Idler sprocket collar
ME(H6DO)-7
(25)
Idler sprocket (upper)

T1: 6.4 (0.64, 4.7)
T2: 7.8 (0.80, 5.8)
T3: <Ref. to ME(H6DO)-51, Cam
Sprocket.>
T4: 16 (1.6, 11.6)
T5: 69 (7.0, 50.6)
T6: <Ref. to LU(H6DO)-8, Oil
Pump.>
General Description
MECHANICAL

T2
(1)
T2
(7)
T4
(2)
(9)
(8)
T3
(10)
(11)
(5)
(14)
(15)
(4)
(16)
(3)
(6)
(17)
(12)
(13)
(18)
(19)
T1
(20)
(21)
T1
(26)
T4
(35)
(22)
(28)
(23)
(27)
(24)
(25)
(32)
(29)
T2
(33)
(30)
(31)
T2
ME(H6DO)-8
T5
(34)
T3
ME-02095
General Description
MECHANICAL
(1)
(2)
(3)
Rocker cover (RH)

Oil switching solenoid valve (RH)
Oil switching solenoid valve holder
(RH)
(4)
Oil switching solenoid valve gasket
(5)
(6)
(7)
Rear chain cover

Oil pipe (RH)
(RH)
(8)
(9)
(10)
(11)
Intake camshaft cap (Center RH)

Intake camshaft cap (Rear RH)
Exhaust camshaft cap (Rear RH)
Exhaust camshaft cap (Center
RH)
(12)
(13)
Exhaust camshaft cap (Front RH)

Front camshaft cap (RH)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
Intake camshaft (RH)

Exhaust camshaft (RH)
Cylinder head (RH)
Water hose
Cylinder head gasket (RH)
Oil switching solenoid valve (LH)
Oil switching solenoid valve holder
(LH)
(21)
Oil switching solenoid valve gasket
(22)
(23)
(24)
(25)
(26)
(27)
(28)
Cylinder head gasket (LH)

Cylinder head (LH)
Intake camshaft (LH)
Exhaust camshaft (LH)
Oil flow control solenoid valve (LH)
Intake camshaft cap (Rear LH)
Intake camshaft cap (Center LH)
ME(H6DO)-9
(29)
(30)
Exhaust camshaft cap (Rear LH)

Exhaust camshaft cap (Center
LH)
(31)
(32)
(33)
(34)
(35)
Exhaust camshaft cap (Front LH)

Front camshaft cap (LH)
Plug
Oil pipe (LH)
Rocker cover (LH)
Tightening torque:Nm (kgf-m, ft-lb)

T1: <Ref. to ME(H6DO)-59, Cylinder
Head.>
T2: <Ref. to ME(H6DO)-55,
Camshaft.>
T3: 9.75 (1.0, 7.2)
T4: 16 (1.6, 12)
T5: 60 (6.1, 44)
General Description
MECHANICAL
(1)
(16)
(4)
(3)
(5)
(6)
(7)
(8) (9) (10) (11)
(2)
(16)
(12)
(4)
(17)
(13)
(14)
(8)
(9)
(15)
ME-02024
(1)
(2)
(3)
(4)
(5)
(6)
Exhaust valve
Intake valve
Intake valve guide
Valve spring seat
Intake valve stem seal
Valve spring (Inner)
(7)
(8)
(9)
(10)
(11)
(12)
Valve spring (Outer)

Retainer
Retainer key
Shim
Valve lifter (Intake)
Exhaust valve guide
ME(H6DO)-10
(13)
(14)
(15)
(16)
(17)
Exhaust valve stem seal

Valve spring
Valve lifter (Exhaust)
Cylinder head plug
Cylinder head
General Description
MECHANICAL
6. CYLINDER BLOCK
T3
T8
(1)
T1
(19)
(3)
(20)
(4)
T1
(19)
(5)
T5
T8
T8
(19)
(2)
(19)
T5
(5)
(19)
(7)
(14)
(17)
(13)
(6)
T2
(5)
(13)
T10
(19)
(18)
(19)
T7
(16)
T4
T2
(5)
T2
(5)
T2
(19)
(13)
(14)
T9
T1
(21)
T2
(13)
(22)
(15)
(23)
(13)
(13)
(8)
T2
(9)
T6
(10)
(14)
T1
T6
(12)
(11)
T1
ME-02108
ME(H6DO)-11
General Description
MECHANICAL
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
Cylinder block (RH)

Cylinder block (LH)
Rear oil seal
Service hole cover
O-ring
Oil pan upper
Oil pressure switch
Oil strainer
Magnet
Oil pan lower
Metal gasket
Drain plug
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
Clamp
Hose
Oil cooler pipe
Oil cooler
Connector
Oil filter
Plug
Crankshaft position sensor holder
Relief valve
Relief valve spring
Plug
ME(H6DO)-12
Tightening torque:Nm (kgf-m, ft-lb)

T1: 6.4 (0.65, 4.7)
T2: 18 (1.8, 13.0)
T3: 25 (2.5, 18)
T4: 16 (1.6, 12)
T5: 37 (3.8, 27)
T6: 44 (4.5, 33)
T7: 54 (5.5, 40)
T8: 70 (7.1, 52)
T9: 23 (2.3, 17)
T10: 90 (9.2, 67)
General Description
MECHANICAL
T1
(7)
(12)
(13)
T2
(1)
(4)
(14)
(9)
(5)
(6)
(7)
(2)
(11)
(8)
(3)
(10)
(11)
(15)
(10)
(11)
(8)
(7)
(13)
(6)
(5)
(12)
(4)
(18)
(16)
(17)
(17)
T1
(7)
(16)
(9)
(17)
(16)
ME-02101
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Reinforcement
Drive plate
Crankshaft sensor plate
Top ring
Second ring
Oil ring
Snap ring
Piston
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
Piston pin
Connecting Rod
Connecting rod bolt
Connecting rod cap
Crankshaft
Woodruff key
Crankshaft bearing #1, #3, #5
ME(H6DO)-13
(17)
(18)
Crankshaft bearing #2, #4, #6

Crankshaft bearing #7

T1: 53 (5.4, 39)
T2: 81 (8.3, 60)
General Description
MECHANICAL
8. ENGINE MOUNTING
(1)
T1
T2
T1
T2
ME-00445
(1)

T1: 35 (3.6, 25.8)
T2: 85 (8.7, 63)
ME(H6DO)-14
General Description
MECHANICAL
C: CAUTION
points.
cable from battery.
assembly.
making rechecks.
ready use.
with coolant or oil. Place a cover over fenders, as
required, for protection.
jacks, etc.
ME(H6DO)-15
General Description
MECHANICAL
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
18250AA010
DESCRIPTION
CYLINDER
HEAD TABLE
REMARKS
18232AA000
ENGINE STAND
Used for disassembling and assembling engine.
CRANKSHAFT
STOPPER
Used for stopping rotation of flywheel or drive

plate when loosening/tightening crank pulley bolt.
PISTON PIN
GUIDE
Used for installing piston in cylinder.
ST18250AA010
ST18232AA000
498497100
ST-498497100
18254AA000
ST18254AA000
ME(H6DO)-16
General Description
MECHANICAL
ILLUSTRATION
TOOL NUMBER
499585500
DESCRIPTION
VALVE OIL SEAL
GUIDE
REMARKS
guide oil seals.
18253AA000
PISTON PIN
GUIDE
18350AA000
CONNECTING
ROD BUSHING
REMOVER AND
INSTALLER

bushing.
PISTON PIN
REMOVER
ASSY
ST-499585500
ST18253AA000
ST18350AA000
499097500
ST-499097500
ME(H6DO)-17
General Description
MECHANICAL
ILLUSTRATION
TOOL NUMBER
499977500
DESCRIPTION
CAM
SPROCKET
WRENCH
REMARKS
Used for removing and installing intake cam
sprocket.
CAM
SPROCKET
WRENCH
Used for removing and installing exhaust cam

sprocket.
499587200
CRANKSHAFT
OIL SEAL
INSTALLER

(499597100).
499597100
CRANKSHAFT
ST-499977500
18231AA020
ST18231AA020
ST-499587200
ST-499597100
ME(H6DO)-18
General Description
MECHANICAL
ILLUSTRATION
TOOL NUMBER
499718000
DESCRIPTION
VALVE SPRING
REMOVER
REMARKS
18251AA040
VALVE GUIDE
ADJUSTER
Used for installing valve guides.
499765700
VALVE GUIDE
REMOVER
499765900
VALVE GUIDE
REAMER
ST-499718000
ST18251AA040
ST-499765700
ST-499765900
ME(H6DO)-19
General Description
MECHANICAL
ILLUSTRATION
TOOL NUMBER
499977100
DESCRIPTION
CRANK PULLEY
WRENCH
REMARKS
CRANKSHAFT
SOCKET
OIL FILTER
WRENCH
Used for removing and installing oil filter.
CARTRIDGE
ST-499977100
18252AA000
ST18252AA000
498547000
ST-498547000
24082AA230
ST24082AA230
ME(H6DO)-20
General Description
MECHANICAL
ILLUSTRATION
TOOL NUMBER
22771AA030
DESCRIPTION
SUBARU
SELECT MONITOR KIT
REMARKS
18233AA000
PISTON PIN
SNAP RING PLIERS
Used for removing and installing snap ring of piston pin.
498277200
STOPPER SET
499057000
TORX PLUS
Used for removing and installing drive plate of flywheel (dual mass flywheel type).
ST22771AA030
ST18233AA000
ST-498277200
ST-499057000
2. GENERAL TOOL
TOOL NAME
Compression gauge
REMARKS
ME(H6DO)-21
General Description
MECHANICAL
E: PROCEDURE
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.
Camshaft
Cylinder head
ME(H6DO)-22
Compression
MECHANICAL
2. Compression
A: INSPECTION
CAUTION:
switch to OFF.
4) Remove all the spark plugs. <Ref. to IG(H6DO)4, REMOVAL, Spark Plug.>
spark plug hole.
NOTE:
ME-00446
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 1,471 kPa (13.0 15.0 kg/cm2, 185
213 psi)
Service limit:
1, 128 kPa (11.5 kgf/cm2, 164 psi)
ME(H6DO)-23
Idle Speed
MECHANICAL
3. Idle Speed
A: INSPECTION
properly.
not illuminate.
2) Idle the engine.
OFF.
4) Insert the cartridge to the Subaru Select Monitor.
connector.
11) Start the engine, and read engine idle speed.
12) Check the idle speed when no-loaded. (Headlight, heater fan, rear defroster, radiator fan, A/C,
etc. are OFF.)
Idle speed [No load and gears in neutral]:
65050 rpm
13) Check the idle speed when loaded. (Turn the
air conditioning switch to ON and operate the
compressor for at least one minute before measurement.)
Idle speed [A/C ON, and gears in neutral]:
77050 rpm
NOTE:
<Ref. to EN(H6DO)(diag)-2, Basic Diagnostic Procedure.>
ME(H6DO)-24
Ignition Timing
MECHANICAL
4. Ignition Timing
A: INSPECTION
CAUTION:
careful not to burn yourself at measurement.
1. WITH SUBARU SELECT MONITOR

1) Before checking the ignition timing speed, check
the following:
clogging, spark plugs are in good condition, and
hoses are connected properly.
not illuminate.
2) Idle the engine.
OFF.
4) Insert the cartridge to the Subaru Select Monitor.
connector.
the idle speed.
158/650
system. Refer to Engine Control System. <Ref. to
EN(H6DO)(diag)-2, Basic Diagnostic Procedure.>
ME(H6DO)-25

MECHANICAL

A: INSPECTION
1) Idle the engine.
2) Disconnect the brake vacuum hose from the intake manifold, and then install the vacuum gauge.
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.
FU-02115

60.0 kPa (450 mmHg, 17.72 inHg) or less
1. Needle is steady but lower than normal position. This tenLeakage around intake manifold gasket, disconnection or damdency becomes more evident as engine temperature rises.
aged vacuum hose
2. Needle intermittently drops to position lower than normal
Leakage around cylinder
position.
3. Needle drops suddenly and intermittently from normal posiValve anchoring
tion.
Defective ignition system or throttle chamber idle adjustment
range.
ME(H6DO)-26
Engine Oil Pressure

MECHANICAL

A: INSPECTION
1) Remove the oil pressure switch from cylinder
block. <Ref. to LU(H6DO)-12, REMOVAL, Oil
Pressure Switch.>
block.
4) Start the engine, and measure oil pressure.
OIL PRESSURE (at oil temperature of 80C
(176F)):
Standard:
135 kPa (1.4 kg/cm2, 20 psi) or more (at 600
rpm)
500 kPa (5.1 kg/cm2, 73 psi) or more (at
5,000 rpm)
CAUTION:
<Ref. to LU(H6DO)-16, INSPECTION, General
Diagnostic Table.>
If the oil pressure warning light come on and
oil pressure is in specification, replace the oil
pressure switch. <Ref. to LU(H6DO)-16, INSPECTION, General Diagnostic Table.>
pressure switch. <Ref. to LU(H6DO)-12, INSTALLATION, Oil Pressure Switch.>
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
ME(H6DO)-27
Fuel Pressure
MECHANICAL
7. Fuel Pressure
A: INSPECTION
WARNING:
Before removing the fuel pressure gauge, release fuel pressure.
NOTE:
filler cap.
3) Disconnect the fuel delivery hose and connect
FU-01122

Fuel pressure:
Standard: 333 363 kPa (3.4 3.7 kgf/cm2,
48 53 psi)
Fuel pressure:
Standard: 279 309 kPa (2.85 3.15 kgf/
cm2, 40 45 psi)
NOTE:
to 0.2 kgf/cm2, 1 to 3 psi) higher than standard values during high-altitude operations.
ME(H6DO)-28
Valve Clearance
MECHANICAL
8. Valve Clearance
(2) Disconnect the PCV hose and blow-by hose

from rocker cover (LH).
A: INSPECTION
ME-00460
(3) Remove the fuel pipe protector (LH).
IN-00203

7) When inspecting RH side cylinders:
(1) Remove the air intake duct and air cleaner
case. <Ref. to IN(H6DO)-8, REMOVAL, Air Intake Duct.> <Ref. to IN(H6DO)-5, REMOVAL,
Air Cleaner Case.>
(2) Remove the fuel tank protector (RH).
FU-02117
(4) Remove the fuel injectors. <Ref. to

FU(H6DO)-26, REMOVAL, Fuel Injector.>
(5) Remove the ignition coil. <Ref. to
IG(H6DO)-7, REMOVAL, Ignition Coil and Ignitor Assembly.>
(6) Remove the rocker cover (LH).
FU-02119
(3) Remove the fuel injectors. <Ref. to

FU(H6DO)-26, REMOVAL, Fuel Injector.>
(4) Disconnect the connector of oil pressure
switch.
(5) Remove the ignition coil. <Ref. to
IG(H6DO)-7, REMOVAL, Ignition Coil and Ignitor Assembly.>
(6) Remove the rocker cover (RH).
8) When inspecting LH side cylinders:
(1) Disconnect the battery cable, and then remove the battery and battery carrier.
ME(H6DO)-29
Valve Clearance
MECHANICAL
9) Turn the crankshaft clockwise until the cam is

set to position shown in the figure.
If the measured value is not within specification,

take notes of the value in order to adjust the valve
clearance later on.
(A)
(3) (4)
(4) (3)
(23 )
(23 )
(1)
(1)
ME-00464
(2)

to ME(H6DO)-30, ADJUSTMENT, Valve Clearance.>
12) Further turn the crank pulley clockwise and
then measure the valve clearances again.
(2)
B: ADJUSTMENT
ME-02565
(1)
(2)
(3)
(4)
Valve clearance (Intake side)

Valve clearance (Exhaust side)
High lift cam
Low lift cam
10) Measure the clearance of intake valve and exhaust valve using thickness gauge (A).
NOTE:
Measure it within the range of 30 that shown in
the figure.
Measure it in low lift cam for intake side.
Insert the thickness gauge in as horizontal a direction as possible with respect to the valve lifter.
Valve clearance
Intake:
0.20+0.040.06 mm (0.0079+0.00160.0024 in)
Exhaust:
0.350.05 mm (0.01380.0020 in)
1. INTAKE SIDE
CAUTION:
Do not wear gloves during removal and installation of valve lifter.
Do not use a valve lifter which got high impact due to drop, etc.
When installing the valve lifter, align the antirotation of valve lifter with groove on cylinder
head, and then insert the valve lifter.
1) Measure all valve clearances.
<Ref. to ME(H6DO)-29, INSPECTION, Valve
Clearance.>
NOTE:
measured.
2) Remove the camshaft. <Ref. to ME(H6DO)-55,
REMOVAL, Camshaft.>
4) Remove the shim from valve lifter.
5) Confirm the thickness of shim by the stamped
mark on the side of removed shim.
6) Select a shim of suitable thickness from the following table using the measured valve clearance
and confirmed shim thickness.
Unit: (mm)
S = (V + T) 0.20
S: Required shim thickness
T: Shim thickness to be used
ME(H6DO)-30
Valve Clearance
MECHANICAL
Part No.
13218AK890
13218AK900
13218AK910
13218AK920
13218AK930
13218AK940
13218AK950
13218AK960
13218AK970
13218AK980
13218AK990
13218AL000
13218AL010
13218AL020
13218AL030
13218AL040
13218AL050
13218AL060
13218AL070
13218AL080
13218AL090
13218AL100
13218AL110
13218AL120
13218AL130
13218AL140
13218AL150
13218AL160
13218AL170
13218AL180
13218AL190
13218AL200
13218AL210
13218AL220
13218AL230
13218AL240
13218AL250
13218AL260
13218AL270
13218AL280
13218AL290
13218AL300
13218AL310
13218AL320
13218AL330
13218AL340
13218AL350
13218AL360
13218AL370
13218AL380
13218AL390
Thickness mm (in)
1.92 (0.0756)
1.94 (0.0764)
1.96 (0.0772)
1.98 (0.0780)
2.00 (0.0787)
2.02 (0.0795)
2.04 (0.0803)
2.06 (0.0811)
2.07 (0.0815)
2.08 (0.0819)
2.09 (0.0823)
2.10 (0.0827)
2.11 (0.0831)
2.12 (0.0835)
2.13 (0.0839)
2.14 (0.0843)
2.15 (0.0846)
2.16 (0.0850)
2.17 (0.0854)
2.18 (0.0858)
2.19 (0.0862)
2.20 (0.0866)
2.21 (0.0870)
2.22 (0.0874)
2.23 (0.0878)
2.24 (0.0882)
2.25 (0.0886)
2.26 (0.0890)
2.27 (0.0894)
2.28 (0.0898)
2.29 (0.0902)
2.30 (0.0906)
2.31 (0.0909)
2.32 (0.0913)
2.33 (0.0917)
2.34 (0.0921)
2.35 (0.0925)
2.36 (0.0929)
2.37 (0.0933)
2.38 (0.0937)
2.39 (0.0941)
2.40 (0.0945)
2.41 (0.0949)
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)
Part No.
13218AL400
13218AL410
13218AL420
13218AL430
13218AL440
13218AL450
13218AL460
13218AL470
13218AL480
13218AL490
13218AL500
13218AL510
13218AL520
13218AL530
13218AL540
13218AL550
13218AL560
13218AL570
13218AL580
13218AL590
Thickness mm (in)
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)
2.59 (0.1020)
2.60 (0.1024)
2.61 (0.1028)
2.62 (0.1032)
2.64 (0.1039)
2.66 (0.1047)
2.68 (0.1055)
2.70 (0.1063)
2.72 (0.1071)
2.74 (0.1079)
2.76 (0.1087)
2. EXHAUST SIDE
CAUTION:
1) Measure all valve clearances.
<Ref. to ME(H6DO)-29, INSPECTION, Valve
Clearance.>
NOTE:
measured.
REMOVAL, Camshaft.>
4) Measure the thickness of valve lifter with a micrometer.
ME(H6DO)-31
ME-00025
Valve Clearance
MECHANICAL
5) Select a valve lifter of suitable thickness using

measured valve clearance and valve lifter thickness, by referring to the following table.
Unit: (mm)
S = (V + T) 0.35
S: Valve lifter thickness required
T: Valve lifter thickness to be used
Part No.
13228AD180
13228AD190
13228AD200
13228AD210
13228AD220
13228AD230
13228AD240
13228AD250
13228AD260
13228AD270
13228AD280
13228AD290
13228AD300
13228AD310
13228AD320
13228AC580
13228AC590
13228AC600
13228AC610
13228AC620
13228AC630
13228AC640
13228AC650
13228AC660
13228AC670
13228AC680
13228AC690
13228AC700
13228AC710
13228AC720
13228AC730
13228AC740
13228AC750
13228AC760
13228AC770
13228AC780
13228AC790
13228AC800
13228AC810
13228AC820
13228AC830
13228AC840
Thickness mm (in)
4.32 (0.1701)
4.34 (0.1709)
4.36 (0.1717)
4.38 (0.1724)
4.40 (0.1732)
4.42 (0.1740)
4.44 (0.1748)
4.46 (0.1756)
4.48 (0.1764)
4.50 (0.1772)
4.52 (0.1780)
4.54 (0.1787)
4.56 (0.1795)
4.58 (0.1803)
4.60 (0.1811)
4.62 (0.1819)
4.63 (0.1823)
4.64 (0.1827)
4.65 (0.1831)
4.66 (0.1835)
4.67 (0.1839)
4.68 (0.1843)
4.69 (0.1846)
4.70 (0.1850)
4.71 (0.1854)
4.72 (0.1858)
4.73 (0.1862)
4.74 (0.1866)
4.75 (0.1870)
4.76 (0.1874)
4.77 (0.1878)
4.78 (0.1882)
4.79 (0.1886)
4.80 (0.1890)
4.81 (0.1894)
4.82 (0.1898)
4.83 (0.1902)
4.84 (0.1906)
4.85 (0.1909)
4.86 (0.1913)
4.87 (0.1917)
4.88 (0.1921)
ME(H6DO)-32
Part No.
13228AC850
13228AC860
13228AC870
13228AC880
13228AC890
13228AC900
13228AC910
13228AC920
13228AC930
13228AC940
13228AC950
13228AC960
13228AC970
13228AC980
13228AC990
13228AC000
13228AC010
13228AC020
13228AC030
13228AC040
13228AC050
13228AC060
13228AC070
13228AC080
13228AC090
13228AC100
13228AC110
13228AC120
13228AC130
13228AC140
13228AC150
13228AC160
13228AC170
13228AD330
13228AD340
13228AD350
13228AD360
13228AD370
13228AD380
13228AD390
13228AD400
13228AD410
13228AD420
13228AD430
13228AD440
13228AD450
13228AD460
13228AD470
13228AD480
13228AD490
13228AD500
Thickness mm (in)
4.89 (0.1925)
4.90 (0.1929)
4.91 (0.1933)
4.92 (0.1937)
4.93 (0.1941)
4.94 (0.1945)
4.95 (0.1949)
4.96 (0.1953)
4.97 (0.1957)
4.98 (0.1961)
4.99 (0.1965)
5.00 (0.1969)
5.01 (0.1972)
5.02 (0.1976)
5.03 (0.1980)
5.04 (0.1984)
5.05 (0.1988)
5.06 (0.1992)
5.07 (0.1996)
5.08 (0.2000)
5.09 (0.2004)
5.10 (0.2008)
5.11 (0.2012)
5.12 (0.2016)
5.13 (0.2020)
5.14 (0.2024)
5.15 (0.2028)
5.16 (0.2032)
5.17 (0.2035)
5.18 (0.2039)
5.19 (0.2043)
5.20 (0.2047)
5.21 (0.2051)
5.23 (0.2059)
5.25 (0.2067)
5.27 (0.2075)
5.29 (0.2083)
5.31 (0.2091)
5.33 (0.2098)
5.35 (0.2106)
5.37 (0.2114)
5.39 (0.2122)
5.41 (0.2130)
5.43 (0.2138)
5.45 (0.2146)
5.47 (0.2154)
5.49 (0.2161)
5.51 (0.2169)
5.53 (0.2177)
5.55 (0.2185)
5.57 (0.2193)
Valve Clearance
MECHANICAL
Part No.
13228AD510
Thickness mm (in)
5.59 (0.2201)
ME(H6DO)-33
V-belt
MECHANICAL
9. V-belt
C: INSPECTION
A: REMOVAL
1) Replace the V-belt, if cracks, fraying or wear is

found.
2) Check that the V-belt automatic belt tension indicator (A) is within the range (D).
1) Install the tool to belt tension adjuster assembly

installation bolt.
2) Rotate the tool clockwise and loosen the V-belt
to remove.
(A)
(D)
(C)
(B)
ME-00473
B: INSTALLATION
(6)
(1)
(4)
(5)
(2)
(3)
(1)
(2)
(3)
(4)
(5)
(6)
ME-00475
ME-00474

Belt tension adjuster ASSY
Crank pulley
A/C compressor
Belt idler
Generator
ME(H6DO)-34
(A)
(B)
(C)
(D)
Indicator
Generator
Service limit
Engine Assembly
MECHANICAL
10.Engine Assembly
A: REMOVAL
2) Open the front hood fully and support with the
front food stay.
AC-20, PROCEDURE, Refrigerant Recovery Procedure.>
ME-02026
(3) Generator connector, terminal and A/C

compressor connector
IN-00203
8) Remove the air intake duct, air cleaner case and

air intake chamber.
<Ref. to IN(H6DO)-8, REMOVAL, Air Intake Duct.>
<Ref. to IN(H6DO)-5, REMOVAL, Air Cleaner
Case.> <Ref. to IN(H6DO)-7, REMOVAL, Air Intake Chamber.>
CO(H6DO)-13, REMOVAL, Radiator.>
10) Remove the V-belts. <Ref. to ME(H6DO)-34,
REMOVAL, V-belt.>
compressor. <Ref. to AC-38, REMOVAL, Hose and
Tube.>
12) Disconnect the following connectors:
FU-02115

(3) Pressure regulator vacuum hose
NOTE:
Do not disconnect the hose and pipe from pump
body.
(B)
(A)
(C)
ME-00482
(A) Power steering pump

(B) Generator
(C) A/C compressor
ME-00476
ME(H6DO)-35
Engine Assembly
MECHANICAL

side wheel apron.

(A)
ME-00483
(A) Cloth

Pipe.>
NOTE:
Be careful not to let the front exhaust pipe interfere
with water pipes on engine side.
18) Remove the ground cable.
ME-00485

plate.
(2) Remove the service hole plug (A).
ME-02027

(A)
ME-00486
ME-00484
ME-00487
ME(H6DO)-36
Engine Assembly
MECHANICAL
23) Disconnect the fuel delivery hose and evaporation hose.

CAUTION:
Catch fuel from the hose into container.
26) Separation of engine and transmission:

(1) Remove the starter. <Ref. to SC(H6DO)-6,
REMOVAL, Starter.>
ME-00491
FU-02116

wire ropes.
27) Set the ST to torque converter clutch case.

ST 498277200
STOPPER SET
ST
ME-00492
ME-00489

CAUTION:
Doing this is very important because the transmission lowers for its own weight. This work is
also of great importance for facilitating reinstallation.

compartment.
NOTE:
(A)
(B)
ME-00490
(A) Transmission
(B) Garage jack
ME-00489
CAUTION:
Before removing the engine away from transmission, check to be sure no work has been
overlooked.
ME(H6DO)-37
Engine Assembly
MECHANICAL
B: INSTALLATION
1) Install the front cushion rubbers.
Tightening torque:
35 Nm (3.6 kgf-m, 25.8 ft-lb)
2) Position the engine in engine compartment and
Tightening torque:
T1: 50 Nm (5.1 kgf-m, 36.9 ft-lb)
T2: 58 Nm (5.9 kgf-m, 42.8 ft-lb)
NOTE:
T2
T1
ME-00493
7) Remove the ST from torque converter clutch

case.
ME-00489

Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
NOTE:
Be careful not to drop the ST into the torque converter clutch case when removing the ST.
ST 498277200
STOPPER SET
8) Install the starter. <Ref. to SC(H6DO)-6, INSTALLATION, Starter.>
using a socket wrench.
NOTE:
Be careful not to drop the ST into the torque converter clutch case when removing the ST.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
ME-00491
ME-00489

ME-02107
ME(H6DO)-38
Engine Assembly
MECHANICAL
(3) Install the service hole plug to prevent foreign matters from being mixed.
Tightening torque:
20.1 Nm (2.05 kgf-m, 14.8 ft-lb)
NOTE:
Be care not to let the front exhaust pipe interfere
with water pipes and crossmember on engine side.
Be care not to scratch the flange surface of front
exhaust pipe with stud bolt on engine.
15) Connect the ground cable.
ME-00450

12) Tighten the nuts which hold lower side of transmission to the engine.
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
ME-02027

18) Connect the following hoses.
(1) Fuel delivery hose and evaporation hose
(4) Pressure regulator vacuum hose
Tightening torque:
14 Nm (1.4 kgf-m, 10.1 ft-lb)
ME-00484

Tightening torque:
85 Nm (8.7 kgf-m, 63 ft-lb)
NOTE:
(A) and locator (B) are securely installed.
(B) (A)
(A) (B)
ME-00476
ME-02026
ME-00494

<Ref. to EX(H6DO)-6, INSTALLATION, Front Exhaust Pipe.>

ME(H6DO)-39
Engine Assembly
MECHANICAL

<Ref. to AC-38, INSTALLATION, Hose and Tube.>
21) Install the V-belts. <Ref. to ME(H6DO)-34, INSTALLATION, V-belt.>
22) Install the radiator to vehicle. <Ref. to
CO(H6DO)-14, INSTALLATION, Radiator.>
23) Install the air intake duct, air cleaner case and
air intake chamber. <Ref. to IN(H6DO)-8, INSTALLATION, Air Intake Duct.> <Ref. to IN(H6DO)-6,
INSTALLATION, Air Cleaner Case.> <Ref. to
IN(H6DO)-7, INSTALLATION, Air Intake Chamber.>
24) Install the battery in the vehicle, and connect
cables.
<Ref. to CO(H6DO)-9, FILLING OF ENGINE
26) Check the ATF level and replenish it if necessary.
27) Charge the A/C system with refrigerant. <Ref.
to AC-21, PROCEDURE, Refrigerant Charging
Procedure.>
hood.
C: INSPECTION
1) Check pipes and hoses are installed firmly.
2) Check the engine coolant and ATF are at specified levels.
ME(H6DO)-40
Engine Mounting
MECHANICAL
11.Engine Mounting
A: REMOVAL
ME(H6DO)-35, REMOVAL, Engine Assembly.>
B: INSTALLATION
Tightening torque:
Engine mounting:
35 Nm (3.6 kgf-m, 25.8 ft-lb)
C: INSPECTION
Make sure that there are no cracks or other damages.
ME(H6DO)-41

MECHANICAL

A: REMOVAL
ME(H6DO)-35, REMOVAL, Engine Assembly.>
2) Set the engine on ST1.
ST 18232AA000
ENGINE STAND
ST
ME-00495
3) Before servicing overhaul, remove the sensor,

pipe and hose that installed to engine.
(1) Remove the intake manifold.
<Ref. to FU(H6DO)-12, REMOVAL, Intake Manifold.>
(2) Remove the generator. <Ref. to SC(H6DO)14, REMOVAL, Generator.>
(3) Remove the A/C compressor. <Ref. to AC33, REMOVAL, Compressor.>
(4) Remove the EGR pipe. <Ref. to FU(H6DO)25, REMOVAL, EGR Valve.>
(5) Disconnect the water pipe and hose.
(6) Disconnect the engine harness.
(7) Remove the spark plug. <Ref. to IG(H6DO)4, REMOVAL, Spark Plug.>
(8) Remove the camshaft position sensor.
<Ref. to FU(H6DO)-20, REMOVAL, Camshaft
Position Sensor.>
(9) Remove the crankshaft position sensor.
<Ref. to FU(H6DO)-19, REMOVAL, Crankshaft
Position Sensor.>
(10)Remove the knock sensor. <Ref. to
FU(H6DO)-21, REMOVAL, Knock Sensor.>
(11)Remove the engine coolant temperature
sensor. <Ref. to FU(H6DO)-18, REMOVAL, Engine Coolant Temperature Sensor.>
(12)Remove the oil pressure switch. <Ref. to
LU(H6DO)-12, REMOVAL, Oil Pressure
Switch.>
(13)Remove the oil filter. <Ref. to LU(H6DO)-13,
REMOVAL, Engine Oil Filter.>
(14)Remove the oil cooler. <Ref. to LU(H6DO)14, REMOVAL, Oil Cooler.>
ME(H6DO)-42
Crank Pulley
MECHANICAL
13.Crank Pulley
3) Install the crank pulley cover.
A: REMOVAL
NOTE:
Attach the O-ring to crank pulley cover.
1) Remove the crank pulley cover.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
ME-02028
ST 499977100
CRANK PULLEY WRENCH
ME-02028
C: INSPECTION
1) Check the crank pulley cover for oil and air leakage.
2) Check crank pulley for looseness.
ME-00497
B: INSTALLATION
2) Install the crank pulley bolt. To lock the crankshaft, use ST.
ST 499977100
CRANK PULLEY WRENCH
(1) Clean the crank pulley thread using compressed air.
and thread.
Tightening torque:
178 Nm (18.1 kgf-m, 131 ft-lb)
ME-00497
ME(H6DO)-43
Front Chain Cover

MECHANICAL
14.Front Chain Cover
3) Install the front chain cover. Temporarily tighten

the bolts.
A: REMOVAL
1) Remove the crank pulley. <Ref. to ME(H6DO)43, REMOVAL, Crank Pulley.>
2) Remove the front chain cover.
CAUTION:
Do not install the bolts in wrong place.
(A)
NOTE:
Chain cover installation bolt has three different sizes. To prevent the confusion in installation, keep
these bolts on container individually.
(C)
(C) (A)
(A)
(B)
(C)
(B)
ME-02029
(A)
(B)
(C)
*:
(C) (A)
(B)
ME-02029
(A)
(B)
(C)
*:
(B)
M6 16
M6 30
M6 45
Sealing washer
M6 16
M6 30
M6 45
Sealing washer
4) Tighten the bolts in the numerical order as

B: INSTALLATION
1) Remove the used liquid gasket from mating surface, and degrease it.
2) Apply liquid gasket to the matching surface of
front chain cover.
Liquid gasket
Applying liquid gasket diameter
2.50.5 mm (0.0980.020 in)
ME-02030
ME(H6DO)-44
Front Chain Cover

MECHANICAL
Tightening torque:
6.6 Nm (0.67 kgf-m, 4.8 ft-lb)
(34)
(25)
(24)
(33)
(23)
(11)
(9)
(35)
(32)
(12)
(13)
(10)
(8)
(26)
(6)
(36)
(1)
(3)
(27)
(28)
(37)
(7)
(5)
(4)
(2)
(38)
(19)
(29)
(30)
(31)
(22)
(40)
(39)
(18)
(17)
(16)
(15)
(14)
(20)
(21)
ME-02031
5) Install the crank pulley. <Ref. to ME(H6DO)-43,

C: INSPECTION
Check the cover surface for scratch and damage.
Check for oil leakage on cover mating surface and
installation part of crank pulley.
ME(H6DO)-45
Timing Chain Assembly

MECHANICAL
15.Timing Chain Assembly
8) Remove the chain tensioner (LH).
A: REMOVAL
NOTE:
Be careful not to come out the plunger.

2) Remove the front chain cover. <Ref. to
ME(H6DO)-44, REMOVAL, Front Chain Cover.>
3) Remove the chain tensioner (RH).
NOTE:
Be careful not to come out the plunger (A).
(A)
ME-02034
9) Remove the chain tensioner lever (LH).
ME-00501
4) Remove the chain guide (RH: between cams).
ME-02035
10) Remove the chain guide (LH: between cams).
ME-02032
5) Remove the chain guide (RH).

6) Remove the chain tensioner lever (RH).
(A)
ME-02036
11) Remove the chain guide (LH).
(B)
ME-02033
(A) Chain guide (RH)

(B) Chain tensioner lever (RH)
ME-02037
7) Remove the timing chain (RH).
ME(H6DO)-46

MECHANICAL
12) Remove the chain guide (CTR).
NOTE:
Work on the rubber mat or other anti-skid materials.
ME-02038
13) Remove the idler sprocket (upper).
ME-00511
2) Using ST, align the Top mark on crank sprocket to 9 oclock position as shown in the figure
ST 18252AA000 CRANKSHAFT SOCKET
ME-02039
14) Remove the timing chain (LH).

15) Remove the idler sprocket (lower).
ME-02040
3) Using ST, align the key groove on exhaust cam

sprocket to 12 oclock position as shown in the figure
ME-00510
B: INSTALLATION
NOTE:
Be careful that the foreign matter is not into or
onto assembled component during installation.
Apply engine oil to the chain guide, chain
tensioner lever and idler sprocket when installing.
1) Preparation for chain tensioner installation
(1) Insert the screw, spring pin and tension rod
into tensioner body.
(2) While depressing the tensioner onto rubber
mat, twist it to shorten tension rod. Then insert
the thin pin into the hole between tension rod
and tension body to keep shortened.
ME(H6DO)-47
ME-02041

MECHANICAL
4) Align the intake cam sprocket as shown in the

figure.
RH
LH
(2) Set the routing of timing chain (LH) on idler

sprocket (lower), water pump, exhaust cam
sprocket (LH) and intake cam sprocket (LH).
NOTE:
Check that the mark on timing chain (A) and cam
sprocket (B) is aligned as same as aligned on crank
sprocket.
(A)
(B)
(C)
(A)
ME-02042
(B)
(A) Top mark

(B) 40
(C) 15
5) Turn the crank sprocket clockwise, align the

Top mark to 12 oclock position (Piston #1 is in
TDC position)
NOTE:
Do not rotate the crank shaft and cam sprocket until
the timing chain routing was completed.
6) Install the idler sprocket (lower).
(B)
Tightening torque:
69 Nm (7.0 kgf-m, 50.6 ft-lb)
(A)
ME-02043
(A) Dark blue

(B) Mark
(3) Install the chain idler (upper).

Tightening torque:
69 Nm (7.0 kgf-m, 50.6 ft-lb)
ME-00510
7) Install the timing chain (LH).

(1) Align the timing mark (B) on the crank
sprocket with mark (A) on the timing chain (LH).
(A)
ME-02039
(4) Install the chain guide (LH: between cams).

Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
(B)
ME-00515
(A) Gold
(B) Mark
ME(H6DO)-48

MECHANICAL
(7) Install the chain tensioner (LH).
NOTE:
Use a new installing bolt.
Tightening torque:
16 Nm (1.6 kgf-m, 11.6 ft-lb)
ME-02036
(5) Install the chain guide (LH).
ME-02034
8) Install the timing chain (RH).

(1) Align the marks of timing chain LH and RH
on the idler sprocket (lower).
Tightening torque:
16 Nm (1.6 kgf-m, 11.6 ft-lb)
(B)
(A)
(C)
(D)
ME-02037
ME-00518
(6) Install the chain tensioner lever (LH).

(A)
(B)
(C)
(D)
Tightening torque:
16 Nm (1.6 kgf-m, 11.6 ft-lb)
Idler sprocket (lower)

Timing chain (RH)
Timing chain (LH)
Dark blue
(2) Set the routing of timing chain (RH) on intake cam sprocket, and then set the routing on
exhaust cam sprocket.
ME-02035
ME(H6DO)-49

MECHANICAL
NOTE:
Check that the mark on timing chain (A) and cam
sprocket (B) is aligned as same as aligned on crank
sprocket.
NOTE:
(A)
(B)
ME-02032
(6) Install the chain tensioner (RH).

Tightening torque:
16 Nm (1.6 kgf-m, 11.6 ft-lb)
(B)
(A)
ME-02044
ME-00520
(A) Gold
(B) Mark
(7) Adjust the clearance between chain guide

(RH) and chain guide (CTR) within 8.4 8.6
mm (0.331 0.339 in). Install the chain guide
(CTR).
(3) Install the chain guide (RH).

(4) Install the chain tensioner lever (RH).
Tightening torque:
16 Nm (1.6 kgf-m, 11.6 ft-lb)
Tightening torque:
7.8 Nm (0.8 kgf-m, 5.8 ft-lb)
NOTE:
(A)
(B)
ME-02033
(A) Chain guide (RH)

(B) Chain tensioner lever (RH)
ME-00521
(5) Install the chain guide (RH: between cams).

Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
(8) Check that each mark on the sprocket and

timing chain is matched, and then draw out the
stopper pin from chain tensioner.
ME(H6DO)-50
Cam Sprocket
MECHANICAL
16.Cam Sprocket
ST
499977500
CAM SPROCKET WRENCH
A: REMOVAL
3) Remove the timing chain assembly.
<Ref. to ME(H6DO)-46, REMOVAL, Timing Chain
Assembly.>
4) Remove the cam sprocket. To lock the crankshaft, use the ST.
ST 499977500
CAM SPROCKET WRENCH
ME-02045
ST
18231AA020
CAM SPROCKET WRENCH
ME-02045
ST
18231AA020
CAM SPROCKET WRENCH
ME-02046
3) Install the timing chain assembly.

<Ref. to ME(H6DO)-47, INSTALLATION, Timing
Chain Assembly.>
4) Install the front chain cover.
<Ref. to ME(H6DO)-44, INSTALLATION, Front
Chain Cover.>
C: INSPECTION
ME-02046
B: INSTALLATION
1) Install the cam sprocket. To lock the crankshaft,
use the ST.

and scratches.
sprocket and key.
Tightening torque:
29.5 Nm (3.0 kgf-m, 21.8 ft-lb)
2) Further tighten the bolt.
Tightening angle:
Intake
455
Exhaust
255
ME(H6DO)-51
Crank Sprocket
MECHANICAL
17.Crank Sprocket
A: REMOVAL
Assembly.>
4) Remove the cam sprocket. <Ref. to ME(H6DO)51, REMOVAL, Cam Sprocket.>
5) Remove the crank sprocket (A).
(A)
ME-02047
B: INSTALLATION
1) Install the crank sprocket (A).
(A)
ME-02047
2) Install the cam sprocket. <Ref. to ME(H6DO)-51,

INSTALLATION, Cam Sprocket.>
Chain Assembly.>
Chain Cover.>
C: INSPECTION
wear and scratches.
sprocket and key.
ME(H6DO)-52
Rear Chain Cover

MECHANICAL
18.Rear Chain Cover
Applying liquid gasket diameter

(A) 1.00.5 mm (0.0390.020 in)
(B) 3.01.0 mm (0.1180.039 in)
A: REMOVAL
3) Remove the timing chain. <Ref. to ME(H6DO)46, REMOVAL, Timing Chain Assembly.>
4) Remove the cam sprocket. <Ref. to ME(H6DO)51, REMOVAL, Cam Sprocket.>
6) Remove the oil pump. <Ref. to LU(H6DO)-8,
REMOVAL, Oil Pump.>
7) Remove the water pump. <Ref. to CO(H6DO)11, REMOVAL, Water Pump.>
8) Remove the rear chain cover.
NOTE:
Installation bolt has seven different sizes. To prevent the confusion in installation, keep these bolts
on container individually.
(A) (B)
(C)
(A)
(B)
ME-02049
3) Install the O-ring.

NOTE:
Do not reuse the O-ring.
Do not install the O-ring in wrong place.
(A)
(A)
(D)
(D)
(E)
(C)
(B)
(G)
(A)
(B)
(C)
(D)
ME-02048
(A)
(B)
(C)
(D)
(E)
(F)
(G)
ME-02050
(F)
M6 14
M6 18 (Silver)
M6 30
M6 18
M8 40
M8 30
M6 22
14.2 1.9
19.2 2.4
25 2
31.2 1.9
4) Temporarily tighten the rear chain cover.
B: INSTALLATION
1) Remove the used liquid gasket from mating surface, and degrease it.
rear chain cover.
Liquid gasket
THREE BOND 1280B (Part No. K0877A018)
ME(H6DO)-53
Rear Chain Cover

MECHANICAL

NOTE:
(A) (B)
(C)
(D)
(E)
(G)
(F)
ME-02048
(A)
(B)
(C)
(D)
(E)
(F)
(G)
M6 14
M6 18 (Silver)
M6 30
M6 18
M8 40
M8 30
M6 22

Tightening torque:
(1) (11)
(12) (19)
(20) (30)
(31) (38)
(39) (45)
9 Nm (0.9 kgf-m, 6.5 ft-lb)

20 Nm (2.0 kgf-m, 14 ft-lb)
9 Nm (0.9 kgf-m, 6.5 ft-lb)
12 Nm (1.2 kgf-m, 8.7 ft-lb)
9 Nm (0.9 kgf-m, 6.5 ft-lb)
(29)
(20)
(45) (31)(32)
(2) (3)
(4)
(1)
(21)
(30)
(33)
(19)
(43)
(22)
(18)
(42)
(23)
(34)
(41)
(24)
(35)
(12)
(6)
(40)
(25)
(26)
(39)
(7)
(5)
(13)
(27)
(38)
(11)
(14) (28)
(8)
(37)
(10) (9)
(36)
(17) (16) (15)
ME-02051
(44)
6) Install the water pump. <Ref. to CO(H6DO)-11,

INSTALLATION, Water Pump.>
7) Install the oil pump. <Ref. to LU(H6DO)-8, INSTALLATION, Oil Pump.>
9) Install the cam sprocket. <Ref. to ME(H6DO)-51,
INSTALLATION, Cam Sprocket.>
10) Install the timing chain. <Ref. to ME(H6DO)-47,
INSTALLATION, Timing Chain Assembly.>
Chain Cover.>
ME(H6DO)-54
Camshaft
MECHANICAL
19.Camshaft
10) Loosen the camshaft cap bolts equally, a little

at a time in alphabetical sequence shown in the figure.
A: REMOVAL
Assembly.>
<Ref. to ME(H6DO)-51, REMOVAL, Cam Sprocket.>
<Ref. to ME(H6DO)-52, REMOVAL, Crank Sprocket.>
<Ref. to ME(H6DO)-53, REMOVAL, Rear Chain
Cover.>
7) Disconnect the oil valve.
(2)
(4)
(3)
(1)
(7)
(9)
(5)
(8)
(10)
(6)
(14)
(16)
(12)
(13)
(15)
(11)
ME-02054
11) Remove the camshaft caps and camshaft (LH).

NOTE:
Arrange camshaft caps in order so that they can be
installed in their original positions.
12) Similarly, remove the camshafts (RH) and related parts.
B: INSTALLATION
1) Apply engine oil to camshaft journals, and install
the camshaft.
2) Install the camshaft cap.
(1) Apply liquid gasket sparingly to back side of
front camshaft cap as shown in the figure.
ME-02052
8) Remove the rocker cover (LH).
CAUTION:
Do not apply fluid packing excessively. Failure
to do so may cause excess gasket to come out
and flow toward cam journal, resulting in engine burnt.
Liquid gasket
Applying liquid gasket diameter:
2.00.5 mm (0.0790.020 in)
ME-00529
9) Remove the plugs (LH).
ME-02057
(2) Apply engine oil to cap bearing surface, and

install the cap to camshaft.
(3) Tighten the rocker cover bolts in the numerical order as shown in the figure.
ME-02055
ME(H6DO)-55
Camshaft
MECHANICAL
Tightening torque:
(1) (12): 16 Nm (1.6 kgf-m, 11.6 ft-lb)
(13) (16): 9.75 Nm (1.0 kgf-m, 7.2 ft-lb)
(15)
(13)
(14)
(16)
(10)
(8)
(12)
(9)
(7)
(11)
(3)
(1)
(5)
RH side
ME-02060
(4)
(2)
(6)
ME-02058
3) Install the plugs.
(2) Tighten the rocker cover bolts in the numerical order as shown in the figure.
Tightening torque:
6.4 Nm (0.64 kgf-m, 4.6 ft-lb)
LH side
Tightening torque:
6.0 Nm (6.1 kgf-m, 44.3 ft-lb)
(10)
(1)
(3)
(7)
(5)
(6)
(9)
(8)
ME-02055

(1) Apply liquid gasket sparingly to the mating
surface of cylinder head and rocker cover as
(2)
ME-02061
RH side
(8)
(1)
(3)
(5)
CAUTION:
Do not apply fluid packing excessively. Failure
to do so may cause excess gasket to come out
and flow toward cam journal, resulting in engine burnt.
Liquid gasket
LH side
(4)
(6)
(7)
(10)
(9)
(4)
(2)
ME-02062
5) Connect the oil pipe.
ME-02052
ME-02059
6) Install the rear chain cover. <Ref. to ME(H6DO)53, INSTALLATION, Rear Chain Cover.>
ME(H6DO)-56
Camshaft
MECHANICAL

<Ref. to ME(H6DO)-52, INSTALLATION, Crank
Sprocket.>
<Ref. to ME(H6DO)-51, INSTALLATION, Cam
Sprocket.>
Chain Assembly.>
Chain Cover.>
Pulley.>
(6) Measure the widest point of the plastigauge

on each journal. If 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)
C: INSPECTION
1) Check the camshaft for bend, and repair or replace if necessary.
ME-00119
(7) Completely remove the plastigauge.

5) Check the cam face condition; remove the minor
faults by grinding with oil stone. Measure the cam
height H. If it exceeds the limit, replace it.
Cam height: H:
ME-00539

3) Measure the outside diameter of camshaft journal. If the journal diameter is not within specifications, check the oil clearance.
Front
Standard
value
mm (in)
Camshaft journal
Except for front
37.946 37.963
(1.4939 1.4946)
25.946 25.963
(1.0215 1.0222)
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 the valve rocker.)
(3) Place a plastigauge across each of the camshaft journals.
(4) Install the bearing cap.
Standard:
Intake
HIGH: 42.09 42.19 mm (1.6571 1.6610
in)
LOW1: 38.14 38.24 mm (1.5016 1.5055
in)
LOW2: 34.94 35.04 mm (1.3756 1.3795
in)
Exhaust
41.65 41.75 mm (1.6398 1.6437 in)
Intake
HIGH: 32.0 mm (1.2598 in)
LOW1: 31.84 mm (1.2535 in)
LOW2: 31.84 mm (1.2535 in)
Exhaust
32.0 mm (1.2598 in)
NOTE:
Do not turn the camshaft.
(5) Remove the bearing caps.
ME(H6DO)-57
ME-00120
Camshaft
MECHANICAL
6) Measure the side clearance of camshaft with dial

gauge. If the side clearance exceeds the limit or offset wearing is emitted, replace the caps and cylinder head as a set. If necessary, replace the
camshaft.
Standard:
Intake
0.075 0.135 mm (0.0030 0.0053 in)
Exhaust
0.030 0.090 mm (0.0012 0.0035 in)
ME(H6DO)-58
Cylinder Head
MECHANICAL
20.Cylinder Head
12) Similarly, remove the cylinder head (RH).
A: REMOVAL
B: INSTALLATION

Assembly.>
Cover.>
REMOVAL, Camshaft.>
8) Remove the cylinder head bolts in the numerical
order as shown in the figure.
Leave bolts (2) and (4) engaged by three or four
(8)
(6)
(2)
(4)
(3)
(1)
(5)
(7)

block.
CAUTION:
of cylinder head and cylinder block.
cylinder head bolt threads.
(2) Install the cylinder head to cylinder block,
and then tighten the bolts with torque of 20 Nm
(2.0 kgf-m, 14 ft-lb) in numerical sequence as
(3) Tighten the bolts with torque of 50 Nm (3.0
kgf-m, 37 ft-lb) in numerical sequence as shown
in the figure.
installation, and back them off again by 180.
(5) Tighten the bolts with torque of 20 Nm (2.0
kgf-m, 14 ft-lb) in numerical sequence as shown
in the figure.
(6) Tighten the bolts (1) and (4) with torque of
48 Nm (3.5 kgf-m, 35.4 ft-lb) in numerical sequence.
(7) Tighten the bolts (5) and (8) with torque of
44 Nm (4.5 kgf-m, 32.5 ft-lb) in numerical sequence.
(8) Tighten the bolts 90 in the numerical order
(9) Tighten the bolt (1) (4) 45 in the numerical order.
(1)
ME-02063

10) Remove the bolts (2) and (4) to remove the cylinder head.
(8)
(3)
(7)
(5)
(6)
(8)
(6)
(4)
(2)
(4)
(1)
(3)
(5)
(7)
ME-02063

CAUTION:
(2)
ME-02064
3) Install the camshaft. <Ref. to ME(H6DO)-55, INSTALLATION, Camshaft.>

4) Install the rear chain cover. <Ref. to ME(H6DO)53, INSTALLATION, Rear Chain Cover.>
Sprocket.>
<Ref. to ME(H6DO)-51, INSTALLATION, Cam
Sprocket.>
ME(H6DO)-59
Cylinder Head
MECHANICAL

Chain Assembly.>
Chain Cover.>
Pulley.>
Install the valve spring with the painted side facing to retainer.
(1)
C: DISASSEMBLY
(2)
1) Set the cylinder head on ST.

ST 18250AA010
CYLINDER HEAD TABLE
3) Set the ST on valve spring retainer. Compress
the valve spring and remove the valve spring retainer key. Remove each valve and valve spring.
ST 499718000
NOTE:
(4)
(3)
ME-00546
(1)
(2)
(3)
(4)
Seat
Valve spring
Retainer
Painted face
(4) Set the ST on valve spring.

ST 499718000
CAUTION:
seals.
ST
ST
ME-00545
ME-00545
D: ASSEMBLY
(1) Set the cylinder head on ST.
ST 18250AA010
CYLINDER HEAD TABLE
NOTE:
When inserting the valve into valve guide, use special care not to damage the oil seal lip.
(3) Install the valve spring and retainer.
NOTE:
Be sure to install the valve springs with their
close-coiled end facing the seat on the cylinder
head.

lightly with a wooden hammer for better seating.
2) Apply oil to the surface of the valve lifter and
valve shim.
3) Install the valve lifter and valve shim.
E: INSPECTION
1. VALVE SPRING
Free length
mm (in)
Intake
Inner
Outer
Exhaust
Inner
Intake
Squareness
Outer
Exhaust
ME(H6DO)-60
39.55 (1.5571)
41.18 (1.6213)
46.32 (1.8236)
2.5, 1.7 mm
(0.067 in)
2.5, 1.8 mm
(0.071 in)
2.5, 2.0 mm
(0.079 in)
Cylinder Head
MECHANICAL

Outer diameter:
32.959 32.975 mm (1.2976 1.2982 in)
ME-00134
ME-00132

SEAL
Replace the oil seal with a new one, if the lip is
damaged or spring is out of place, or when the surfaces of intake valve and valve seat are reconditioned or intake valve guide is replaced.
1) Set the cylinder head on ST1.
2) Press-fit the oil seal to the specified dimension
indicated in the figure using ST2.
ST1 18250AA010 CYLINDER HEAD TABLE
ST2 499585500
VALVE OIL SEAL GUIDE
NOTE:
Apply engine oil to oil seal before force-fitting.
When press-fitting the oil seal, do not use a hammer or strike in.
3) Measure the inner diameter of valve lifter hole of

cylinder head.
Inner diameter:
32.994 33.016 mm (1.2990 1.2998 in)
ME-00550
NOTE:
If difference between outer diameter of valve lifter
and inner diameter of valve lifter hole is out of the
standard or offset wearing is emitted, replace the
cylinder head.
Standard:
0.019 0.057 mm (0.0007 0.0022 in)
F: ADJUSTMENT
1. CYLINDER HEAD
ME-00548
3. VALVE LIFTER
1) Check the valve lifter visually.
2) Measure the outer diameter of valve lifter.
1) Make sure that no crack or other damages do

not exist. In addition to visual inspection, inspect
important areas using liquid penetrant tester.
Check that there are no marks of gas leaking or water leaking on gasket installing surface.
2) Set the cylinder head on ST.
ST 18250AA010
CYLINDER HEAD TABLE
3) Measure the flatness of the cylinder head surface that mates with crankcase using a straight
edge (A) and thickness gauge (B).
Flatness:
Standard
0.02 mm (0.0008 in)
1240.05 mm (4.880.0020 in)
ME(H6DO)-61
Cylinder Head
MECHANICAL
NOTE:
Uneven torque for the cylinder head nuts can
cause warping. When reinstalling, pay special attention to the torque so as to tighten evenly.
2) If the clearance between valve guide and stem is

out of standard, replace the valve guide or valve itself whichever shows greater amount of wear or
damaged and etc. See the following procedure for
valve guide replacement.
5.500 5.512 mm (0.2165 0.2170 in)
(A)
(B)
ME-00551
2. VALVE SEAT

Intake
5.445 5.470 mm (0.2144 0.2154 in)
Exhaust
5.455 5.460 mm (0.2148 0.2150 in)
guides enter the holes in ST1.
(2) Insert ST2 into the valve guide and press it
ST1 18250AA010 CYLINDER HEAD TABLE
ST2 499765700
VALVE GUIDE REMOVER
Valve seat width W:

Intake
Standard
1.0 mm (0.039 in)
Exhaust
Standard
1.5 mm (0.059 in)
ME-00553

ST 18251AA040
W
ST
ME-00127
3. VALVE GUIDE
respectively the outer diameter of valve stem and
inner diameter of valve guide with a micrometer.
stem:
Standard
Intake
0.030 0.057 mm (0.0012 0.0022 in)
Exhaust
0.040 0.067 mm (0.0016 0.0026 in)
ME-00757

cylinder head.
guide. Press in until the valve guide upper end is
ST1 499765700
VALVE GUIDE REMOVER
ME(H6DO)-62
Cylinder Head
MECHANICAL
ST2 18251AA040
ST1

Intake (A)
99.7 mm (3.925 in)
Exhaust (B)
105.2 mm (4.142 in)
ST2
(A)
ME-00130

11.4 11.8 mm (0.449 0.465 in)
reamer slowly clockwise while pushing it lightly.
Bring the reamer back while rotating it clockwise. After reaming, clean the valve guide to remove chips.
ST 499765900
VALVE GUIDE REAMER
NOTE:
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 chip, use a new
reamer or remedy the reamer.
guide.
90
+1
0
90
+1
0
(B)
ME-02096

seat surface and lap the valve and seat surface. Install a new intake valve oil seal after lapping.

1) Inspect the flange and stem of valve, and replace if damaged, worn or deformed, or if H is exceed the standard value or offset wearing is
emitted.
H:
Intake (A)
Standard
1.0 mm (0.039 in)
Exhaust (B)
Standard
1.2 mm (0.047 in)
ME(H6DO)-63
Cylinder Block
MECHANICAL
21.Cylinder Block
11) Remove the crankshaft position sensor bracket.
A: REMOVAL
NOTE:
Before conducting this procedure, drain the engine
oil completely.
Assembly.>
Cover.>
REMOVAL, Camshaft.>
8) Remove the cylinder head. <Ref. to ME(H6DO)59, REMOVAL, Cylinder Head.>
9) Remove the drive plate using ST.
ST1 498497100 CRANKSHAFT STOPPER
ST2 499057000 TORX PLUS
ME-00559
12) Rotate the engine to set oil pan upper.

13) Remove the bolts which secure oil pan lower to
oil pan upper.
ME-00560
14) Insert a oil pan cutter blade between cylinder

block-to-oil pan clearance and remove the oil pan.
CAUTION:
Do not use a screwdriver or similar tools in
place of oil pan cutter.
ST
ME-00557
10) Remove the crankshaft position sensor plate.

ME-00561
ME-00558
ME(H6DO)-64
Cylinder Block
MECHANICAL
16) Remove the bolts which install oil pan upper

onto cylinder block.
NOTE:
Installation bolts have five different sizes. To prevent the confusion in installation, keep these bolts
on container individually.
(B)
(C) (D)
NOTE:
(E) (E)
(D)
(A)
(A)
(A)
(A)
(A)
(B)
(A)
(A)
(A)
(A)
(A)
(A)
(A)
(A)
(B)
(C)
(D)
(E)
19) Draw out the piston pin from #1 and #2 pistons

using ST.
ST 499097500
PISTON PIN REMOVER
(A) (A)
(A)
(A)
ME-02065
ME-00565
20) Similarly remove the piston pins from #3, #4, #5

and #6 pistons.
21) Remove the bolts which secure the cylinder
block.
M8 40
M8 65
M8 85
M8 130
M8 24

hole plugs using a hexagon wrench.
ME-00566
22) Separate the cylinder block (LH) and (RH).
ME-00563
#2 cylinders using ST.
ST 18233AA000
PISTON PIN SNAP RING
PRIERS
NOTE:
the connecting rod to fall and damage the cylinder
block.
NOTE:
Do not confuse the combination of crankshaft
bearings.
Press the bearing at the end opposite to locking
lip.
ST4
ME-00564
NOTE:
ME(H6DO)-65
Cylinder Block
MECHANICAL
B: INSTALLATION
1) After setting the cylinder block to ST, install the
crankshaft bearing.
ST 18232AA000
ENGINE STAND
NOTE:
Remove oil on the mating surface of bearing and
2) Position the crankshaft and connecting rod on
the #2, #4 and #6 cylinder block.
3) Apply liquid gasket to the mating surface of #1,
#3 and #5 cylinder block, and position it on #2, #4
and #6 cylinder block.
6) Retighten all bolts in the numerical order as

Tightening torque:
(1) (11), (13): 25 Nm (2.5 kgf-m, 18 ft-lb)
(12), (14): 20 Nm (2.0 kgf-m, 14 ft-lb)
(14)
(6)
(1)
(3)
(9) (11)
(13)
Liquid gasket
THREE BOND 1215B (Part No. 004403007)
NOTE:
Do not allow liquid gasket to jut into O-ring grooves,
oil passages, bearing grooves, etc.
(8)
(12) (10) (4)
(2)
(5)
(7)
ME-00568
7) Tighten all bolts 90 in the numerical order as

(14)

1.00.2 mm (0.0390.008 in)
(8)
(6)
(1)
(3)
(9) (11)
(13)
(12) (10) (4)
(2)
(5)
(7)
ME-00568
8) Install the upper bolt to cylinder block.

ME-00567
4) Apply a coat of engine oil to washers and bolt

threads.
5) Tighten all bolts in the numerical order as shown
in the figure.
Tightening torque:
(1) (11), (13): 25 Nm (2.5 kgf-m, 18 ft-lb)
(12), (14): 20 Nm (2.0 kgf-m, 14 ft-lb)
(14)
(8)
(6)
(1)
(3)
Tightening torque:
25 Nm (2.5 kgf-m, 18 ft-lb)
NOTE:
Remove the liquid gasket which is running over to
sealing surface between cylinder block and rear
chain cover, cylinder block and oil pan upper, after
tightening the bolts which combine the cylinder
block.
(9) (11)
(13)
(12) (10) (4)
(2)
(5)
(7)
ME-00569
ME-00568

ST1 499597100
CRANKSHAFT OIL SEAL
GUIDE
ST2 499587200
CRANKSHAFT OIL SEAL INSTALLER
ME(H6DO)-66
Cylinder Block
MECHANICAL

NOTE:
Apply engine oil to the pressing-in portion.
NOTE:
Use new snap rings.
(A)
#5
(B)
#3
#6
ST2
ST1
ME-00570
#1
#4
(A) Rear oil seal

(B) Drive plate installation bolt
ME-00573
(A) Front side of vehicle
16) Installing the piston:

(1) Using ST1, turn the crankshaft so that #3
and #4 connecting rods small end are set on the
service hole (A).
ST1 18252AA000 CRANKSHAFT SOCKET
180
(A)
#2
(A)
10) Position the top ring gap at (A) in the figure.

11) Position the second ring gap at (B).
(B)
(A)
ME-02066

13) Position the expander gap at (D) in the figure.
14) Position the lower rail gap at (E) in the figure.
(A)
(E)
(C)
ST1
ME-00574
(2) Apply a thin coat of engine oil to piston and

cylinder.
(3) Using ST2, press-fit the piston into cylinder.
ST2 18254AA000 PISTON GUIDE
35
25
(D)
ME-02067
CAUTION:
skirt area.
Ensure R mark faces to top side of piston.
ME(H6DO)-67
ST2
ME-00576
Cylinder Block
MECHANICAL
NOTE:
Piston front mark (A) faces towards the front of engine.

oil pan upper.
Liquid gasket
Full line part
3.01.0 mm (0.120.04 in)
Broken line part
1.0 mm (0.04 in)
(A)
(A)
(A)
(A)
ME-02076
(A)
17) Installing piston pin:

(1) Apply a coat of engine oil to ST3 before insertion, and then insert it into the service hole to
align piston pin hole with connecting rod small
end.
ST3 18253AA000 PISTON GUIDE
ME-02068
(A) O-ring
ST3
NOTE:
Use new O-rings.
20) Temporarily tighten the oil pan upper.
NOTE:
(B)
ME-00577

(3) Using the ST4, install the snap ring.
ST4 18233AA000 PISTON PIN SNAP RING
PRIERS
(A)
(A)
(A)
(B)
(C)
(D)
(E)
*:
(4) Similarly install the #1, #2, #5 and #6 pistons.

18) Install the service hole plug and O-ring.
NOTE:
Use a new O-ring.
ME(H6DO)-68
(D)
(A)
(B)
(A)
(A)
(A)
(A)
(A)
(A)
ME-00564
(E) (E)
(A)
(A)
NOTE:
Use new snap rings.
ST4
(C) (D)
(A)
M8 40
M8 65
M8 85
M8 130
M8 24
Coating
(A) (A)
(A)
(A)
ME-02069
Cylinder Block
MECHANICAL
21) Tighten the oil pan upper installing bolts in the

numerical order as shown in the figure.
24) Tighten the oil pan lower installing bolts in the

Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
(2)
(19) (8) (10) (20) (22)

(24)
(21)
(3)
(1)
(18)
(13)
(4)
(12)
(2)
(4)
(12)
(5)
(14)
(23)
(26)
(13)
(16)
(11)
(15)
(14)
(3)
(5)
(17)
(1) (15)
(11)
(6)
(10)
(25)
(9) (6)
(7)
(27)
(7)
ME-02070
(8)
(9)
ME-00582
22) Install the oil strainer.
25) Install the crankshaft sensor bracket.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
NOTE:
Use new O-rings.
ME-00559
26) Install the crankshaft sensor plate.

ME-00561

oil pan lower.
Liquid gasket
5.01.0 mm (0.200.04 in)
ME-00558
27) Install the drive plate using ST.

ME-00581
ME(H6DO)-69
Cylinder Block
MECHANICAL
Tightening torque:
81 Nm (8.3 kgf-m, 60 ft-lb)
ST
ME-00557
28) Install the cylinder head. <Ref. to ME(H6DO)59, INSTALLATION, Cylinder Head.>
29) Install the camshaft. <Ref. to ME(H6DO)-55,
30) Install the rear chain cover. <Ref. to
ME(H6DO)-53, INSTALLATION, Rear Chain Cover.>
Sprocket.>
32) Install the cam sprocket. <Ref. to ME(H6DO)51, INSTALLATION, Cam Sprocket.>
Chain Assembly.>
Chain Cover.>
Pulley.>
ME(H6DO)-70
Cylinder Block
MECHANICAL
C: DISASSEMBLY
(6)
(1)
(3)
(4)
(5)
(2)
(2)
(1)
(5)
(4)
(2)
(3)
(6)
ME-02097
(1)
(2)
Connecting rod cap

(3)
(4)
Top ring
Second ring

NOTE:
rod cap and bearing in order, to prevent confusion.
3) Remove the piston rings using the piston ring expander.
NOTE:
Arrange the removed piston rings in proper order,
to prevent confusion.
ME(H6DO)-71
(5)
(6)
Oil ring
Snap ring
Cylinder Block
MECHANICAL
D: ASSEMBLY
(6)
(1)
(3)
(4)
(5)
(7)
(2)
(2)
(7)
(2)
(1)
(5)
(4)
(3)
(6)
ME-02098
(1)
(2)
(3)
(4)
Connecting rod cap

Top ring
Second ring
(5)
(6)
(7)

T: 53 (5.4, 39)
Oil ring
Snap ring
Connecting rod

bearings. Install the connecting rod bearings on
connecting rods and connecting rod caps.
2) Install the connecting rod on crankshaft.
NOTE:
Position each connecting rod with the side marked
facing forward.
3) Install the connecting rod cap.
Ensure the arrow on connecting rod cap faces the
front during installation.
CAUTION:
4) Install the oil ring spacer, upper rail and lower rail
in this order by hand. Then install the second ring
and top ring with a piston ring expander.
E: INSPECTION
1. CYLINDER BLOCK
3) Inspect the crankcase surface that mates with
cylinder head for warping by using a straight edge.
202 mm (7.95 in)

NOTE:
ME(H6DO)-72
Cylinder Block
MECHANICAL
Standard diameter:
A: 89.205 89.215 mm (3.5120 3.5124 in)
B: 89.195 89.205 mm (3.5116 3.5120 in)
Cylindricality:
Standard
0.030 mm (0.0012 in)
Out-of-roundness:
Standard
0.010 mm (0.0004 in)
(A)
(B)
B B B
#6
#4 #5
#2 #3
#1
H1
(B)
H2
2 4
2 4
#7
#6
#5
#4
#3
#2
#1
B A B
(A)
H3
(C)
ME-00585
(A) Main journal size mark

(B) Cylinder bore size mark
(C) Cylinder block (RH) (LH) combination mark
Unit: mm (in)
(A)
(B)
H1:
H2:
H3:

NOTE:
ME-00586

Thrust direction
10 mm (0.39 in)
45 mm (1.77 in)
80 mm (3.15 in)

NOTE:
ME(H6DO)-73
Cylinder Block
MECHANICAL

37.3 mm (1.4685 in)
Piston outer diameter:
Standard
A: 89.205 89.215 mm (3.5120 3.5124
in)
B: 89.195 89.205 mm (3.5116 3.5220
in)
89.445 89.465 mm (3.5215 3.5222 in)
89.695 89.715 mm (3.5313 3.5321 in)

cracks and wear, and the piston ring grooves for
each cylinder. <Ref. to ME(H6DO)-72, CYLINDER
AND PISTON, INSPECTION, Cylinder Block.> If
any of the clearances is not within specification, replace the piston or bore the cylinder to use an oversize piston.
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)
H
ME-00172

piston.
NOTE:
ME-00173

Standard
0.010 0.010 mm (0.00039 0.00039 in)
6) Boring and honing:
(1) If the value of cylindricality, out-of-roundness, or cylinder-to-piston clearance measured
is out of standard or if there is any damage on
the cylinder wall, rebore it to use an oversize piston.
CAUTION:
(2) If the cylinder inner diameter exceeds
89.715 mm (3.5321 in) after boring and honing,
replace the crankcase.
ME-00174
4) Check the snap ring installation groove (A) on

the piston for burr. If necessary, remove burr from
(A)
NOTE:
rise. Thus, pay attention to this when measuring
the cylinder diameter.
ME-00175

cracks and wear.
ME(H6DO)-74
Cylinder Block
MECHANICAL
4. PISTON RING
1) If the piston ring is broken, damaged, or worn, or
CAUTION:
Mark is displayed on the end of top and second rings. When installing the rings to the piston, face this mark upward.
and lower rail. When installing on piston, be
careful of each rails direction.

NOTE:
Before measuring the clearance, clean the piston
ring groove and piston ring.
Standard
Clearance
between piston
ring and piston
ring groove
Top ring
Second ring
Clearance between oil ring

and oil ring groove
mm (in)
0.040 0.080
(0.0016 0.0031)
0.030 0.070
(0.0012 0.0028)
0.045 0.125
(0.0018 0.0049)
(A)
(B)
(a)
(b)
(C)
(c)
ME-00591
(A)
(B)
(C)
(a)
(b)
(c)
Top ring
Second ring
Oil ring
Upper rail
Expander
Lower rail
ME-00178
Standard
Top ring
Piston ring gap
Second ring
Oil ring
mm (in)
0.20 0.35
(0.0079 0.0138)
0.35 0.50
(0.0138 0.0197)
0.20 0.60
(0.0079 0.0236)
ME-00592
ME(H6DO)-75
Cylinder Block
MECHANICAL
5. CONNECTING ROD
aligner. Replace the connecting rod if it has the
bend or twist.
(A)
Standard
0.016 0.043 mm (0.0006 0.0017 in)
Unit: mm (in)
Bearings
(B)
Standard
0.03
(0.0012)
undersize
0.05
(0.0020)
undersize
0.25
(0.0098)
undersize
(A)
(B)
ME-00179
Bearing size
1.490 1.506
(0.0587 0.0593)
51.984 52.000
(2.0466 2.0472)
1.509 1.513
(0.0594 0.0596)
51.954 51.970
(2.0454 2.0461)
1.519 1.523
(0.0598 0.0600)
51.934 51.950
(2.0446 2.0453)
1.619 1.623
(0.0637 0.0639)
51.734 51.750
(2.0368 2.0374)
Outer diameter of
crank pin

end.
Standard
0 0.022 mm (0 0.0009 in)
(A) Thickness gauge

(B) Connecting rod

clearance). If side clearance exceeds the limit or
offset wearing is emitted, replace the connecting
rod.
Standard
0.070 0.330 mm (0.0028 0.0130 in)
ME-00181
ME-00180

ME(H6DO)-76
ME-00174
Cylinder Block
MECHANICAL

with ST and press.
ST 18350AA000
Crank pin and crank journal:

Out-of-roundness
0.005 mm (0.0002 in)
Cylindricality
0.006 mm (0.0002 in)
ST
ME-00184
ME-00597
(3) Make two 3 mm (0.12 in) holes in bushing.


BEARING
cracks using liquid penetrant tester. Replace if defective.
2) Check the crankshaft for bend, and repair or replace if needed.
NOTE:
the crankshaft on these bearings, and then check
the crankshaft for bend using a dial gauge.
ME-00598

ME(H6DO)-77
Cylinder Block
MECHANICAL
Unit: mm (in)
Journal O.D.
Standard:
Bearing size
(Thickness at
center)
Crank journal diameter

#1, #3, #5, #7
#2, #4, #6
63.992 64.008
(2.5194 2.5200)
1.992 2.005
(0.0784 0.0789)
63.962 63.978
(2.5182 2.5188)
Journal O.D.
0.03 (0.0012)
undersize
Bearing size
(Thickness at
center)
2.011 2.014
(0.0792 0.0793)
Bearing size
(Thickness at
center)
2.021 2.024
(0.0796 0.0797)
Bearing size
(Thickness at
center)
2.025 2.028
(0.0797 0.0798)
63.742 63.758
(2.5095 2.5102)
Journal O.D.
0.25 (0.0098)
undersize
2.015 2.018
(0.0793 0.0794)
63.942 63.958
(2.5174 2.5180)
Journal O.D.
0.05 (0.0020)
undersize
1.996 2.009
(0.0786 0.0791)
2.121 2.124
(0.0835 0.0836)
2.125 2.128
(0.0837 0.0838)
4) Measure the thrust clearance of crankshaft at

center bearing. If clearance exceeds the limit, replace the bearing.
Standard
0.030 0.115 mm (0.0012 0.0045 in)
ME-00600

of flaking, seizure, melting, and wear.
Standard
0.010 0.030 mm (0.0004 0.0012 in)
ME(H6DO)-78

51.984 52.000
(2.0466 2.0472)
1.490 1.506
(0.0587 0.0593)
51.954 51.970
(2.0454 2.0461)
1.509 1.513
(0.0594 0.0596)
51.934 51.950
(2.0446 2.0453)
1.519 1.523
(0.0598 0.0600)
51.734 51.750
(2.0368 2.0374)
1.619 1.623
(0.0637 0.0639)
Oil Flow Control Solenoid Valve

MECHANICAL
22.Oil Flow Control Solenoid

Valve
A: REMOVAL
Oil flow control solenoid valve is a unit with camshaft cap.
Refer to Camshaft for removal. <Ref. to
ME(H6DO)-55, REMOVAL, Camshaft.>
B: INSTALLATION
ME(H6DO)-79
Oil Switching Solenoid Valve

MECHANICAL
23.Oil Switching Solenoid Valve
B: INSTALLATION
A: REMOVAL
1) Install the oil switching solenoid valve holder.
NOTE:
(1) Temporarily tighten the bolts by tightening
torque of 5 10 Nm (0.5 1.0 kgf-m, 3.7
7.4 ft-lb) in order indicated in the figure.
(2) Tighten the bolts by tightening torque of
100.5 Nm (1.00.05 kgf-m, 7.40.37 ft-lb).
(5)
(2)
(1)
IN-00203
2) Remove the air intake chamber.

<Ref. to IN(H6DO)-7, REMOVAL, Air Intake Chamber.>
3) Disconnect the connector from oil switching solenoid valve.
ME-02071
(3)
(4)
ME-02073
2) Install the oil temperature sensor.

<Ref. to FU(H6DO)-29, INSTALLATION, Oil Temperature Sensor.>
3) Install the variable valve lift diagnosis oil pressure switch.
<Ref. to FU(H6DO)-28, INSTALLATION, Variable
Valve Lift Diagnosis Oil Pressure Switch.>
4) Install the oil switching solenoid valve.
5) Connect the connector to oil switching solenoid
valve.
4) Remove the oil switching solenoid valve.

5) Remove the variable valve lift diagnosis oil pressure switch.
<Ref. to FU(H6DO)-28, REMOVAL, Variable Valve
Lift Diagnosis Oil Pressure Switch.>
6) Remove the oil temperature sensor.
<Ref. to FU(H6DO)-29, REMOVAL, Oil Temperature Sensor.>
7) Remove the oil flow control solenoid valve holder from cylinder head.
ME-02071

<Ref. to IN(H6DO)-7, INSTALLATION, Air Intake
Chamber.>
ME-02072
ME(H6DO)-80
ATF Warmer Cock

MECHANICAL
24.ATF Warmer Cock
B: INSTALLATION
A: REMOVAL

Tightening torque:
16 Nm (1.6 kgf-m, 11.8 ft-lb)
(A)
(B)
(A)
IN-00203

Pipe.>
7) Disconnect the water hose from ATF warmer
cock.
8) Remove the ATF warmer cock from cylinder
head.
(A)
(B)
(A)
ME-02074
(A) Water pipe

(B) ATF warmer
ME(H6DO)-81
(A) Water pipe

(B) ATF warmer
ME-02075

MECHANICAL

A: INSPECTION
NOTE:
RANK shown in the chart refers to the possibility of reason for the trouble in order (Very often to Rarely)
A Very often
B Sometimes
C Rarely
Symptom

not occur.
Problem parts, etc.

Starter
Possible cause

Defective inhibitor switch or neutral switch
Defective starter
Battery
Run-down battery
Friction
Seized camshaft
Starter
Defective starter
Engine control system <Ref. to EN(H6DO)(diag)-2, Basic Diagnostic Procedure.>
Fuel line
Chain
Trouble
Defective timing
Compression
Trouble of tappet
Trouble of tappet (In case noise occurs with valve
moving or harness trouble involved to variable valve lift
occurred in past time.)
ME(H6DO)-82
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
C
B

MECHANICAL
Symptom

combustion.
Problem parts, etc.

Possible cause
Intake system
Fuel line
Clogged fuel line
Chain
Trouble
Defective timing
Compression
Trouble of tappet
Intake system
Fuel line
Clogged fuel line
Chain
Trouble
Defective timing
Compression
Trouble of tappet
ME(H6DO)-83
RANK
A
B
B
C
C
B
B
B
C
C
C
C
C
B
C
B
B
C
B
A
B
C
C
B
B
C
C
B
B
B
C
C
C
C
C
B
C
B
B
C
B

MECHANICAL
Symptom
stall
Problem parts, etc.

Possible cause
Intake system
Defective PCV valve
Fuel line
Clogged fuel line
Chain
Defective timing
Compression
Trouble of tappet
Lubrication system
Cooling system
Over-heating
Other
ME(H6DO)-84
RANK
A
A
A
A
B
B
C
B
C
C
C
B
C
B
B
B
B
C
B
B
A
B
C
B
B
C
C
A
B

MECHANICAL
Symptom
poor acceleration
Problem parts, etc.

Possible cause
Intake system
Defective PCV valve
Fuel line
Clogged fuel line
Chain
Defective timing
Compression
Trouble of tappet
Lubrication system
Cooling system
Over-heating
Over-cooling
Other
ME(H6DO)-85
RANK
A
A
A
B
B
B
B
B
A
B
B
C
B
B
B
B
B
C
B
C
A
B
C
B
B
C
C
A

MECHANICAL
Symptom
4. Surging

idle.
Problem parts, etc.

Possible cause
Intake system
Defective PCV valve
Fuel line
Clogged fuel line
Chain
Defective timing
Compression
Trouble of tappet
Cooling system
Over-heating
Other
Intake system
Other
Cooling system
Over-heating
Other
ME(H6DO)-86
RANK
A
A
A
A
B
B
B
B
B
B
B
C
B
B
C
C
C
C
C
C
A
B
C
B
B
C
A
A
A
A
B
B

MECHANICAL
Symptom
system
8. Knocking
Problem parts, etc.

Possible cause
Intake system
Defective PCV valve
Chain
Defective timing
Compression
Trouble of tappet
Lubrication system
Cooling system
Over-cooling
Other
Intake system
Chain
Defective timing
Compression
Trouble of tappet
Cooling system
Over-heating
Intake system
Defective PCV valve
Compression
Lubrication system
Defective oil filter o-ring
ME(H6DO)-87
RANK
A
C
C
B
B
C
B
B
C
C
B
C
C
C
A
C
B
C
C
C
A
B
B
C
B
C
B
A
A
B
C
A
A
B
B
B
B
B
B

MECHANICAL
Symptom
Problem parts, etc.
Possible cause
10. Excessive fuel consump- Engine control system <Ref. to EN(H6DO)(diag)-2, Basic Diagnostic Procedure.>
tion
Intake system
Chain
Defective timing
Compression
Trouble of tappet
Lubrication system
Cooling system
Over-cooling
ME(H6DO)-88
RANK
A
A
B
B
C
C
B
C
C
B
B
C
B
C
C
Engine Noise
MECHANICAL
26.Engine Noise
A: INSPECTION
Type of sound
High-pitched clank

1,000 to 2,000 rpm

and engine is warm
Squeaky sound
Rubbing sound
engine
a dry cloth
Hissing sound
Timing belt noise
Valve tappet noise
Condition
Possible cause
Worn valve rocker
speed increases.
Worn camshaft
Broken valve spring
Worn connecting rod bearing (big end)
Improper gasoline
(NOTE*)
(NOTE*)


Loose drive belt

Loss of compression

Loose timing belt
Belt contacting with case/adjacent part

Trouble of tappet
NOTE*:
Therefore, carry out the clear memory mode <Ref. to EN(H6DO)(diag)-40, OPERATION, Clear Memory Mode.> and inspection
mode <Ref. to EN(H6DO)(diag)-33, PROCEDURE, Inspection Mode.> after connecting the fuel injector connector.
ME(H6DO)-89
Engine Noise
MECHANICAL
ME(H6DO)-90
EXHAUST
EX(H6DO)
1.
2.
3.
4.
Page
Rear Exhaust Pipe ......................................................................................8
Muffler .......................................................................................................10
General Description
EXHAUST
A: COMPONENT
(16)
(24)
(24)
(26)
(24)
(17)
(26)
T6
(25)
(24)
(21)
(24)
(25)
(20)
(23)
T6
(22)
(19)
T4
(18)
(1)
T1
T5
T2
(8)
(2)
T3
(15)
(14)
T3
T3
(3)
(5)
(7)
(9)
(13)
(4)
(12) (10)
T1
(6)
T3
(11)
T4
T4
EX-02013
EX(H6DO)-2
General Description
EXHAUST
(1)

cover (RH)
(11)

cover (LH)
(2)

cover (RH)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
Gasket
Front exhaust pipe (RH)
Front catalytic converter (RH)
Front oxygen (A/F) sensor (RH)
Rear oxygen sensor (RH)
Gasket
Gasket
cover (LH)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
Front exhaust pipe (LH)

Front catalytic converter (LH)
Front oxygen (A/F) sensor (LH)
Rear oxygen sensor (LH)
Muffler (RH)
Muffler (LH)
Bracket
Gasket
Spring
Chamber
EX(H6DO)-3
(23)
(24)
(25)
(26)
Rear exhaust pipe

Cushion rubber
Self-locking nut
Gasket

T1: 13 (1.3, 9.4)
T2: 18 (1.8, 13.0)
T3: 21 (2.1, 15.2)
T4: 30 (3.1, 22.4)
T5: 35 (3.6, 26.0)
T6: 48 (4.9, 35.4)
General Description
EXHAUST
B: CAUTION
points.
cable from battery.
EX(H6DO)-4
Front Exhaust Pipe

EXHAUST
CAUTION:
Be careful not to pull down the front exhaust
pipe assembly.
A: REMOVAL
EX-02016
IN-00203

4) Disconnect the front oxygen (A/F) sensor connector (A) and rear oxygen sensor connector (B).
7) Remove the bolts which hold front exhaust pipe

assembly to hanger bracket.
(A)
(B)
EX-00061
EX-02014
5) Separate the front exhaust pipe from rear exhaust pipe.

CAUTION:
Be careful, exhaust pipe is hot.
8) Remove the front exhaust pipe assembly from

vehicle.
CAUTION:
Be careful not to let the front exhaust pipe assembly fall off when removing, as it is quite
heavy.
After removing the front exhaust pipe assembly, do not apply excessive pulling force on the
rear exhaust pipe.
9) Disconnect the front exhaust pipe (RH) from
front exhaust pipe assembly.
EX-02015

onto cylinder heads.
EX-02017
10) Remove the front oxygen (A/F) sensor and rear

oxygen sensor. <Ref. to FU(H6DO)-30, REMOVAL, Front Oxygen (A/F) Sensor.> <Ref. to
FU(H6DO)-32, REMOVAL, Rear Oxygen Sensor.>
EX(H6DO)-5
Front Exhaust Pipe

EXHAUST
B: INSTALLATION
1) Install the front oxygen (A/F) sensor and rear oxygen sensor. <Ref. to FU(H6DO)-30, INSTALLATION, Front Oxygen (A/F) Sensor.> <Ref. to
FU(H6DO)-32, INSTALLATION, Rear Oxygen
Sensor.>
2) Install the front exhaust pipe (RH) to front exhaust pipe assembly.
7) Tighten the bolts which install the front exhaust

pipe to rear exhaust pipe.
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
NOTE:
Use a new gasket.
Tightening torque:
30 Nm (3.1 kgf-m, 22.4 ft-lb)
EX-02015
8) Tighten the bolts which hold the front exhaust

pipe assembly to hanger bracket.
Tightening torque:
35 Nm (3.6 kgf-m, 26.0 ft-lb)
EX-02017
3) Install the front exhaust pipe assembly to vehicle.

4) Temporarily tighten the bolts which hold front exhaust pipe assembly to hanger bracket.
EX-00061
9) Connect the front oxygen (A/F) sensor connector (A) and rear oxygen sensor connector (B).
(A)
EX-00061
5) Install the nuts to cylinder head which hold front

exhaust pipe.
(B)
Tightening torque:
30 Nm (3.1 kgf-m, 22.4 ft-lb)
EX-02014
EX-02016
EX(H6DO)-6
Front Exhaust Pipe

EXHAUST
IN-00203
C: INSPECTION
EX(H6DO)-7
Rear Exhaust Pipe

EXHAUST
4) Remove the rear exhaust pipe bracket from

cushion rubber.
A: REMOVAL
1) Separate the rear exhaust pipe from front exhaust pipe.
CAUTION:
EX-00219
B: INSTALLATION
EX-02015
1) Apply a coat of spray type lubricant to the mating

2) Install the rear exhaust pipe bracket to cushion
rubber.
2) Separate the rear exhaust pipe from muffler.

CAUTION:
pipe.
LH side
EX-00219
3) Install the rear exhaust pipe to muffler.

NOTE:
EX-00222
RH side
Tightening torque:
48 Nm (4.9 kgf-m, 35.4 ft-lb)
LH side
EX-00218

EX(H6DO)-8
EX-00222
Rear Exhaust Pipe

EXHAUST
RH side
EX-00218

pipe.
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
EX-02015
C: INSPECTION
cracked.
EX(H6DO)-9
Muffler
EXHAUST
4. Muffler
3) Remove the front and rear cushion rubber, and

then remove the muffler.
A: REMOVAL
1) Separate the muffler from rear exhaust pipe.
CAUTION:
LH side
B: INSTALLATION
NOTE:
Tightening torque:
48 Nm (4.9 kgf-m, 35.4 ft-lb)
LH side
EX-00222
RH side
EX-00222
RH side
EX-00218

LH side
EX-00218
C: INSPECTION
cracked.
EX-00220
RH side
EX-00221
EX(H6DO)-10
COOLING
CO(H6DO)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Page
Engine Coolant............................................................................................9
Water Pump ..............................................................................................11
Thermostat ................................................................................................12
Radiator.....................................................................................................13
Radiator Cap .............................................................................................16
Reservoir Tank..........................................................................................22
Radiator Fan Control Unit .........................................................................23
General Description
COOLING
A: SPECIFICATION
Cooling system
Model with ATF warmer (LHD)
Model with ATF warmer (RHD)
2 (US qt, Imp qt)
Model without ATF warmer
Type
Discharge amount
mance I
pressure
Water pump
Impeller diameter
mm (in)
Number of pump sprocket teeth
Type
Thermostat
Fully opens
Valve lift
mm (in)
Valve bore
mm (in)
Main fan
W
Motor input
Sub fan
W
Radiator fan
Main
fan
Fan diameter /
Blades
Sub fan
Type
Width Height Thickness
Core dimensions
mm (in)
Radiator
Pressure range in
which cap valve is
open

Approx. 7.7 (8.1, 6.8)
Approx. 7.8 (8.2, 6.9)
Approx. 7.2 (7.6, 6.3)
kPa (kg/cm2, psi)
Fins
Reservoir
tank
Capacity
2 (US qt, Imp qt)
CO(H6DO)-2
320 (84.5, 70.4)

5,500 rpm 176.5 kPa (18 mAq)
80C (176F)
73.2 (2.88)
6
22
Wax pellet type
80 84C (176 183F)
95C (203F)
9.0 (0.354) or more
35 (1.38)
160
160
320 mm (12.60 in) /5
320 mm (12.6 in) /7
Down flow, pressure type
690 349 16 (27.17 13.74 0.63)
Above: 10815
(1.10.15, 162)
Below: 1.0 4.9
(0.01 0.05, 0.1 0.7)
Corrugated fin type
0.5 (0.5, 0.4)
General Description
COOLING
B: COMPONENT
1. WATER PUMP
(4)
(3)
(5)
(2)
(1)
CO-02036
(1)
(2)
(3)
Water pump ASSY

O-ring
Thermostat
(4)
(5)
Gasket
Thermostat cover
CO(H6DO)-3

T: 6.4 (0.65, 4.7)
General Description
COOLING

(27)
T4
T2
(14)
(13)
(19)
(12)
T4
(16)
(18)
T5
(5)
(9)
(8)
(6)
T4
T1
(4)
T3
(7)
(20)
(22)
(3)
(7)
(10)
(21)
(17)
(9)
T1
T3
(23)
(15)
T4
(7)
T4
(11)
(21)
(21)
(24)
(7)
(25)
(2)
(21)
(21)
(1)
(21)
(21)
(26)
CO-02027
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)

Engine coolant drain cock
Radiator
Clamp
Radiator inlet hose A
Clamp
Radiator inlet hose B
Radiator sub fan
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
Radiator sub fan motor

Radiator main fan
Radiator main fan motor
Over flow hose
ATF hose clamp
ATF inlet hose A
ATF outlet hose A
ATF pipe
CO(H6DO)-4
(25)
(26)
(27)
ATF inlet hose B

ATF outlet hose B
Radiator fan control unit

T1: 3.8 (0.39, 2.8)
T2: 5.4 (0.55, 4.0)
T3: 6.2 (0.63, 4.6)
T4: 7.5 (0.76, 5.5)
T5: 12 (1.2, 8.7)
General Description
COOLING
C: CAUTION

points.
cable from battery.
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
499977100
DESCRIPTION
CRANK PULLEY
WRENCH
REMARKS
Used for stopping crank pulley when loosening and tightening crank pulley bolts.
499977500
CAM SPROCKET
WRENCH
Used for removing and installing intake cam

sprocket.
18231AA020
CAM SPROCKET
WRENCH
Used for removing and installing exhaust

cam sprocket.
ST-499977100
ST-499977500
ST18231AA020
2. GENERAL TOOL
TOOL NAME
Radiator cap tester
REMARKS
Used for measuring pressure.
CO(H6DO)-5
Radiator Fan System

COOLING

A: WIRING DIAGRAM
SBF-1
SBF-7
No.2
IGNITION
SWITCH
No.26
MAIN FUSE BOX (M/B)

MAIN
FAN
RELAY 1
B: B143
F36
B7
E6
E:
THROUGH
JOINT CONNECTOR
16
B361
F108
PWM
CONTROLLER
A: B134
B: B135
E
M
MAIN FAN MOTOR
B361
F108
1 2 3
1 2 3
4 5 6
7 8 9 10 11 12 13 14
5 6 7 8
1 2 3 4
9 10 11 12 13 14 15 16 17 18
B: B143
F36
1 2
4 5
3
7
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
ECM
SUB FAN MOTOR
F106
E:
B30
A31
F17
F106
F17
A: B134
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B: B135
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
1 2
CO-02028
CO(H6DO)-6
Radiator Fan System

COOLING
B: RADIATOR FAN CONTROL OUTPUT WAVEFORM
(V)
(A)
0
(B)
CO-02026
(A)
5V
(B)
2 ms
C: INSPECTION
A/C switch is OFF.
TROUBLE SYMPTOMS:
Radiator main fan and sub fan do not rotate under the above conditions.
Step
holder.
fan relay 1 switch.
1) Connect the terminal of main fan relay 1
coil to battery.
CHECK POWER SUPPLY TO ECM.
4) Measure the voltage between ECM terminal and chassis ground.
Check
M?
Yes
Go to step 2.
No
Replace the main
fan relay 1.

?
Go to step 3.
Replace the main

fan relay 1.
Repair the power

supply line.
CO(H6DO)-7
Radiator Fan System

COOLING
Step
CHECK POWER SUPPLY TO RADIATOR
FAN CONTROL UNIT.
3) Disconnect the connector from radiator fan
control unit.
5) Measure the voltage between radiator fan
control unit terminal and chassis ground.
CHECK HARNESS BETWEEN ECM AND RADIATOR FAN CONTROL UNIT.
3) Measure the resistance between radiator
fan control unit and ECM connector.
(B134) No. 31 (F106) No. 2:
CHECK RADIATOR FAN CONTROL UNIT
AND GROUND CIRCUIT.
1) Connect the connector to ECM and radiator
fan control unit.
2) Measure the resistance between radiator
fan control unit connector and chassis ground.
CHECK FAN MOTOR.
control unit.
2) Connect the battery positive (+) terminal to
terminal No. 1, and the ground () terminal to
terminal No. 3 of radiator fan control unit.
CHECK ECM OUTPUT SIGNAL.
4) Using the oscilloscope, check the output
signal. <Ref. to CO(H6DO)-7, RADIATOR FAN
CONTROL OUTPUT WAVEFORM, Radiator
Fan System.>
Check
Yes
No
Repair the power
supply line.

?
Go to step 6.
Repair the open

circuit in harness
between ECM and
radiator fan control unit.

?
Go to step 7.
Repair the open

circuit in harness
between radiator
fan control unit
connector and
chassis ground.
Does the fan motor rotate?
Go to step 8.
Replace the fan

motor which does
not rotate.
Is the waveform output?
Replace the radiator fan control unit.

<Ref. to
CO(H6DO)-23,
Radiator Fan Control Unit.>
Replace the ECM.

<Ref. to
FU(H6DO)-34,
Engine Control
Module (ECM).>
CO(H6DO)-8
Engine Coolant
COOLING
3. Engine Coolant

FULL level.
A: REPLACEMENT
into container.
(1)
(2)
NOTE:
Remove the coolant filler tank cap so that engine
coolant will drain faster.
CO-00110
(1) FULL
(2) LOW
CO-02012

1) Fill engine coolant into coolant filler tank up to
the filler neck position.
Model with ATF warmer (LHD)
Model with ATF warmer (RHD)
Model without ATF warmer
3) Warm-up the engine completely for more than

4) If the engine coolant level drops in coolant filler
tank, add engine coolant to filler neck position.
level.
6) Attach the coolant filler tank cap and reservoir
tank cap properly.
B: INSPECTION
CONCENTRATION AND FREEZING TEMPERATURE
NOTE:
SUBARU Genuine Coolant containing anti-freeze
and anti-rust agents is especially made for SUBARU engine, which has an aluminum crankcase. Always use SUBARU Genuine Coolant, since other
coolant may cause corrosion.
CO(H6DO)-9
Engine Coolant
COOLING

Concentration
of coolant
1.100
1.080
2
(2.1,
1.8)
1
(1.1,
0.9)
60%
1.070
C
B
50%
(1.054)
1.050
40%
1.040
1.030
Freezing
temperature
20%
25 C
(77 F)
1.000
45%
A
35%
40%
30%
25%
20%
10% 15%
10
20
30
40
50
30%
1.020
1.010
of coolant
3
(3.2,
2.6)
1.090
1.060

only.
Specific gravity
of coolant
[Example]
If the coolant temperature is 25C (77F), its specific gravity is 1.054, the concentration is 45% (point
A), the safe operating temperature is 14C (7F)
(point B), and the freezing temperature is 20C
(4F) (point C).

CO-00012
10%
0
10 20 30 40 50
-40 -30 -20 -10
(-40) (-22) (-4) (14) (32) (50) (68) (86) (104) (122)
CO-00237

[Example]
CO(H6DO)-10
Water Pump
COOLING
4. Water Pump
A: REMOVAL
1) Remove the radiator. <Ref. to CO(H6DO)-13,
REMOVAL, Radiator.>
2) Remove the V-belts.
<Ref. to ME(H6DO)-34, REMOVAL, V-belt.>
3) Remove the front chain cover.
<Ref. to ME(H6DO)-44, REMOVAL, Front Chain
Cover.>
Assembly.>
NOTE:
When the water pump cannot be removed easier,
screw-in the bolts (A) to screw part to remove water
pump.

Chain Cover.>
4) Install the V-belts.
<Ref. to ME(H6DO)-34, INSTALLATION, V-belt.>
5) Install the radiator. <Ref. to CO(H6DO)-14, INSTALLATION, Radiator.>
6) Fill with engine coolant. <Ref. to CO(H6DO)-9,
FILLING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>
C: INSPECTION
2) Check the water pump sprocket for abnormalities.
(A)
(A)
CO-02013
B: INSTALLATION
1) Install the water pump to rear chain cover.
NOTE:
Apply engine coolant to O-ring.
Tightening torque
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
NOTE:
Use new O-rings.
Apply engine coolant to O-ring to install water
pump easier.
CO-02014

Chain Assembly.>
CO(H6DO)-11
Thermostat
COOLING
5. Thermostat
A: REMOVAL
<Ref. to CO(H6DO)-9, DRAINING OF ENGINE
CO-02015
6) Remove the thermostat cover and then remove

the thermostat.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
cover.
6) Fill with engine coolant. <Ref. to CO(H6DO)-9,
FILLING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>
C: INSPECTION
Inspection method
During the test, agitate the water for even temperature distribution. The measurement should conform to the specification.
80 84C (176 183F)
Fully opens:
95C (203F)
Valve lift:
(A)
CO-02016
B: INSTALLATION
(B)
1) Install the gasket to thermostat.

NOTE:
Use a new gasket.
2) Install the thermostat and thermostat cover.
NOTE:
The thermostat must be installed with the jiggle pin
facing upward.
CO-02016
CO(H6DO)-12
CO-00033
(A) Thermometer
(B) Thermostat
Radiator
COOLING
6. Radiator
A: REMOVAL
WARNING:
CO-02017
control unit.
IN-00203

7) Disconnect the outlet hose from radiator.
CO-02018
13) Remove the reservoir tank. <Ref.

CO(H6DO)-22, REMOVAL, Reservoir Tank.>
14) Disconnect the inlet hose from radiator.
(A)
CO-02015
8) Disconnect the ATF cooler hose from radiator.

(model without ATF warmer)
(B)
CO-02019
(A) Radiator inlet hose

(B) Radiator upper bracket
CO-00253
CO(H6DO)-13
to
Radiator
COOLING
B: INSTALLATION
the vehicle.

Duct.>
8) Install the hood stay holder.
CO-00126
CO-02017

NOTE:
the bolts.

10) Connect the ATF cooler hoses. (model without
ATF warmer)
Tightening torque:
12 Nm (1.2 kgf-m, 8.7 ft-lb)
4) Connect the radiator inlet hose.
(A)
CO-00253
(B)
CO-02019
(A) Radiator inlet hose

(B) Radiator upper bracket
5) Install the reservoir tank. <Ref. to CO(H6DO)22, INSTALLATION, Reservoir Tank.>

6) Connect the connector to radiator fan control
unit.
CO-02015

CO-02018
IN-00203
CO(H6DO)-14
Radiator
COOLING
15) Fill with engine coolant.

16) Check the ATF level.
C: INSPECTION
1) Remove the radiator cap, top off the radiator with
coolant, and then attach the tester in place of cap.
CO-00127

Engine coolant leaks at/around radiator.
CAUTION:
Be careful not to deform the filler neck of radiator when installing or removing the tester.
CO(H6DO)-15
Radiator Cap
COOLING
7. Radiator Cap
A: INSPECTION
CO-00044

Standard pressure:
93 123 kPa (0.95 1.25 kg/cm2, 14 18
psi)
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.
Do not confuse the cap of coolant filler tank
with cap of radiator.
CO(H6DO)-16

COOLING

Motor
13) Remove the reservoir tank. <Ref.

CO(H6DO)-22, REMOVAL, Reservoir Tank.>
14) Disconnect the inlet hose from radiator.
to
A: REMOVAL
CO-02020
15) Remove the radiator sub fan motor assembly.
IN-00203
CO-00129
16) Remove the radiator main fan motor assembly.
CO-02017
6) Disconnect the connector from radiator fan control unit.
NOTE:
When removing the main fan assembly with lifting it
up, the main fan shroud contacts to inlet part of engine coolant. To avoid contacting it, move the main
fan assembly to sub fan assembly side before removal.
CO-00130
CO-02029

10) Disconnect the ATF hose from the clip of radiator main fan shroud. (model without ATF warmer)
11) Remove the radiator main fan motor harness
from clip.
CO(H6DO)-17

COOLING
B: INSTALLATION
D: ASSEMBLY
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
Tightening torque:
3.8 Nm (0.39 kgf-m, 2.8 ft-lb)
CO-00130
C: DISASSEMBLY
CO-00133
Tightening torque:
6.2 Nm (0.63 kgf-m, 4.6 ft-lb)
CO-00132
CO-00132
2) Remove the screws which hold the fan motor

onto shroud.
E: INSPECTION
NOTE:
Do not remove the main fan motor harness connector.
CO-00133
CO-02018
CO(H6DO)-18

COOLING
2) Connect the battery to radiator fan control unit as

CO-02037
3) Check the fan motor for operations. If it does not

operate, replace the fan motor.
CO(H6DO)-19

COOLING

Motor
7) Remove the bolts which hold sub fan shroud to

radiator.
A: REMOVAL
CO-00129

10) Remove the radiator sub fan shroud through
the under side of vehicle.
IN-00203
B: INSTALLATION
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
CO-02017
CO-00129
C: DISASSEMBLY
CO-02029
CO-00136
CO(H6DO)-20

COOLING
2) Remove the screws which hold the fan motor

onto shroud.
NOTE:
Do not remove the main fan motor harness connector.
CO-00133
3) Remove the bolts which hold the radiator fan

control unit onto shroud.
D: ASSEMBLY
CO-02018
2) Connect the battery to radiator fan control unit as


Radiator fan control unit bolt tightening torque:
5.4 Nm (0.55 kgf-m, 4.0 ft-lb)
Tightening torque:
3.8 Nm (0.39 kgf-m, 2.8 ft-lb)
CO-02037
3) Check the fan motor for operations. If it does not

operate, replace the fan motor.
CO-00133
Tightening torque:
6.2 Nm (0.63 kgf-m, 4.6 ft-lb)
CO-00136
E: INSPECTION
CO(H6DO)-21
Reservoir Tank
COOLING
10.Reservoir Tank
A: REMOVAL
2) Pull out the reservoir tank to the direction of arrow while pushing the pawl (A).
(A)
CO-02021
B: INSTALLATION
C: INSPECTION
FULL and LOW.
CO(H6DO)-22
Radiator Fan Control Unit

COOLING
11.Radiator Fan Control Unit

A: SPECIFICATION
Radiator fan control unit forms a unit with radiator
sub fan motor. Refer to Radiator Sub Fan and Fan
Motor for removal and installation.
<Ref. to CO(H6DO)-20, REMOVAL, Radiator Sub
Fan and Fan Motor.> <Ref. to CO(H6DO)-20, INSTALLATION, Radiator Sub Fan and Fan Motor.>
<Ref. to CO(H6DO)-20, DISASSEMBLY, Radiator
Sub Fan and Fan Motor.> <Ref. to CO(H6DO)-21,
ASSEMBLY, Radiator Sub Fan and Fan Motor.>
CO(H6DO)-23

COOLING

A: INSPECTION
Trouble
Over-heating
Over-cooling
Engine coolant
leaks
Noise
Possible cause
Corrective action
Replace.
c. Malfunction of water pump
Replace.
d. Clogged engine coolant passage
Clean.
Inspect and repair ignition control system. <Ref. to
e. Improper ignition timing
EN(H6DO)(diag)-2, PROCEDURE, Basic Diagnostic
Procedure.>
f. Clogged or leaking radiator
g. Improper engine oil in engine coolant
Inspect and repair fuel injection system. <Ref. to
h. Air/fuel mixture ratio too lean
EN(H6DO)(diag)-2, PROCEDURE, Basic Diagnostic
Procedure.>
i. Excessive back pressure in exhaust system
Clean or replace.
j. Insufficient clearance between piston and cylinder Adjust or replace.
k. Slipping clutch
Correct or replace.
l. Dragging brake
Adjust.
m. Faulty transmission gear oil
Replace.
n. Malfunction of radiator fan
sensor or fan motor, and replace them.
Replace.
a. Loosened or damaged connecting units on hoses Correct or replace.
Replace.
Correct or replace.
e. Damaged or cracked cylinder head and crankcase Correct or replace.
Correct or replace.
Correct or replace.
a. Defective drive belt
Replace.
Replace.
Replace water pump.
Replace water pump.
CO(H6DO)-24
LUBRICATION
LU(H6DO)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Page
Engine Oil....................................................................................................7
Oil Pump .....................................................................................................8
Oil Pump Relief Valve ...............................................................................10
Oil Cooler ..................................................................................................14
General Description
LUBRICATION
A: SPECIFICATION
Lubrication method
Pump type
Inner rotor
Outer rotor
Tip clearance between inner and outer rotors
Side clearance between inner rotor and pump case
Case clearance between outer rotor and pump case
Filter type
Number of teeth
Oil pump
mm (in)
mm (in)
mm (in)
mm (in)
cm2 (sq in)
Filtration area
Oil filter
kPa (kg/cm , psi)

mm (in)

Relief valve operation pressure
Oil pressure
switch
kPa (kg/cm2, psi)
Type
Operating voltage Power consumption
Forced lubrication
Trochoid type
7
8
86 13 (3.39 0.51)
0.04 0.14 (0.0016 0.0055)
0.020 0.046 (0.0008 0.0018)
0.110 0.175 (0.0043 0.0069)
1,300 (201.5)
160 (1.63, 23.2)
80 75 (3.15 2.95)
M 20 1.5
708 (7.2, 102.7)
12 V 3.4 W or less
kPa (kg/cm2, psi)
15 (0.15, 2.2)
Proof pressure
kPa (kg/cm2, psi)

2 (US qt, Imp qt)
980 (10.0, 142) or more
Recommended oil
For the API specification SL and SJ, use the
logo mark with Energy Conserving (If the
SL, SJ grade is not available, use SH grade).
ACEA specification A1, A2 or A3
CCMC specification G4 or G5
New API specification mark (Star burst mark)
label is on the container.
SAE (1)
( C) -30 -20 -15
( F) -22 -4 5
0
32
15
59
5.5 (5.8, 4.8)
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.
30 40
86 104
10W-30
5W-30 (2)
LU-02031

(2) Recommended
The proper viscosity helps the vehicle to get good

cold and hot starting by reducing viscous friction
and thus increasing cranking speed.
LU(H6DO)-2
General Description
LUBRICATION
B: COMPONENT
(14)
(13)
(15)
(12)
T2
(10)
(8)
T7
(7)
(6)
(17)
T6
(7)
(16)
(8)
(20)
(9)
(11)
T9
(18)
T8
(19)
(8)
T3
T4
(7)
T4
(6)
(8)
T4
(7)
(21)
(25)
T5
(5)
(7)
(22)
(24)
(7)
T1
(23)
(6)
(2)
T4
T8
(1)
T1
T7
(3)
(4)
T1
LU-02010
LU(H6DO)-3
General Description
LUBRICATION
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
Oil pan lower

Magnet
Drain plug
Gasket
Oil cooler pipe
Hose
Clamp
O-ring
Oil cooler
Connector
Oil filter
Oil pump cover
Inner rotor
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
Outer rotor
Crank sprocket
Oil pan upper
Plug
Plug
Plug
Oil pressure switch
Plug
Oil strainer
Plug
Relief valve spring
Relief valve
C: CAUTION

T1: 6.4 (0.65, 4.7)
T2: <Ref. to LU(H6DO)-8,
INSTALLATION, Oil Pump.>
T3:
T4:
T5:
T6:
T7:
T8:
T9:
16 (1.6, 12)
18 (1.8, 13)
23 (2.3, 17)
25 (2.5, 18)
37 (3.8, 27)
44 (4.5, 33)
90 (9.2, 66)

points.
cable from battery.
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
499977100
DESCRIPTION
CRANK PULLEY
WRENCH
REMARKS
removing and tightening crank pulley bolt.
OIL FILTER
WRENCH
Used for removing and installing oil filter.
ST-499977100
498547000
ST-498547000
LU(H6DO)-4
Oil Pressure System

LUBRICATION

A: WIRING DIAGRAM
B72
IGNITION
SWITCH
BATTERY
No.5
SBF-7
3
A3
A4
SBF-1
OIL PRESSURE
WARNING LIGHT
COMBINATION
METER
i10
A15
A:
17
i3
31
B38
B21
E2
E11
E
OIL PRESSURE
SWITCH
B21
B72
1 2 3
4 5 6
A:
i10
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
B38
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
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 45
46 47
48 49 50 51 52 53 54
LU-00241
LU(H6DO)-5
Oil Pressure System

LUBRICATION
B: INSPECTION
1
Step
OFF)
2) Check the warning light of combination
meter.
Check
Does the warning light illuminate?

switch.
4) Measure the voltage of harness between oil
?
2) Remove the combination meter.
3) Measure the resistance of combination
meter.
Terminals
No. 4 No. 15:
No. 3 No. 15:
LU(H6DO)-6
Yes
Go to step 2.
Replace the oil

pressure switch.

pressure switch.
No
Repair or replace
the combination
Combination
Meter System.>
Go to step 3.
Repair or replace
the combination
Combination
Meter System.>
Engine Oil
LUBRICATION
3. Engine Oil
NOTE:
Prepare a container for draining of engine oil.
A: INSPECTION
2) Extract the oil level gauge and wipe it clean.
orientated.
4) Remove it again and check the reading. If the
engine oil level is below L line, add oil to bring the
level up to F line.
the level.
NOTE:
NOTE:
(D)
Oil level gauge

Upper level
Lower level
B: REPLACEMENT
Engine oil capacity (when replacing engine oil):

5.5 2 (5.8 US qt, 4.8 Imp qt)
level gauge.
(B)
(A)

the engine oil.
plug.
Recommended oil:
Refer to SPECIFICATION for the recommended oil. <Ref. to LU(H6DO)-2, SPECIFICATION, General Description.>
F
L
(C)
LU-00111
(A)
(B)
(C)
(D)

engine oil.
Tightening torque:
44 Nm (4.5 kgf-m, 32.5 ft-lb)
point on level gauge. Make sure that the vehicle is
(B)
(A)
LU-02011
(C)
(D)
LU-00111
(A)
(B)
(C)
(D)
LU(H6DO)-7
Oil level gauge

Upper level
Lower level
Oil Pump
LUBRICATION
4. Oil Pump
B: INSTALLATION
A: REMOVAL
1) Apply a coat of engine oil to the whole area of inner rotor and outer rotor.

LU-02032
IN-00203

5) Drain engine coolant. <Ref. to CO(H6DO)-9,
DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>
7) Remove the radiator. <Ref. to CO(H6DO)-13,
REMOVAL, Radiator.>
8) Remove the V-belts. <Ref. to ME(H6DO)-34,
REMOVAL, V-belt.>
10) Remove the timing chain. <Ref. to ME(H6DO)46, REMOVAL, Timing Chain Assembly.>
12) Remove the oil pump cover.
2) Set the inner rotor onto opening edge of crank

shaft, and install the inner rotor, and then assemble
the outer rotor.
CAUTION:
Ensure that the bolt is installed in correct position.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
(3)
(9)
(7)
(2)
(5)
(8)
(1) (6)
(12)
(16)
(11)
(17)
(4)
(10)
(14)
(15) (13)
LU-02013
LU-02012
13) Remove the inner rotor and outer rotor.
Bolt installing position

(1) and (3)
(2) and (4)
(5), (6), (7), (8), (9), (10) and (11)
(12), (15), (16) and (17)
(13) and (14)
Bolt dimension
6 14 14
6 35 18
6 35 15
6 16 16
6 26 15

6) Install the timing chain. <Ref. to ME(H6DO)-47,
INSTALLATION, Timing Chain Assembly.>
7) Install the front chain cover. <Ref. to ME(H6DO)44, INSTALLATION, Front Chain Cover.>
8) Install the V-belts. <Ref. to ME(H6DO)-34, INSTALLATION, V-belt.>
9) Install the radiator. <Ref. to CO(H6DO)-14, INSTALLATION, Radiator.>
LU(H6DO)-8
Oil Pump
LUBRICATION

C: INSPECTION
1. TIP CLEARANCE
exceeds the limit, replace the rotors as a matched
set.
3. SIDE CLEARANCE
Measure the clearance between oil pump inner rotor and rear chain cover. If the clearance exceeds
the limit, replace rotors as a matched set.
Side clearance:
Standard value
0.020 0.046 mm (0.0008 0.0018 in)
Tip clearance:
Standard value
0.04 0.14 mm (0.0016 0.0055 in)
LU-02016
4. OIL PUMP CASE

Check the worn shaft hole, clogged oil passage,
crank and other parts for faults.
LU-02014
2. CASE CLEARANCE
Measure the clearance between the outer rotor and
rear chain cover rotor housing. If the clearance exceeds the limit, replace the outer rotor.
Case clearance:
Standard value
0.110 0.175 mm (0.0043 0.0069 in)
LU-02015
LU(H6DO)-9
Oil Pump Relief Valve

LUBRICATION
5. Oil Pump Relief Valve
2. OIL PAN UPPER SIDE
A: REMOVAL
1) Install the relief valve, relief valve spring and

plug.
1. REAR CHAIN COVER SIDE
NOTE:
Apply the engine oil to relief valve.
Oil pump relief valve is integrated into oil pump cover as one unit; therefore, refer to Oil Pump for removal procedure. <Ref. to LU(H6DO)-8,
REMOVAL, Oil Pump.>
Tightening torque:
T: 44 Nm (4.5 kgf-m, 33 ft-lb)
2. OIL PAN UPPER SIDE

1) Remove the oil pan. <Ref. to LU(H6DO)-11, REMOVAL, Oil Pan and Strainer.>
2) Remove the plug, relief valve spring and relief
valve.
T
(1)
(2)
LU-02034
2) Install the oil pan. <Ref. to LU(H6DO)-11, INSTALLATION, Oil Pan and Strainer.>
(3)
C: INSPECTION
LU-02033
Check the worn shaft hole of oil pump relief valve

case, clogged oil passage, crank and other parts
for faults.
(1) Relief valve

(2) Relief valve spring
(3) Plug
B: INSTALLATION
1. REAR CHAIN COVER SIDE
Oil pump relief valve is integrated into oil pump cover as one unit; therefore, refer to Oil Pump for installation procedure. <Ref. to LU(H6DO)-8,
INSTALLATION, Oil Pump.>
LU(H6DO)-10

LUBRICATION
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
A: REMOVAL
NOTE:
Before removing the oil pan upper, remove the engine from vehicle. <Ref. to ME(H6DO)-35, REMOVAL, Engine Assembly.> <Ref. to ME(H6DO)64, REMOVAL, Cylinder Block.>
4) Drain the engine oil. <Ref. to LU(H6DO)-7, REPLACEMENT, Engine Oil.>
5) Insert the oil pan cutter blade between oil pan
upper and oil pan lower.
CAUTION:
of oil pan cutter.
6) Remove the oil pan lower.
LU-00124

Liquid gasket
Liquid gasket applying diameter
5.01.0 mm (0.1970.039 in)
LU-00123
LU-00125
3) Tighten the oil pan lower installing bolts in the

Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
(2)
(1)
(15)
(14)
(13)
(3)
(4)
LU-00124
(5)
B: INSTALLATION
(11)
(6)
CAUTION:
Before installing the oil pan, wipe clean the
mating surface of oil pan lower and oil pan upper.
1) Install the oil strainer to oil pan upper.
NOTE:
(12)
(10)
(7)
(8)
(9)
LU-00126

5) Fill engine oil. <Ref. to LU(H6DO)-7, INSPECTION, Engine Oil.>
C: INSPECTION
Visually check that the oil pan, oil strainer and oil
strainer stay are not damaged.
LU(H6DO)-11
Oil Pressure Switch

LUBRICATION
B: INSTALLATION
A: REMOVAL

threads.

Liquid gasket
equivalent
IN-00203

LU-00129
2) Install the oil pressure switch.

Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
LU-00127

LU-00128
3) Connect the terminal of oil pressure switch.
LU-00128
LU-00127
C: INSPECTION
Make sure oil does not leak or seep from where the
oil pressure switch is installed.
LU(H6DO)-12
Engine Oil Filter

LUBRICATION

A: REMOVAL
1) Drain the engine oil by removing engine oil drain
plug.
LU-02011

ST 4985447000 OIL FILTER WRENCH
LU-02035
B: INSTALLATION
1) Clean the oil filter installing surface of oil cooler.
3) Install the oil filter turning it by hand, being careful not to damage seal rubber.
4) Tighten more (approx. 3/4 turn) after the seal
rubber contacts the oil cooler. Do not tighten excessively, or oil may leak.
7) Fill engine oil. <Ref. to LU(H6DO)-7, INSPECTION, Engine Oil.>
C: INSPECTION
1) After installing the oil filter, run engine and make
sure that no oil is leaking around seal rubber.
NOTE:
2) Check the engine oil level. <Ref. to LU(H6DO)7, INSPECTION, Engine Oil.>
LU(H6DO)-13
Oil Cooler
LUBRICATION
9. Oil Cooler
8) Remove the connector and remove oil cooler.
A: REMOVAL
3) Drain the engine coolant.
4) Drain the engine oil. <Ref. to LU(H6DO)-7, REPLACEMENT, Engine Oil.>
5) Remove the bolts which hold the water pipe to
engine.
(A)
(B)
(C)
LU-00135
(A) Connector
(B) Oil cooler
(C) O-ring
B: INSPECTION
1) Check that engine coolant passages are not
clogged using an compressed air.
2) Check that the oil pan upper and O-ring installing
surface of oil filter are not damaged.
LU-02036
6) Disconnect the water hose from oil cooler.
C: INSTALLATION
1) Install the oil cooler to oil pan upper with connector pipe.
Tightening torque:
T: 54 Nm (5.5 kgf-m, 39.8 ft-lb)
NOTE:
Use new O-rings.
(A)
LU-02037
7) Remove the oil filter using ST. <Ref. to

LU(H6DO)-13, REMOVAL, Engine Oil Filter.>
ST 498547000
OIL FILTER WRENCH
T
(B)
NOTE:
Set a container under the vehicle.
(C)
LU-00136
(A) Connector
(B) Oil cooler
(C) O-ring
2) Install the oil filter using ST. <Ref. to LU(H6DO)13, INSTALLATION, Engine Oil Filter.>
LU-00134
LU(H6DO)-14
Oil Cooler
LUBRICATION
ST
498547000
OIL FILTER WRENCH
LU-00134
3) Connect the water hose.
LU-02037
4) Install the water pipe to engine.

Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
LU-02036
5) Fill engine oil. <Ref. to LU(H6DO)-7, REPLACEMENT, Engine Oil.>

6) Fill engine coolant. <Ref. to CO(H6DO)-9, FILLING OF ENGINE COOLANT, REPLACEMENT,
Engine Coolant.>
7) Check the engine oil level. <Ref. to LU(H6DO)7, INSPECTION, Engine Oil.>
LU(H6DO)-15

LUBRICATION

A: INSPECTION
Symptom

on.

not come on.

momentarily.
Possible cause
Cracked
failure
2) Low oil pressure
Clogged oil passage
pump rotor and gear
3) No oil pressure
3) Low oil pressure
LU(H6DO)-16
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).
SP(H6DO)
1.
Page
General Description
A: SPECIFICATION
Specifications for 3.0 L DOHC Non-turbo model is
the same as SOHC model. <Ref. to SP(H4SO 2.0)2, General Description.>
SP(H6DO)-2
IGNITION
IG(H6DO)
1.
2.
3.
Page
Spark Plug...................................................................................................4
General Description
IGNITION
A: SPECIFICATION
ASSY
Spark plug
Item
Model
Ignition system
Manufacturer
Manufacturer and type
Spark plug gap
Electrode
mm
mm (in)
Specification
FK0140
Independent ignition coil
Diamond Electric
NGK: ILFR6B
14, 1.25, 26.5
0.7 0.8 (0.028 0.031)
Iridium
B: COMPONENT
T1
(1)
(2)
T2
(1)
(2)
T2
T1
IG-00052
(1)
(2)

T1: 16 (1.6, 11.7)
T2: 21 (2.1, 15.2)
Spark plug
IG(H6DO)-2
General Description
IGNITION
C: CAUTION
points.
cable from battery.
IG(H6DO)-3
Spark Plug
IGNITION
2. Spark Plug
A: REMOVAL
CAUTION:
Spark plug:
NGK: ILFR6B
1. RH SIDE
IG-02005
(B)
(B)
(C)
(D)
(A)
IG-02011
IN-00203

Case.>
4) Remove the bracket.
(A)
(B)
(C)
(D)
Ratchet handle
Extension bar
Universal joint
Spark plug socket
2. LH SIDE
NOTE:
Turn the #5 ignition coil to remove it.
(A)
NOTE:
Turn the #6 ignition coil to remove it.
(A)
(B)
IG-02004
(A) Bracket
(B) Connector
(B)
(A) Bracket
(B) Connector
IG(H6DO)-4
IG-02006
Spark Plug
IGNITION
2. LH SIDE
21 Nm (2.1 kgf-m, 15.2 ft-lb)
16 Nm (1.6 kgf-m, 11.7 ft-lb)
IG-02007
NOTE:
C: INSPECTION
(B)
(B)
(C)

(D)
(A)
(A)
(B)
IG-02011
(A)
(B)
(C)
(D)
Ratchet handle
Extension bar
Universal joint
Spark plug socket
(C)
(D)
(E)
IG-00010
B: INSTALLATION
(A)
(B)
(C)
(D)
(E)
1. RH SIDE
21 Nm (2.1 kgf-m, 15.2 ft-lb)
16 Nm (1.6 kgf-m, 11.7 ft-lb)
NOTE:
Spark plug gap

Crack
Damage
Damaged gasket
1) Normal:
IG-00011
IG(H6DO)-5
Spark Plug
IGNITION
2) Carbon fouled:
cleaner, etc.
D: ADJUSTMENT
Clean the spark plugs using a wire brush.
Clean and remove the carbon or oxide deposits.
But do not wear away ceramic insulator at this time.
If deposits are too stubborn, replace the spark
plugs.
After cleaning the spark plugs, measurement the
spark plug gap using a gap gauge.
NOTE:
Do not use a plug cleaner because the spark plugs
are applied with iridium tip.
Spark plug gap: L
0.7 0.8 mm (0.028 0.031 in)
IG-00012
3) Oil fouled:
guides and stems.
IG-02035
IG-00013
4) Overheating:
overheating. Moreover, those appearance also results from incorrect ignition timing, loose spark
plugs, wrong selection of fuel, etc.
IG-00014
IG(H6DO)-6

IGNITION

A: REMOVAL
Direct ignition type has been adopted. Refer to
Spark Plug for removal procedure. <Ref. to
IG(H6DO)-4, REMOVAL, Spark Plug.>
B: INSTALLATION
Tightening torque:
16 Nm (1.6 kgf-m, 11.7 ft-lb)
C: INSPECTION
For inspection procedure, refer to Diagnostics for
Engine Starting Failure. <Ref. to EN(H6DO)(diag)59, IGNITION CONTROL SYSTEM, Diagnostics
IG(H6DO)-7

IGNITION
IG(H6DO)-8
SC(H6DO)
1.
2.
3.
4.
Page
Starter .........................................................................................................6
Generator ..................................................................................................14
Battery.......................................................................................................20
General Description
A: SPECIFICATION
Starter
Item
Type
Model
Manufacturer
Voltage and output
Revolving direction
Number of pinion teeth
Voltage
No-load characCurrent
teristics
Rotating speed
Voltage
Load character- Current
istics
Torque
Rotating speed
Voltage
Lock characterCurrent
istics
Torque
Model
Generator
Model
Manufacturer
Voltage and output
Polarity on ground side
Revolving direction
Armature connection
Output current
Regulated voltage
Battery
For Europe
Type and capacFor other destiity
nations
Specification
Reduction type
M000T20171
Mitsubishi Electric
12 V 1.4 kW
Counterclockwise (when observed from pinion)
9
11 V
90 A or less
2,000 rpm or more
7.7 V
400 A
16.7 Nm (1.70 kgf-m, 12.3 ft-lb) or more
710 rpm or more
3.5 V
960 A or less
31 Nm (3.16 kgf-m, 22.9 ft-lb) or more
Rotating-field three-phase type, voltage regulator built-in type, with load
response control system
A3TG0591
Mitsubishi Electric
12 V 110 A
Negative
Clockwise (when observed from pulley side)
3-phase Y-type
14.1 14.8 V [20C (68F)]
12 V 52 AH (75D23L)
12V 48 AH (55D23L)
SC(H6DO)-2
General Description
B: COMPONENT
1. STARTER
(1)
(4)
(10)
(9)
(3)
(2)
(8)
(7)
(6)
(5)
(16)
(12)
(11)
(14)
(15)
(13)
SC-02005
(1)
(2)
(3)
(4)
(5)
(6)
Front bracket
Sleeve bearing
Lever set
Magnet switch ASSY
Stopper set
Overrunning clutch
(7)
(8)
(9)
(10)
(11)
(12)
Internal gear ASSY

Shaft ASSY
Gear ASSY
Packing
Yoke ASSY
Armature
SC(H6DO)-3
(13)
(14)
(15)
(16)
Brush holder ASSY

Sleeve bearing
Rear cover
Rear cover set
General Description
2. GENERATOR
(7)
(6)
(5)
(4)
(3)
T1
(2)
(1)
T1
T2
(13)
(12)
(11)
(10)
(9)
(8)
SC-00163
(1)
(2)
(3)
(4)
(5)
(6)
Pulley nut
Pulley
Front cover
Ball bearing
Bearing retainer
Rotor
(7)
(8)
(9)
(10)
(11)
(12)
Bearing
Stator coil
IC regulator with brush
Brush
Rectifier
Rear cover
SC(H6DO)-4
(13)
Terminal

T1: 4.7 (0.48, 3.5)
T2: 108 (11.0, 80)
General Description
C: CAUTION
points.
cable from battery.
SC(H6DO)-5
Starter
2. Starter
B: INSTALLATION
A: REMOVAL

Tightening torque:
50 Nm (5.1 kgf-m, 37 ft-lb)

SC-00165
IN-00203

starter.
C: DISASSEMBLY
1. STARTER ASSEMBLY
1) Loosen the nut which holds terminal M of switch
assembly, and then disconnect the connector.
(A)
SC-00164
SC-00059
5) Remove the starter from transmission.
(A) Terminal M
2) Remove the bolts which hold switch assembly,

and then remove the switch assembly, plunger and
plunger spring from starter as a unit.
(A)
SC-00165
SC-00060
(A) Switch ASSY
SC(H6DO)-6
Starter
3) Remove the nuts of both sides, and then remove

rear cover set.
6) Remove the packing A, planetary gear and

packing B.
(C)
(A)
(A)
(B)
SC-00061
SC-00064
(A) Rear cover set
4) Remove the through-bolts and brush holder

screws of both sides, and then detach the rear cover and brush holder assembly.
(A) Packing A
(B) Planetary gear
(C) Packing B
7) Remove the plate.
(A)
(A)
(B)
SC-00062

(B) Rear cover
SC-00065
(A) Plate
5) Remove the armature and yoke assembly from

front bracket.
(B)
8) Remove the shaft assembly and overrunning

clutch from front bracket as a unit.
NOTE:
Check the following points before removal.
Lever direction
Position of internal gear assembly
(A)
(A)
(C)
SC-00063
(A) Armature
(B) Yoke ASSY
(C) Front bracket
(B)
(C)
(A)
(B)
(C)
(D)
SC(H6DO)-7
Lever
Shaft ASSY
Overrunning clutch
Internal gear ASSY
(D)
SC-00066
Starter
9) Remove the overrunning clutch from shaft assembly as follows:

(1) Remove the stopper from ring by lightly tapping the stopper with an appropriate tool (such
as a fit socket wrench).
(2) Remove the ring, stopper and clutch from
shaft.
(1) Insert the ring into the shaft groove by lightly

tapping it with an appropriate tool (such as a fit
socket wrench).
(A)
(B)
(A)
(B)
SC-00067
(D)
(C)
(2) Install the stopper to ring using a press.

(A)
(B)
SC-00068
(A) Ring
(B) Stopper
SC-00014
(A)
(B)
(C)
(D)
3) Install the shaft assembly to front bracket while

taking care of the following points.
(1) Lever direction
Socket wrench
Ring
Shaft
Stopper
D: ASSEMBLY
NOTE:
Apply grease to the following parts before assembly.
Sleeve bearing
Pinion shaft rotating part
Shaft spline portion
Inside of reduction system
Lever fulcrum/Clutch rotating part
1) Install the overrunning clutch to shaft assembly.
2) Install the stopper to shaft assembly as follows.
SC-00069
(2) Internal gear position
SC-00070
SC(H6DO)-8
Starter
4) Install the plate.
(1) Press the brush down into brush holder, and

then fix the brush in that position using an appropriate tool (such as a fit socket wrench).
(A)
SC-00065
(A) Plate
SC-00073
5) Install the planetary gear.

6) Install the packing A and B while taking care of
installing positions.
(2) Match the brush holder to groove of yoke,

and then slide the brush holder into yoke assembly to install.
(B)
(A)
SC-00074
SC-00071
10) Install the rear cover matching its groove to

brush holder assembly.
(A) Packing A
(B) Packing B
7) Install the armature to yoke assembly.

8) Install the yoke to front bracket matching front
bracket to the groove of yoke assembly.
(A)
(B)
SC-00062

(B) Rear cover
SC-00072
9) Install the brush holder to yoke assembly as follows.
SC(H6DO)-9
Starter
E: INSPECTION
11) Install rear cover set.
1. ARMATURE
1) Check the 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 for run-out, and then replace if it exceeds the limit.
(A)
SC-00061
(A) Rear cover set
12) Install the switch assembly to front bracket as

follows.
(1) Insert the plunger and plunger spring into
switch assembly.
(2) Hook the plunger protrusion on lever edge
to install plunger to front bracket.
Commutator run-out:
Standard
0.05 mm (0.0020 in)
Service limit
(A)
(A)
(B)
SC-00021
(A) Dial gauge

(B) V-block
SC-00060
(A) Switch ASSY
13) Connect the connector to terminal M of switch

assembly.
3) Depth of segment mold

Check the depth of segment mold.
Depth of segment mold:
0.5 mm (0.020 in)
(B)
(C)
(A)
(A)
SC-00022
SC-00059
(A) Terminal M
SC(H6DO)-10
(A) Depth of mold

(B) Segment
(C) Mold
Starter
4) Armature short-circuit test

Check the armature for short-circuit by placing it on
growler tester. Hold an iron sheet against the armature core while slowly rotating the armature. A
short-circuited armature will cause the iron sheet to
vibrate and to be attracted to core. If the iron sheet
is attracted or vibrates, the armature, which is
short-circuited, must be replaced or repaired.
(A)
4. BRUSH AND BRUSH HOLDER

1) Brush length
Measure the brush length, and then 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)
(B)
(A)
SC-00023
(A) Iron sheet

(B) Growler tester
(B)
SC-00102
5) Armature ground test

Using a circuit tester, touch one probe to the commutator segment and the other to shaft. There
should be no continuity. If there is continuity, the armature is grounded.
Replace the armature if it is grounded.
SC-00024
(A) Service limit line

(B) Brush
2) Brush movement
Be sure the brush moves smoothly inside brush
holder.
3) Brush spring force
Measure the brush spring force with a spring scale.
If it is less than the service limit, replace the brush
holder.
Brush spring force:
Standard
15.9 19.5 N (1.62 1.99 kgf, 3.57 4.38
lb) (when new)
Service limit
2.5 N (0.25 kgf, 0.56 lb)
2. YOKE
5. SWITCH ASSEMBLY
Make sure the pole is set in position.
Be sure there is continuity between the 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.
3. OVERRUNNING CLUTCH
Inspect the teeth of pinion for wear and damage.
Replace if it is damaged. Rotate the pinion in the
right direction of rotation (counterclockwise). It
should rotate smoothly. But in the opposite direction, it should be locked.
CAUTION:
Do not clean the overrunning clutch with oil to
prevent grease from flowing out.
SC(H6DO)-11
Starter
7. PERFORMANCE TEST
Terminal / Specified resistance:

S M / Less than 1
S Ground / Less than 1
M B / More than 1 M
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.
B
S
M
SC-00075
S
6. SWITCH ASSEMBLY OPERATION
(B)
(A)
1) Using a lead wire, connect the terminal S of

switch assembly to positive terminal of battery, and
starter body to ground terminal of battery. The pinion should be forced endwise on shaft.
CAUTION:
With the 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 the connector from terminal M. Then
using a lead wire, connect the positive terminal of
battery and terminal M and ground terminal to starter body.
In this test set up, the pinion should return to its
original position even when it is pulled out with a
screwdriver.
(C)
12V
V
A
SC-00077
(A) Variable resistor

(B) Magnetic switch
(C) Starter body
1) No-load test
With switch on, adjust the variable resistor to obtain
11 V, take the ammeter reading, and then measure
the starter speed. Compare these values with the
specifications.
No-load test (standards):
Voltage/Current
MAX. 11 V/90 A
(A)
Rotating speed
More than 2,000 rpm
2) Load test
Apply the specified braking torque to starter. The
condition is satisfactory if the current draw and
starter speed are within the specifications.
(B)
SC-00076
(A) Terminal S
(B) Terminal M
Load test (standards):

Voltage/Load
7.7 V/16.7 Nm (1.70 kgf-m, 12.3 ft-lb)
Current/Speed
More than 400 A/710 rpm
SC(H6DO)-12
Starter
3) Lock test
With the starter stalled, or not rotating, measure the
torque developed and current draw when the voltage is adjusted to specified voltage.
Lock test (standards):
Voltage/Current
Less than 3.5 V/960 A
Torque
31 Nm (3.16 kgf-m, 22.9 ft-lb)
SC(H6DO)-13
Generator
3. Generator
B: INSTALLATION
A: REMOVAL

Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
CAUTION:
Check and adjust the V-belt tension.
<Ref. to ME(H6DO)-34, INSPECTION, V-belt.>
(B)
IN-00203

generator.
(A)
SC-00141
C: DISASSEMBLY
1) Remove the four through-bolts.
SC-02003
4) Remove the V-belt.

<Ref. to ME(H6DO)-34, REMOVAL, V-belt.>
5) Remove the bolt (A) and loosen the bolt (B), and
then remove the generator from bracket.
SC-00078
2) Heat the portion (A) of rear cover to 50C

(122F) with a heater drier.
(B)
(A)
(A)
SC-00141
SC-00079
SC(H6DO)-14
Generator
3) Then insert the tip of a flat-tip screwdriver into

the gap between stator core and front cover. Pry
them apart to disassemble.
5) Remove the ball bearing as follows.

(1) Remove the bolt, and then remove the bearing retainer.
(A)
(A)
SC-00080
SC-00081
(2) Firmly install an appropriate tool (such as a

fit socket wrench) to bearing inner race.
(A) Screwdriver
4) Hold the rotor with a vise and remove pulley nut.
SC-00082
SC-00035
CAUTION:
When holding the rotor with a vise, place aluminum plates or wooden pieces on the vise jaws
to prevent rotor from damage.
(3) Push the ball bearing off the front cover using a press.
6) Remove the bearing from rotor using a bearing
puller.
(A)
(B)
SC-00046
(C)
(D)
(A)
(B)
(C)
(D)
SC-00036
Front cover
Pulley
Nut
Rotor
SC(H6DO)-15
Generator
7) Unsolder the connection between rectifier and

stator coil to remove stator coil.
9) Remove the brush as follows.

(1) Remove the cover A.
CAUTION:
Do not allow a 180 270 W soldering iron to
contact the terminals for more than 5 seconds
at once because the rectifier cannot withstand
so much heat.
(A)
SC-00086
(A) Cover A
(2) Remove the cover B.

(A)
SC-00083
8) Remove the IC regulator as follows.

(1) Remove the screws which secure IC regulator to rear cover.
SC-00087
(A) Cover B
(3) Separate the brush from connection to remove.

SC-00084
(2) Unsolder the connection between IC regulator and rectifier to remove IC regulator.
SC-00088
10) Remove the rectifier as follows.

(1) Remove the bolts which secure rectifier.
SC-00085
SC-00089
SC(H6DO)-16
Generator
(2) Remove the cover of terminal B.
3) Press the bearing (rear side) into the rotor shaft

using a press to install.
4) Heat the bearing box in rear cover [50 to 60C
(122 to 140F)], and then press the rear bearing
into rear cover.
SC-00090
(3) Remove the nut of terminal B, and then remove the rectifier.
SC-00091
CAUTION:
Grease should not be applied to rear bearing.
Remove the oil completely if it is found on bearing box.
5) After reassembly, turn the pulley by hand to
check that rotor turns smoothly.
E: INSPECTION
1. DIODE
CAUTION:
Never use a mega tester (designed for reading
high voltage) or any other similar instrument
for this test; otherwise, the diodes may be damaged.
1) Checking positive diode
Check for continuity between the diode lead and
positive side heat sink. The positive diode is in
direction from the diode lead to heat sink.
D: ASSEMBLY
1) Pulling up brush
Before assembling, press the brush down into
brush holder, and then fix them in that position by
passing a [1 mm (0.08 in) dia. 40 to 50 mm (1.6 to
2.0 in) long] wire through the hole as shown in the
figure.
(A)
(B)
CAUTION:
Be sure to remove the wire after reassembly.
SC-00042
(A) Diode lead

(B) Heat sink (positive side)
(A)
SC-00092
(A) Wire
2) Install the ball bearing.

(1) Set the ball bearing on the front cover, and
then securely install an appropriate tool (such as
a fit socket wrench) to the bearing outer race.
(2) Press the ball bearing into the specified position using a press.
(3) Install the bearing retainer.
SC(H6DO)-17
Generator
2) Checking negative diode

Check for continuity between the negative side
heat sink and diode lead. The negative diode is in
direction from the heat sink to diode lead.
4) Insulation test
Check the continuity between slip ring and rotor
core or shaft. If resistance is 1 or less, the rotor
coil is grounded, and so replace the rotor assembly.
(A)
(B)
SC-00043
SC-00045
5) Ball bearing (rear side)

Check the rear ball bearing. Replace if it is noisy or
if the rotor does not turn smoothly.
(A) Diode lead

(B) Heat sink (negative side)
2. ROTOR
3. STATOR
1) Slip ring surface

Inspect the slip rings for contamination or any
roughness on the sliding surface. Repair the slip
ring surface using a lathe or sand paper.
2) Slip ring outer diameter
Measure the slip ring outer diameter. If the slip ring
is worn, replace the rotor assembly.
1) Continuity test
Inspect the stator coil for continuity between each
end of the lead wires. If resistance is 1 M or more,
the lead wire is broken, and so replace the stator
assembly.
(A)
Slip ring outer diameter:

Standard
22.7 mm (0.894 in)
Limit
22.1 mm (0.870 in)
3) Continuity test
Check the resistance between slip rings using circuit tester.
If the resistance is not within the specified range,
replace the rotor assembly.
Specified resistance:
Approx. 2.0 2.4
SC-00047
(A) Stator
2) Insulation test
Inspect the stator coil for continuity between stator
core and each end of lead wire. If resistance is 1
or less, the stator coil is grounded, and so replace
the stator assembly.
SC-00044
SC-00048
SC(H6DO)-18
Generator
4. BRUSH
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:
Service limit (1)
5.0 mm (0.197 in)
Standard (2)
18.5 mm (0.728 in)
(1)
(A)
(2)
SC-00162
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 brush
spring. If the pressure is less than 2.2 N (224 g,
7.91 oz), replace the brush spring with a new one.
The new spring must have a pressure of 4.8 to 6.0
N (489 to 612 g, 17.26 to 21.60 oz).
SC-00093
5. BEARING (FRONT SIDE)

Check the front ball bearing. If the resistance is felt
while rotating, or if noise is heard, replace the ball
bearing.
SC(H6DO)-19
Battery
4. Battery
A: REMOVAL
1) Remove the battery cable holder from battery
rod.
2) Disconnect the positive (+) terminal after disconnecting the negative () terminal of battery.
3) Remove the flange nuts from battery rods and
take off battery holder.
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. This
may cause short circuit.
1. EXTERNAL PARTS
(A)
Check the battery case, top cover, vent plugs, and

terminal posts for dirt or cracks. If necessary, clean
with water and wipe with a dry cloth.
Apply a thin coat of grease on the terminal posts to
prevent corrosion.
(B)
2. ELECTROLYTE LEVEL
SC-02004
(A) Battery cable holder

(B) Battery rod
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
B: INSTALLATION
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:
C: INSPECTION
WARNING:
Electrolyte has toxicity; be careful of handling the fluid.
Avoid contact with skin, eyes or clothing. Especially at contact with eyes, flush with water
for 15 minutes and get prompt medical attention.
Batteries produce explosive gases. 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.
S20 = St + 0.0007 (t 20)

S20: Specific gravity corrected at electrolyte
temperature of 20C (68F)
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
[20C (68F)]
2) Measuring the specific gravity of the electrolyte
in the battery will disclose the state of charge of the
battery. The relation between specific gravity and
state of charge is as shown in the figure.
Battery with standard specific gravity 1,280 (20 C)
1.28
SC(H6DO)-20
Good
NOTE:
Clean the battery cable terminals and apply
grease to retard the formation of corrosion.
Connect the positive (+) terminal, and then connect the negative () terminal of battery.
performed after battery installation. For this reason,
start the engine after 10 seconds or more have
1.24
1.22
1.20
Need to charge
Tightening torque:
3.4 Nm (0.35 kgf-m, 2.5 ft-lb)
Specific gravity ( C)
1.16
1.12
1.08
1.04
10
20
30
40
50
60
Amount of discharge (%)
70
80
90
100
SC-00054
Battery
D: MEASUREMENT
4. QUICK CHARGING
WARNING:
Do not bring an open flame close to the battery
at this time.
Quick charging is a method that 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).
Also 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:
Prior to charging, corroded terminals should
be cleaned with a brush and common caustic
soda solution.
Be careful since battery electrolyte overflows
while charging the battery.
Observe instructions when handling the battery charger.
Before charging the battery on the vehicle,
disconnect the battery ground terminal to prevent damage of generator diodes or other electrical units.
1. JUDGMENT OF BATTERY IN CHARGED

CONDITION
CAUTION:
Observe the items in 3. NORMAL CHARGING.
Never use more than 10 A when charging the
battery because it will shorten the battery life.
1) Specific gravity of electrolyte should be held

within the specific range from 1.250 to 1.290 for
more than one hour.
2) Voltage per battery cell should be held at a specific value in a range from 2.5 to 2.8 volts for more
than one hour.
2. CHECK HYDROMETER FOR STATE OF

CHARGE
Hydrometer
indicator
Green
Dark
Charge batCorrective action

tery
Above 65%
Load test
Below 65%
Charge battery
Low electroReplace battery*
Clear
lyte
(If cranking is difficult)
* Check electrical system before replacement.
3. NORMAL CHARGING
Charge the battery at the current value specified by
manufacturer or at approximately 1/10 of batterys
ampere-hour rating.
SC(H6DO)-21
Battery
SC(H6DO)-22
EN(H6DO)(diag)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
Page
Inspection Mode........................................................................................33
Drive Cycle................................................................................................38


A: PROCEDURE
1. ENGINE
Step
<Ref. to EN(H6DO)(diag)-3, CHECK, Check
List for Interview.>

INDICATOR LIGHT.

link connector.

EN(H6DO)(diag)-40, Clear Memory Mode.>
EN(H6DO)(diag)-33, Inspection Mode.>
Check
No
Inspection using
Diagnostics for
Engine Start Failure. <Ref. to
EN(H6DO)(diag)52, Diagnostics for
Engine Starting
Failure.>
Does check malfunction indica- Go to step 3.
Inspection using
tor light illuminate?
EN(H6DO)(diag)265, INSPECTION, General
Diagnostic Table.>
aru Select Monitor?
cause. <Ref. to
NOTE:
EN(H6DO)(diag)- If DTC is not
66, List of Diagshown on display
nostic Trouble
although the malCode (DTC).> Go function indicator
to step 4.
light
illuminates,
perform the diagnostics of malfunction indicator light
circuit or combination meter. <Ref. to
EN(H6DO)(diag)43, Malfunction Indicator Light.>
nostic Procedure sis.
with Diagnostic
Trouble Code
(DTC)
<Ref. to
EN(H6DO)(diag)72, Diagnostic
Procedure with
EN(H6DO)(diag)-2
Yes
Go to step 2.


A: CHECK
1. CHECK LIST No. 1
NOTE:
Customers name
Date of sale
Date of repair
V.I.N.
Weather
Engine No.
Fuel brand
Fine
Cloudy
Rainy
Snowy
Various/Others:
C (F)
Place
Engine temperature
Engine speed
Vehicle speed
Driving conditions
Headlight
Blower
A/C compressor
Radiator fan
Front wiper
Rear wiper
km
miles
Odometer reading
Hot
Warm
Cool
Cold
Highway
Suburbs
Inner city
Uphill
Downhill
Rough road
Others:
Cold
Warming-up
After warming-up
Any temperature
Others:
rpm
km/h (MPH)
Not affected
At starting
While idling
At racing
While accelerating
While cruising
While decelerating
ON / OFF
ON / OFF
ON / OFF
ON / OFF
ON / OFF
ON / OFF
Rear defogger
Audio
Car phone
EN(H6DO)(diag)-3
ON / OFF
ON / OFF
ON / OFF

2. CHECK LIST No. 2

NOTE:
ABS warning light
b) Fuel level
What:
What:
What:
Where:
From where:
What kind:
From where:
What kind:
Rough idling
Poor acceleration
Back fire
After fire
Does not shift.
EN(H6DO)(diag)-4
General Description

A: CAUTION
CAUTION:
All air bag system wiring harnesses and connectors are yellow. Do not use the electrical
test equipment on these circuits.
Be careful not to damage the Airbag system
The fuel injector and other part will be damaged.
engine is running.
sensor and the ECM, be sure to turn the ignition
switch to OFF. Perform the clear memory mode after connecting the connectors.
(A)
EN-00001
(A) Stud bolt
9) Use engine grounding terminal or engine proper

as the grounding point to chassis when measuring
EN-02473
10) Use TCU mounting stud bolts as the body side

grounding point to chassis when measuring voltage
and resistance inside the passenger compartment.
CAUTION:
7) Connectors to each sensor in the engine compartment and the harness connectors on the engine side and body side are all designed to be
(A)
EN-00154
(A) Stud bolt

not drop them.
CAUTION:
under the steering column, inside of the instrument panel lower trim panel.)
EN(H6DO)(diag)-5
General Description

matching.
special attention to the three items above mentioned.
the operation of the ECM.
three causes (engine, electrical control system,
transmission) must be distinguished clearly when
three causes (engine, electrical control system,
transmission).
16) In AT models, do not continue the stall for more
than five seconds at a time. (from closed throttle,
fully open throttle to stall speed reading, and then
decrease engine speed.).
perform the ABS memory clearance procedure of
self-diagnosis system.
B: INSPECTION
items which might affect engine problems:
1. BATTERY
electrolyte.
proper grounding.
2. ENGINE GROUND
Make sure the engine grounding terminal is properly connected to the engine.
EN-02473
C: NOTE
EN(H6DO)(diag)-6
General Description


D: PREPARATION TOOL
ILLUSTRATION
TOOL NUMBER
24082AA230
DESCRIPTION
CARTRIDGE
REMARKS
22771AA030
SUBARU SELECT
MONITOR KIT

ST24082AA230
ST22771AA030
EN(H6DO)(diag)-7


A: LOCATION
1. ENGINE
Control module
LHD model
(3)
(1)
(2)
(4)
EN-02474
RHD model
(4)
(2)
(1)
(2)

(1)
(3)
(3)
Test mode connector
EN(H6DO)(diag)-8
EN-02475
(4)
Data link connector

(1)
(2)
EN-01147
EN-01966
(4)
(3)
EN-02414
EN(H6DO)(diag)-9
AT-01877

Sensor
(6)
(4)
(5)
(1)
(7)
(5)
(2)
(6) (8)
(3)
EN-02478
(1)
(3)
(2)
(4)
(5)

Knock sensor
EN(H6DO)(diag)-10
(6)
(7)
(8)


(1)
(2)
EN-02479
EN-02535
(4)
(3)
EN-02536
EN-00895
(5)
(6)
(5)
EN-02537
EN-00897
(7)
(8)
EN-00899
EN(H6DO)(diag)-11
EN-02538

(7)
(2)
(4)
(1)
(3)
(6)
(5)
EN-02480
(1)
(2)
(3)
Front oxygen (A/F) sensor LH

Front oxygen (A/F) sensor RH
Rear oxygen sensor LH
(4)
(5)
(6)
Rear oxygen sensor RH

Front catalytic converter LH
Front catalytic converter RH
(7)
(2)
(5)
(1)
(6)
EN-02539
EN-02540
(4)
(3)
EN-02541
EN(H6DO)(diag)-12
EN-02542

(7)
EN-02543
(3)
(6)
(5)
(1)
(2)
(5)
(4)
(6)
(3)
(4)
EN-02481
(1)
(2)
(3)

EGR valve
(4)
(5)

Oil switching solenoid valve
EN(H6DO)(diag)-13
(6)

pressure switch

(1)
(2)
EN-02482
EN-02483
(4)
(3)
EN-02484
(5)
(6)
EN-02486
EN(H6DO)(diag)-14
EN-02485

LHD model
(3)
(1)
(4)
(5)
(2)
(7)
(6)
(2)
EN-02487
RHD model
(2)
(1)
(6)
(1)
(2)
(3)
Inhibitor switch
Fuel pump
Main relay
(7)
(5) (4)
(4)
(5)
(6)
(2)
(3)
Fuel pump relay

Radiator fan relay
EN(H6DO)(diag)-15
EN-02488
(7)
Starter

(2)
EN-02093
EN-00178
(5)
(4)
(6)
(3)
EN-02544
(7)
EN-02490
EN(H6DO)(diag)-16
EN-02489


To B135
To B134
7 6 5 4 3
17 16 15 14 13 12 11
27 26 25 24 23 22 21
34 33
32 31
2 1
10 9 8
20 19 18
30 29 28
To B137
To B136
7 6 5 4 3
2 1
19 18 17 16 15 14 13 12 11 10 9 8
27 26
25 24
23 22 21 20
35 34
33 32
31 30 29 28
6 5
4 3 2 1
16 15 14 13 12 11 10 9 8 7
27 26 25 24 23 22 21 20 19 18 17
30 29 28
35 34 33 32 31
7 6 5 4 3 2 1
17 16 15 14 13 12 11 10 9 8
25 24
23 22 21 20 19 18
31 30
29 28
27 26
EN-01812
Terminal
No.
B135
B135
B135
10
22
31
B135
0.275
0 or 5
Waveform
B135
0.275
0 or 5
Waveform
Main
B136
18
0.64 0.94
Fully opens: 4.01
Sub
B136
29
1.51 1.76
Fully opens: 4.23
B137
Duty waveform
Duty waveform
B137
Duty waveform
Duty waveform
B137
10 13
12 14
B135
35
17
ON: 0
OFF: 13 14
Fully closed: 1
Fully opens: 3.3

turned to ON: ON
B136
ON: 0
OFF: 10 13
Fully closed: 1
Fully opens: 3.6
B136
15
B136
34
28
0
Fully closed: 1
Fully opens: 3.3
B136
0
Fully closed: 1
Fully opens: 3.7
B136
14
1.0 1.4
1.0 1.4
B137
Cranking: 8 14
Signal (+)
Signal ()
Shield
(LH)
(RH)
Crankshaft
position sensor
Electronic
throttle control

motor (+)
motor ()
motor power supply
motor relay
Main
Accelerator
position sensor
Signal (V)
Ignition SW ON
Engine ON
(engine OFF)
(idling)
0
7 +7
0
0
0
0
Connector
No.
Description
Power
supply
Ground
Sub

Starter switch
EN(H6DO)(diag)-17
0.64 0.72
(After engine is
warmed-up.)
1.51 1.58
(After engine is
warmed-up.)
Reference
Waveform
Fully closed: 0.6

Fully opened: 4.01
Fully closed: 1.48
Fully opens: 4.23

Signal (V)
Ignition SW ON
Engine ON
(engine OFF)
(idling)
ON: 0
ON: 0
OFF: 10 13
OFF: 13 14
ON: 10 13
ON: 13 14
OFF: 0
OFF: 0
10 13
13 14
Connector
No.
Terminal
No.
Starter relay
B135
32
A/C switch
B137
17
Ignition switch
B137
14
B137
Test mode connector

Signal
Knock sensor
1
Shield
Signal
Knock sensor
2
Shield
B137
B136
B136
B136
B136
15
25
33
24
33
12 14
2.4
0
2.4
0
12 14
2.4
0
2.4
0
B135
19
10 13
13 14
Control module power

supply
Sensor power supply
#1
#2
#3
Ignition control
#4
#5
#6
#1
#2
#3
Fuel injector
#4
#5
#6
B135
B135
B136
B135
B135
B135
B135
B135
B135
B136
B136
B136
B136
B136
B136
6
5
16
18
17
16
15
14
13
6
5
4
3
2
1
A/C relay control
B135
33
Radiator fan control
B134
31
13 14
13 14
5
13 14
13 14
13 14
13 14
13 14
13 14
1 14
1 14
1 14
1 14
1 14
1 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
Description
ON: 0
OFF: 120.5
Radiator fan control power

supply
Self-shutoff control
B135
30
B137
16
10 13
10 13
5
0
0
0
0
0
0
10 13
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
0
B134
17
Engine speed output

Purge control solenoid
valve
Signal A+
EGR solenoid Signal A
valve
Signal B+
Signal B
B134
23
B134
14
B134
B134
B134
B134
11
10
9
8
B137
10
ON: 1, or less
OFF: 10 13
10 13
10 13
10 13
10 13
ON: 1, or less
OFF: 10 13
0 13, or more
ON: 1, or less
OFF: 13 14
10 13
10 13
10 13
10 13
ON: 1, or less
OFF: 13 14
B136
22
3.5 4.8
1.1 1.9
EN(H6DO)(diag)-18
Reference
Switch is ON when select

lever is shifted into P or
N range.
When connected: 0
Ignition switch OFF: 10

13
Waveform
Waveform
Waveform
Waveform
Waveform
Waveform
Waveform
Waveform
Waveform
Waveform
Waveform
Waveform
Light ON: 1, or less

Light OFF: 10 14
Waveform

Signal (V)
Ignition SW ON
Engine ON
(engine OFF)
(idling)
0.74
0.3 4.5
0
0
0
0
Connector
No.
Terminal
No.
B136
B136
B136
23
32
31
B136
13
3.15 3.33
3.15 3.33
B134
B134
B134
B134
33
26
25
3
2.8 3.2
2.4 2.7
0
12 14
2.8 3.2
2.4 2.7
0
intake air temperature:25C (75F)
Waveform
B134
12 14
Waveform
B134
B134
B134
B134
34
27
25
1
2.8 3.2
2.4 2.7
0
12 14
2.8 3.2
2.4 2.7
0
Waveform
B135
12 14
Waveform
B137
B137
24
31
0
0
0 0.9
0
B135
12 14
Waveform
B137
B137
25
31
0
0
0 0.9
0
B135
12 14
Waveform
B137
19
10
10
B137
27
10
10
B137
B135
28
27
Brake switch 1
B136
Brake switch 2
B136

switch
B136
11
Cruise control main switch
B136
Description
Signal
Shield
Ground
sensor
Signal (+)
Front oxygen
(A/F) sensor
Signal ()
RH
Shield
Front oxygen
Signal 1
(A/F) sensor
Signal 2
heater RH
Signal (+)
Front oxygen
(A/F) sensor
Signal ()
LH
Shield
Front oxygen
Signal 1
(A/F) sensor
Signal 2
heater LH
Signal
Rear oxygen
sensor RH
Shield
Rear oxygen sensor
heater RH signal
Signal
Rear oxygen
sensor LH
Shield
Rear oxygen sensor
heater LH signal
Immobilizer communication 1
Immobilizer communication 2
Signal 1
Fuel pump
control unit
Signal 2
Air flow sensor
0
13 14
0
0 or 5
When brake pedal is When brake pedal is
depressed: 0
depressed: 0
released: 10 13
released: 13 14
depressed: 10 13 depressed: 13 14
released: 0
released: 0
When operating
When operating
nothing: 3.5 4.5
nothing: 3.5 4.5
When operating
When operating
RES/ACC:
RES/ACC:
2.5 3.5
2.5 3.5
When operating SET/ When operating SET/
COAST:
COAST:
0.5 1.5
0.5 1.5
When operating
When operating
CANCEL:
CANCEL:
0 0.5
0 0.5
ON: 0
ON: 0
OFF: 5
OFF: 5
EN(H6DO)(diag)-19
Reference

Signal (V)
Ignition SW ON
Engine ON
(engine OFF)
(idling)
0
0.6
Connector
No.
Terminal
No.
B134
18
B134
28
B134
19
0.6
B134
29
B134
21
1.9
B134
20
B135
25
1.9
B135
24
B136
27
1.0 1.4
1.0 1.4
B135
21
B135
29
B134
22
B137
20
GND (sensor)
GND (injector)
B136
B137
B135
B135
B135
B137
B137
35
7
12
4
1
2
1
0 6.5
Less than 1
More than 4
0
0
0
0
0
0
0
0 6.5
Less than 1
More than 4
0
0
0
0
0
0
0
B134
B134
B137
Description
Oil flow conSignal (+)
trol solenoid
Signal ()
valve RH
Oil flow conSignal (+)
trol solenoid
Signal ()
valve LH
Oil switching
Signal (+)
solenoid valve
Signal ()
RH
Oil switching
Signal (+)
solenoid valve
Signal ()
LH
signal
Variable valve lift diagnosis
oil pressure switch RH
Variable valve lift diagnosis
oil pressure switch LH
Generator control
GND (power supply)

GND (Front oxygen (A/F)
sensor heater RH)
GND (Front oxygen (A/F)
sensor heater LH)
control)
EN(H6DO)(diag)-20
Reference


Remarks
Engine load
Specification
1.6 2.9 (%): Idling
6.4 12.8 (%): 2,500 rpm racing
Turn the A/C to OFF.
Turn all accessory switches to OFF.
EN(H6DO)(diag)-21
Data Link Connector


A: NOTE
CAUTION:
Do not connect any scan tools other than the Subaru Select Monitor and the general scan tools, because the circuit for the Subaru Select Monitor may be damaged.
9 10 11 12 13 14 15 16
EN-00037
Terminal No.
1
2
3
4
5
6
7
8
Remarks
Power supply
Empty
Empty
Empty
Empty
Empty
Empty
Empty
Terminal No.
9
10
11
12
13
14
15
16
EN(H6DO)(diag)-22
Remarks
Empty
Empty
Ground
Ground
Empty
Empty
Empty
General Scan Tool


A: OPERATION
J1978.
2) Open the cover and connect the general scan
tool to the data link connector located in the lower
side).

freeze frame data.
data
DTC
Read out data according to repair procedures. (For
detailed operation procedures, refer to the General
Scan Tool Operation Manual.)
NOTE:
For details concerning DTCs, refer to the List of Diagnostic Trouble Code (DTC). <Ref. to
EN(H6DO)(diag)-66, List of Diagnostic Trouble
Code (DTC).>
EN-02533

Refers to data denoting the current operating condition of analog input/output, digital input/output and/or the
powertrain system.
PID
01
03
04
05
06
07
08
09
0B
0C
0D
0E
10
11
13
24
28
1C
Data
Number of emission-related powertrain DTC and malfunction indicator light status
Short term fuel trim (bank 1)
Long term fuel trim (bank 1)
Engine revolution
Vehicle speed
Air flow rate of manifold absolute pressure sensor
Throttle valve opening angle
Oxygen sensor output voltage and short term fuel trim associated with oxygen sensor (bank
1)
Oxygen sensor output voltage and short term fuel trim associated with oxygen sensor (bank
2)
On-board diagnostic system
Unit of measure
ON/OFF
%
C
%
%
%
%
kPa
rpm
km/h
g/sec
%
V and %
V and %
NOTE:
Refer to general scan tool manufacturers instruction manual to access generic OBD-II PIDs (MODE $01).
EN(H6DO)(diag)-23
General Scan Tool


Refers to data denoting the operating condition when trouble is sensed by the on-board diagnosis system.
PID
02
03
04
05
06
07
08
09
0B
0C
0D
Data
DTC that caused CARB required freeze frame data storage
Engine speed
Vehicle speed
Unit of measure
%
C
%
%
%
%
kPa
rpm
km/h
NOTE:
Refer to general scan tool manufacturers instruction manual to access freeze frame data (MODE $02).
4. MODE $03 (EMISSION-RELATED POWERTRAIN DTC)

Refer to Read Diagnostic Trouble Code for information about data denoting emission-related powertrain
DTC. <Ref. to EN(H6DO)(diag)-32, Read Diagnostic Trouble Code (DTC).>

Refers to the mode used to clear or reset emission-related diagnostic information (OBD-II trouble diagnostic
information).
NOTE:
Refer to general scan tool manufacturers instruction manual to clear or reset emission-related diagnostic information (MODE $04).
EN(H6DO)(diag)-24


A: OPERATION
CAUTION:
Do not connect the scan tools except for Subaru Select Monitor and general scan tool.

EN(H6DO)(diag)-7, PREPARATION TOOL, General Description.>
(A)
EN-00040
(A) Power switch

EN-00038

Monitor.
<Ref. to EN(H6DO)(diag)-7, PREPARATION


EN(H6DO)(diag)-32, Read Diagnostic Trouble
Code (DTC).>

EN(H6DO)(diag)-32, Read Diagnostic Trouble
Code (DTC).>
EN-00039

connector.
(1) Data link connector located in the lower portion of the instrument panel (on the drivers
side).
EN-02533

connector.
EN(H6DO)(diag)-25


[YES] key.
Remarks
Engine load
A/F compensation 1
A/F learning 1
A/F compensation 2
A/F learning 2
Engine speed signal
Meter vehicle speed signal
Front oxygen sensor voltage value 1
Front oxygen sensor voltage value 2
Battery voltage
Knock sensor compensation
Radiator fan output
Purge control solenoid valve duty ratio
EGR step number
Generator duty
Fuel pump duty
Variable valve timing advance angle amount R
Variable valve timing advance angle amount L
Oil flow control solenoid valve duty R
Oil flow control solenoid valve duty L
Oil flow control solenoid valve current R
Oil flow control solenoid valve current L
Display
Engine load
A/F Compensation 1
A/F learning 1
A/F Compensation 2
A/F learning 2
Intake manifold absolute
pressure
Engine speed
Meter vehicle speed
Ignition timing
Throttle valve angle
Front oxygen sensor
voltage value 1
Front oxygen sensor
voltage value 2
Battery Voltage
Knock correction
Atmospheric pressure
Intake manifold relative
pressure
Acceleration opening
angle
Radiator fan output
CPC duty
EGR step number
ALT duty
Fuel pump duty
VVT advance angle
amount R
VVT advance angle
amount L
OCV duty R
OCV duty L
OCV current R
OCV current L
EN(H6DO)(diag)-26
Unit of
measure
%
Note (at idling)
%
%
%
%
3.5%
75C (After engine is
warmed-up.)
3.1%
0.0%
4.7%
0.0%
mmHg
200 300 mmHg
rpm
km/h
deg
C
g/s
%
600 800 rpm

0 km/h
13 15 deg
3.8 g/s
1.2 1.6%
0.035 V
0.020 V
V
V
ms
ms
deg
mmHg
12 14 V
1.1 1.2 V
2.82 ms
2.82 ms
0 deg
(Atmospheric pressure)
(Intake manifold absolute
pressure Atmospheric
pressure)
mmHg
%
0%
%
%
STEP
%
%
0%
0 3%
0
0%
33%
deg
0 deg
deg
0 deg
%
%
mA
mA
9.4%
9.4%
64 mA
64 mA

Remarks
Display
Unit of
measure
Note (at idling)
mA
0.0 mA
mA
0.0 mA
31
31
1.01
1.00
%
%
%
0.16%
0.0%
27%
(Battery voltage)
1.50 V
0.64 V
1.10 V
0.98 V
km/h
%
%

A/F compensation 4
A/F learning 4
A/F sensor current value

1
A/F sensor current value
2
A/F sensor resistance
value 1
A/F sensor resistance
value 2
A/F sensor output
lambda 1
A/F sensor output
lambda 2
A/F Compensation 3
A/F learning 3
Throttle motor duty
Throttle power supply
voltage
Sub acceleration sensor
voltage
Main acceleration sensor
voltage
A/F compensation 4
A/F learning 4
Fuel level resistance
Engine oil temperature
Oil Temperature
Oil switching solenoid valve duty R

Oil switching solenoid valve duty L
Oil switching solenoid valve current R
Oil switching solenoid valve current L
Variable valve lift lift mode
OSV duty R
OSV duty L
OSV current R
OSV current L
VVL Lift Mode
#1 cylinder roughness
monitor
monitor
monitor
monitor
monitor
monitor
Test mode terminal
Neutral SW
Soft idle SW
Ignition SW
Power steering SW input
signal
%
%
mA
mA
0 km/h
0.31%
0.0%
4 96
85C (After engine is
warmed-up.)
17.3%
17.3%
192 mA
192 mA
1
U check
Neutral
In idle
ON input
OFF input (when OFF)
Front oxygen (A/F) sensor current value 1

Front oxygen (A/F) sensor current value 2
Front oxygen (A/F) sensor resistance value 1
Front oxygen (A/F) sensor resistance value 2
Front oxygen (A/F) sensor output lambda 1
Front oxygen (A/F) sensor output lambda 2
A/F compensation 3
A/F learning 3
Throttle motor duty
#1 cylinder roughness monitor

Test mode terminal
Idle switch signal
EN(H6DO)(diag)-27

Remarks
Display

Steering wheel switch signal
Front oxygen monitor 1
Knocking signal
Light switch signal
Wiper switch signal
A/C lock signal
A/C compressor relay signal
Vehicle dynamics control (VDC) torque down prohibition
output
Vehicle dynamics control (VDC) torque down demand
Electronic throttle control motor relay signal
RESUME/ACCEL switch signal
Brake switch signal
Main switch signal
Body integrated unit data reception
Body integrated unit counter update
Cruise control cancel switch signal
A/C SW
Steering wheel SW
Starter SW
Knock signal
Crankshaft angle signal
Camshaft angle signal
Rear defogger SW
Blower fan SW
Light SW
Wiper SW
A/C lock signal
A/C middle pressure SW
A/C compressor relay
output
AT coordinate retard
angle demand
AT coordinate fuel cut
demand
VDC torque down prohibition output
VDC torque down
demand
ETC motor relay
Stop light SW
SET/COAST SW
RESUME/ACCEL SW
Brake SW
Main SW
Body Int. Unit Data
CC Cancel SW
EN(H6DO)(diag)-28
Unit of
measure

Hi input
OFF input
Rich
Rich
No
Yes
Yes
OFF input
OFF input
OFF output
Yes
No
ON
OFF
ON
ON
OFF
OFF
OFF
OFF
OFF
ON
ON
OFF
Note (at idling)


5) On the OBD Menu display screen, select the {Current Data Display/Save}, and press the [YES] key.
DESCRIPTION
Test of catalyst
Test of EGR system
A/F control #1
A/F control #2
Load
A/F compensation #1
A/F learning #1
A/F compensation #2
A/F learning #2
Engine speed
Vehicle speed
Ignition timing #1
Throttle valve angle
Oxygen sensor #12
A/F compensation #12
OBD system
Oxygen sensor #11
Oxygen sensor #12
A/F sensor #11
A/F sensor #11
Display
MI (MIL)
Misfire monitoring
Catalyst Diagnosis
Heated catalyst
Oxygen sensor
Oxygen sensor heater
EGR system
Fuel system for Bank 1
Fuel system for Bank 2
Calculated load valve
Coolant Temp.
Engine Speed
Vehicle Speed
Ignition timing adv. #1
Intake Air Temp.
Mass Air Flow
Oxygen sensor #12
Short term fuel trim #12
OBD System
Oxygen sensor #11
Oxygen sensor #12
A/F sensor #11
A/F sensor #11
Unit of measure
0
OFF
No
Finish
Finish
No
No
No
No
No
Finish
Finish
Finish
OPEN early period
OPEN early period
%
C
%
%
%
%
kPa
rpm
km/h
C
g/s
%
V
%
Support
Support
NOTE:
For detailed operation procedures, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.
EN(H6DO)(diag)-29


DESCRIPTION
DTC of freeze frame data
Engine load data
Short term fuel trim by front oxygen (A/F) sensor (bank 1)
Long term fuel trim by front oxygen (A/F) sensor (bank 1)
Short term fuel trim by front oxygen (A/F) sensor (bank 2)
Long term fuel trim by front oxygen (A/F) sensor (bank 2)
Engine speed signal
Display
Freeze frame data
Fuel system for bank 2
Engine Load
Coolant Temp.
Engine Speed
Vehicle Speed
Unit of measure
DTC
%
C or F
%
%
%
%
rpm
km/h or MPH
NOTE:
EN(H6DO)(diag)-30


[YES] key.
Remarks
Test mode signal
Idle switch signal
Steering wheel switch signal
Knocking signal
Light switch signal
Windshield wiper switch signal
Air conditioning lock signal
Air conditioner compressor relay signal
AT retard angle demand signal
AT fuel cut signal
VDC torque down prohibition output
VDC torque down demand
Electronic throttle control motor relay
signal
RESUME/ACCEL switch signal
Brake switch signal
Main switch signal
Body integrated unit data reception
Body integrated unit counter update
Cruise control cancel switch signal
Display
Test mode terminal
Neutral SW
Soft idle SW
Ignition SW
Power steering SW
A/C SW
Steering wheel SW
Starter SW
FtO2 monitor 1
FtO2 monitor 2
Knock signal
Crankshaft angle signal
Camshaft angle signal
Rear defogger SW
Blower fan SW
Light SW
Wiper SW
A/C lock signal
A/C middle pressure SW
Message
D check/U check
Neutral/Other than neutral
Idle/Other than idle
ON Input/OFF Input
ON Input/OFF Input
ON Input/OFF Input
Hi input/Low input
ON Input/OFF Input
Lean/Rich
Lean/Rich
Yes/No
Yes/No
Yes/No
ON Input/OFF Input
ON Input/OFF Input
ON Input/OFF Input
ON Input/OFF Input
ON Input/OFF Input
ON Input/OFF Input
When LED ON required

D check
Neutral
In idle
ON input
ON input
ON input
Low input
ON input
Rich
Rich
Yes
Yes
Yes
ON input
ON input
ON input
ON input
ON input
ON input
Compressor relay
ON output/OFF output
ON output
AT retard angle demand

AT fuel cut
Torque down output
Torque down demand
AT coordinate permission
signal
Yes/No
Yes/No
ON/OFF
Yes/No
Yes
Yes
Prohibition
Yes
ON/OFF
Permission
ETC motor relay
ON/OFF
ON
Stop SW
SET/CST SW
RES/ACC SW
Brake SW
Main SW
Body Int. Unit Data
CC Cancel SW
ON Input/OFF Input
ON Input/OFF Input
ON Input/OFF Input
ON Input/OFF Input
ON Input/OFF Input
Yes/No
Yes/No
ON Input/OFF Input
ON input
ON input
ON input
ON input
ON input
Yes
Yes
ON input
NOTE:
EN(H6DO)(diag)-31


Code (DTC)
A: OPERATION
MODE)
key.

Refers to data denoting emission-related powertrain DTC.
For details concerning DTCs, refer to the List of Diagnostic Trouble Code (DTC). <Ref. to
Code (DTC).>
NOTE:
Refer to general scan tool manufacturers instruction manual to access power train DTC (MODE
$03).
NOTE:
SUBARU SELECT MONITOR OPERATION MANUAL.
For details concerning DTC, refer to the List of
Code (DTC).>

MODE)
key.
NOTE:
Code (DTC).>
EN(H6DO)(diag)-32
Inspection Mode
11.Inspection Mode
A: PROCEDURE
When performing the diagnose without the List of Diagnostic Trouble Code (DTC), refer the item of drive cycle. <Ref. to EN(H6DO)(diag)-38, Drive Cycle.>
DTC
P0011
P0021
P0031
P0032
P0037
P0038
P0051
P0052
P0057
P0058
P0077
P0083
P0102
P0103
P0107
P0108
P0112
P0113
P0117
P0118
P0122
P0123
P0131
Item
A Camshaft Position-Timing Over-Advanced or System Performance (Bank 1)
A Camshaft Position-Timing Over-Advanced or System Performance (Bank 2)
Intake Valve Control Solenoid Circuit High (Bank 1)
Intake Valve Control Solenoid Circuit High (Bank 2)
Mass or Volume Air Flow Circuit Low Input
Mass or Volume Air Flow Circuit High Input
P0132
P0137
P0138
P0151
P0152
P0157
P0158
P0171
P0172
P0174
P0175
P0197
P0198
P0222
P0223
P0230
P0327
P0328
P0332
P0333
P0335
P0340

Engine Oil Temperature Sensor Circuit Low
Engine Oil Temperature Sensor Circuit High
Knock Sensor 2 Circuit Low Input (Bank 2)
Knock Sensor 2 Circuit High Input (Bank 2)
EN(H6DO)(diag)-33
On condition
Inspection Mode
DTC
P0345
P0458
P0462
P0463
P0500
P0512
P0519
P0558
P0600
P0604
P0605
P0607
P0638
P0691
P0692
P0700
P1160
P1518
P1560
P2088
P2089
P2092
P2093
P2101
P2102
P2103
P2109
P2122
P2123
P2127
P2128
P2135
P2138
Item
Camshaft Position Sensor A Circuit (Bank 2)
Transmission Control System (MIL Request)
Starter Switch Circuit Low input
OCV Solenoid Valve Signal A Circuit Open (Bank 1)
OCV Solenoid Valve Signal A Circuit Short (Bank 1)
OCV Solenoid Valve Signal A Circuit Open (Bank 2)
OCV Solenoid Valve Signal A Circuit Short (Bank 2)

MODE
1) Check battery voltage is more than 12 V and fuel
remains half [20 40 2 (5.3 10.6 US gal, 4.4
8.8 Imp gal)].
it on rigid racks or drive the vehicle onto free rollers.
On condition

and the vehicle.
WARNING:
brakes are applied.
wheels.
EN(H6DO)(diag)-34
Inspection Mode


EN-00039
(A)
(B)

(A)
EN-00041
EN-02424
(A) Rigid racks

(B) Free rollers


1) After clearing the memory, check for any remaining unresolved trouble data. <Ref. to EN(H6DO)(diag)-40, Clear Memory Mode.>
2) Idle the engine.
EN-02533
CAUTION:
EN-00038

Monitor.
EN(H6DO)(diag)-35
Inspection Mode


(A)
(A)
EN-00040
(A) Power switch

key.
NOTE:
<Ref. to EN(H6DO)(diag)-66, List of Diagnostic

1) After performing the diagnostics and clearing the
memory, check for any remaining unresolved trouble data: <Ref. to EN(H6DO)(diag)-40, Clear Memory Mode.>
2) Idle the engine.
EN-02424

connector in the lower portion of the instrument
CAUTION:
EN-02533

NOTE:
Ensure the select lever is placed in the P position before starting. (AT model)
Depress the clutch pedal when starting the engine. (MT model)
position switch and the N position switch to ON.
7) Depress the brake pedal to turn the brake switch
ON. (AT model)
8) Keep the engine speed in the 2,500 3,000
rpm range for 40 seconds.
9) Shift the select lever or shift lever in the D
range (AT model) or 1st gear (MT model) and
drive the vehicle at 5 to 10 km/h (3 to 6 MPH).
NOTE:
On AWD vehicles, release the parking brake.
EN(H6DO)(diag)-36
Inspection Mode
NOTE:
<Ref. to EN(H6DO)(diag)-66, List of Diagnostic
EN(H6DO)(diag)-37
Drive Cycle
12.Drive Cycle
A: PROCEDURE
For the troubleshooting, there are three driving patterns. By driving the vehicle with specified pattern, following trouble items could be diagnosed. After the repair of following trouble items, be sure to drive the vehicle
with specified patterns to check the trouble was repaired correctly.
1. PREPARATION FOR DRIVE CYCLE

1) Check battery voltage is more than 12 V and fuel remains half [20 40 2 (5.3 10.6 US gal, 4.4 8.8
Imp gal)].
2) After performing the diagnostics and clearing the memory, check for any remaining unresolved trouble data: <Ref. to EN(H6DO)(diag)-40, Clear Memory Mode.>
NOTE:
Perform the diagnosis after warming up the engine except the engine coolant temperature was specified
at engine start.
Perform the diagnosis twice if the DTC marked with *. After completing the first diagnosis, stop the engine
and perform second diagnosis in same condition.
2. DRIVE THE VEHICLE WITH 80 KM/H (50 MPH) FOR 20 MINUTES, AND THEN IDLE THE ENGINE FOR A MINUTE.
DTC
Item
On condition
Engine coolant temperature at
engine start is 20C (68F) or
less.
*P0125
Insufficient Coolant Temperature For Closed Loop Fuel Control
*P0133
*P0153
*P0420
Catalyst System Efficiency Below Threshold (Bank 1)
3. 10 MINUTES IDLING
NOTE:
Drive the vehicle in more than 10 km/h (6 MPH) before diagnosis.
DTC
*P0030
*P0050
*P0459
Item
EN(H6DO)(diag)-38
On condition
Drive Cycle
4. DRIVE THE VEHICLE WITH FOLLOWING DRIVE PATTERNS

(H)
(C)
97 (60)
(D)
64 (40)
(G)
(F)
(E)
(B)
(A)
0
50
100
(I)
150
EN-00842
(A)
(B)
(C)
Idle the engine for more than 10

seconds.
Accelerate the vehicle to 97 km/h
(60 MPH) within 20 seconds.
(D)
Drive the vehicle at 97 km/h (60

MPH) for 20 seconds.
(F)
DTC
P0076
P0082
*P0101
(E)
Decelerate the vehicle to 64 km/h

(40 MPH) with throttle fully closed.
Drive the vehicle at 64 km/h (40
MPH) for 20 seconds.
(G)
(H)
(I)
Stop the vehicle with throttle fully

closed.
Sec.
Accelerate the vehicle to 97 km/h

(60 MPH) within 10 seconds.
On condition
P0134
Item
Intake Valve Control Solenoid Circuit Low (Bank 1)
Intake Valve Control Solenoid Circuit Low (Bank 2)
Mass or Volume Air Flow Circuit Range/Performance
P0154
*P0301
*P0302
*P0303
*P0304
*P0305
*P0306
P0400
P0559
P1026
P1028
P1492
P1493
P1494
P1495
P1496
P1497
P1498
P1499

VVL System 1 Malfunction
VVL System 2 Malfunction
EN(H6DO)(diag)-39
Diagnosis may complete at once

Clear Memory Mode

A: OPERATION
For clear memory procedures using the general

scan tool, refer to the General Scan Tool Instruction Manual.

MODE)
key.
switch to OFF.
NOTE:

MODE)
key.
7) Turn the ignition switch to OFF and then turn off
the Subaru Select Monitor.
NOTE:
EN(H6DO)(diag)-40


Check Mode

A: OPERATION
EN-02533
EN-00038

Monitor.
CAUTION:
on the Subaru Select Monitor switch.
(A)
EN-00040
(A) Power switch

EN-00039

(A)
EN-02424

key.
the [YES] key.
12) Select the desired actuator on the Actuator
ON/OFF Operation display screen and press the
[YES] key.
screen.
EN(H6DO)(diag)-41


table.
DESCRIPTION
operation check
operation check
Display
Fuel Pump
Radiator Fan Relay
CPC Solenoid
NOTE:
Display
EGR Solenoid
ASV Solenoid
FICD Solenoid
Pressure Switching Solenoid 1
Pressure Switching Solenoid 2
Supercharger Control Solenoid
PCV Solenoid
AAI Solenoid
Atmospheric pressure switching solenoid
Exhaust Bypass Valve Control Permit Flag

EN(H6DO)(diag)-42


A: PROCEDURE
1. Activation of malfunction indicator light. <Ref. to EN(H6DO)(diag)-43, ACTIVATION OF MALFUNCTION INDICATOR LIGHT,
2. Malfunction indicator light does not come on. <Ref. to EN(H6DO)(diag)-45, MALFUNCTION INDICATOR LIGHT DOES NOT
COME ON, Malfunction Indicator Light.>
3. Malfunction indicator light does not go off. <Ref. to EN(H6DO)(diag)-47, MALFUNCTION INDICATOR LIGHT DOES NOT GO
OFF., Malfunction Indicator Light.>
4. Malfunction indicator light does not blink. <Ref. to EN(H6DO)(diag)-48, MALFUNCTION INDICATOR LIGHT DOES NOT
BLINK., Malfunction Indicator Light.>
5. Malfunction indicator light keep blinking. <Ref. to EN(H6DO)(diag)-50, MALFUNCTION INDICATOR LIGHT REMAINS BLINKING., Malfunction Indicator Light.>
INDICATOR LIGHT
off), the malfunction indicator light (A) in the combination meter illuminates.
NOTE:
EN(H6DO)(diag)-45, MALFUNCTION INDICATOR
the emission control system is malfunctioning.
(1)
(3)
(4)
(2)
(3)
(4)
(5)
(6)
EN-01679
(1)
(2)
(3)
(4)
(5)
(6)
(A)
EN-01984
No faulty
Trouble occurs
ON
OFF
Ignition switch ON
Engine start

(2) After the engine starts, malfunction indicator
light blinks in a cycle of 0.5 Hz. (During diagnosis)
EN(H6DO)(diag)-43

(3) After the diagnosis is completed, malfunction indicator light does not blink at a cycle of 3
Hz if there is no fault. Malfunction indicator light
illuminates when the trouble occurs.
(1)
(2)
(4)
(3)
EN-01681
(1)
(2)
(3)
(4)
ON
OFF
Ignition switch ON
1 second
EN(H6DO)(diag)-44


DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B72
IGNITION
SWITCH
BATTERY
SBF-7
No.5
3
3
4
SBF-1
COMBINATION
METER
16
i10
i3
17
B38
B134 ECM
B134
B72
1 2 3
4 5 6
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
i10
B38
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
EN-01985
Step
CHECK POOR CONTACT.
Check for poor connection when shaking or
pulling ECM connector and harness.
Check
Yes
Go to step 4.

light illuminate?
contact in ECM
connector.
EN(H6DO)(diag)-45
No
Go to step 2.
Go to step 3.

Step

combination meter.
(B134) No. 17 (i10) No. 16:
Check
Yes
connected?
<Ref. to
FU(H6DO)-34,
Engine Control
Module (ECM).>
Go to step 5.
?
CHECK POOR CONTACT.

16, Combination
Meter.>
EN(H6DO)(diag)-46
No
connector.

NOTE:
In this case repair
the following:
Open circuit in
harness between
Poor contact in
coupling connector
Go to step 6.

necessary.
NOTE:
Brown out fuse
(No. 5)
Open or short
circuit in harness
between fuse (No.
Poor contact in


DIAGNOSIS:
TROUBLE SYMPTOM:
Monitor display.
WIRING DIAGRAM:
B72
IGNITION
SWITCH
BATTERY
SBF-7
No.5
3
3
4
SBF-1
COMBINATION
METER
16
i10
i3
17
B38
B134 ECM
B134
B72
1 2 3
4 5 6
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
i10
B38
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
EN-01985
Step
Check
Yes
light illuminate?
circuit in harness
ECM connector.
EN(H6DO)(diag)-47
No
Replace the ECM.
<Ref. to
FU(H6DO)-34,
Engine Control
Module (ECM).>


DIAGNOSIS:
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B72
IGNITION
SWITCH
BATTERY
SBF-7
No.5
3
3
4
SBF-1
COMBINATION
METER
*1
LHD: 3
RHD: TERMINAL No. RANDOM ARRANGEMENT
*2
LHD: 2
*3
LHD: B122
RHD: B138
16
i10
*3
8
i3
B75
B76
*
*2
D15
A17
B38
A: B134
B75
B72
1
2
1 2 3
4 5 6
A:
1
8 9
18 19
28 29
2
10
20
30
B134
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
D: B137
ECM
i10
1 2 3 4 5
11 12 13 14 15 16
B38
6 7 8 9 10
17 18 19 20 21 22
D:
B137
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
28 29
30 31
26 27
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
B122
B138
1 2 3 4
5 6 7 8
EN-02491
EN(H6DO)(diag)-48

Step
OFF)
Check
Yes
light illuminate?

ground.

light illuminate?
circuit in harness
ECM connector.
Go to step 4.
Repair the har?
ness and connector.
CHECK POOR CONTACT.


connector?

CHECK POOR CONTACT.

?

connector?
EN(H6DO)(diag)-49
Repair the poor

contact in ECM
connector.
Go to step 6.
Repair the poor

contact in ECM
connector.
No
to
EN(H6DO)(diag)45, MALFUNCTION INDICATOR LIGHT
DOES NOT
COME ON, Malfunction Indicator
Light.>
Go to step 3.
NOTE:
In this case repair
the following:
Open circuit in
harness between
ground
Go to step 5.
Repair the open

circuit in harness
between ECM and
Replace the ECM.

<Ref. to
FU(H6DO)-34,
Engine Control
Module (ECM).>


DIAGNOSIS:
TROUBLE SYMPTOM:
Malfunction indicator light blinks without test mode connector connected.
WIRING DIAGRAM:
B72
IGNITION
SWITCH
BATTERY
SBF-7
No.5
3
3
4
SBF-1
COMBINATION
METER
*1
LHD: 3
*2
LHD: 2
*3
LHD: B122
RHD: B138
16
i10
*3
8
i3
B75
B76
*
*2
D15
A17
B38
A: B134
B75
B72
1
2
1 2 3
4 5 6
A:
1
8 9
18 19
28 29
2
10
20
30
ECM
D: B137
i10
1 2 3 4 5
11 12 13 14 15 16
B134
B38
6 7 8 9 10
17 18 19 20 21 22
D:
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B137
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
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
B122
B138
1 2 3 4
5 6 7 8
EN-02491
Step
Check
Yes
light blink?
EN(H6DO)(diag)-50
No
System is in good
order.
NOTE:
Malfunction indicator light blinks
when test mode
connector is connected.

Step
Check
MINAL.
EN(H6DO)(diag)-51
Yes
Repair the short
circuit in harness
between ECM and
No
Replace the ECM.
<Ref. to
FU(H6DO)-34,
Engine Control
Module (ECM).>


A: PROCEDURE
2. Inspection of starter motor circuit <Ref. to EN(H6DO)(diag)-53, STARTER MOTOR CIRCUIT, Diagnostics for Engine Starting
Failure.>
3. Inspection of ECM power supply and ground line. <Ref. to EN(H6DO)(diag)-56, CHECK POWER SUPPLY AND GROUND
4. Inspection of ignition control system. <Ref. to EN(H6DO)(diag)-59, IGNITION CONTROL SYSTEM, Diagnostics for Engine
Starting Failure.>
5. Inspection of fuel pump circuit. <Ref. to EN(H6DO)(diag)-62, FUEL PUMP CIRCUIT, Diagnostics for Engine Starting Failure.>
6. Inspection of fuel injector circuit. <Ref. to EN(H6DO)(diag)-64, FUEL INJECTOR CIRCUIT, Diagnostics for Engine Starting
Failure.>
EN(H6DO)(diag)-52


CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H6DO)(diag)-40,
OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H6DO)(diag)-33, PROCEDURE,
Inspection Mode.>.
WIRING DIAGRAM:
IGNITION
SWITCH
B72
BATTERY
SBF-1
SBF-7
No.21
3
2
*1
*3
STARTER
RELAY
STARTER MOTOR
*4
*2
B225
D8
B32
B14
*1
LHD: 15
RHD: 16
*2
LHD: 16
RHD: 15
*3
LHD: 13
RHD: 14
*4
LHD: 14
RHD: 13
ECM
B: B135
D: B137
B72
B225
B: B135
1 2 3
4 5 6
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
1
8 9
20 21
28 29
2
3
10 11 12 13
22 23
30 31
4 5 6
7
14 15 16 17 18 19
24 25
26 27
32 33
34 35
D: B137
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
EN-02492
EN(H6DO)(diag)-53

1
2
3
Step
Check
CHECK BATTERY.
CHECK DTC.
EN(H6DO)(diag)-32, OPERATION, Read Diagnostic Trouble
Code (DTC).>
Yes
Go to step 2.
Go to step 3.

List of Diagnostic
Trouble Code
(DTC). <Ref. to
EN(H6DO)(diag)66, List of Diagnostic Trouble
Code (DTC).>
TOR.
motor.
ground.
NOTE:
Shift the select lever to P or N range.
MOTOR.
starter motor.
ground.
switch.
switch.
switch terminals while turning the ignition
Terminals
No. 2 No. 3:

?
Check the starter

motor. <Ref. to
SC(H6DO)-6,
Starter.>
No
Charge or replace
the battery.
Go to step 4.
Repair the poor
contact in ECM
connector.
Go to step 6.
Repair the open

circuit of ground
cable.
Repair the open

circuit in harness
between ignition
fuse SBF No.7 and
SBF No.1.

?
EN(H6DO)(diag)-54
Go to step 8.

10
Step
relay connector and chassis ground while turning the ignition switch to START position.
LHD model
RHD model
relay terminals.
Terminals
No. 13 No. 14:
chassis ground.
Check
Yes
No
Repair the open
circuit in harness
between starter
relay and ignition
switch.

?
Replace the
starter relay.
Go to step 10.

<Ref. to
FU(H6DO)-34,
Engine Control
Module (ECM).>
EN(H6DO)(diag)-55
Repair the open or

between ECM and
starter relay.

CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
MAIN RELAY
TO OXYGEN SENSOR
3
5
SBF-6
SBF-8
6
4
No.13
2
1
IGNITION
SWITCH
B72
BATTERY
No.12
B47
SBF-7
3
B19
D14
D16
B5
B6
SBF-1
A: B134
B: B135
ECM
A4
A5
A6
A7
B12
D3
D7
D1
D2
B1
B4
D: B137
35
12
37
34
36
54
52
B21
E2
B72
1 2 3
4 5 6
B47
1
3
5
2
4
6
A:
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
1
8 9
18 19
28 29
2
10
20
30
B134
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B:
B135
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
D:
B137
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
28 29
30 31
26 27
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
EN-02493
EN(H6DO)(diag)-56

Step
CHECK MAIN RELAY.
No. 1 and No. 2.
terminals.
Terminals
No. 3 No. 5:
No. 4 No. 6:
and chassis ground.
Check
?
Yes
Go to step 2.
No
Replace the main
relay.

?
Go to step 3.
Repair the open

circuit in harness
between ECM
connector and
engine grounding
terminal.
Repair the open or

Repair the open or

Repair the open

circuit in harness
between ECM
connector and
Repair the open or
between ECM
connector and

relay.
CHECK INPUT VOLTAGE OF MAIN RELAY. Is the voltage more than 10 V? Go to step 8.
EN(H6DO)(diag)-57
Repair the open or


Step
Check
Yes
control system.
<Ref. to
EN(H6DO)(diag)59, IGNITION
EN(H6DO)(diag)-58
No
Repair the open or
between ECM
connector and


CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
RELAY
HOLDER
B225
B327
MAIN
RELAY 2
SBF-8
16
13
14
16
15
ECM
15
17
14
13
49
18
B135
B21
18
17
E2
E46
2
E45
3
E34
E33
E32
E31
E
IGNITION COIL
No. 1
E31
E34
E32
E45
E33
E46
1
2
3
IGNITION COIL
No. 2
IGNITION COIL
No. 3
2
4
6
IGNITION COIL
No. 5
B225
B327
1
3
5
IGNITION COIL
No. 4
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
IGNITION COIL
No. 6
B21
B135
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
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
32 33
34 35
28 29 30 31
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
EN-02494
Step
CHECK SPARK PLUG CONDITION.
1) Remove the spark plug. <Ref. to
IG(H6DO)-4, REMOVAL, Spark Plug.>
2) Check the spark plug condition. <Ref. to
IG(H6DO)-5, INSPECTION, Spark Plug.>
Check
Yes
Is the spark plugs status OK? Go to step 2.
EN(H6DO)(diag)-59
No
Replace the spark
plug.

Step
CHECK IGNITION SYSTEM FOR SPARKS.
1) Connect the spark plug to ignition coil.
engine.
4) While opening the throttle valve fully, start
cylinder.
CHECK POWER SUPPLY CIRCUIT FOR IGNITION COIL & IGNITOR ASSY.
& ignitor ASSY.
engine ground.
CHECK HARNESS OF IGNITION COIL & IGNITOR ASSY GROUND CIRCUIT.
ground.
& ignitor ASSY.
connector.
(B135) No. 18 (E31) No. 1:
(B135) No. 17 (E32) No. 1:
(B135) No. 16 (E33) No. 1:
(B135) No. 15 (E34) No. 1:
(B135) No. 14 (E45) No. 1:
(B135) No. 13 (E46) No. 1:
Check
Does spark occur at each cylinder?
Yes
No
system. <Ref. to
EN(H6DO)(diag)62, FUEL PUMP
Starting Failure.>

NOTE:
In this case repair
the following:
Open circuit in
harness between
ignition coil & ignitor ASSY, and ignition switch
connector
Poor contact in
coupling connector

?
Go to step 5.

NOTE:
In this case repair
the following:
Open circuit in
harness between
grounding terminal

?
EN(H6DO)(diag)-60
Go to step 6.

NOTE:
In this case repair
the following:
Open circuit in
harness between
ECM and ignition
coil & ignitor ASSY
connector.
Poor contact in
coupling connector

Step
CHECK POOR CONTACT.
Check
M?
Yes
Go to step 7.
No
Repair the ground
ECM and ignition
coil & ignitor ASSY
connector.

connector?
Repair the poor

contact in ECM
connector.
Check fuel pump

circuit. <Ref. to
EN(H6DO)(diag)62, FUEL PUMP
Starting Failure.>
EN(H6DO)(diag)-61


CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
BATTERY
No.11
2
FUEL PUMP
RELAY
*
*3
B362
10
*71
FUEL PUMP
CONTROL UNIT
*1
LHD: 16
RHD: 4
*2
LHD: B97
RHD: B98
*3
LHD: R1
RHD: R2
*4
LHD: 6
RHD: 5
*5
LHD: 15
RHD: 6
*3
*2
D28
B27
5
6
* 54
*
9
8
7
6
R122
FUEL
PUMP
ECM
R58
B: B135
D: B137
B362
1 2
3
4
5
7 8
6
B98
R122
1
2 3
4 5 6 7 8
3 4
1 2
5 6 7 8 9 10
B97
R58
1 2
3 4
5 6
B:
B135
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
D: B137
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
28 29
30 31
26 27
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
EN-02504
EN(H6DO)(diag)-62

Step
Check
PUMP.
operating sound?
Make sure that fuel pump is in operation for
two seconds when turning the ignition switch to
ON.
NOTE:
Mode for procedures. <Ref. to
EN(H6DO)(diag)-41, Compulsory Valve Operation Check Mode.>
EN(H6DO)(diag)-63
Yes
Check the fuel
injector circuit.
<Ref. to
EN(H6DO)(diag)64, FUEL INJECTOR CIRCUIT,
Diagnostics for
Engine Starting
Failure.>
No
Display DTC.
<Ref. to
EN(H6DO)(diag)32, OPERATION,
Read Diagnostic
Trouble Code
(DTC).>


CAUTION:
After repair or replacement of faulty parts, conduct Clear Memory Mode <Ref. to EN(H6DO)(diag)40, OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H6DO)(diag)-33, PROCEDURE, Inspection Mode.>.
WIRING DIAGRAM:
BATTERY
MAIN RELAY
SBF-8
6
4
5
3
2
1
B47
47
45
46
ECM
44
5
43
42
48
B136
B21
E2
E44
E5
E16
E6
E17
1 2
FUEL INJECTOR
No. 2
B47
1
3
5
2
4
6
FUEL INJECTOR
No. 3
FUEL INJECTOR
No. 5
E44
2
FUEL INJECTOR
No. 4
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
E43
E17
2
FUEL INJECTOR
No. 1
E43
E6
E16
E5
FUEL INJECTOR
No. 6
B21
5 6
14 15 16
25 26 27
33 34 35
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 45
46 47
48 49 50 51 52 53 54
EN-02505
Step
Check
CHECK OPERATION OF EACH FUEL INJEC- Does the fuel injector emit
TOR.
operating sound?
While cranking the engine, check that each
fuel injector emits operating sound. Use a
sound scope or apply a screwdriver to the
injector for this check.
EN(H6DO)(diag)-64
Yes
No
Check the fuel
Go to step 2.
pressure. <Ref. to
ME(H6DO)-28,
INSPECTION,
Fuel Pressure.>

Step
Check
Yes
INJECTOR.
No
NOTE:
In this case repair
the following:
Open circuit in
harness between
main relay and fuel
injector connector
Poor contact in
Poor contact in
coupling connector
Poor contact in

#1 (B136) No. 6 (E5) No. 1:
#2 (B136) No. 5 (E16) No. 1:
#3 (B136) No. 4 (E6) No. 1:
#4 (B136) No. 3 (E17) No. 1:
#5 (B136) No. 2 (E43) No. 1:
#6 (B136) No. 1 (E44) No. 1:

?

injector terminals.
Terminals
No. 1 No. 2:
CHECK POOR CONTACT.

M?
Go to step 5.
Go to step 6.
Replace the faulty

fuel injector.

connector?
Repair the poor

contact in ECM
connector.
Inspection using
General Diagnostics Table. <Ref.
to
EN(H6DO)(diag)265, INSPECTION, General
Diagnostic Table.>
EN(H6DO)(diag)-65
Go to step 4.
NOTE:
In this case repair
the following:
Open circuit in
harness between
ECM and fuel
injector connector
Poor contact in
coupling connector
Repair the ground
ECM and fuel
injector connector.


A: LIST
DTC
P0011
P0021
P0030
Item
A Camshaft Position-Timing OverAdvanced or System Performance
(Bank 1)
A Camshaft Position-Timing OverAdvanced or System Performance
(Bank 2)
Sensor 1)
P0031

(Bank 1 Sensor 1)
P0032

(Bank 1 Sensor 1)
P0037

(Bank 1 Sensor 2)
P0038

(Bank 1 Sensor 2)
P0050

Sensor 1)
P0051

(Bank 2 Sensor 1)
P0052

(Bank 2 Sensor 1)
P0057

(Bank 2 Sensor 2)
P0058

(Bank 2 Sensor 2)
P0076
Intake Valve Control Solenoid Circuit

Low (Bank 1)
P0077

High (Bank 1)
P0082

Low (Bank 2)
P0083

High (Bank 2)
P0101

Range/Performance
P0102
Mass or Volume Air Flow Circuit Low

Input
Reference
<Ref. to EN(H6DO)(diag)-72, DTC P0011 INTAKE CAMSHAFT POSITION TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 1),
<Ref. to EN(H6DO)(diag)-73, DTC P0021 INTAKE CAMSHAFT POSITION TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 2),
<Ref. to EN(H6DO)(diag)-74, DTC P0030 HO2S HEATER CONTROL CIRCUIT (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
<Ref. to EN(H6DO)(diag)-76, DTC P0031 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic
<Ref. to EN(H6DO)(diag)-79, DTC P0032 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic
<Ref. to EN(H6DO)(diag)-86, DTC P0050 HO2S HEATER CONTROL CIRCUIT (BANK 2 SENSOR 1), Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
<Ref. to EN(H6DO)(diag)-98, DTC P0076 INTAKE VALVE CONTROL
SOLENOID CIRCUIT LOW (BANK 1), Diagnostic Procedure with Diagnostic
SOLENOID CIRCUIT HIGH (BANK 1), Diagnostic Procedure with Diagnostic
SOLENOID CIRCUIT LOW (BANK 2), Diagnostic Procedure with Diagnostic
SOLENOID CIRCUIT HIGH (BANK 2), Diagnostic Procedure with Diagnostic
<Ref. to EN(H6DO)(diag)-106, DTC P0101 MASS OR VOLUME AIR FLOW
CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnostic
CIRCUIT LOW INPUT, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
EN(H6DO)(diag)-66

DTC
P0103
Item
Mass or Volume Air Flow Circuit High
Input
P0107
P0108
P0112

Input
P0113

Input
P0117

Low Input
P0118

High Input
P0122

P0123

P0125
Insufficient Coolant Temperature For

P0131

1 Sensor 1)
P0132

(Bank 1 Sensor 1)
P0133

(Bank 1 Sensor 1)
P0134

P0137

1 Sensor 2)
P0138

(Bank 1 Sensor 2)
P0151

2 Sensor 1)
P0152

(Bank 2 Sensor 1)
P0153

(Bank 2 Sensor 1)
Reference
CIRCUIT HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to EN(H6DO)(diag)-113, DTC P0107 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT LOW INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H6DO)(diag)-116, DTC P0108 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H6DO)(diag)-119, DTC P0112 INTAKE AIR TEMPERATURE
Code (DTC).>
<Ref. to EN(H6DO)(diag)-121, DTC P0113 INTAKE AIR TEMPERATURE
Code (DTC).>
<Ref. to EN(H6DO)(diag)-124, DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to EN(H6DO)(diag)-126, DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to EN(H6DO)(diag)-129, DTC P0122 THROTTLE/PEDAL POSITION
SENSOR/SWITCH A CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
SENSOR/SWITCH A CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H6DO)(diag)-133, DTC P0125 INSUFFICIENT COOLANT
<Ref. to EN(H6DO)(diag)-134, DTC P0131 O2 SENSOR CIRCUIT LOW
<Ref. to EN(H6DO)(diag)-136, DTC P0132 O2 SENSOR CIRCUIT HIGH
<Ref. to EN(H6DO)(diag)-138, DTC P0133 O2 SENSOR CIRCUIT SLOW
RESPONSE (BANK 1 SENSOR 1), Diagnostic Procedure with Diagnostic
<Ref. to EN(H6DO)(diag)-140, DTC P0134 O2 SENSOR CIRCUIT NO
<Ref. to EN(H6DO)(diag)-153, DTC P0153 O2 SENSOR CIRCUIT SLOW
RESPONSE (BANK 2 SENSOR 1), Diagnostic Procedure with Diagnostic
EN(H6DO)(diag)-67

DTC
P0154
Item
P0157

2 Sensor 2)
P0158

(Bank 2 Sensor 2)
P0171
P0172
P0174
P0175
P0197
Engine Oil Temperature Sensor Circuit Low
P0198
Engine Oil Temperature Sensor Circuit High
P0222

P0223

P0230
P0301
P0302
P0303
P0304
P0305
P0306
P0327

P0328

P0332

(Bank 2)
P0333

(Bank 2)
Reference
<Ref. to EN(H6DO)(diag)-155, DTC P0154 O2 SENSOR CIRCUIT NO
<Ref. to EN(H6DO)(diag)-163, DTC P0171 SYSTEM TOO LEAN (BANK 1),
<Ref. to EN(H6DO)(diag)-163, DTC P0172 SYSTEM TOO RICH (BANK 1),
<Ref. to EN(H6DO)(diag)-163, DTC P0174 SYSTEM TOO LEAN (BANK 2),
<Ref. to EN(H6DO)(diag)-164, DTC P0175 SYSTEM TOO RICH (BANK 2),
<Ref. to EN(H6DO)(diag)-166, DTC P0197 ENGINE OIL TEMPERATURE
SENSOR CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
<Ref. to EN(H6DO)(diag)-168, DTC P0198 ENGINE OIL TEMPERATURE
SENSOR CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
SENSOR/SWITCH B CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
SENSOR/SWITCH B CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H6DO)(diag)-174, DTC P0230 FUEL PUMP PRIMARY CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H6DO)(diag)-177, DTC P0301 CYLINDER 1 MISFIRE
<Ref. to EN(H6DO)(diag)-185, DTC P0327 KNOCK SENSOR 1 CIRCUIT
LOW (BANK 1 OR SINGLE SENSOR), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
HIGH (BANK 1 OR SINGLE SENSOR), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
LOW INPUT (BANK 2), Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
HIGH INPUT (BANK 2), Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
EN(H6DO)(diag)-68

DTC
P0335
Item
P0340

P0345

(Bank 2)
P0400
P0420

Threshold (Bank 1)
P0458
P0459
P0462
P0463
P0500
P0512
P0519
P0558

(Fail-Safe)
Alternator Circuit Low
P0559
Alternator Circuit High
P0600
P0604
Internal Control Module Random

P0605

Memory (ROM) Error
P0607
P0638
P0691
P0692
P0700

Request)
Reference
<Ref. to EN(H6DO)(diag)-193, DTC P0335 CRANKSHAFT POSITION SENSOR A CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to EN(H6DO)(diag)-195, DTC P0340 CAMSHAFT POSITION SENSOR A CIRCUIT (BANK 1 OR SINGLE SENSOR), Diagnostic Procedure
<Ref. to EN(H6DO)(diag)-197, DTC P0345 CAMSHAFT POSITION SENSOR A CIRCUIT (BANK 2), Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
<Ref. to EN(H6DO)(diag)-199, DTC P0400 EXHAUST GAS RECIRCULATION FLOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H6DO)(diag)-202, DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H6DO)(diag)-203, DTC P0458 EVAPORATIVE EMISSION
<Ref. to EN(H6DO)(diag)-205, DTC P0459 EVAPORATIVE EMISSION
<Ref. to EN(H6DO)(diag)-207, DTC P0462 FUEL LEVEL SENSOR CIRCUIT LOW INPUT, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to EN(H6DO)(diag)-207, DTC P0463 FUEL LEVEL SENSOR CIRCUIT HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to EN(H6DO)(diag)-207, DTC P0500 VEHICLE SPEED SENSOR,
<Ref. to EN(H6DO)(diag)-208, DTC P0512 STARTER REQUEST CIRCUIT,
<Ref. to EN(H6DO)(diag)-211, DTC P0519 IDLE CONTROL SYSTEM PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H6DO)(diag)-211, DTC P0558 ALTERNATOR CIRCUIT LOW,
<Ref. to EN(H6DO)(diag)-212, DTC P0559 GENERATOR CIRCUIT HIGH,
<Ref. to EN(H6DO)(diag)-213, DTC P0600 SERIAL COMMUNICATION
<Ref. to EN(H6DO)(diag)-214, DTC P0604 INTERNAL CONTROL MODULE
RANDOM ACCESS MEMORY (RAM) ERROR, Diagnostic Procedure with
<Ref. to EN(H6DO)(diag)-215, DTC P0605 INTERNAL CONTROL MODULE
READ ONLY MEMORY (ROM) ERROR, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H6DO)(diag)-216, DTC P0607 CONTROL MODULE PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H6DO)(diag)-217, DTC P0638 THROTTLE ACTUATOR CONTROL RANGE/PERFORMANCE (BANK 1), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H6DO)(diag)-218, DTC P0691 FAN 1 CONTROL CIRCUIT
<Ref. to EN(H6DO)(diag)-218, DTC P0692 FAN 1 CONTROL CIRCUIT
<Ref. to EN(H6DO)(diag)-218, DTC P0700 TRANSMISSION CONTROL
Code (DTC).>
EN(H6DO)(diag)-69

DTC
P1026
Item
VVL System 1 Performance
P1028
VVL System 2 Performance
P1160
P1492
P1493
P1494
P1495
P1496
P1497
P1498
P1499
P1518
P1560
P2088
OCV Solenoid Valve Signal A Circuit

Open (Bank 1)
P2089

Short (Bank 1)
P2092

Open (Bank 2)
P2093

Short (Bank 2)
P2101
P2102
P2103
Reference
<Ref. to EN(H6DO)(diag)-219, DTC P1026 VVL SYSTEM 1 PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H6DO)(diag)-221, DTC P1028 VVL SYSTEM 2 PERFORMANCE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H6DO)(diag)-223, DTC P1160 RETURN SPRING FAILURE,
<Ref. to EN(H6DO)(diag)-223, DTC P1492 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Procedure with
<Ref. to EN(H6DO)(diag)-223, DTC P1493 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Procedure
<Ref. to EN(H6DO)(diag)-228, DTC P1518 STARTER SWITCH CIRCUIT
<Ref. to EN(H6DO)(diag)-231, DTC P1560 BACK-UP VOLTAGE CIRCUIT
MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to EN(H6DO)(diag)-233, DTC P2088 INTAKE CAMSHAFT POSITION
ACTUATOR CONTROL CIRCUIT LOW (BANK 1), Diagnostic Procedure
ACTUATOR CONTROL CIRCUIT HIGH (BANK 1), Diagnostic Procedure
ACTUATOR CONTROL CIRCUIT LOW (BANK 2), Diagnostic Procedure
ACTUATOR CONTROL CIRCUIT HIGH (BANK 2), Diagnostic Procedure
<Ref. to EN(H6DO)(diag)-241, DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure
<Ref. to EN(H6DO)(diag)-246, DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to EN(H6DO)(diag)-248, DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(H6DO)(diag)-70

DTC
P2109
Item
Throttle Angle Sensor Closed Position Error
P2122

P2123

P2127

P2128

P2135

P2138

Reference
SENSOR A MINIMUM STOP PERFORMANCE, Diagnostic Procedure with
SENSOR/SWITCH D CIRCUIT LOW INPUT, Diagnostic Procedure with
SENSOR/SWITCH D CIRCUIT HIGH INPUT, Diagnostic Procedure with
SENSOR/SWITCH E CIRCUIT LOW INPUT, Diagnostic Procedure with
SENSOR/SWITCH E CIRCUIT HIGH INPUT, Diagnostic Procedure with
SENSOR/SWITCH A / B VOLTAGE CORRELATION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
SENSOR/SWITCH D / E VOLTAGE CORRELATION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(H6DO)(diag)-71


A: DTC P0011 INTAKE CAMSHAFT POSITION - TIMING OVER-ADVANCED OR
SYSTEM PERFORMANCE (BANK 1)
TROUBLE SYMPTOM:
Engine stalls.
Erroneous idling
CAUTION:
OPERATION, Clear Memory Mode.> and Inspection Mode <Ref. to EN(H6DO)(diag)-33, Inspection
Mode.>.
Step
Check
Yes
List of Diagnostic
Trouble Code
(DTC). <Ref. to
Code (DTC).>
Is the AVCS system operating Check the followCHECK CURRENT DATA.
angle approx. 0 deg., and oil
ing and repair or
1) Start the engine and let it idle.
2) Measure the AVCS system operating angle flow control solenoid valve duty replace if necessary.
and oil flow control solenoid valve duty output output approx. 10%?
Oil pipe (clog)
using Subaru Select Monitor or general scan
Oil flow contool.
trol solenoid
NOTE:
valve (clog or
dirt of oil routFor detailed operation procedures, refer to the
ing, setting of
READ CURRENT DATA SHOWN ON DISspring, clog of
PLAY FOR ENGINE. <Ref. to
valve)
EN(H6DO)(diag)-25, Subaru Select Monitor.>
Intake cam General scan tool
shaft (dirt, damFor detailed operation procedures, refer to the
age of
camshaft)
Timing chain
(matching of
timing mark)
EN(H6DO)(diag)-72
No
Go to step 2.
A temporary malfunction.
Perform the following, and clean the
oil routing.
Replace the
engine oil and idle
the engine for 5
minutes, and then
replace the oil filter
and engine oil.

B: DTC P0021 INTAKE CAMSHAFT POSITION - TIMING OVER-ADVANCED OR

SYSTEM PERFORMANCE (BANK 2)
TROUBLE SYMPTOM:
Engine stalls.
Erroneous idling
CAUTION:
Mode.>.
Step
Check
Yes
List of Diagnostic
Trouble Code
(DTC). <Ref. to
Code (DTC).>
Is the AVCS system operating Check the followCHECK CURRENT DATA.
angle approx. 0 deg., and oil
ing and repair or
2) Measure the AVCS system operating angle flow control solenoid valve duty replace if necessary.
and oil flow control solenoid valve duty output output approx. 10%?
Engine oil
using Subaru Select Monitor or general scan
(amount, dirt)
tool.
Oil pipe (clog)
NOTE:
Oil flow con Subaru Select Monitor
trol solenoid
valve (clog or
READ CURRENT DATA SHOWN ON DISdirt of oil routPLAY FOR ENGINE. <Ref. to
ing, setting of
spring, clog of
General scan tool
valve)
Intake camGeneral Scan Tool Operation Manual.
shaft (dirt, damage of
camshaft)
Timing chain
(matching of
timing mark)
EN(H6DO)(diag)-73
No
Go to step 2.
A temporary malfunction.
Perform the following, and clean the
oil routing.
Replace the
engine oil and idle
the engine for 5
minutes, and then
replace the oil filter
and engine oil.

C: DTC P0030 HO2S HEATER CONTROL CIRCUIT (BANK 1 SENSOR 1)

CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
MAIN RELAY
BATTERY
SBF-6
6
4
5
3
E47
3
E24
2
FRONT
OXYGEN
( A/F )
SENSOR RH
FRONT
OXYGEN
( A/F )
SENSOR LH
B47
E3
B22
2
1
E3
A33
A26
ECM
B: B135
52
54
A4
A5
A6
A7
A: B134
A2
A3
A25
B7
A1
A27
A34
B22
B21
E2
E47
E24
B47
1
3
5
1 2
3 4
B22
1
5
9
13
2
6
10
14
3
7
11
15
2
4
6
A: B134
1
8 9
18 19
28 29
2
10
20
30
B: B135
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
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
32 33
34 35
28 29 30 31
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
4
8
12
16
EN-02495
EN(H6DO)(diag)-74

Step
1) Start the engine, and warm-up the engine.
connector.
(B134) No. 2 (E47) No. 1:
(B134) No. 3 (E47) No. 1:
(B134) No. 26 (E47) No. 4:
(B134) No. 33 (E47) No. 3:
(B47) No. 3 (E47) No. 2:
Terminals
No. 2 No. 1:
CHECK POOR CONTACT.
Check poor contact in ECM and front oxygen
(A/F) sensor connector.
Check
?
Yes
Go to step 2.
No
Repair the open
circuit in harness
between ECM and
front oxygen (A/F)
sensor connector.

?
Go to step 3.
Repair the open

circuit in harness
between ECM and
front oxygen (A/F)
sensor connector.

?
Go to step 4.
Repair the open

circuit in harness
between main
relay and front

?
Go to step 5.
Replace the front

FU(H6DO)-30,
Front Oxygen (A/
F) Sensor.>
Replace the front
front oxygen (A/F) sensor con- contact in ECM or oxygen (A/F) sennector?
sensor connector. FU(H6DO)-30,
Front Oxygen (A/
F) Sensor.>
EN(H6DO)(diag)-75


CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
MAIN RELAY
BATTERY
SBF-6
6
4
5
3
E47
3
E24
2
FRONT
OXYGEN
( A/F )
SENSOR RH
FRONT
OXYGEN
( A/F )
SENSOR LH
B47
E3
B22
2
1
E3
A33
A26
ECM
B: B135
52
54
A4
A5
A6
A7
A: B134
A2
A3
A25
B7
A1
A27
A34
B22
B21
E2
E47
E24
B47
1
3
5
1 2
3 4
B22
1
5
9
13
2
6
10
14
3
7
11
15
2
4
6
A: B134
1
8 9
18 19
28 29
2
10
20
30
B: B135
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
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
32 33
34 35
28 29 30 31
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
4
8
12
16
EN-02495
EN(H6DO)(diag)-76

Step
Check
Yes
GEN (A/F) SENSOR.
(A/F) sensor.


?
CHECK CURRENT DATA.

heater current using Subaru Select Monitor or
the general scan tool.
NOTE:
READ CURRENT DATA SHOWN ON DISPLAY FOR ENGINE. <Ref. to
General scan tool
and chassis ground.
Go to step 3.
Repair the poor

contact in connector.
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
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 4.
NOTE:
In this case repair
the following:
Poor contact in
front oxygen (A/F)
sensor connector
Poor contact in
coupling connector
Poor contact in
ECM connector
Go to step 6.

Repair the poor
EN(H6DO)(diag)-77
No
Repair the power
supply line.
Go to step 5.
Go to step 6.

Step
Check
?
Terminals
No. 2 No. 1:
EN(H6DO)(diag)-78
Yes
No
sor. <Ref. to
FU(H6DO)-30,
NOTE:
In this case repair Front Oxygen (A/
F) Sensor.>
the following:
Open or ground
Poor contact in
front oxygen (A/F)
sensor connector
Poor contact in
ECM connector
Poor contact in
coupling connector


CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
MAIN RELAY
BATTERY
SBF-6
6
4
5
3
E47
3
E24
2
FRONT
OXYGEN
( A/F )
SENSOR RH
FRONT
OXYGEN
( A/F )
SENSOR LH
B47
E3
B22
2
1
E3
A33
A26
ECM
B: B135
52
54
A4
A5
A6
A7
A: B134
A2
A3
A25
B7
A1
A27
A34
B22
B21
E2
E47
E24
B47
1
3
5
1 2
3 4
B22
1
5
9
13
2
6
10
14
3
7
11
15
2
4
6
A: B134
1
8 9
18 19
28 29
2
10
20
30
B: B135
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
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
32 33
34 35
28 29 30 31
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
4
8
12
16
EN-02495
EN(H6DO)(diag)-79

Step
Check
HEATER CURRENT.
connector.
NOTE:
READ CURRENT DATA SHOWN ON DISPLAY FOR ENGINE. <Ref. to EN(H6DO)(diag)-25, Subaru Select Monitor.>
connector?
and chassis ground.
EN(H6DO)(diag)-80
Yes
Go to step 2.
No
Go to step 3.

<Ref. to
FU(H6DO)-34,
Engine Control
Module (ECM).>

ECM and front

F: DTC P0037 HO2S HEATER CONTROL CIRCUIT LOW (BANK 1 SENSOR 2)

CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
MAIN RELAY
BATTERY
SBF-6
6
4
5
3
E61
11
10
12
3
16
13
E25
2
REAR
OXYGEN
SENSOR RH
REAR
OXYGEN
SENSOR LH
B47
E3
15
B22
14
2
1
E3
A: B134
C: B136
B: B135
D: B137
C35
B2
B3
D31
D25
D24
B22
4
5
8
B83
52
54
A4
A5
A6
A7
ECM
B21
E2
E25
E61
A: B134
B47
1
3
5
1 2
3 4
B83
2
4
6
1
8 9
18 19
28 29
2
10
20
30
B: B135
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B22
C: B136
1 2 3 4
5 6 7 8
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
32 33
34 35
28 29 30 31
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
D: B137
5 6
14 15 16
25 26 27
33 34 35
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
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
EN-02496
EN(H6DO)(diag)-81

Step
Check
Yes
sensor.

?
Go to step 3.
CHECK CURRENT DATA.

current using Subaru Select Monitor or the
general scan tool.
NOTE:
General scan tool
and chassis ground.
NOTE:
In this case repair
the following:
Open circuit in
harness between
main relay and
Poor contact in
Poor contact in
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 4.
NOTE:
In this case repair
the following:
Poor contact in
Poor contact in
coupling connector
Poor contact in
ECM connector
Go to step 7.

Repair the poor
EN(H6DO)(diag)-82
No
Repair the power
supply line.
Go to step 5.
Go to step 6.

Step
Check
sensor.

?
Terminals
No. 1 No. 2:
EN(H6DO)(diag)-83
Yes
Replace the ECM.
<Ref. to
FU(H6DO)-34,
Engine Control
Module (ECM).>
No
Repair the battery
repair, replace the
ECM. <Ref. to
FU(H6DO)-34,
Engine Control
Module (ECM).>
Replace the rear
Repair the harness and connec- oxygen sensor.
<Ref. to
tor.
FU(H6DO)-32,
NOTE:
In this case repair Rear Oxygen Sensor.>
the following:
Open circuit in
harness between
Poor contact in
Poor contact in
ECM connector
Poor contact in
coupling connector

G: DTC P0038 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 1 SENSOR 2)

CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
MAIN RELAY
BATTERY
SBF-6
6
4
5
3
E61
11
10
12
3
16
13
E25
2
REAR
OXYGEN
SENSOR RH
REAR
OXYGEN
SENSOR LH
B47
E3
15
B22
14
2
1
E3
A: B134
C: B136
B: B135
D: B137
C35
B2
B3
D31
D25
D24
B22
4
5
8
B83
52
54
A4
A5
A6
A7
ECM
B21
E2
E25
E61
A: B134
B47
1
3
5
1 2
3 4
B83
2
4
6
1
8 9
18 19
28 29
2
10
20
30
B: B135
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B22
C: B136
1 2 3 4
5 6 7 8
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
32 33
34 35
28 29 30 31
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
D: B137
5 6
14 15 16
25 26 27
33 34 35
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
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
EN-02496
EN(H6DO)(diag)-84

Step
Check
and chassis ground.
CHECK CURRENT DATA.
general scan tool.
NOTE:
General scan tool
CHECK POOR CONTACT.
connector?
EN(H6DO)(diag)-85
Yes
Go to step 2.
No
Go to step 3.

<Ref. to
FU(H6DO)-34,
Engine Control
Module (ECM).>
Repair the poor

contact in ECM
connector.
END.

H: DTC P0050 HO2S HEATER CONTROL CIRCUIT (BANK 2 SENSOR 1)

CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
MAIN RELAY
BATTERY
SBF-6
6
4
5
3
E47
3
E24
2
FRONT
OXYGEN
( A/F )
SENSOR RH
FRONT
OXYGEN
( A/F )
SENSOR LH
B47
E3
B22
2
1
E3
A33
A26
ECM
B: B135
52
54
A4
A5
A6
A7
A: B134
A2
A3
A25
B7
A1
A27
A34
B22
B21
E2
E47
E24
B47
1
3
5
1 2
3 4
B22
1
5
9
13
2
6
10
14
3
7
11
15
2
4
6
A: B134
1
8 9
18 19
28 29
2
10
20
30
B: B135
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
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
32 33
34 35
28 29 30 31
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
4
8
12
16
EN-02495
EN(H6DO)(diag)-86

Step
1) Start the engine, and warm-up the engine.
connector.
(B134) No. 1 (E24) No. 1:
(B135) No. 7 (E24) No. 1:
(B134) No. 27 (E24) No. 4:
(B134) No. 34 (E24) No. 3:
(B47) No. 3 (E24) No. 2:
Terminals
No. 2 No. 1:
CHECK POOR CONTACT.
Check poor contact in ECM and front oxygen
(A/F) sensor connector.
Check
?
Yes
Go to step 2.
No
Repair the open
circuit in harness
between ECM and
front oxygen (A/F)
sensor connector.

?
Go to step 3.
Repair the open

circuit in harness
between ECM and
front oxygen (A/F)
sensor connector.

?
Go to step 4.
Repair the open

circuit in harness
between main
relay and front

?
Go to step 5.
Replace the front

FU(H6DO)-30,
Front Oxygen (A/
F) Sensor.>
Replace the front
front oxygen (A/F) sensor con- contact in ECM or oxygen (A/F) sennector?
sensor connector. FU(H6DO)-30,
Front Oxygen (A/
F) Sensor.>
EN(H6DO)(diag)-87

I:
DTC P0051 HO2S HEATER CONTROL CIRCUIT LOW (BANK 2 SENSOR 1)

CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
MAIN RELAY
BATTERY
SBF-6
6
4
5
3
E47
3
E24
2
FRONT
OXYGEN
( A/F )
SENSOR RH
FRONT
OXYGEN
( A/F )
SENSOR LH
B47
E3
B22
2
1
E3
A33
A26
ECM
B: B135
52
54
A4
A5
A6
A7
A: B134
A2
A3
A25
B7
A1
A27
A34
B22
B21
E2
E47
E24
B47
1
3
5
1 2
3 4
B22
1
5
9
13
2
6
10
14
3
7
11
15
2
4
6
A: B134
1
8 9
18 19
28 29
2
10
20
30
B: B135
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
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
32 33
34 35
28 29 30 31
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
4
8
12
16
EN-02495
EN(H6DO)(diag)-88

Step
Check
Yes
GEN (A/F) SENSOR.
(A/F) sensor.


?
CHECK CURRENT DATA.

heater current using Subaru Select Monitor or
the general scan tool.
NOTE:
General scan tool
and chassis ground.
Go to step 3.
Repair the poor

contact connector.
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
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 4.
NOTE:
In this case repair
the following:
Poor contact in
front oxygen (A/F)
sensor connector
Poor contact in
coupling connector
Poor contact in
ECM connector
Go to step 6.

Repair the poor
EN(H6DO)(diag)-89
No
Repair the power
supply line.
Go to step 5.
Go to step 6.

Step
Check
?
Terminals
No. 2 No. 1:
EN(H6DO)(diag)-90
Yes
No
sor. <Ref. to
FU(H6DO)-30,
NOTE:
In this case repair Front Oxygen (A/
F) Sensor.>
the following:
Open or ground
Poor contact in
front oxygen (A/F)
sensor connector
Poor contact in
ECM connector
Poor contact in
coupling connector

J: DTC P0052 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 2 SENSOR 1)

CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
MAIN RELAY
BATTERY
SBF-6
6
4
5
3
E47
3
E24
2
FRONT
OXYGEN
( A/F )
SENSOR RH
FRONT
OXYGEN
( A/F )
SENSOR LH
B47
E3
B22
2
1
E3
A33
A26
ECM
B: B135
52
54
A4
A5
A6
A7
A: B134
A2
A3
A25
B7
A1
A27
A34
B22
B21
E2
E47
E24
B47
1
3
5
1 2
3 4
B22
1
5
9
13
2
6
10
14
3
7
11
15
2
4
6
A: B134
1
8 9
18 19
28 29
2
10
20
30
B: B135
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
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
32 33
34 35
28 29 30 31
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
4
8
12
16
EN-02495
EN(H6DO)(diag)-91

Step
Check
HEATER CURRENT.
connector.
NOTE:
connector?
and chassis ground.
EN(H6DO)(diag)-92
Yes
Go to step 2.
No
Go to step 3.

<Ref. to
FU(H6DO)-34,
Engine Control
Module (ECM).>

ECM and front

K: DTC P0057 HO2S HEATER CONTROL CIRCUIT LOW (BANK 2 SENSOR 2)

CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
MAIN RELAY
BATTERY
SBF-6
6
4
5
3
E61
11
10
12
3
16
13
E25
2
REAR
OXYGEN
SENSOR RH
REAR
OXYGEN
SENSOR LH
B47
E3
15
B22
14
2
1
E3
A: B134
C: B136
B: B135
D: B137
C35
B2
B3
D31
D25
D24
B22
4
5
8
B83
52
54
A4
A5
A6
A7
ECM
B21
E2
E25
E61
A: B134
B47
1
3
5
1 2
3 4
B83
2
4
6
1
8 9
18 19
28 29
2
10
20
30
B: B135
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B22
C: B136
1 2 3 4
5 6 7 8
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
32 33
34 35
28 29 30 31
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
D: B137
5 6
14 15 16
25 26 27
33 34 35
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
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
EN-02496
EN(H6DO)(diag)-93

Step
Check
Yes
sensor.

?
Go to step 3.

CHECK CURRENT DATA.
general scan tool.
NOTE:
General scan tool
and chassis ground.
NOTE:
In this case repair
the following:
Open circuit in
harness between
main relay and
Poor contact in
Poor contact in
coupling 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 4.
NOTE:
In this case repair
the following:
Poor contact in
Poor contact in
coupling connector
Poor contact in
ECM connector
Go to step 7.

Repair the poor
EN(H6DO)(diag)-94
No
Repair the power
supply line.
Go to step 5.
Go to step 6.

Step
Check
sensor.

?
Terminals
No. 1 No. 2:
EN(H6DO)(diag)-95
Yes
Replace the ECM.
<Ref. to
FU(H6DO)-34,
Engine Control
Module (ECM).>
No
Repair the battery
repair, replace the
ECM. <Ref. to
FU(H6DO)-34,
Engine Control
Module (ECM).>
Replace the rear
Repair the harness and connec- oxygen sensor.
<Ref. to
tor.
FU(H6DO)-32,
NOTE:
In this case repair Rear Oxygen Sensor.>
the following:
Open circuit in
harness between
Poor contact in
Poor contact in
ECM connector
Poor contact in
coupling connector

L: DTC P0058 HO2S HEATER CONTROL CIRCUIT HIGH (BANK 2 SENSOR 2)

CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
MAIN RELAY
BATTERY
SBF-6
6
4
5
3
E61
11
10
12
3
16
13
E25
2
REAR
OXYGEN
SENSOR RH
REAR
OXYGEN
SENSOR LH
B47
E3
15
B22
14
2
1
E3
A: B134
C: B136
B: B135
D: B137
C35
B2
B3
D31
D25
D24
B22
4
5
8
B83
52
54
A4
A5
A6
A7
ECM
B21
E2
E25
E61
A: B134
B47
1
3
5
1 2
3 4
B83
2
4
6
1
8 9
18 19
28 29
2
10
20
30
B: B135
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B22
C: B136
1 2 3 4
5 6 7 8
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
32 33
34 35
28 29 30 31
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
D: B137
5 6
14 15 16
25 26 27
33 34 35
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
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
EN-02496
EN(H6DO)(diag)-96

Step
Check
and chassis ground.
CHECK CURRENT DATA.
general scan tool.
NOTE:
General scan tool
CHECK POOR CONTACT.
connector?
EN(H6DO)(diag)-97
Yes
Go to step 2.
No
Go to step 3.

<Ref. to
FU(H6DO)-34,
Engine Control
Module (ECM).>
Repair the poor

contact in ECM
connector.
END.

M: DTC P0076 INTAKE VALVE CONTROL SOLENOID CIRCUIT LOW (BANK 1)

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
B134 ECM
1
8 9
18 19
28 29
20
21
B134
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
25
26
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B21
E69
E2
1 2
1
2
E69
OIL SWITCHING
SOLENOID VALVE RH
EN-02497
EN(H6DO)(diag)-98

Step
Check
SWITCHING SOLENOID VALVE.
?
switching solenoid valve.
oil switching solenoid valve.
(B134) No. 21 (E69) No. 1:
(B134) No. 20 (E69) No. 2:
Yes
Go to step 2.
CHECK OIL SWITCHING SOLENOID VALVE. Is the resistance 6 12 ?

1) Remove the oil switching solenoid valve
connector.
2) Measure the resistance between oil switching solenoid valve terminals.
Terminals
No. 1 No. 2:
Repair the poor

contact in ECM
and oil switching
solenoid valve.
EN(H6DO)(diag)-99
No
Repair the open
circuit in harness
between ECM and
oil switching solenoid valve connector.
NOTE:
In this case repair
the following:
Open circuit in
harness between
ECM and oil
switching solenoid
valve connector
Poor contact in
coupling connector
Replace the oil
switching solenoid
valve. <Ref. to
ME(H6DO)-79, Oil
Flow Control Solenoid Valve.>

N: DTC P0077 INTAKE VALVE CONTROL SOLENOID CIRCUIT HIGH (BANK 1)

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
B134 ECM
1
8 9
18 19
28 29
20
21
B134
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
25
26
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B21
E69
E2
1 2
1
2
E69
OIL SWITCHING
SOLENOID VALVE RH
EN-02497
EN(H6DO)(diag)-100

Step
Check
M?
3) Measure the resistance between oil switching solenoid valve and engine ground.
connector.
Terminals
No. 1 No. 2:
EN(H6DO)(diag)-101
Yes
Go to step 2.
No
Repair the short
circuit between
ECM and oil
switching solenoid
valve connector.
Repair the poor

contact in ECM
and oil switching
solenoid valve.
Replace the oil

switching solenoid
valve. <Ref. to
ME(H6DO)-79, Oil

O: DTC P0082 INTAKE VALVE CONTROL SOLENOID CIRCUIT LOW (BANK 2)

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
B135
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
32 33
34 35
28 29 30 31
24
25
B135 ECM
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
29
30
E70
1 2
B21
E2
1
2
E70
OIL SWITCHING
SOLENOID VALVE LH
EN-02498
EN(H6DO)(diag)-102

Step
Check
?
oil switching solenoid valve.
(B135) No. 25 (E70) No. 1:
(B135) No. 24 (E70) No. 2:
Yes
Go to step 2.

connector.
Terminals
No. 1 No. 2:
Repair the poor

contact in ECM
and oil switching
solenoid valve.
EN(H6DO)(diag)-103
No
Repair the open
circuit in harness
between ECM and
oil switching solenoid valve connector.
NOTE:
In this case repair
the following:
Open circuit in
harness between
ECM and oil
switching solenoid
valve connector
Poor contact in
coupling connector
Replace the oil
switching solenoid
valve. <Ref. to
ME(H6DO)-79, Oil

P: DTC P0083 INTAKE VALVE CONTROL SOLENOID CIRCUIT HIGH (BANK 2)

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
B135
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
32 33
34 35
28 29 30 31
24
25
B135 ECM
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
29
30
E70
1 2
B21
E2
1
2
E70
OIL SWITCHING
SOLENOID VALVE LH
EN-02498
EN(H6DO)(diag)-104

Step
Check
M?
3) Measure the resistance between oil switching solenoid valve and engine ground.
connector.
Terminals
No. 1 No. 2:
EN(H6DO)(diag)-105
Yes
Go to step 2.
No
Repair the short
circuit between
ECM and oil
switching solenoid
valve connector.
Repair the poor

contact in ECM
and oil switching
solenoid valve.
Replace the oil

switching solenoid
valve. <Ref. to
ME(H6DO)-79, Oil

Q: DTC P0101 MASS OR VOLUME AIR FLOW CIRCUIT RANGE/PERFORMANCE

TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
Mode.>.
WIRING DIAGRAM:
MAIN RELAY
5
3
BATTERY
SBF-8
6
4
2
1
B47
MASS AIR FLOW AND INTAKE

AIR TEMPERATURE SENSOR
B3
* 12
*
LHD: 2
*2
LHD: 8
31
13
23
32
35
B83
*1
E
B136
B3
1 2 3 4 5
B47
1
3
5
2
4
6
ECM
B83
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
1 2 3 4
5 6 7 8
EN-02499
EN(H6DO)(diag)-106

Step
Check
Yes
List of Diagnostic
Trouble Code
(DTC). <Ref. to
Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0101.
EN(H6DO)(diag)-107
No
Replace the mass
air flow and intake
air temperature
sensor. <Ref. to
FU(H6DO)-24,
Mass Air Flow and

R: DTC P0102 MASS OR VOLUME AIR FLOW CIRCUIT LOW INPUT

TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
MAIN RELAY
5
3
BATTERY
SBF-8
6
4
2
1
B47

B3
* 12
*
LHD: 2
*2
LHD: 8
31
13
23
32
35
B83
*1
E
B136
B3
1 2 3 4 5
B47
1
3
5
2
4
6
ECM
B83
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
1 2 3 4
5 6 7 8
EN-02499
EN(H6DO)(diag)-108

Step
Check
SELECT MONITOR.
link connector.
NOTE:

FLOW SENSOR.
flow sensor.
(B136) No. 23 (B3) No. 3:
(B136) No. 31 (B3) No. 2:
(B136) No. 35 (B3) No. 5:
Yes
No
Even if the malGo to step 2.
function indicator
light illuminates,
the circuit has
in the connector or
harness may be
the cause. Repair
air flow sensor.
NOTE:
In this case repair
the following:
Open or ground
Poor contact in
Go to step 3.

Select Monitor?

?
EN(H6DO)(diag)-109
Repair the poor

contact in ECM
connector.
Go to step 5.
Go to step 6.
Replace the ECM.

<Ref. to
FU(H6DO)-34,
Engine Control
Module (ECM).>
Repair the open
circuit between
mass air flow sensor and main relay
Repair the open

circuit between
ECM and mass air

Step
CHECK POOR CONTACT.
connector.
Check
M?
Yes
Go to step 7.
No
Repair the ground
short circuit
between ECM and

Repair the poor

contact in mass air
Replace the mass

air flow and intake
air temperature
sensor. <Ref. to
FU(H6DO)-24,
Mass Air Flow and
EN(H6DO)(diag)-110

S: DTC P0103 MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT

TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
MAIN RELAY
5
3
BATTERY
SBF-8
6
4
2
1
B47

B3
* 12
*
LHD: 2
*2
LHD: 8
31
13
23
32
35
B83
*1
E
B136
B3
1 2 3 4 5
B47
1
3
5
2
4
6
ECM
B83
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
1 2 3 4
5 6 7 8
EN-02499
EN(H6DO)(diag)-111

Step
Check
SELECT MONITOR.
link connector.
NOTE:
?
sensor connector.
(B3) No. 2 (B136) No. 31:
EN(H6DO)(diag)-112
Yes
light illuminates,
the circuit has
this time.
No
Go to step 2.

ECM connector.
Replace the mass

air flow sensor.
<Ref. to
FU(H6DO)-24,
Mass Air Flow and
Repair the open

circuit in harness
between mass air
connector.

T: DTC P0107 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE

CIRCUIT LOW INPUT
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
E28
1 2 3
1
2
MANIFOLD
ABSOLUTE
PRESSURE
SENSOR
E77
E28
1 2 3 4
6
7
5
9 10
8
5
8
E77
E76
B83
B122
1 2 3 4
5 6 7 8
20
19
7
E2
B21
B83
RHD
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
*2
LHD: 8
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B136
B136
16
LHD: 3
RHD
35
22
*1
B21
LHD LHD
B122
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
ECM
EN-02500
EN(H6DO)(diag)-113

Step
Check
CHECK CURRENT DATA.
Is the measured value less
than 13.3 kPa (100 mmHg,
2) Read the data of intake manifold absolute 3.94 inHg)?
pressure signal using Subaru Select Monitor or
general scan tool.
Yes
Go to step 3.
NOTE:
General scan tool
CHECK POOR CONTACT.
Check poor contact in ECM and manifold pres- manifold pressure sensor con- contact in ECM or
manifold pressure
sure sensor connector.
nector?
sensor connector.

and chassis ground.
and chassis ground.

Repair the poor
connector?
connector.

Repair the poor

contact in ECM
connector.
NOTE:
engine ground.
EN(H6DO)(diag)-114
No
Go to step 2.

light illuminates,
the circuit has
this time.
Go to step 4.
Replace the ECM.

<Ref. to
FU(H6DO)-34,
Engine Control
Module (ECM).>
Go to step 6.
Go to step 7.
Repair the open

circuit in harness
between ECM and
manifold absolute
pressure sensor
connector.

Step
sensor connector.
(B136) No. 35 (E28) No. 1:
CHECK POOR CONTACT.
Check
?
Yes
Go to step 9.
No
Repair the open
circuit in harness
between ECM and
manifold absolute
pressure sensor
connector.

connector?
Repair the poor

connector.

to FU(H6DO)-23,
Manifold Absolute
Pressure Sensor.>
EN(H6DO)(diag)-115

U: DTC P0108 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE

CIRCUIT HIGH INPUT
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
E28
1 2 3
1
2
MANIFOLD
ABSOLUTE
PRESSURE
SENSOR
E77
E28
1 2 3 4
6
7
5
9 10
8
5
8
E77
E76
B83
B122
1 2 3 4
5 6 7 8
20
19
7
E2
B21
B83
RHD
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
*2
LHD: 8
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B136
B136
16
LHD: 3
RHD
35
22
*1
B21
LHD LHD
B122
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
ECM
EN-02500
EN(H6DO)(diag)-116

Step
and chassis ground.
and chassis ground.
CHECK INPUT SIGNAL OF ECM.
and chassis ground.
CHECK INPUT SIGNAL OF ECM (USING
NOTE:
to EN(H6DO)(diag)-25, Subaru Select Monitor.>
engine ground.
sensor connector.
(B136) No. 22 (E28) No. 2:
CHECK HARNESS BETWEEN MANIFOLD
ABSOLUTE PRESSURE SENSOR CONNECTOR.
Check
Yes
No
Go to step 2.

Repair the poor
connector?
connector.
Replace the ECM.

<Ref. to
FU(H6DO)-34,
Engine Control
Module (ECM).>
Go to step 4.

Repair the poor

contact in ECM
connector.
Go to step 5.
Repair the open

circuit of harness
between ECM and
manifold absolute
pressure sensor
connector.

?
Repair the open

circuit of harness
between ECM and
manifold absolute
pressure sensor
connector.
Go to step 7.
Is the voltage more than 4.5 V? Repair the battery Go to step 8.

short of harness
between ECM and
manifold absolute
pressure sensor
connector.
EN(H6DO)(diag)-117

Step
sensor connector.
(B136) No. 35 (E28) No. 1:
CHECK POOR CONTACT.
Check
?
Yes
Go to step 9.
No
Repair the open
circuit of harness
between ECM and
manifold absolute
pressure sensor
connector.

connector?
Repair the poor

connector.

to FU(H6DO)-23,
Manifold Absolute
Pressure Sensor.>
EN(H6DO)(diag)-118

V: DTC P0112 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT LOW

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
MAIN RELAY
5
3
BATTERY
SBF-8
6
4
2
1
B47

B3
* 12
*
LHD: 2
*2
LHD: 8
31
13
23
32
35
B83
*1
E
B136
B3
1 2 3 4 5
B47
1
3
5
2
4
6
ECM
B83
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
1 2 3 4
5 6 7 8
EN-02499
EN(H6DO)(diag)-119

Step
CHECK CURRENT DATA.
Select Monitor or general scan tool.
Check
Yes
Go to step 2.
NOTE:
General scan tool
2

Select Monitor.
NOTE:
EN(H6DO)(diag)-120
Replace the mass

air flow and intake
air temperature
sensor. <Ref. to
FU(H6DO)-24,
Mass Air Flow and
No
Repair the poor
contact.
NOTE:
In this case repair
the following:
Poor contact in
mass air flow and
Poor contact in
ECM
Poor contact in
coupling connector
Poor contact in
joint connector
Repair the ground
mass air flow and
ECM connector.

W: DTC P0113 INTAKE AIR TEMPERATURE SENSOR 1 CIRCUIT HIGH

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
MAIN RELAY
5
3
BATTERY
SBF-8
6
4
2
1
B47

B3
* 12
*
LHD: 2
*2
LHD: 8
31
13
23
32
35
B83
*1
E
B136
B3
1 2 3 4 5
B47
1
3
5
2
4
6
ECM
B83
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
1 2 3 4
5 6 7 8
EN-02499
EN(H6DO)(diag)-121

Step
CHECK CURRENT DATA.
Select Monitor or general scan tool.
NOTE:
General scan tool
Check
Yes
Go to step 2.
No
Repair the poor
contact.
NOTE:
In this case repair
the following:
Poor contact in
mass air flow and
Poor contact in
ECM
Poor contact in
coupling connector
Poor contact in
joint connector
mass air flow and
ECM connector.

and engine ground.
and engine ground.
and engine ground.
EN(H6DO)(diag)-122

mass air flow and
ECM connector.
Go to step 5.

NOTE:
In this case repair
the following:
Open circuit in
harness between
mass air flow and
ECM connector
Poor contact in
mass air flow and
Poor contact in
ECM
Poor contact in
coupling connector
Poor contact in
joint connector

Step
Check
?
between mass air flow and intake air temperature sensor connector and engine ground.
EN(H6DO)(diag)-123
Yes
Replace the mass
air flow and intake
air temperature
sensor. <Ref. to
FU(H6DO)-24,
Mass Air Flow and
No
NOTE:
In this case repair
the following:
Open circuit in
harness between
mass air flow and
ECM connector
Poor contact in
mass air flow and
Poor contact in
ECM
Poor contact in
joint connector

X: DTC P0117 ENGINE COOLANT TEMPERATURE CIRCUIT LOW

TROUBLE SYMPTOM:
Hard to start
Erroneous idling
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
ENGINE
COOLANT
TEMPERATURE
SENSOR
E8
2
1
1 2
E8
B83
1 2 3 4
5 6 7 8
8
19
E2
B21
B21
*1
*2
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 45
46 47
48 49 50 51 52 53 54
B83
LHD: 3
*2
LHD: 8
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
14
35
*1
B136
ECM
EN-02501
EN(H6DO)(diag)-124

Step
Check
Yes
CHECK CURRENT DATA.
2) Read the data of engine coolant temperature sensor signal using Subaru Select Monitor
or general scan tool.
No
Repair the poor
contact.
NOTE:
In this case repair
the following:
Poor contact in
NOTE:
engine coolant
temperature senREAD CURRENT DATA SHOWN ON DISsor
PLAY FOR ENGINE. <Ref. to
Poor contact in
ECM
General scan tool
Poor contact in
coupling connector
Poor contact in
joint connector
Is engine coolant temperature Replace the
Repair the ground
engine coolant
short circuit in harCOOLANT TEMPERATURE SENSOR AND less than 40C (40F)?
temperature sen- ness between
ECM CONNECTOR.
sor. <Ref. to
engine coolant
FU(H6DO)-18,
temperature sen2) Disconnect the connectors from the engine
Engine Coolant
sor and ECM concoolant temperature sensor.
Temperature Sen- nector.
sor.>
NOTE:
EN(H6DO)(diag)-125

Y: DTC P0118 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH

TROUBLE SYMPTOM:
Hard to start
Erroneous idling
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
ENGINE
COOLANT
TEMPERATURE
SENSOR
E8
2
1
1 2
E8
B83
1 2 3 4
5 6 7 8
8
19
E2
B21
B21
*1
*2
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 45
46 47
48 49 50 51 52 53 54
B83
LHD: 3
*2
LHD: 8
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
14
35
*1
B136
ECM
EN-02501
EN(H6DO)(diag)-126

Step
Check
Yes
CHECK CURRENT DATA.
2) Read the data of engine coolant temperature sensor signal using Subaru Select Monitor
or general scan tool.
NOTE:
General scan tool
No
Repair the 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
ECM and engine

ECM CONNECTOR.
ground.
ECM CONNECTOR.
ground.
ECM CONNECTOR.
ground.
EN(H6DO)(diag)-127

ECM and engine
Go to step 5.

NOTE:
In this case repair
the following:
Open circuit in
harness between
ECM and engine
Poor contact in
engine coolant
Poor contact in
ECM connector
Poor contact in
coupling connector
Poor contact in
joint connector

Step
ECM CONNECTOR.
Check
?
EN(H6DO)(diag)-128
Yes
Replace the
engine coolant
FU(H6DO)-18,
Engine Coolant
No
NOTE:
In this case repair
the following:
Open circuit in
harness between
ECM and engine
Poor contact in
engine coolant
Poor contact in
ECM connector
Poor contact in
coupling connector
Poor contact in
joint connector

Z: DTC P0122 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT

LOW
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
WIRING DIAGRAM:
BATTERY
ELECTRONIC
THROTTLE
CONTROL RELAY
SBF-8
B362
7
5
6
8
B35
D6
MAIN RELAY
ECM
C: B136
C29
C18
D3
D1
D2
B1
B4
D: B137
C16
D4
D5
C35
B: B135
B122
B83
RHD
LHD
LHD
RHD
*1
LHD: 6
RHD: TERMINAL No.
RANDOM ARRANGEMENT
*2
LHD: 2
RHD: TERMINAL No.
RANDOM ARRANGEMENT
*3
LHD: B122
RHD: B138
*4
LHD: 8
RHD: TERMINAL No.
RANDOM ARRANGEMENT
*5
LHD: 3
RHD: TERMINAL No.
RANDOM ARRANGEMENT
*3
16
15
B20
*1
*2
E1
20
39
38
19
37
36
35
B21
4
6
5
1
2
3
E2
ELECTRONIC
THROTTLE CONTROL
E57
B362
B122
B21
B20
B83
1 2
3
4
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
B138
5
7 8
6
1 2 3 4
5 6 7 8
B: B135
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
C:
1
5
9
13
2
6
10
14
3
7
11
15
E57
4
8
12
16
1 2 3 4 5 6
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B136
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
D:
B137
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
EN-02502
EN(H6DO)(diag)-129

Step
CHECK POOR CONTACT.
Check
Yes
No
Go to step 3.


3) Disconnect the connector from the electronic throttle control.
(E136) No. 18 (E57) No. 6:
(E136) No. 16 (E57) No. 5:
THROTTLE CONTROL.

?
Go to step 4.
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.

M?
Go to step 5.
Go to step 6.

harness.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
to FU(H6DO)-34,
Engine Control
Module (ECM).>
Is the resistance more than 10 Repair the poor
Repair the poor
?
contact in eleccontact in ECM
trol connector.
Replace the ECM
erator position
to FU(H6DO)-34,
sensor if defective. Engine Control
Module (ECM).>
EN(H6DO)(diag)-130

AA:DTC P0123 THROTTLE/PEDAL POSITION SENSOR/SWITCH A CIRCUIT

HIGH
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
WIRING DIAGRAM:
BATTERY
ELECTRONIC
THROTTLE
CONTROL RELAY
SBF-8
B362
7
5
6
8
B35
D6
MAIN RELAY
ECM
C: B136
C29
C18
D3
D1
D2
B1
B4
D: B137
C16
D4
D5
C35
B: B135
B122
B83
RHD
LHD
LHD
RHD
*1
LHD: 6
RHD: TERMINAL No.
RANDOM ARRANGEMENT
*2
LHD: 2
RHD: TERMINAL No.
RANDOM ARRANGEMENT
*3
LHD: B122
RHD: B138
*4
LHD: 8
RHD: TERMINAL No.
RANDOM ARRANGEMENT
*5
LHD: 3
RHD: TERMINAL No.
RANDOM ARRANGEMENT
*3
16
15
B20
*1
*2
E1
20
39
38
19
37
36
35
B21
4
6
5
1
2
3
E2
ELECTRONIC
THROTTLE CONTROL
E57
B362
B122
B21
B20
B83
1 2
3
4
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
B138
5
7 8
6
1 2 3 4
5 6 7 8
B: B135
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
C:
1
5
9
13
2
6
10
14
3
7
11
15
E57
4
8
12
16
1 2 3 4 5 6
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B136
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
D:
B137
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
EN-02502
EN(H6DO)(diag)-131

Step
CHECK POOR CONTACT.
Check
V?
Yes
Go to step 2.

(B136) No. 18 (E57) No. 6:
(B136) No. 35 (E57) No. 3:

?
Go to step 4.

?
Go to step 5.



M?
(B136) No. 18 (B136) No. 16:
EN(H6DO)(diag)-132
No
Go to step 3.
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
to FU(H6DO)-34,
Engine Control
Module (ECM).>
Go to step 6.
Repair the battery
ECM connector
and electronic
throttle control
connector.
Repair the poor
Repair the short
power supply.
Repair the electronic throttle control.

AB:DTC P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP

FUEL CONTROL
TROUBLE SYMPTOM:
Engine would not return to idling.
CAUTION:
Inspection Mode.>.
Step
CHECK TIRE SIZE.
CHECK ENGINE COOLANT.

Amount of engine coolant
Coolant freeze
Contamination of engine coolant
CHECK THERMOSTAT.
Check
Yes
No
vant DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0125.
Go to step 3.
Replace the tire.
Is the tire same size as specified tire and one same size as
other three wheels?
Is the engine coolant normal? Go to step 4.
Does the thermostat remain

opened?
EN(H6DO)(diag)-133

CO(H6DO)-12,
Thermostat.>
Fill or replace the

engine coolant.
<Ref. to
CO(H6DO)-9,
INSPECTION,
Engine Coolant.>
Replace the
engine coolant
FU(H6DO)-18,
Engine Coolant

AC:DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1)

CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
MAIN RELAY
BATTERY
SBF-6
6
4
5
3
E47
3
E24
2
FRONT
OXYGEN
( A/F )
SENSOR RH
FRONT
OXYGEN
( A/F )
SENSOR LH
B47
E3
B22
2
1
E3
A33
A26
ECM
B: B135
52
54
A4
A5
A6
A7
A: B134
A2
A3
A25
B7
A1
A27
A34
B22
B21
E2
E47
E24
B47
1
3
5
1 2
3 4
B22
1
5
9
13
2
6
10
14
3
7
11
15
2
4
6
A: B134
1
8 9
18 19
28 29
2
10
20
30
B: B135
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
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
32 33
34 35
28 29 30 31
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
4
8
12
16
EN-02495
EN(H6DO)(diag)-134

Step
Check
M?
EN(H6DO)(diag)-135
Yes
Replace the front
FU(H6DO)-30,
Front Oxygen (A/
F) Sensor.>
No
Repair the ground
ECM and front

AD:DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1)

CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
MAIN RELAY
BATTERY
SBF-6
6
4
5
3
E47
3
E24
2
FRONT
OXYGEN
( A/F )
SENSOR RH
FRONT
OXYGEN
( A/F )
SENSOR LH
B47
E3
B22
2
1
E3
A33
A26
ECM
B: B135
52
54
A4
A5
A6
A7
A: B134
A2
A3
A25
B7
A1
A27
A34
B22
B21
E2
E47
E24
B47
1
3
5
1 2
3 4
B22
1
5
9
13
2
6
10
14
3
7
11
15
2
4
6
A: B134
1
8 9
18 19
28 29
2
10
20
30
B: B135
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
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
32 33
34 35
28 29 30 31
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
4
8
12
16
EN-02495
EN(H6DO)(diag)-136

Step
Check
(A/F) sensor.
EN(H6DO)(diag)-137
Yes
Replace the front
FU(H6DO)-30,
Front Oxygen (A/
F) Sensor.>
No
Repair the battery
ECM and front

AE:DTC P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1)

CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
MAIN RELAY
BATTERY
SBF-6
6
4
5
3
E47
3
E24
2
FRONT
OXYGEN
( A/F )
SENSOR RH
FRONT
OXYGEN
( A/F )
SENSOR LH
B47
E3
B22
2
1
E3
A33
A26
ECM
B: B135
52
54
A4
A5
A6
A7
A: B134
A2
A3
A25
B7
A1
A27
A34
B22
B21
E2
E47
E24
B47
1
3
5
1 2
3 4
B22
1
5
9
13
2
6
10
14
3
7
11
15
2
4
6
A: B134
1
8 9
18 19
28 29
2
10
20
30
B: B135
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
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
32 33
34 35
28 29 30 31
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
4
8
12
16
EN-02495
EN(H6DO)(diag)-138

Step

NOTE:
Check

system?
EN(H6DO)(diag)-139
Yes
No
Inspect the DTC
Go to step 2.
Code (DTC).
<Ref. to
Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0133.
Repair exhaust
Replace the front
system.
FU(H6DO)-30,
Front Oxygen (A/
F) Sensor.>

AF:DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 1)

CAUTION:
Inspection Mode.>.
EN(H6DO)(diag)-140

WIRING DIAGRAM:
MAIN RELAY
BATTERY
SBF-6
6
4
5
3
E47
3
E24
2
FRONT
OXYGEN
( A/F )
SENSOR RH
FRONT
OXYGEN
( A/F )
SENSOR LH
B47
E3
B22
2
1
E3
A33
A26
ECM
B: B135
52
54
A4
A5
A6
A7
A: B134
A2
A3
A25
B7
A1
A27
A34
B22
B21
E2
E47
E24
B47
1
3
5
1 2
3 4
B22
1
5
9
13
2
6
10
14
3
7
11
15
2
4
6
A: B134
1
8 9
18 19
28 29
2
10
20
30
B: B135
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
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
32 33
34 35
28 29 30 31
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
4
8
12
16
EN-02495
EN(H6DO)(diag)-141

Step
connector.
(B134) No. 26 (E47) No. 4:
(B134) No. 33 (E47) No. 3:
Check
?
CHECK POOR CONTACT.


EN(H6DO)(diag)-142
Yes
Go to step 2.
No
NOTE:
In this case repair
the following:
Open circuit in
harness between
ECM and front
Poor contact in
front oxygen (A/F)
sensor connector
Poor contact in
ECM connector
Repair the poor
Replace the front
contact in front
FU(H6DO)-30,
sor connector.
Front Oxygen (A/
F) Sensor.>

AG:DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2)

CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
MAIN RELAY
BATTERY
SBF-6
6
4
5
3
E61
11
10
12
3
16
13
E25
2
REAR
OXYGEN
SENSOR RH
REAR
OXYGEN
SENSOR LH
B47
E3
15
B22
14
2
1
E3
A: B134
C: B136
B: B135
D: B137
C35
B2
B3
D31
D25
D24
B22
4
5
8
B83
52
54
A4
A5
A6
A7
ECM
B21
E2
E25
E61
A: B134
B47
1
3
5
1 2
3 4
B83
2
4
6
1
8 9
18 19
28 29
2
10
20
30
B: B135
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B22
C: B136
1 2 3 4
5 6 7 8
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
32 33
34 35
28 29 30 31
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
D: B137
5 6
14 15 16
25 26 27
33 34 35
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
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
EN-02496
EN(H6DO)(diag)-143

Step
Check

mV?
NOTE:
?
rear oxygen sensor.
(B137) No. 24 (E61) No. 3:
(B136) No. 35 (E61) No. 4:
sensor.
EN(H6DO)(diag)-144
Yes
No
Inspect the DTC
Go to step 2.
Code (DTC).
<Ref. to
Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0137.
Go to step 5.
Go to step 3.
Repair the open

Go to step 4.
circuit in harness
between ECM and
Replace the rear

oxygen sensor.
<Ref. to
FU(H6DO)-32,

NOTE:
In this case repair
the following:
Open circuit in
harness between
Poor contact in
Poor contact in
ECM connector

Step
Check
system?
NOTE:
sensor
EN(H6DO)(diag)-145
Yes
Repair or replace
the faulty part.
No
Replace the rear
oxygen sensor.
<Ref. to
FU(H6DO)-32,

AH:DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2)

CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
MAIN RELAY
BATTERY
SBF-6
6
4
5
3
E61
11
10
12
3
16
13
E25
2
REAR
OXYGEN
SENSOR RH
REAR
OXYGEN
SENSOR LH
B47
E3
15
B22
14
2
1
E3
A: B134
C: B136
B: B135
D: B137
C35
B2
B3
D31
D25
D24
B22
4
5
8
B83
52
54
A4
A5
A6
A7
ECM
B21
E2
E25
E61
A: B134
B47
1
3
5
1 2
3 4
B83
2
4
6
1
8 9
18 19
28 29
2
10
20
30
B: B135
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B22
C: B136
1 2 3 4
5 6 7 8
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
32 33
34 35
28 29 30 31
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
D: B137
5 6
14 15 16
25 26 27
33 34 35
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
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
EN-02496
EN(H6DO)(diag)-146

Step
Check

mV?
NOTE:
?
rear oxygen sensor.
(B137) No. 24 (E61) No. 3:
(B136) No. 35 (E61) No. 4:
sensor.
EN(H6DO)(diag)-147
Yes
No
Inspect the DTC
Go to step 2.
Code (DTC).
<Ref. to
Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0138.
Go to step 5.
Go to step 3.
Repair the open

Go to step 4.
circuit in harness
between ECM and
Replace the rear

oxygen sensor.
<Ref. to
FU(H6DO)-32,

NOTE:
In this case repair
the following:
Open circuit in
harness between
Poor contact in
Poor contact in
ECM connector

Step
Check
system?
NOTE:
sensor
EN(H6DO)(diag)-148
Yes
Repair or replace
the faulty part.
No
Replace the rear
oxygen sensor.
<Ref. to
FU(H6DO)-32,

AI: DTC P0151 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 2 SENSOR 1)

CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
MAIN RELAY
BATTERY
SBF-6
6
4
5
3
E47
3
E24
2
FRONT
OXYGEN
( A/F )
SENSOR RH
FRONT
OXYGEN
( A/F )
SENSOR LH
B47
E3
B22
2
1
E3
A33
A26
ECM
B: B135
52
54
A4
A5
A6
A7
A: B134
A2
A3
A25
B7
A1
A27
A34
B22
B21
E2
E47
E24
B47
1
3
5
1 2
3 4
B22
1
5
9
13
2
6
10
14
3
7
11
15
2
4
6
A: B134
1
8 9
18 19
28 29
2
10
20
30
B: B135
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
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
32 33
34 35
28 29 30 31
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
4
8
12
16
EN-02495
EN(H6DO)(diag)-149

Step
Check
M?
EN(H6DO)(diag)-150
Yes
Replace the front
FU(H6DO)-30,
Front Oxygen (A/
F) Sensor.>
No
Repair the ground
ECM and front

AJ:DTC P0152 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 2 SENSOR 1)

CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
MAIN RELAY
BATTERY
SBF-6
6
4
5
3
E47
3
E24
2
FRONT
OXYGEN
( A/F )
SENSOR RH
FRONT
OXYGEN
( A/F )
SENSOR LH
B47
E3
B22
2
1
E3
A33
A26
ECM
B: B135
52
54
A4
A5
A6
A7
A: B134
A2
A3
A25
B7
A1
A27
A34
B22
B21
E2
E47
E24
B47
1
3
5
1 2
3 4
B22
1
5
9
13
2
6
10
14
3
7
11
15
2
4
6
A: B134
1
8 9
18 19
28 29
2
10
20
30
B: B135
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
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
32 33
34 35
28 29 30 31
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
4
8
12
16
EN-02495
EN(H6DO)(diag)-151

Step
Check
(A/F) sensor.
EN(H6DO)(diag)-152
Yes
Replace the front
FU(H6DO)-30,
Front Oxygen (A/
F) Sensor.>
No
Repair the battery
ECM and front

AK:DTC P0153 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 2 SENSOR 1)

CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
MAIN RELAY
BATTERY
SBF-6
6
4
5
3
E47
3
E24
2
FRONT
OXYGEN
( A/F )
SENSOR RH
FRONT
OXYGEN
( A/F )
SENSOR LH
B47
E3
B22
2
1
E3
A33
A26
ECM
B: B135
52
54
A4
A5
A6
A7
A: B134
A2
A3
A25
B7
A1
A27
A34
B22
B21
E2
E47
E24
B47
1
3
5
1 2
3 4
B22
1
5
9
13
2
6
10
14
3
7
11
15
2
4
6
A: B134
1
8 9
18 19
28 29
2
10
20
30
B: B135
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
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
32 33
34 35
28 29 30 31
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
4
8
12
16
EN-02495
EN(H6DO)(diag)-153

Step

NOTE:
Check

system?
EN(H6DO)(diag)-154
Yes
No
Inspect the DTC
Go to step 2.
Code (DTC).
<Ref. to
Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0133.
Repair exhaust
Replace the front
system.
FU(H6DO)-30,
Front Oxygen (A/
F) Sensor.>

AL:DTC P0154 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 2 SENSOR 1)

CAUTION:
Inspection Mode.>.
EN(H6DO)(diag)-155

WIRING DIAGRAM:
MAIN RELAY
BATTERY
SBF-6
6
4
5
3
E47
3
E24
2
FRONT
OXYGEN
( A/F )
SENSOR RH
FRONT
OXYGEN
( A/F )
SENSOR LH
B47
E3
B22
2
1
E3
A33
A26
ECM
B: B135
52
54
A4
A5
A6
A7
A: B134
A2
A3
A25
B7
A1
A27
A34
B22
B21
E2
E47
E24
B47
1
3
5
1 2
3 4
B22
1
5
9
13
2
6
10
14
3
7
11
15
2
4
6
A: B134
1
8 9
18 19
28 29
2
10
20
30
B: B135
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
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
32 33
34 35
28 29 30 31
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
4
8
12
16
EN-02495
EN(H6DO)(diag)-156

Step
connector.
(B134) No. 27 (E24) No. 4:
(B134) No. 34 (E24) No. 3:
Check
?
CHECK POOR CONTACT.


EN(H6DO)(diag)-157
Yes
Go to step 2.
No
NOTE:
In this case repair
the following:
Open circuit in
harness between
ECM and front
Poor contact in
front oxygen (A/F)
sensor connector
Poor contact in
ECM connector
Repair the poor
Replace the front
contact in front
FU(H6DO)-30,
sor connector.
Front Oxygen (A/
F) Sensor.>

AM:DTC P0157 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 2 SENSOR 2)

CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
MAIN RELAY
BATTERY
SBF-6
6
4
5
3
E61
11
10
12
3
16
13
E25
2
REAR
OXYGEN
SENSOR RH
REAR
OXYGEN
SENSOR LH
B47
E3
15
B22
14
2
1
E3
A: B134
C: B136
B: B135
D: B137
C35
B2
B3
D31
D25
D24
B22
4
5
8
B83
52
54
A4
A5
A6
A7
ECM
B21
E2
E25
E61
A: B134
B47
1
3
5
1 2
3 4
B83
2
4
6
1
8 9
18 19
28 29
2
10
20
30
B: B135
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B22
C: B136
1 2 3 4
5 6 7 8
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
32 33
34 35
28 29 30 31
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
D: B137
5 6
14 15 16
25 26 27
33 34 35
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
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
EN-02496
EN(H6DO)(diag)-158

Step
Check

mV?
NOTE:
?
rear oxygen sensor.
(B137) No. 25 (E25) No. 3:
(B136) No. 35 (E25) No. 4:
sensor.
EN(H6DO)(diag)-159
Yes
No
Inspect the DTC
Go to step 2.
Code (DTC).
<Ref. to
Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0137.
Go to step 5.
Go to step 3.
Repair the open

Go to step 4.
circuit in harness
between ECM and
Replace the rear

oxygen sensor.
<Ref. to
FU(H6DO)-32,

NOTE:
In this case repair
the following:
Open circuit in
harness between
Poor contact in
Poor contact in
ECM connector

Step
Check
system?
NOTE:
sensor
EN(H6DO)(diag)-160
Yes
Repair or replace
the faulty part.
No
Replace the rear
oxygen sensor.
<Ref. to
FU(H6DO)-32,

AN:DTC P0158 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 2 SENSOR 2)

CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
MAIN RELAY
BATTERY
SBF-6
6
4
5
3
E61
11
10
12
3
16
13
E25
2
REAR
OXYGEN
SENSOR RH
REAR
OXYGEN
SENSOR LH
B47
E3
15
B22
14
2
1
E3
A: B134
C: B136
B: B135
D: B137
C35
B2
B3
D31
D25
D24
B22
4
5
8
B83
52
54
A4
A5
A6
A7
ECM
B21
E2
E25
E61
A: B134
B47
1
3
5
1 2
3 4
B83
2
4
6
1
8 9
18 19
28 29
2
10
20
30
B: B135
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B22
C: B136
1 2 3 4
5 6 7 8
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
32 33
34 35
28 29 30 31
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
D: B137
5 6
14 15 16
25 26 27
33 34 35
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
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
EN-02496
EN(H6DO)(diag)-161

Step
Check

mV?
NOTE:
?
rear oxygen sensor.
(B137) No. 25 (E25) No. 3:
(B136) No. 35 (E25) No. 4:
sensor.
EN(H6DO)(diag)-162
Yes
No
Inspect the DTC
Go to step 2.
Code (DTC).
<Ref. to
Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0138.
Go to step 5.
Go to step 3.
Repair the open

Go to step 4.
circuit in harness
between ECM and
Replace the rear

oxygen sensor.
<Ref. to
FU(H6DO)-32,

NOTE:
In this case repair
the following:
Open circuit in
harness between
Poor contact in
Poor contact in
ECM connector

Step
Check
system?
NOTE:
sensor
Yes
Repair or replace
the faulty part.
No
Replace the rear
oxygen sensor.
<Ref. to
FU(H6DO)-32,
AO:DTC P0171 SYSTEM TOO LEAN (BANK 1)

Refer to DTC P0175 for diagnostic procedure. <Ref. to EN(H6DO)(diag)-164, DTC P0175 SYSTEM TOO
AP:DTC P0172 SYSTEM TOO RICH (BANK 1)

AQ:DTC P0174 SYSTEM TOO LEAN (BANK 2)

EN(H6DO)(diag)-163

AR:DTC P0175 SYSTEM TOO RICH (BANK 2)

TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
CAUTION:
Inspection Mode.>.
Step
EGR VALVE CHECK.
Check
on exhaust system?
intake system?

VALVE.

valve stuck?
PCV VALVE CHECK.

kPa (3.4 3.7 kg/cm2, 48
Warning:
Place NO FIRE signs near the working 53 psi)?
area.
pump relay.
more seconds.
6) Measure the fuel pressure while disconnecting pressure regulator vacuum hose from
intake manifold.
Warning:
NOTE:
pressure again.
EN(H6DO)(diag)-164
Yes
Repair exhaust
system.
Repair air intake
system.
Replace the EGR
valve.
Replace the purge
control solenoid
valve.
Replace the PCV
valve.
Go to step 7.
No
Go to step 2.
Go to step 3.
Go to step 4.
Go to step 5.
Go to step 6.
Fuel pressure is
too high:
Clogged fuel
return line or
bent hose
Fuel pressure is
too low:
Improper fuel
pump discharge
Clogged fuel
supply line

Step
Check
kPa (2.85 3.15 kg/cm2, 40
45 psi)?
Yes
Go to step 8.
Warning:
NOTE:
If out of specification as measured at this
step, check or replace pressure regulator and
pressure regulator vacuum hose.

ture 70 100C (158
SENSOR.
1) Start the engine and warm-up completely. 212F)?
NOTE:
SIGNAL.
(140F).
2) Shift the select lever to N or P range.
Is the measurement value at

idling: 24.0 41.3 kPa (180
310 mmHg, 7.09 12.20
inHg), when ignition ON: 73.3
106.6 kPa (550 800
mmHg, 21.65 31.50 inHg)?
NOTE:
EN(H6DO)(diag)-165
Replace the ECM.

<Ref. to
FU(H6DO)-34,
Engine Control
Module (ECM).>
No
Fuel pressure is
too high:
Clogged fuel
return line or
bent hose
Fuel pressure is
too low:
Improper fuel
pump discharge
Clogged fuel
supply line
Replace the
engine coolant
FU(H6DO)-18,
Engine Coolant

to FU(H6DO)-23,
Manifold Absolute
Pressure Sensor.>

AS:DTC P0197 ENGINE OIL TEMPERATURE SENSOR CIRCUIT LOW

TROUBLE SYMPTOM:
Hard to start
Erroneous idling
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
E75
1 2
OIL
TEMPERATURE
SENSOR
E75
B20
1
5
9
13
3
7
11
15
4
8
12
16
19
E2
3
E1
2
6
10
14
B20
B21
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
*1
*2
B83
B83
1 LHD: 3
RHD: TERMINAL No.
RANDOM ARRANGEMENT
35
27
*2
LHD: 8
RHD: TERMINAL No.
RANDOM ARRANGEMENT
1 2 3 4
5 6 7 8
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B136 ECM
5 6
14 15 16
25 26 27
33 34 35
EN-02503
EN(H6DO)(diag)-166

Step
CHECK HARNESS BETWEEN OIL TEMPERATURE SENSOR AND ECM CONNECTOR.
1) Disconnect the ECM connector and oil temperature sensor connector.
between oil temperature sensor connector and
engine ground.
CHECK POOR CONTACT.
Check poor contact in oil temperature sensor
connector.
Check
M?
Yes
Go to step 2.
Is there poor contact in oil tem- Repair the poor

perature sensor connector?
contact.
EN(H6DO)(diag)-167
No
Repair the ground
short circuit
between ECM and
oil temperature
sensor connector.
Replace the oil

FU(H6DO)-29, Oil

AT:DTC P0198 ENGINE OIL TEMPERATURE SENSOR CIRCUIT HIGH

TROUBLE SYMPTOM:
Hard to start
Erroneous idling
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
E75
1 2
OIL
TEMPERATURE
SENSOR
E75
B20
1
5
9
13
3
7
11
15
4
8
12
16
19
E2
3
E1
2
6
10
14
B20
B21
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
*1
*2
B83
B83
1 LHD: 3
RHD: TERMINAL No.
RANDOM ARRANGEMENT
35
27
*2
LHD: 8
RHD: TERMINAL No.
RANDOM ARRANGEMENT
1 2 3 4
5 6 7 8
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B136 ECM
5 6
14 15 16
25 26 27
33 34 35
EN-02503
EN(H6DO)(diag)-168

Step
Check
CHECK HARNESS BETWEEN OIL TEMPER- Is the voltage more than 10 V?
ATURE SENSOR AND ECM CONNECTOR.
2) Disconnect the connector from the oil temperature sensor.
3) Measure the voltage between oil temperature sensor connector and engine ground.
2) Measure the voltage between oil temperature sensor connector and engine ground.
Measure the voltage between oil temperature
sensor connector and engine ground.
CHECK HARNESS BETWEEN OIL TEMPER- Is the resistance less than 5

ATURE SENSOR AND ECM CONNECTOR. ?
between oil temperature sensor connector and
engine ground.
EN(H6DO)(diag)-169
Yes
No
ECM and oil temperature sensor
connector.

connector.
Go to step 4.

NOTE:
In this case repair
the following:
Open circuit in
harness between
connector
Poor contact in
oil temperature
sensor connector
Poor contact in
ECM connector
Poor contact in
coupling connector
Replace the oil

FU(H6DO)-29, Oil NOTE:
Temperature Sen- In this case repair
sor.>
the following:
Open circuit in
harness between
connector
Poor contact in
oil temperature
sensor connector
Poor contact in
ECM connector
Poor contact in
coupling connector
Poor contact in
joint connector

AU:DTC P0222 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT

LOW
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
WIRING DIAGRAM:
BATTERY
ELECTRONIC
THROTTLE
CONTROL RELAY
SBF-8
B362
7
5
6
8
B35
D6
MAIN RELAY
ECM
C: B136
C29
C18
D3
D1
D2
B1
B4
D: B137
C16
D4
D5
C35
B: B135
B122
B83
RHD
LHD
LHD
RHD
*1
LHD: 6
RHD: TERMINAL No.
RANDOM ARRANGEMENT
*2
LHD: 2
RHD: TERMINAL No.
RANDOM ARRANGEMENT
*3
LHD: B122
RHD: B138
*4
LHD: 8
RHD: TERMINAL No.
RANDOM ARRANGEMENT
*5
LHD: 3
RHD: TERMINAL No.
RANDOM ARRANGEMENT
*3
16
15
B20
*1
*2
E1
20
39
38
19
37
36
35
B21
4
6
5
1
2
3
E2
ELECTRONIC
THROTTLE CONTROL
E57
B362
B122
B21
B20
B83
1 2
3
4
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
B138
5
7 8
6
1 2 3 4
5 6 7 8
B: B135
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
C:
1
5
9
13
2
6
10
14
3
7
11
15
E57
4
8
12
16
1 2 3 4 5 6
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B136
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
D:
B137
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
EN-02502
EN(H6DO)(diag)-170

Step
Check
Yes
CHECK POOR CONTACT.
Repair the poor
contact.
(B136) No. 29 (E57) No. 4:
(B136) No. 16 (E57) No. 5:

?
Go to step 4.

M?
Go to step 5.
Go to step 6.
No
Go to step 3.
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.

harness.
Repair the poor

contactrepair the
poor contact in
ECM connector.
Replace the ECM
if defective. <Ref.
to FU(H6DO)-34,
Engine Control
Module (ECM).>
Is the resistance more than 10 Repair the poor
Repair the poor
?
contact in eleccontact in ECM
trol connector.
Replace the ECM
tronic throttle con- to FU(H6DO)-34,
trol if defective.
Engine Control
Module (ECM).>
EN(H6DO)(diag)-171

AV:DTC P0223 THROTTLE/PEDAL POSITION SENSOR/SWITCH B CIRCUIT

HIGH
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
WIRING DIAGRAM:
BATTERY
ELECTRONIC
THROTTLE
CONTROL RELAY
SBF-8
B362
7
5
6
8
B35
D6
MAIN RELAY
ECM
C: B136
C29
C18
D3
D1
D2
B1
B4
D: B137
C16
D4
D5
C35
B: B135
B122
B83
RHD
LHD
LHD
RHD
*1
LHD: 6
RHD: TERMINAL No.
RANDOM ARRANGEMENT
*2
LHD: 2
RHD: TERMINAL No.
RANDOM ARRANGEMENT
*3
LHD: B122
RHD: B138
*4
LHD: 8
RHD: TERMINAL No.
RANDOM ARRANGEMENT
*5
LHD: 3
RHD: TERMINAL No.
RANDOM ARRANGEMENT
*3
16
15
B20
*1
*2
E1
20
39
38
19
37
36
35
B21
4
6
5
1
2
3
E2
ELECTRONIC
THROTTLE CONTROL
E57
B362
B122
B21
B20
B83
1 2
3
4
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
B138
5
7 8
6
1 2 3 4
5 6 7 8
B: B135
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
C:
1
5
9
13
2
6
10
14
3
7
11
15
E57
4
8
12
16
1 2 3 4 5 6
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B136
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
D:
B137
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
EN-02502
EN(H6DO)(diag)-172

Step
CHECK POOR CONTACT.
Check
V?
Yes
Go to step 2.

(B136) No. 35 (E57) No. 3:
(B136) No. 29 (E57) No. 4:

?
Go to step 4.

?
Go to step 5.



M?
terminals.
(B136) No. 29 (B136) No. 16:
EN(H6DO)(diag)-173
No
Go to step 3.
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
to FU(H6DO)-34,
Engine Control
Module (ECM).>
Go to step 6.
Repair the battery
ECM connector
and electronic
throttle control
connector.
Repair the poor
Sensor power supcontact. Repair the ply circuit may be
electronic throttle shorted.
control.

AW:DTC P0230 FUEL PUMP PRIMARY CIRCUIT

CAUTION:
OPERATION, Clear Memory Mode.> and Inspection Mode. <Ref. to EN(H6DO)(diag)-33, PROCEDURE,
Inspection Mode.>
WIRING DIAGRAM:
BATTERY
No.11
2
FUEL PUMP
RELAY
*
*3
B362
10
*71
FUEL PUMP
CONTROL UNIT
*1
LHD: 16
RHD: 4
*2
LHD: B97
RHD: B98
*3
LHD: R1
RHD: R2
*4
LHD: 6
RHD: 5
*5
LHD: 15
RHD: 6
*3
*2
D28
B27
5
6
* 54
*
9
8
7
6
R122
FUEL
PUMP
ECM
R58
B: B135
D: B137
B362
1 2
3
4
5
7 8
6
B98
R122
R58
1
2 3
4 5 6 7 8
3 4
1 2
5 6 7 8 9 10
1 2
3 4
5 6
B97
B:
B135
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
D: B137
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
28 29
30 31
26 27
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
EN-02504
EN(H6DO)(diag)-174

Step
Check
Yes
CHECK POWER SUPPLY CIRCUIT TO FUEL Is the voltage more than 10 V? Go to step 2.
PUMP CONTROL UNIT.
2) Disconnect the connector from fuel pump
control unit.
4) Measure the voltage between fuel pump
control unit and chassis ground.
CHECK GROUND CIRCUIT OF FUEL PUMP Is the resistance less than 5

CONTROL UNIT.
?
between fuel pump control unit and chassis
ground.
Go to step 3.

between fuel pump control unit and fuel pump
connector.
(R122) No. 7 (R58) No. 5:
(R122) No. 6 (R58) No. 6:

?
Go to step 4.

M?
Go to step 5.
EN(H6DO)(diag)-175
No
Repair the power
supply circuit.
NOTE:
In this case repair
the following:
Open or ground
pump relay and
fuel pump control
unit.
Poor contact in
fuel pump control
unit connector.
Poor contact in
fuel pump relay
connector.
NOTE:
In this case repair
the following:
Open circuit
between fuel pump
control unit and
chassis ground.
Poor contact in
fuel pump control
unit connector.
Repair the open
circuit between
fuel pump control
unit and fuel
pump.
Repair the ground

short circuit
between fuel pump
control unit and
fuel pump.

Step
Check
?
between fuel pump control unit and ECM connector.
(R122) No. 9 (B137) No. 28:
(R122) No. 8 (B135) No. 27:
Yes
Go to step 6.

CHECK POOR CONTACT.
Check poor contact in ECM and fuel pump
control unit connector.
Go to step 7.

M?
No
NOTE:
In this case repair
the following:
Open circuit
between fuel pump
control unit and
ECM.
Poor contact in
fuel pump control
unit and ECM connector
Repair the ground
short circuit
between fuel pump
control unit and
ECM.

Repair the poor
Go to step 8.
and fuel pump control unit con- contactrepair the
nector?
poor contact in
ECM and fuel
pump control unit
connector.
CHECK EXPERIENCE OF RUNNING OUT OF Did the vehicle experience run- Finish the diagno- Replace the fuel
pump control unit.
FUEL.
ning out of fuel?
sis.
<Ref. to
NOTE:
DTC record may FU(H6DO)-38,
be conducted as a Fuel Pump Control
result of fuel pump Unit.>
idling while running
out of gas.
EN(H6DO)(diag)-176

AX:DTC P0301 CYLINDER 1 MISFIRE DETECTED

NOTE:
For the diagnostic procedure, refer to DTC P0306. <Ref. to EN(H6DO)(diag)-178, DTC P0306 CYLINDER 6
MISFIRE DETECTED, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
AY:DTC P0302 CYLINDER 2 MISFIRE DETECTED

NOTE:
AZ:DTC P0303 CYLINDER 3 MISFIRE DETECTED

NOTE:
BA:DTC P0304 CYLINDER 4 MISFIRE DETECTED

NOTE:
BB:DTC P0305 CYLINDER 5 MISFIRE DETECTED

NOTE:
EN(H6DO)(diag)-177

BC:DTC P0306 CYLINDER 6 MISFIRE DETECTED

TROUBLE SYMPTOM:
Engine stalls.
Erroneous idling
Rough driving
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
BATTERY
MAIN RELAY
SBF-8
6
4
5
3
2
1
B47
47
45
46
ECM
44
5
43
42
48
B136
B21
E2
E44
E5
E16
E6
E17
1 2
FUEL INJECTOR
No. 2
B47
1
3
5
2
4
6
FUEL INJECTOR
No. 3
FUEL INJECTOR
No. 5
E44
2
FUEL INJECTOR
No. 4
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
E43
E17
2
FUEL INJECTOR
No. 1
E43
E6
E16
E5
FUEL INJECTOR
No. 6
B21
5 6
14 15 16
25 26 27
33 34 35
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 45
46 47
48 49 50 51 52 53 54
EN-02505
EN(H6DO)(diag)-178

Step

on faulty cylinder.
faulty cylinders.
#1 (B136) No. 6 (E5) No. 1:
#2 (B136) No. 5 (E16) No. 1:
#3 (B136) No. 4 (E6) No. 1:
#4 (B136) No. 3 (E17) No. 1:
#5 (B136) No. 2 (E43) No. 1:
#6 (B136) No. 1 (E44) No. 2:
Terminals
No. 1 No. 2:
Check
Yes
No
Inspect the DTC
Go to step 2.
Code (DTC).
<Ref. to
Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0301,
P0302,
P0304, P0305 and
P0306.
Go to step 3.

M?
Go to step 4.
Repair the ground

injector and ECM
connector.

?
Go to step 5.
EN(H6DO)(diag)-179
Go to step 6.
NOTE:
In this case repair
the following:
Open circuit in
harness between
ECM and fuel
injector connector
Poor contact in
coupling connector
Replace the faulty
to FU(H6DO)-26,
Fuel Injector.>

10
11
Step
Check
Yes
injector circuit.
No
NOTE:
In this case repair
the following:
Open circuit in
harness between
main relay and fuel
injector on faulty
cylinders
Poor contact in
coupling connector
Poor contact in
Poor contact in
cylinders
ECM and fuel
injector. After
repair, replace the
ECM. <Ref. to
FU(H6DO)-34,
Engine Control
Module (ECM).>

on faulty cylinder.
?
Terminals
No. 1 No. 2:
Replace the faulty

fuel injector and
ECM. <Ref. to
FU(H6DO)-26,
Fuel Injector.>
<Ref. to
FU(H6DO)-34,
Engine Control
Module (ECM).>
CHECK INSTALLATION OF CAMSHAFT PO- Is the camshaft position sensor Tighten camshaft
SITION SENSOR/CRANKSHAFT POSITION or crankshaft position sensor position sensor or
SENSOR.
loosely installed?
crankshaft position sensor.
CHECK CRANK PLATE.
Is the crank sprocket rusted or Replace the crank
the teeth of crank plate broplate. <Ref. to
ken?
ME(H6DO)-64,
Cylinder Block.>
Is the timing chain dislocated Repair installation
TIMING CHAIN.
condition of timing
Turn the crankshaft using ST, and align alignchain. <Ref. to
ment mark on crank sprocket with alignment
ME(H6DO)-46,
mark on cylinder block.
Timing Chain
ST 18252AA000 CRANKSHAFT SOCKET
Assembly.>
EN(H6DO)(diag)-180
Go to step 9.
Go to step 10.
Go to step 11.
Go to step 12.

12
13
14
15
Step
CHECK FUEL LEVEL.
Check
lower than the Lower level?
Yes
No
Replenish fuel so Go to step 13.
fuel meter indication is higher than
the Lower level.
After replenishing
fuel, Go to step 13.
Go to step 14.
light illuminate or blink?

Monitor.
<Ref. to EN(H6DO)(diag)-40, Clear Memory
Mode.>
than 10 minutes.
CHECK CAUSE OF MISFIRE DIAGNOSED. Was the cause of misfire
detected when the engine is
running?

system?
Finish diagnostics
operation, if the
engine has no
abnormality.
Repair air intake

system.
NOTE:
Are there air
caused by loose or
dislocated nuts
and bolts?
Are there cracks
EN(H6DO)(diag)-181
Repair the poor

contact.
NOTE:
In this case repair
the following:
Poor contact in
Poor contact in
cylinders
Poor contact in
ECM connector
Poor contact in
coupling connector
Go to step 16.

17
Step
CHECK MISFIRE SYMPTOM.
2) READ DTC.
<Ref. to EN(H6DO)(diag)-32, Read Diagnostic
18
CHECK DTC ON DISPLAY.
19
20
21
22
ONLY ONE CYLINDER.
23
GROUP OF #1 AND #2 CYLINDERS.
16
Check
Yes
Does the Subaru Select Moni- Go to step 22.
tor or general scan tool indicate a DTC?
No
Go to step 17.
Is DTC P0301 and P0302 displayed?

Is DTC P0301, P0303 and
P0305 displayed?
Is DTC P0302, P0304 and
P0306 displayed?
Go to step 23.
Go to step 18.
Go to step 24.
Go to step 19.
Go to step 25.
Go to step 20.
Go to step 26.
Go to step 21.
Go to step 27.
Go to step 28.
Is there any fault in #1 and #2

cylinders?
EN(H6DO)(diag)-182
Repair or replace
the faulty part.
Inspect the DTC

P0171, P0172,
P0174 or P0175
NOTE:
Check the follow- using List of Diagnostic Trouble
ing items:
Code (DTC).
Spark plug
<Ref. to
Fuel injector
EN(H6DO)(diag) Compression
66, List of Diagratio
nostic Trouble
Code (DTC).>
Repair or replace Inspect the DTC
the faulty part.
P0171, P0172,
P0174 or P0175
NOTE:
using List of Diag Check the folnostic Trouble
lowing items:
Code (DTC).
Spark plug
Fuel injector <Ref. to
EN(H6DO)(diag) Ignition coil
66, List of Diag Compresnostic Trouble
sion ratio
If no abnormal is Code (DTC).>
discovered, check
for IGNITION
cylinders side.
<Ref. to

24
Step
25
26
GROUP OF #1, #3 AND #5 CYLINDERS.
Check
Is there any fault in #3 and #4
cylinders?
No
Inspect the DTC
P0171, P0172,
P0174 or P0175
NOTE:
lowing items:
Code (DTC).
Spark plug
If no abnormal is 66, List of Diagdiscovered, check nostic Trouble
Code (DTC).>
for IGNITION
cylinders side.
<Ref. to
Is there any fault in #5 and #6 Repair or replace Inspect the DTC
P0171, P0172,
cylinder?
the faulty part.
P0174 or P0175
NOTE:
lowing items:
Code (DTC).
Spark plug
66, List of Diag Compresnostic Trouble
sion ratio
If no abnormal is Code (DTC).>
discovered, check
for IGNITION
cylinders side.
<Ref. to
Is there any fault in #1, #3 and Repair or replace Inspect the DTC
P0171, P0172,
#5 cylinders?
the faulty part.
P0174 or P0175
NOTE:
ing items:
Code (DTC).
Spark plug
<Ref. to
Fuel injector
Skipping timing EN(H6DO)(diag)66, List of Diagchain teeth
nostic Trouble
Code (DTC).>
EN(H6DO)(diag)-183
Yes
Repair or replace
the faulty part.

27
Step
GROUP OF #2, #4 AND #6 CYLINDERS.
Check
Yes
Is there any fault in #2, #4 and Repair or replace
#6 cylinders?
the faulty part.
28
CYLINDER AT RANDOM.
Is the engine idle rough?
EN(H6DO)(diag)-184
No
Inspect the DTC
P0171, P0172,
P0174 or P0175
NOTE:
ing items:
Code (DTC).
Spark plug
<Ref. to
Fuel injector
EN(H6DO)(diag) Compression
Skipping timing nostic Trouble
Code (DTC).>
chain teeth
Inspect the DTC
Repair or replace
P0171, P0172,
the faulty part.
P0174 or P0175
NOTE:
using List of Diag- Check the follownostic Trouble
ing items:
Code (DTC).
Spark plug
<Ref. to
Fuel injector
EN(H6DO)(diag)- Compression
nostic Trouble
Code (DTC).>

BD:DTC P0327 KNOCK SENSOR 1 CIRCUIT LOW (BANK 1 OR SINGLE SENSOR)

TROUBLE SYMPTOM:
Knocking occurs.
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
KNOCK
SENSOR
1(RH)
KNOCK
SENSOR
2(LH)
E48
E14
13
14
E1
B136
33
25
24
B20
ECM
E48
E14
1 2
B20
1
5
9
13
2
6
10
14
3
7
11
15
B136
4
8
12
16
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
EN-02506
EN(H6DO)(diag)-185

Step
Check
700 k?
Yes
Go to step 2.
CHECK KNOCK SENSOR.

sor.
Terminals
Go to step 3.

INSTALLATION.
No
NOTE:
In this case repair
the following:
Open circuit in
harness between
knock sensor and
ECM connector
Poor contact in
Poor contact in
coupling connector
NOTE:
In this case repair
the following:
Poor contact in
sensor. <Ref. to
FU(H6DO)-21,
securely.
Knock Sensor.>
EN(H6DO)(diag)-186

BE:DTC P0328 KNOCK SENSOR 1 CIRCUIT HIGH (BANK 1 OR SINGLE SENSOR)

TROUBLE SYMPTOM:
Knocking occurs.
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
KNOCK
SENSOR
1(RH)
KNOCK
SENSOR
2(LH)
E48
E14
13
14
E1
B136
33
25
24
B20
ECM
E48
E14
1 2
B20
1
5
9
13
2
6
10
14
3
7
11
15
B136
4
8
12
16
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
EN-02506
EN(H6DO)(diag)-187

Step
CHECK KNOCK SENSOR.
Terminals
Check
Yes
k?
No
Go to step 3.

k?
sensor. <Ref. to
FU(H6DO)-21,
Knock Sensor.>
Repair the ground

connector.

sensor.
chassis ground.

light illuminates,
the circuit has
remains.)
NOTE:
In this case repair
the following:
Poor contact in
Poor contact in
ECM connector
Poor contact in
coupling connector
EN(H6DO)(diag)-188
NOTE:
are
shielded. Repair
harness covered
with shield.
Repair the poor
contact in ECM
connector.

BF:DTC P0332 KNOCK SENSOR 2 CIRCUIT LOW INPUT (BANK 2)

TROUBLE SYMPTOM:
Driving performance problem
Knocking is occurred.
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
KNOCK
SENSOR
1(RH)
KNOCK
SENSOR
2(LH)
E48
E14
13
14
E1
B136
33
25
24
B20
ECM
E48
E14
1 2
B20
1
5
9
13
2
6
10
14
3
7
11
15
B136
4
8
12
16
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
EN-02506
EN(H6DO)(diag)-189

Step
Check
700 k?
Yes
Go to step 2.
CHECK KNOCK SENSOR.

sor.
Terminals
Go to step 3.

INSTALLATION.
No
NOTE:
In this case repair
the following:
Open circuit in
harness between
knock sensor and
ECM connector
Poor contact in
Poor contact in
coupling connector
NOTE:
In this case repair
the following:
Poor contact in
sensor. <Ref. to
FU(H6DO)-21,
securely.
Knock Sensor.>
EN(H6DO)(diag)-190

BG:DTC P0333 KNOCK SENSOR 2 CIRCUIT HIGH INPUT (BANK 2)

TROUBLE SYMPTOM:
Driving performance problem
Knocking occurs.
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
KNOCK
SENSOR
1(RH)
KNOCK
SENSOR
2(LH)
E48
E14
13
14
E1
B136
33
25
24
B20
ECM
E48
E14
1 2
B20
1
5
9
13
2
6
10
14
3
7
11
15
B136
4
8
12
16
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
EN-02506
EN(H6DO)(diag)-191

Step
CHECK KNOCK SENSOR.
Terminals
Check
Yes
k?
No
Go to step 3.

k?
sensor. <Ref. to
FU(H6DO)-21,
Knock Sensor.>
Repair the ground

connector.

sensor.
chassis ground.

light illuminates,
the circuit has
remains.)
NOTE:
In this case repair
the following:
Poor contact in
Poor contact in
ECM connector
Poor contact in
coupling connector
EN(H6DO)(diag)-192
NOTE:
are
shielded. Repair
harness covered
with shield.
Repair the poor
contact in ECM
connector.

BH:DTC P0335 CRANKSHAFT POSITION SENSOR A CIRCUIT

TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
CRANKSHAFT
POSITION
SENSOR
E10
2
1
1 2
E10
B20
1
5
9
13
E1
2
6
10
14
3
7
11
15
4
8
12
16
8
7
B135
B20
22
10
31
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
B135
ECM
E
EN-02507
EN(H6DO)(diag)-193

Step
Check
NECTOR.
2) Disconnect the connector from the crankshaft position sensor.
and engine ground.

NECTOR.
engine ground.

NECTOR.
engine ground.
Yes
No
ness and connector.
NOTE:
In this case repair
the following:
Open circuit in
harness between
ECM connector
Poor contact in
ECM connector
Poor contact in
coupling connector
ECM connector.
NOTE:
are
shielded. Repair
the ground short
circuit in harness
together
with
shield.
Go to step 4.
NOTE:
In this case repair
the following:
Open circuit in
harness between
ECM connector
Poor contact in
ECM connector
Poor contact in
coupling connector
securely.
Repair the poor
sor connector.
FU(H6DO)-19,
Terminals
tion Sensor.>
EN(H6DO)(diag)-194

BI: DTC P0340 CAMSHAFT POSITION SENSOR A CIRCUIT (BANK 1 OR SINGLE SENSOR)
TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
Inspection Mode.>
WIRING DIAGRAM:
MAIN RELAY
5
3
BATTERY
SBF-8
6
4
2
1
2
3
2
3
CAMSHAFT
POSITION
SENSOR RH
CAMSHAFT
POSITION
SENSOR LH
B47
E74
E73
48
B21
E2
19
E2
E1
2
1
B21
B20
* 12
*
*2
LHD: 8
RHD: TERMINAL No.
RANDOM ARRANGEMENT
B83
B8
B9
LHD: 3
RHD: TERMINAL No.
RANDOM ARRANGEMENT
C35
*1
B: B135
ECM
C: B136
E73
E74
1 2 3
1
3
5
2
4
6
B:
B20
B47
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
B135
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
32 33
34 35
28 29 30 31
C:
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B21
5 6
14 15 16
25 26 27
33 34 35
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 45
46 47
48 49 50 51 52 53 54
B83
1 2 3 4
5 6 7 8
EN-02508
EN(H6DO)(diag)-195

Step
Check
Yes
No
Inspect the DTC
Go to step 2.
Code (DTC).
<Ref. to
Code (DTC).>
short circuit
POSITION SENSOR.
between main
relay connector
and camshaft
position sensor.
position sensor
connector.
Repair open or
battery short cirPOSITION SENSOR.
cuit between main
relay connector
and camshaft
position sensor
connector.
Go to step 5.
Repair the open
?
circuit between
ECM.
camshaft position
sensor and ECM.
(E73) No. 2 (B135) No. 9:
(E73) No. 3 (B136) No. 35:
Repair the ground
M?
short circuit
ECM.
between camshaft
position sensor
and ECM.
securely.
shaft position sen<Ref. to EN(H6DO)(diag)-17, Engine Control
sor. <Ref. to
Module (ECM) I/O Signal.>
FU(H6DO)-19,
CHECK POOR CONTACT.
Repair the poor
Replace the ECM.
connector?
contact in ECM
<Ref. to
connector.
FU(H6DO)-34,
Engine Control
Module (ECM).>
EN(H6DO)(diag)-196

BJ:DTC P0345 CAMSHAFT POSITION SENSOR A CIRCUIT (BANK 2)

TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
Inspection Mode.>
WIRING DIAGRAM:
MAIN RELAY
5
3
BATTERY
SBF-8
6
4
2
1
2
3
2
3
CAMSHAFT
POSITION
SENSOR RH
CAMSHAFT
POSITION
SENSOR LH
B47
E74
E73
48
B21
E2
19
E2
E1
2
1
B21
B20
* 12
*
*2
LHD: 8
RHD: TERMINAL No.
RANDOM ARRANGEMENT
B83
B8
B9
LHD: 3
RHD: TERMINAL No.
RANDOM ARRANGEMENT
C35
*1
B: B135
ECM
C: B136
E73
E74
1 2 3
1
3
5
2
4
6
B:
B20
B47
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
B135
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
32 33
34 35
28 29 30 31
C:
B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B21
5 6
14 15 16
25 26 27
33 34 35
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 45
46 47
48 49 50 51 52 53 54
B83
1 2 3 4
5 6 7 8
EN-02508
EN(H6DO)(diag)-197

Step
Check
Yes
No
Inspect the DTC
Go to step 2.
Code (DTC).
<Ref. to
Code (DTC).>
short circuit
POSITION SENSOR.
between main
relay connector
and camshaft
position sensor.
position sensor
connector.
Repair open or
battery short cirPOSITION SENSOR.
cuit between main
relay connector
and camshaft
position sensor
connector.
Go to step 5.
Repair the open
?
circuit between
ECM.
camshaft position
sensor and ECM.
(E74) No. 2 (B135) No. 8:
(E74) No. 3 (B136) No. 35:
Repair the ground
M?
short circuit
ECM.
between camshaft
position sensor
and ECM.
securely.
shaft position sen<Ref. to EN(H6DO)(diag)-17, Engine Control
sor. <Ref. to
Module (ECM) I/O Signal.>
FU(H6DO)-20,
Camshaft Position
Sensor.>
CHECK POOR CONTACT.
Repair the poor
Replace the ECM.
connector?
contact in ECM
<Ref. to
connector.
FU(H6DO)-34,
Engine Control
Module (ECM).>
EN(H6DO)(diag)-198

BK:DTC P0400 EXHAUST GAS RECIRCULATION FLOW

TROUBLE SYMPTOM:
Movement performance problem when engine low speed
Erroneous idling
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
E18
MAIN RELAY
5
3
1 2 3
4 5 6
BATTERY
SBF-8
6
4
B47
2
1
48
B21
1
3
5
E2
B47
2
4
6
10
E76
E77
E77
5
2
1 2 3 4
6
5
7
9 10
8
EGR
VALVE
B21
E18
6
3
4
1
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 45
46 47
48 49 50 51 52 53 54
6
4
7
3
E77
E76
22
32
33
21
E2
B21
B134
8
11
9
10
1
8 9
18 19
28 29
B134
ECM
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
EN-02509
EN(H6DO)(diag)-199

Step
Check
Yes
No
Inspect the DTC
Go to step 2.
Code (DTC).
<Ref. to
Code (DTC).>
CHECK CURRENT DATA.
fold pressure sen2) Read the data of intake manifold absolute
sor and throttle
pressure signal using Subaru Select Monitor or
body are tightgeneral scan tool.
ened firmly.
NOTE:
General scan tool
Repair the open
LENOID VALVE.
circuit in harness
between main
valve.
relay and EGR
solenoid valve
3) Measure the voltage between EGR soleconnector.
noid valve and engine ground.
Is the resistance between 20 Go to step 5.
Replace the EGR
30 ?
solenoid valve.
Measure the resistance between EGR sole<Ref. to
FU(H6DO)-25,
NOTE:
EGR Valve.>
Terminals
No. 1 No. 2:
No. 3 No. 2:
No. 4 No. 5:
No. 6 No. 5:
Repair the poor
Go to step 6.
OUTPUT SIGNAL FROM ECM.
contact in ECM
connector.
solenoid valve.
chassis ground.
EN(H6DO)(diag)-200

Step
valve and ECM.
(B134) No. 8 (E18) No. 6:
(B134) No. 10 (E18) No. 1:
(B134) No. 9 (E18) No. 4:
(B134) No. 11 (E18) No. 3:
CHECK POOR CONTACT.
Check the poor contact in ECM and EGR solenoid valve connector.
Check
?
Yes
Go to step 7.
No
Repair the open
circuit in harness
between ECM and
EGR solenoid
valve connector.

M?
Go to step 8.
Repair the short

circuit in harness
between main
relay and EGR
solenoid valve
connector.

EGR solenoid valve conneccontactrepair the
tor?
poor contact in
ECM and EGR
solenoid valve
connector.
EN(H6DO)(diag)-201

light illuminates,
the circuit has
this time.

BL:DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD (BANK

1)
TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
Inspection Mode.>.
Step

Check

system?
Yes
No
vant DTC using
List of Diagnostic
Trouble Code
(DTC). <Ref. to
Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0420.
the exhaust system.
NOTE:
pipe
catalytic converter
CHECK REAR CATALYTIC CONVERTER.
Is there damage at rear face of Front catalytic conSeparate the rear catalytic converter from rear rear catalyst?
verter <Ref. to
exhaust pipe.
EC(H6DO)-3,
Front Catalytic
Converter.> and
rear catalytic converter<Ref. to
EC(H6DO)-4,
Rear Catalytic
Converter.>
CHECK FRONT CATALYTIC CONVERTER. Is there damage at rear face or Front Catalytic
Separate the front catalytic converter.
Converter<Ref. to
EC(H6DO)-3,
Front Catalytic
Converter.>
EN(H6DO)(diag)-202
Go to step 4.
Contact the SUBARU dealer.

NOTE:
Inspection by DTM
is required for fear
of deterioration of
some parts.

BM:DTC P0458 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE

CIRCUIT LOW
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
MAIN RELAY
E4
5
3
BATTERY
1 2
SBF-8
6
4
2
1
B47
1
3
5
B47
2
4
6
B21
B134 ECM
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
14
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
48
41
E77
1 2 3 4
6
5
7
9 10
8
B21
E2
B134
10
2
E76
1
8 9
18 19
28 29
1
2
E77
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
E4
PURGE CONTROL
SOLENOID VALVE
EN-02510
EN(H6DO)(diag)-203

Step
chassis ground.
Check
Yes
light illuminates,
the circuit has
this time.
NECTOR.
Go to step 4.
NECTOR.
ECM and purge control solenoid valve of harness connector.
(B134) No. 14 (E4) No. 2:

VALVE.
Terminals
No. 1 No. 2:
CHECK POOR CONTACT.
valve connector.
No
Go to step 2.
Repair the ground

ECM and purge
control solenoid
valve connector.
Repair the open

circuit in harness
between ECM and
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 the purge
control solenoid
valve. <Ref. to
EC(H6DO)-7,
Purge Control
Solenoid Valve.>
Repair the open

circuit in harness
between main
relay and purge
control solenoid
valve connector.

tor?
control solenoid
valve connector.
Replace the ECM.

<Ref. to
FU(H6DO)-34,
Engine Control
Module (ECM).>
EN(H6DO)(diag)-204

BN:DTC P0459 EVAPORATIVE EMISSION SYSTEM PURGE CONTROL VALVE

CIRCUIT HIGH
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
MAIN RELAY
E4
5
3
BATTERY
1 2
SBF-8
6
4
2
1
B47
1
3
5
B47
2
4
6
B21
B134 ECM
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
14
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
48
41
E77
1 2 3 4
6
5
7
9 10
8
B21
E2
B134
10
2
E76
1
8 9
18 19
28 29
1
2
E77
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
E4
PURGE CONTROL
SOLENOID VALVE
EN-02510
EN(H6DO)(diag)-205

Step
Check
drivers side).
chassis ground.
Yes
Go to step 2.
NOTE:
procedures. <Ref. to EN(H6DO)(diag)-41,
chassis ground.
CHECK POOR CONTACT.
Repair the poor
connector?
contact in ECM
connector.
No
light illuminates,
the circuit has
this time. In this
case repair the
poor contact in
ECM connector.
Go to step 3.
Replace the ECM.

<Ref. to
FU(H6DO)-34,
Engine Control
Module (ECM).>
NECTOR.
ECM and purge
control solenoid
After repair,
replace the ECM.
<Ref. to
chassis ground.
FU(H6DO)-34,
Engine Control
Module (ECM).>
VALVE.
?
control solenoid
valve. <Ref. to
EC(H6DO)-7,
Purge Control
Terminals
Solenoid Valve.>
No. 1 No. 2:
and ECM <Ref. to
FU(H6DO)-34,
Engine Control
Module (ECM).>
CHECK POOR CONTACT.
Repair the poor
Replace the ECM.
connector?
contact in ECM
<Ref. to
connector.
FU(H6DO)-34,
Engine Control
Module (ECM).>
EN(H6DO)(diag)-206

BO:DTC P0462 FUEL LEVEL SENSOR CIRCUIT LOW INPUT

NOTE:
For the diagnostic procedure, refer to DTC P0463. <Ref. to EN(H6DO)(diag)-207, DTC P0463 FUEL LEVEL
SENSOR CIRCUIT HIGH INPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
BP:DTC P0463 FUEL LEVEL SENSOR CIRCUIT HIGH INPUT

CAUTION:
Inspection Mode.>.
Step
Check
Is DTC P0462 or P0463 displayed on the Subaru Select
Monitor?
Yes
<Ref. to IDI-16,
Combination
Meter.>
No
Temporary poor
contact occurs.
BQ:DTC P0500 VEHICLE SPEED SENSOR

CAUTION:
Inspection Mode.>.
Step
CHECK DTC OF ABS.
Check DTC of ABS.
Check
EN(H6DO)(diag)-207
Yes
No
DTC. <Ref. to
ABS(diag)-39, List

BR:DTC P0512 STARTER REQUEST CIRCUIT

TROUBLE SYMPTOM:
CAUTION:
Inspection Mode.>.
EN(H6DO)(diag)-208

WIRING DIAGRAM:
IGNITION
SWITCH
B72
BATTERY
SBF-1
SBF-7
No.21
3
2
*1
*3
STARTER
RELAY
STARTER MOTOR
*4
*2
B225
D8
B32
B14
*1
LHD: 15
RHD: 16
*2
LHD: 16
RHD: 15
*3
LHD: 13
RHD: 14
*4
LHD: 14
RHD: 13
ECM
B: B135
D: B137
B72
B225
B: B135
1 2 3
4 5 6
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
1
8 9
20 21
28 29
2
3
10 11 12 13
22 23
30 31
4 5 6
7
14 15 16 17 18 19
24 25
26 27
32 33
34 35
D: B137
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
EN-02492
EN(H6DO)(diag)-209

Step
Check
CHECK OPERATION OF STARTER MOTOR. Does the starter motor operTurn the ignition switch to ON.
ate?
NOTE:
EN(H6DO)(diag)-210
Yes
Repair the battery
short circuit in
starter motor circuit.
No
Check starter
to
EN(H6DO)(diag)53, STARTER

BS:DTC P0519 IDLE CONTROL SYSTEM PERFORMANCE

TROUBLE SYMPTOM:
CAUTION:
Inspection Mode.>.
Step

throttle body
body gasket
Check

system?

control?
Yes
No
Inspect the DTC
Go to step 2.
Code (DTC).
<Ref. to
Code (DTC).>
NOTE:
In this case, it is
not necessary to
inspect
DTC
P0519.
and leaks.
Remove foreign
matters from the
electronic throttle
control.

P2101.
BT:DTC P0558 ALTERNATOR CIRCUIT LOW

NOTE:
For diagnostic procedure, refer to DTC P0559. <Ref. to EN(H6DO)(diag)-212, DTC P0559 GENERATOR
CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
EN(H6DO)(diag)-211

BU:DTC P0559 GENERATOR CIRCUIT HIGH

CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
F26
1 2 3
22
B134 ECM
B134
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
1
8 9
18 19
28 29
GENERATOR
F26
EN-02511
EN(H6DO)(diag)-212

Step
AND ECM CONNECTOR.
2) Disconnect the connector from generator
and ECM.
ground.
AND ECM CONNECTOR.
ECM and generator.
(B136) No. 22 (F26) No. 3:
Check
M?
Yes
Go to step 2.
No
Repair the ground
ECM and generator connector.

?
Repair the poor

Repair the open
contact connector. circuit in harness
between ECM and
NOTE:
In this case repair
the following:
Open circuit in
harness between
Poor contact in
coupling connector
BV:DTC P0600 SERIAL COMMUNICATION LINK

NOTE:
EN(H6DO)(diag)-213

BW:DTC P0604 INTERNAL CONTROL MODULE RANDOM ACCESS MEMORY

(RAM) ERROR
TROUBLE SYMPTOM:
Engine stalls.
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
MAIN RELAY
TO OXYGEN SENSOR
3
5
SBF-6
SBF-8
6
4
No.13
2
1
IGNITION
SWITCH
B72
BATTERY
No.12
B47
SBF-7
3
B19
D14
D16
B5
B6
SBF-1
A: B134
B: B135
ECM
A4
A5
A6
A7
B12
D3
D7
D1
D2
B1
B4
D: B137
35
12
37
34
36
54
52
B21
E2
B72
1 2 3
4 5 6
B47
1
3
5
2
4
6
A:
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
1
8 9
18 19
28 29
2
10
20
30
B134
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B:
B135
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
D:
B137
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
28 29
30 31
26 27
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
EN-02493
EN(H6DO)(diag)-214

Step
Check
Yes
No
Inspect the releTemporary poor
vant DTC using
contact occurs.
List of Diagnostic
Trouble Code
(DTC). <Ref. to
Code (DTC).>
BX:DTC P0605 INTERNAL CONTROL MODULE READ ONLY MEMORY (ROM)

ERROR
NOTE:
For the diagnostic procedure, refer to DTC P0607. <Ref. to EN(H6DO)(diag)-216, DTC P0607 CONTROL
EN(H6DO)(diag)-215

BY:DTC P0607 CONTROL MODULE PERFORMANCE

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
MAIN RELAY
TO OXYGEN SENSOR
3
5
SBF-6
SBF-8
6
4
No.13
2
1
IGNITION
SWITCH
B72
BATTERY
No.12
B47
SBF-7
3
B19
D14
D16
B5
B6
SBF-1
A: B134
B: B135
ECM
A4
A5
A6
A7
B12
D3
D7
D1
D2
B1
B4
D: B137
35
12
37
34
36
54
52
B21
E2
B72
1 2 3
4 5 6
B47
1
3
5
2
4
6
A:
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
1
8 9
18 19
28 29
2
10
20
30
B134
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B:
B135
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
D:
B137
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
28 29
30 31
26 27
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
EN-02493
EN(H6DO)(diag)-216

Step
Check
and chassis ground.
Yes
Go to step 2.
No
Repair the open or
Go to step 3.
Repair the open or

Repair the poor

Further tighten the
contact in ECM
minal.
Replace the ECM
if defective. <Ref.
to FU(H6DO)-34,
Engine Control
Module (ECM).>
BZ:DTC P0638 THROTTLE ACTUATOR CONTROL RANGE/PERFORMANCE

(BANK 1)
NOTE:
For diagnostic procedure, refer to DTC P2101. <Ref. to EN(H6DO)(diag)-241, DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/PERFORMANCE, Diagnostic Procedure with Diagnostic
EN(H6DO)(diag)-217

CA:DTC P0691 FAN 1 CONTROL CIRCUIT LOW

TROUBLE SYMPTOM:
Over-heating
CAUTION:
Inspection Mode.>.
Step
Check
Is DTC P0691 displayed?
Yes
No
Check radiator fan Temporary poor
system. <Ref. to
contact occurs.
CO(H6DO)-6,
Radiator Fan System.>
CB:DTC P0692 FAN 1 CONTROL CIRCUIT HIGH

TROUBLE SYMPTOM:
Over-heating
CAUTION:
Inspection Mode.>.
Step
Check
Is DTC P0692 displayed?
Yes
No
Check radiator fan Temporary poor
system. <Ref. to
contact occurs.
CO(H6DO)-6,
Radiator Fan System.>
CC:DTC P0700 TRANSMISSION CONTROL SYSTEM (MIL REQUEST)

NOTE:
EN(H6DO)(diag)-218

CD:DTC P1026 VVL SYSTEM 1 PERFORMANCE

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
B20
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
21
B135 ECM
B135
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
32 33
34 35
28 29 30 31
B20
E1
E71
VARIABLE VALVE LIFT DIAGNOSIS

OIL PRESSURE SWITCH RH
EN-02512
EN(H6DO)(diag)-219

Step
Check

VARIABLE VALVE LIFT DIAGNOSIS OIL
PRESSURE SWITCH CONNECTOR.
1) Idle the engine.
variable valve lift diagnosis oil pressure switch
connector.
between variable valve lift diagnosis oil pressure switch connector and engine ground.
Measure the resistance in harness between
ECM and variable valve lift diagnosis oil pressure switch connector.
(B135) No. 21 (E71) No. 1:

M?
CHECK DTC.
2) Check the DTC after idle the engine.
Is DTC displayed?
CHECK DTC.
Is DTC displayed?

?
EN(H6DO)(diag)-220
Yes
No
Inspect the DTC
Go to step 2.
Code (DTC).
<Ref. to
Code (DTC).>
Go to step 3.
Repair the ground
ECM and variable
valve lift diagnosis
oil pressure switch
connector.
Replace the variable valve lift oil

pressure switch.
<Ref. to
FU(H6DO)-28,
Variable Valve Lift
Diagnosis Oil
Pressure Switch.>
Go to step 4.
Replace the oil
switching solenoid
valve. <Ref. to
ME(H6DO)-80, Oil
Switching Solenoid Valve.>
Go to step 5.
Check for oil routing.
Repair the open

circuit in harness
between ECM and
variable valve lift
diagnosis oil pressure switch connector.
Temporary poor
contact occurs.
Temporary poor
contact occurs.

CE:DTC P1028 VVL SYSTEM 2 PERFORMANCE

TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
Inspection Mode.>
WIRING DIAGRAM:
B20
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
29
B135 ECM
B135
10
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
32 33
34 35
28 29 30 31
B20
E1
E72
VARIABLE VALVE LIFT DIAGNOSIS

OIL PRESSURE SWITCH LH
EN-02513
EN(H6DO)(diag)-221

Step
Check

1) Idle the engine.
variable valve lift diagnosis oil pressure switch
connector.
between variable valve lift diagnosis oil pressure switch connector and engine ground.
ECM and variable valve lift diagnosis oil pressure switch connector.
(B135) No. 29 (E72) No. 1:

M?
CHECK DTC.
Is DTC displayed?
CHECK DTC.
Is DTC displayed?

?
EN(H6DO)(diag)-222
Yes
No
Inspect the DTC
Go to step 2.
Code (DTC).
<Ref. to
Code (DTC).>
Go to step 3.
Repair the ground
ECM and variable
valve lift diagnosis
oil pressure switch
connector.
Replace the variable valve lift oil

pressure switch.
<Ref. to
FU(H6DO)-28,
Variable Valve Lift
Diagnosis Oil
Pressure Switch.>
Go to step 4.
Replace the oil
switching solenoid
valve. <Ref. to
ME(H6DO)-80, Oil
Switching Solenoid Valve.>
Go to step 5.
Check for oil routing.
Repair the open

circuit in harness
between ECM and
variable valve lift
diagnosis oil pressure switch connector.
Temporary poor
contact occurs.
Temporary poor
contact occurs.

CF:DTC P1160 RETURN SPRING FAILURE

NOTE:
CG:DTC P1492 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION

(LOW INPUT)
NOTE:
For the diagnostic procedure, refer to DTC P1498. <Ref. to EN(H6DO)(diag)-224, DTC P1498 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (LOW INPUT), Diagnostic Procedure with Diagnostic
CH:DTC P1493 EGR SOLENOID VALVE SIGNAL #1 CIRCUIT MALFUNCTION

(HIGH INPUT)
NOTE:
For the diagnostic procedure, refer to DTC P1499. <Ref. to EN(H6DO)(diag)-226, DTC P1499 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION (HIGH INPUT), Diagnostic Procedure with Diagnostic
CI: DTC P1494 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION

(LOW INPUT)
NOTE:
CJ:DTC P1495 EGR SOLENOID VALVE SIGNAL #2 CIRCUIT MALFUNCTION

(HIGH INPUT)
NOTE:
CK:DTC P1496 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION

(LOW INPUT)
NOTE:
CL:DTC P1497 EGR SOLENOID VALVE SIGNAL #3 CIRCUIT MALFUNCTION

(HIGH INPUT)
NOTE:
EN(H6DO)(diag)-223

CM:DTC P1498 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION

(LOW INPUT)
TROUBLE SYMPTOM:
Erroneous idling
Engine breathing
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
E18
MAIN RELAY
5
3
1 2 3
4 5 6
BATTERY
SBF-8
6
4
B47
2
1
48
B21
1
3
5
E2
B47
2
4
6
10
E76
E77
E77
5
2
1 2 3 4
6
5
7
9 10
8
EGR
VALVE
B21
E18
6
3
4
1
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 45
46 47
48 49 50 51 52 53 54
6
4
7
3
E77
E76
22
32
33
21
E2
B21
B134
8
11
9
10
1
8 9
18 19
28 29
B134
ECM
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
EN-02509
EN(H6DO)(diag)-224

Step
Check
Yes

?
DTC P1492; (B134) No. 11 (E18) No. 3:
DTC P1494; (B134) No. 10 (E18) No. 1:
DTC P1496; (B134) No. 9 (E18) No. 4:
DTC P1498; (B134) No. 8 (E18) No. 6:
Go to step 3.

ground:
ground:
ground:
ground:
CHECK POOR CONTACT.

M?
Go to step 4.

valve connector?
Repair the poor

contact in ECM
connector or EGR
solenoid valve
connector.
EN(H6DO)(diag)-225
No
NOTE:
In this case repair
the following:
Open circuit in
harness between
EGR solenoid
valve and main
relay connector
Poor contact in
coupling connector
NOTE:
In this case repair
the following:
Open circuit in
harness between
ECM and EGR
solenoid valve
connector.
Poor contact in
coupling connector
Repair ground
short in harness
between ECM and
EGR solenoid
valve connector.
Replace the EGR

solenoid valve.
<Ref. to
FU(H6DO)-25,
EGR Valve.>

CN:DTC P1499 EGR SOLENOID VALVE SIGNAL #4 CIRCUIT MALFUNCTION

(HIGH INPUT)
TROUBLE SYMPTOM:
Erroneous idling
Engine breathing
CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
E18
MAIN RELAY
5
3
1 2 3
4 5 6
BATTERY
SBF-8
6
4
B47
2
1
48
B21
1
3
5
E2
B47
2
4
6
10
E76
E77
E77
5
2
1 2 3 4
6
5
7
9 10
8
EGR
VALVE
B21
E18
6
3
4
1
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 45
46 47
48 49 50 51 52 53 54
6
4
7
3
E77
E76
22
32
33
21
E2
B21
B134
8
11
9
10
1
8 9
18 19
28 29
B134
ECM
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
EN-02509
EN(H6DO)(diag)-226

Step
Check
Yes
Inspect the DTC
Code (DTC).
<Ref. to
Code (DTC).>
Is the voltage more than 10 V? Repair battery
short in harness
between ECM and
EGR solenoid
noid valve.
After repair,
replace the ECM.
4) Measure the voltage between ECM con<Ref. to
FU(H6DO)-34,
Engine Control
DTC P1493; (B134) No. 11 (+) Chassis
Module (ECM).>
ground ():
DTC P1495; (B134) No. 10 (+) Chassis
ground ():
ground ():
ground ():
EN(H6DO)(diag)-227
No
Go to step 2.
Replace the ECM.

<Ref. to
FU(H6DO)-34,
Engine Control
Module (ECM).>

CO:DTC P1518 STARTER SWITCH CIRCUIT LOW INPUT

TROUBLE SYMPTOM:
CAUTION:
Inspection Mode.>.
EN(H6DO)(diag)-228

WIRING DIAGRAM:
IGNITION
SWITCH
B72
BATTERY
SBF-1
SBF-7
No.21
3
2
*1
*3
STARTER
RELAY
STARTER MOTOR
*4
*2
B225
D8
B32
B14
*1
LHD: 15
RHD: 16
*2
LHD: 16
RHD: 15
*3
LHD: 13
RHD: 14
*4
LHD: 14
RHD: 13
ECM
B: B135
D: B137
B72
B225
B: B135
1 2 3
4 5 6
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
1
8 9
20 21
28 29
2
3
10 11 12 13
22 23
30 31
4 5 6
7
14 15 16 17 18 19
24 25
26 27
32 33
34 35
D: B137
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
EN-02492
EN(H6DO)(diag)-229

Step
Check
Yes
No
CHECK OPERATION OF STARTER MOTOR. Does the starter motor operate Repair the harCheck starter
Set the inhibitor switch to P or N range.
ness and connec- motor circuit. <Ref.
START?
tor.
to
EN(H6DO)(diag)NOTE:
In this case repair 53, STARTER
MOTOR CIRthe following:
Open or ground CUIT, Diagnostics
short circuit in har- for Engine Starting Failure.>
ness between
ECM and starter
motor connector.
Poor contact in
ECM connector
EN(H6DO)(diag)-230

CP:DTC P1560 BACK-UP VOLTAGE CIRCUIT MALFUNCTION

CAUTION:
Inspection Mode.>.
WIRING DIAGRAM:
MAIN RELAY
TO OXYGEN SENSOR
3
5
SBF-6
SBF-8
6
4
No.13
2
1
IGNITION
SWITCH
B72
BATTERY
No.12
B47
SBF-7
3
B19
D14
D16
B5
B6
SBF-1
A: B134
B: B135
ECM
A4
A5
A6
A7
B12
D3
D7
D1
D2
B1
B4
D: B137
35
12
37
34
36
54
52
B21
E2
B72
1 2 3
4 5 6
B47
1
3
5
2
4
6
A:
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
1
8 9
18 19
28 29
2
10
20
30
B134
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B:
B135
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
D:
B137
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
28 29
30 31
26 27
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
EN-02493
EN(H6DO)(diag)-231

Step
chassis ground.
CHECK FUSE No. 13.
Check
Yes
contact in ECM
connector.
No
Go to step 2.

?

ECM connector
Replace the fuse.

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(H6DO)(diag)-232

CQ:DTC P2088 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT

LOW (BANK 1)
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
Inspection Mode.>
WIRING DIAGRAM:
B134
1
8 9
18 19
28 29
28
18
B134 ECM
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
23
24
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B21
E67
E2
1 2
1
2
E67
OIL FLOW CONTROL

SOLENOID VALVE RH
EN-02514
EN(H6DO)(diag)-233

Step
Check
?
(B134) No. 18 (E67) No. 1:
(B134) No. 28 (E67) No. 2:

VALVE.
1) Remove the oil flow control solenoid valve
connector.
Terminals
No. 1 No. 2:
EN(H6DO)(diag)-234
Yes
Go to step 2.
No
Repair the open
circuit in harness
between ECM and
oil flow control
solenoid valve
connector.
NOTE:
In this case repair
the following:
Open circuit in
harness between
ECM and oil flow
control solenoid
valve connector
Poor contact in
coupling connector
Repair the poor
Replace the oil
contact in ECM
trol solenoid valve. to ME(H6DO)-79,
Oil Flow Control
Solenoid Valve.>

CR:DTC P2089 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT

HIGH (BANK 1)
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
Inspection Mode.>
WIRING DIAGRAM:
B134
1
8 9
18 19
28 29
28
18
B134 ECM
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
23
24
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B21
E67
E2
1 2
1
2
E67
OIL FLOW CONTROL

SOLENOID VALVE RH
EN-02514
EN(H6DO)(diag)-235

Step
Check
M?
VALVE.
connector.
Terminals
No. 1 No. 2:
EN(H6DO)(diag)-236
Yes
Go to step 2.
No
Repair the short
circuit between
ECM and oil flow
control solenoid
valve connector.
Repair the poor

contact in ECM
Replace the oil

to ME(H6DO)-79,
Oil Flow Control
Solenoid Valve.>

CS:DTC P2092 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT

LOW (BANK 2)
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
Inspection Mode.>
WIRING DIAGRAM:
B134
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
29
19
B134 ECM
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
27
28
E68
1 2
B21
E2
1
2
E68
OIL FLOW CONTROL

SOLENOID VALVE LH
EN-02515
EN(H6DO)(diag)-237

Step
Check
?
(B134) No. 19 (E68) No. 1:
(B134) No. 29 (E68) No. 2:

VALVE.
connector.
Terminals
No. 1 No. 2:
EN(H6DO)(diag)-238
Yes
Go to step 2.
No
Repair the open
circuit in harness
between ECM and
oil flow control
solenoid valve
connector.
NOTE:
In this case repair
the following:
Open circuit in
harness between
ECM and oil flow
control solenoid
valve connector
Poor contact in
coupling connector
Repair the poor
Replace the oil
contact in ECM
trol solenoid valve. to ME(H6DO)-79,
Oil Flow Control
Solenoid Valve.>

CT:DTC P2093 INTAKE CAMSHAFT POSITION ACTUATOR CONTROL CIRCUIT

HIGH (BANK 2)
TROUBLE SYMPTOM:
Erroneous idling
CAUTION:
Inspection Mode.>
WIRING DIAGRAM:
B134
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
29
19
B134 ECM
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
27
28
E68
1 2
B21
E2
1
2
E68
OIL FLOW CONTROL

SOLENOID VALVE LH
EN-02515
EN(H6DO)(diag)-239

Step
Check
M?
VALVE.
connector.
Terminals
No. 1 No. 2:
EN(H6DO)(diag)-240
Yes
Go to step 2.
No
Repair the short
circuit between
ECM and oil flow
control solenoid
valve connector.
Repair the poor

contact in ECM
Replace the oil

to ME(H6DO)-79,
Oil Flow Control
Solenoid Valve.>

CU:DTC P2101 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT RANGE/

PERFORMANCE
TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
WIRING DIAGRAM:
BATTERY
ELECTRONIC
THROTTLE
CONTROL RELAY
SBF-8
B362
7
5
6
8
B35
D6
MAIN RELAY
ECM
C: B136
C29
C18
D3
D1
D2
B1
B4
D: B137
C16
D4
D5
C35
B: B135
B122
B83
RHD
LHD
LHD
RHD
*1
LHD: 6
RHD: TERMINAL No.
RANDOM ARRANGEMENT
*2
LHD: 2
RHD: TERMINAL No.
RANDOM ARRANGEMENT
*3
LHD: B122
RHD: B138
*4
LHD: 8
RHD: TERMINAL No.
RANDOM ARRANGEMENT
*5
LHD: 3
RHD: TERMINAL No.
RANDOM ARRANGEMENT
*3
16
15
B20
*1
*2
E1
20
39
38
19
37
36
35
B21
4
6
5
1
2
3
E2
ELECTRONIC
THROTTLE CONTROL
E57
B362
B122
B21
B20
B83
1 2
3
4
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
B138
5
7 8
6
1 2 3 4
5 6 7 8
B: B135
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
C:
1
5
9
13
2
6
10
14
3
7
11
15
E57
4
8
12
16
1 2 3 4 5 6
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B136
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
D:
B137
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
EN-02502
EN(H6DO)(diag)-241

Step
Terminals
No. 7 No. 8:
ground.
ground.
ground.
(B135) No. 35 (B362) No. 6:
(B137) No. 6 (B362) No. 8:
CHECK POOR CONTACT.
Check
?
Yes
Go to step 2.
No
Repair the open or


harness between

M?
Go to step 5.
Repair the ground


?
Go to step 6.
Repair the open

circuit in harness
between ECM and
electronic throttle
control relay.
Go to step 9.
Go to step 9.
Go to step 13.
EN(H6DO)(diag)-242
Repair the poor

contact.

10
11
Step
(B136) No. 18 (E57) No. 6:
(B136) No. 29 (E57) No. 4:
(B136) No. 16 (E57) No. 5:
Check
?
Yes
Go to step 10.
No
Repair the open
circuit of harness
connector.

M?
Go to step 11.
Repair the ground

Go to step 12.
Go to step 14.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
to FU(H6DO)-34,
Engine Control
Module (ECM).>
Repair the poor
contact in ECM
connector.
Replace the ECM
if defective. <Ref.
to FU(H6DO)-34,
Engine Control
Module (ECM).>
Go to step 16.
Go to step 15.
Go to step 16.
Repair the poor

contact.
Go to step 21.

?
Go to step 17.
Repair the open

circuit of harness
connector.
12

?
13

CHECK POOR CONTACT.
(B136) No. 35 (E57) No. 3:
(B136) No. 18 (E57) No. 6:
(B136) No. 29 (E57) No. 4:
14
15
16
EN(H6DO)(diag)-243

17
18
19
20
21
22
23
Step
Check
?
2) Remove the ECM.
(B136) No. 18 (B136) No. 16:
(B136) No. 29 (B136) No. 16:
2) Connect the connectors except of the electric throttle control relay.
Yes
Go to step 18.
No
Repair the poor
contact in ECM
connector.
Replace the ECM
if defective. <Ref.
to FU(H6DO)-34,
Engine Control
Module (ECM).>
Repair the battery
ECM connector
and electronic
throttle control
connector.
Repair the short
circuit in harness
between ECM
connector and
electronic throttle
control connector.
Go to step 19.
Go to step 20.

M?
Go to step 21.
Repair the short

circuit to sensor
power supply.
Go to step 22.
Go to step 23.
Repair the poor

contact in electronic throttle control connector.
Repair the poor
contact in ECM
connector.
Repair the open
circuit of harness
connector.

ELECTRONIC THROTTLE CONTROL MO?
TOR.
(B137) No. 5 (E57) No. 2:
(B137) No. 4 (E57) No. 1:
EN(H6DO)(diag)-244
Go to step 24.

24
25
26
27
28
29
Step
(E57) No. 2 (E57) No. 1:
Terminals
No. 1 No. 2:
fully closed positions with fingers
Check the valve returns to the specified position when releasing fingers.
Check
Yes
Go to step 25.
No
harness between

M?
Go to step 26.
Repair the short

circuit of harness.

M?
Go to step 27.
Repair the short

circuit of harness.

?
Go to step 28.
Repair the open

circuit of harness.

?
Go to step 29.
Repair the electronic throttle control.

specified position?
Repair the poor

Repair the eleccontact in ECM
trol.
Replace the ECM
if defective. <Ref.
to FU(H6DO)-34,
Engine Control
Module (ECM).>
EN(H6DO)(diag)-245

CV:DTC P2102 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT LOW

TROUBLE SYMPTOM:
Erroneous idling
Engine stalls.
WIRING DIAGRAM:
BATTERY
ELECTRONIC
THROTTLE
CONTROL RELAY
SBF-8
B362
7
5
6
8
B35
D6
MAIN RELAY
ECM
C: B136
C29
C18
D3
D1
D2
B1
B4
D: B137
C16
D4
D5
C35
B: B135
B122
B83
RHD
LHD
LHD
RHD
*1
LHD: 6
RHD: TERMINAL No.
RANDOM ARRANGEMENT
*2
LHD: 2
RHD: TERMINAL No.
RANDOM ARRANGEMENT
*3
LHD: B122
RHD: B138
*4
LHD: 8
RHD: TERMINAL No.
RANDOM ARRANGEMENT
*5
LHD: 3
RHD: TERMINAL No.
RANDOM ARRANGEMENT
*3
16
15
B20
*1
*2
E1
20
39
38
19
37
36
35
B21
4
6
5
1
2
3
E2
ELECTRONIC
THROTTLE CONTROL
E57
B362
B122
B21
B20
B83
1 2
3
4
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
B138
5
7 8
6
1 2 3 4
5 6 7 8
B: B135
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
C:
1
5
9
13
2
6
10
14
3
7
11
15
E57
4
8
12
16
1 2 3 4 5 6
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B136
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
D:
B137
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
EN-02502
EN(H6DO)(diag)-246

Step
Terminals
No. 7 No. 8:
ground.
ground.
ground.
(B135) No. 35 (B362) No. 6:
(B137) No. 6 (B362) No. 8:
Check
?
Yes
Go to step 2.
No
Repair the open or


harness between

M?
Go to step 5.
Repair the ground


?
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
to FU(H6DO)-34,
Engine Control
Module (ECM).>
Repair the open

circuit in harness
between ECM and
electronic throttle
control relay.
EN(H6DO)(diag)-247

CW:DTC P2103 THROTTLE ACTUATOR CONTROL MOTOR CIRCUIT HIGH

WIRING DIAGRAM:
BATTERY
ELECTRONIC
THROTTLE
CONTROL RELAY
SBF-8
B362
7
5
6
8
B35
D6
MAIN RELAY
ECM
C: B136
C29
C18
D3
D1
D2
B1
B4
D: B137
C16
D4
D5
C35
B: B135
B122
B83
RHD
*4
LHD
LHD
RHD
LHD: 6
RHD: TERMINAL No.
RANDOM ARRANGEMENT
*2
LHD: 2
RHD: TERMINAL No.
RANDOM ARRANGEMENT
*3
LHD: B122
RHD: B138
*4
LHD: 8
RHD: TERMINAL No.
RANDOM ARRANGEMENT
*5
LHD: 3
RHD: TERMINAL No.
RANDOM ARRANGEMENT
*3
16
15
*1
B20
*1
*2
E1
20
39
38
19
37
36
35
B21
4
6
5
1
2
3
E2
ELECTRONIC
THROTTLE CONTROL
E57
B362
B122
B21
B20
B83
1 2
3
4
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
B138
5
7 8
6
1 2 3 4
5 6 7 8
B: B135
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
C:
1
5
9
13
2
6
10
14
3
7
11
15
E57
4
8
12
16
1 2 3 4 5 6
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B136
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
D:
B137
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
EN-02502
EN(H6DO)(diag)-248

Step
Terminals
No. 7 No. 8:
RELAY.
ground.
Check
M?
Yes
Go to step 2.
No
Go to step 3.

harness between

M?
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
to FU(H6DO)-34,
Engine Control
Module (ECM).>
Repair the ground

CX:DTC P2109 THROTTLE/PEDAL POSITION SENSOR A MINIMUM STOP

PERFORMANCE
NOTE:
EN(H6DO)(diag)-249

CY:DTC P2122 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT

LOW INPUT
TROUBLE SYMPTOM:
Erroneous idling
WIRING DIAGRAM:
MAIN
B315
SUB
1 2 3 4 5 6
ACCELERATOR
POSITION
SENSOR
B83
B122
B315
B138
RHD
LHD
LHD
1 2 3 4
5 6 7 8
B21
RHD
7
B122
* 23
*
B83
C35
C28
C16
C34
C17
C15
* 45
*
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 45
46 47
48 49 50 51 52 53 54
B: B135
C: B136
ECM
B: B135
B4
B1
D2
D1
D3
D: B137
1 LHD: B122
RHD: B138
*2
LHD: 7
RHD: TERMINAL No.
RANDOM ARRANGEMENT
LHD: 2
RHD: TERMINAL No.
RANDOM ARRANGEMENT
*4
LHD: 1
RHD: TERMINAL No.
RANDOM ARRANGEMENT
*5
LHD: 8
RHD: TERMINAL No.
RANDOM ARRANGEMENT
*
35
36
37
B21
E2
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
32 33
34 35
28 29 30 31
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
D: B137
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
28 29
30 31
26 27
E
EN-02516
Step
Check
Yes
SOR OUTPUT.
EN(H6DO)(diag)-250
No
Go to step 3.

Step
CHECK POOR CONTACT.
Check
Yes
Repair the poor
contact.

(B136) No. 17 (B315) No. 5:
(B136) No. 15 (B315) No. 3:
sensor.
Terminals
No. 3 No. 4:
sensor.
Terminals
No. 5 No. 4:
pedal.
sensor.
Terminals
No. 5 No. 4:

?
Go to step 4.

M?
Go to step 5.

harness.
Go to step 6.

k?
Go to step 7.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
to FU(H6DO)-34,
Engine Control
Module (ECM).>
sensor.

k?
Go to step 8.

k?
Repair the poor

erator position
connector.
sensor.
Replace the ECM
if defective. <Ref.
to FU(H6DO)-34,
Engine Control
Module (ECM).>
EN(H6DO)(diag)-251
No
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.

sensor.

CZ:DTC P2123 THROTTLE/PEDAL POSITION SENSOR/SWITCH D CIRCUIT

HIGH INPUT
TROUBLE SYMPTOM:
Erroneous idling
WIRING DIAGRAM:
MAIN
B315
SUB
1 2 3 4 5 6
ACCELERATOR
POSITION
SENSOR
B83
B122
B315
B138
RHD
LHD
LHD
1 2 3 4
5 6 7 8
B21
RHD
7
B122
* 23
*
B83
C35
C28
C16
C34
C17
C15
* 45
*
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 45
46 47
48 49 50 51 52 53 54
B: B135
C: B136
ECM
B: B135
B4
B1
D2
D1
D3
D: B137
1 LHD: B122
RHD: B138
*2
LHD: 7
RHD: TERMINAL No.
RANDOM ARRANGEMENT
LHD: 2
RHD: TERMINAL No.
RANDOM ARRANGEMENT
*4
LHD: 1
RHD: TERMINAL No.
RANDOM ARRANGEMENT
*5
LHD: 8
RHD: TERMINAL No.
RANDOM ARRANGEMENT
*
35
36
37
B21
E2
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
32 33
34 35
28 29 30 31
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
D: B137
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
28 29
30 31
26 27
E
EN-02516
Step
Check
Yes
SOR OUTPUT.
EN(H6DO)(diag)-252
No
Go to step 3.

Step
CHECK POOR CONTACT.
Check
Yes
Repair the poor
contact.

(B136) No. 34 (B315) No. 4:
ground.
(B136) No. 17 (B136) No. 15:
(B136) No. 17 (B136) No. 16:

?
Go to step 4.

?
Go to step 5.
Go to step 6.

M?
Repair the poor

Repair the short
sor connector.
EN(H6DO)(diag)-253
No
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
to FU(H6DO)-34,
Engine Control
Module (ECM).>
Repair the battery
ECM connector
and accelerator
position sensor
connector.

DA:DTC P2127 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT

LOW INPUT
TROUBLE SYMPTOM:
Erroneous idling
WIRING DIAGRAM:
MAIN
B315
SUB
1 2 3 4 5 6
ACCELERATOR
POSITION
SENSOR
B83
B122
B315
B138
RHD
LHD
LHD
1 2 3 4
5 6 7 8
B21
RHD
7
B122
* 23
*
B83
C35
C28
C16
C34
C17
C15
* 45
*
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 45
46 47
48 49 50 51 52 53 54
B: B135
C: B136
ECM
B: B135
B4
B1
D2
D1
D3
D: B137
1 LHD: B122
RHD: B138
*2
LHD: 7
RHD: TERMINAL No.
RANDOM ARRANGEMENT
LHD: 2
RHD: TERMINAL No.
RANDOM ARRANGEMENT
*4
LHD: 1
RHD: TERMINAL No.
RANDOM ARRANGEMENT
*5
LHD: 8
RHD: TERMINAL No.
RANDOM ARRANGEMENT
*
35
36
37
B21
E2
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
32 33
34 35
28 29 30 31
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
D: B137
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
28 29
30 31
26 27
E
EN-02516
Step
Check
Yes
EN(H6DO)(diag)-254
No
Go to step 3.

Step
CHECK POOR CONTACT.
Check
Yes
Repair the poor
contact.

(B136) No. 28 (B315) No. 2:
(B136) No. 16 (B315) No. 1:
sensor.
Terminals
No. 1 No. 6:
Terminals
No. 2 No. 6:
Terminals
No. 2 No. 6:
depressed.

?
Go to step 4.

M?
Go to step 5.

harness.
Go to step 6.

k?
Go to step 7.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
to FU(H6DO)-34,
Engine Control
Module (ECM).>
sensor.

k?
Go to step 8.

k?
Repair the poor

erator position
connector.
sensor.
Replace the ECM
if defective. <Ref.
to FU(H6DO)-34,
Engine Control
Module (ECM).>
EN(H6DO)(diag)-255
No
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.

sensor.

DB:DTC P2128 THROTTLE/PEDAL POSITION SENSOR/SWITCH E CIRCUIT

HIGH INPUT
TROUBLE SYMPTOM:
Erroneous idling
WIRING DIAGRAM:
MAIN
B315
SUB
1 2 3 4 5 6
ACCELERATOR
POSITION
SENSOR
B83
B122
B315
B138
RHD
LHD
LHD
1 2 3 4
5 6 7 8
B21
RHD
7
B122
* 23
*
B83
C35
C28
C16
C34
C17
C15
* 45
*
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 45
46 47
48 49 50 51 52 53 54
B: B135
C: B136
ECM
B: B135
B4
B1
D2
D1
D3
D: B137
1 LHD: B122
RHD: B138
*2
LHD: 7
RHD: TERMINAL No.
RANDOM ARRANGEMENT
LHD: 2
RHD: TERMINAL No.
RANDOM ARRANGEMENT
*4
LHD: 1
RHD: TERMINAL No.
RANDOM ARRANGEMENT
*5
LHD: 8
RHD: TERMINAL No.
RANDOM ARRANGEMENT
*
35
36
37
B21
E2
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
32 33
34 35
28 29 30 31
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
D: B137
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
28 29
30 31
26 27
E
EN-02516
Step
Check
Yes
EN(H6DO)(diag)-256
No
Go to step 3.

Step
CHECK POOR CONTACT.
Check
Yes
Repair the poor
contact.

(B136) No. 35 (B315) No. 6:
ground.
(B136) No. 28 (B136) No. 15:
(B136) No. 28 (B136) No. 16:

?
Go to step 4.

?
Go to step 5.
Go to step 6.

M?
Repair the poor

Repair the short
sor connector.
EN(H6DO)(diag)-257
No
Temporary poor
contact occurred,
but it is normal at
present.
Repair the open
circuit of harness
connector.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
to FU(H6DO)-34,
Engine Control
Module (ECM).>
Repair the battery
ECM connector
and accelerator
position sensor
connector.

DC:DTC P2135 THROTTLE/PEDAL POSITION SENSOR/SWITCH A / B

VOLTAGE CORRELATION
TROUBLE SYMPTOM:
Erroneous idling
WIRING DIAGRAM:
BATTERY
ELECTRONIC
THROTTLE
CONTROL RELAY
SBF-8
B362
7
5
6
8
B35
D6
MAIN RELAY
ECM
C: B136
C29
C18
D3
D1
D2
B1
B4
D: B137
C16
D4
D5
C35
B: B135
B122
B83
RHD
LHD
LHD
RHD
*1
LHD: 6
RHD: TERMINAL No.
RANDOM ARRANGEMENT
*2
LHD: 2
RHD: TERMINAL No.
RANDOM ARRANGEMENT
*3
LHD: B122
RHD: B138
*4
LHD: 8
RHD: TERMINAL No.
RANDOM ARRANGEMENT
*5
LHD: 3
RHD: TERMINAL No.
RANDOM ARRANGEMENT
*3
16
15
B20
*1
*2
E1
20
39
38
19
37
36
35
B21
4
6
5
1
2
3
E2
ELECTRONIC
THROTTLE CONTROL
E57
B362
B122
B21
B20
B83
1 2
3
4
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
B138
5
7 8
6
1 2 3 4
5 6 7 8
B: B135
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
C:
1
5
9
13
2
6
10
14
3
7
11
15
E57
4
8
12
16
1 2 3 4 5 6
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
B136
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
D:
B137
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
EN-02502
EN(H6DO)(diag)-258

Step
CHECK POOR CONTACT.
(B136) No. 18 (E57) No. 6:
(B136) No. 29 (E57) No. 4:
(B136) No. 16 (E57) No. 5:
Check
Yes
No
Go to step 4.
Go to step 4.
Repair the poor

contact.
Go to step 14.

?
Go to step 5.
Repair the open

circuit of harness
connector.

M?
Go to step 6.
Repair the ground

Go to step 7.

V?
Go to step 9.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
to FU(H6DO)-34,
Engine Control
Module (ECM).>
Repair the poor
contact in ECM
connector.
Replace the ECM
if defective. <Ref.
to FU(H6DO)-34,
Engine Control
Module (ECM).>
Go to step 11.

V?
Go to step 10.
Go to step 11.
Repair the poor

contact.
Temporary poor
contact occurred,
but it is normal at
present.

?

CHECK POOR CONTACT.
10
EN(H6DO)(diag)-259

11
12
13
14
15
16
Step
(B136) No. 35 (E57) No. 3:
(B136) No. 18 (E57) No. 6:
(B136) No. 29 (E57) No. 4:
Check
?
Yes
Go to step 12.
No
Repair the open
circuit of harness
connector.

?
Go to step 13.

(B136) No. 18 (B136) No. 16:
(B136) No. 29 (B136) No. 16:
(E57) No. 6 (E57) No. 4:
Go to step 14.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
to FU(H6DO)-34,
Engine Control
Module (ECM).>
Repair the battery
ECM connector
and electronic
throttle control
connector.
Go to step 15.
Repair the short

circuit in harness
between ECM
connector and
electronic throttle
control connector.

M?
Go to step 16.
Repair the short

circuit to sensor
power supply.

M?
Repair the poor

Repair the short
contact in ECM
circuit of harness.
connector.
Replace the ECM
if defective. <Ref.
to FU(H6DO)-34,
Engine Control
Module (ECM).>
EN(H6DO)(diag)-260

DD:DTC P2138 THROTTLE/PEDAL POSITION SENSOR/SWITCH D / E

VOLTAGE CORRELATION
TROUBLE SYMPTOM:
Erroneous idling
WIRING DIAGRAM:
MAIN
B315
SUB
1 2 3 4 5 6
ACCELERATOR
POSITION
SENSOR
B83
B122
B315
B138
RHD
LHD
LHD
1 2 3 4
5 6 7 8
B21
RHD
7
B122
* 23
*
B83
C35
C28
C16
C34
C17
C15
* 45
*
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 45
46 47
48 49 50 51 52 53 54
B: B135
C: B136
ECM
B: B135
B4
B1
D2
D1
D3
D: B137
1 LHD: B122
RHD: B138
*2
LHD: 7
RHD: TERMINAL No.
RANDOM ARRANGEMENT
LHD: 2
RHD: TERMINAL No.
RANDOM ARRANGEMENT
*4
LHD: 1
RHD: TERMINAL No.
RANDOM ARRANGEMENT
*5
LHD: 8
RHD: TERMINAL No.
RANDOM ARRANGEMENT
*
35
36
37
B21
E2
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
32 33
34 35
28 29 30 31
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
D: B137
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
28 29
30 31
26 27
E
EN-02516
Step
Check
Yes
SOR OUTPUT.
EN(H6DO)(diag)-261
No
Go to step 3.

Step
CHECK POOR CONTACT.
(B136) No. 17 (B315) No. 5:
(B136) No. 15 (B315) No. 3:
(B136) No. 28 (B315) No. 2:
(B136) No. 16 (B315) No. 1:
sensor.
Terminals
No. 3 No. 4:
sensor.
Terminals
No. 1 No. 6:
pedal.
Terminals
No. 5 No. 4:
Check
Yes
Repair the poor
contact.
No
Go to step 12.

?
Go to step 4.
Repair the open

circuit of harness
connector.

M?
Go to step 5.
Repair the ground

Go to step 6.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
to FU(H6DO)-34,
Engine Control
Module (ECM).>

k?
Go to step 7.

sensor.

k?
Go to step 8.

sensor.

k?
Go to step 9.

sensor.
EN(H6DO)(diag)-262

10
11
12
13
14
15
16
Step
pedal.
Terminals
No. 2 No. 6:
Terminals
No. 5 No. 4:
Terminals
No. 2 No. 6:
CHECK POOR CONTACT.
(B136) No. 34 (B315) No. 4:
(B136) No. 35 (B315) No. 6:
ground.
Check
k?
Yes
Go to step 10.
No
sensor.

k?
Go to step 11.

sensor.

k?
Go to step 12.

sensor.
Go to step 14.
Repair the poor

contact.
Go to step 18.

?
Go to step 15.
Repair the open

circuit of harness
connector.

?
Go to step 16.
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
to FU(H6DO)-34,
Engine Control
Module (ECM).>
Go to step 17.
Repair the battery

ECM connector
and accelerator
position sensor
connector.
EN(H6DO)(diag)-263

17
18
Step
(B136) No. 17 (B136) No. 15:
(B136) No. 17 (B136) No. 16:
(B136) No. 28 (B136) No. 15:
(B136) No. 28 (B136) No. 16:
(B315) No. 5 (B315) No. 2:
Check
M?
Yes
Go to step 18.
No
Repair the short
circuit to sensor
power supply.

M?
Repair the poor

contact in ECM
connector.
Replace the ECM
if defective. <Ref.
to FU(H6DO)-34,
Engine Control
Module (ECM).>
Repair the short

circuit in harness
between ECM
connector and
EN(H6DO)(diag)-264


A: INSPECTION
1. ENGINE
NOTE:
Malfunction of parts other than those listed is also possible. <Ref. to ME(H6DO)-82, Engine Trouble in General.>
Symptom
2. Rough idling
5. Engine stalls or engine sags or hesitates at

acceleration.
Problem parts
10) Oxygen sensor
12) EGR valve
5) EGR valve
6) Accelerator position sensor
7) Oil temperature sensor
12) EGR valve
13) Accelerator position sensor
14) Oil temperature sensor
10) EGR valve
EN(H6DO)(diag)-265

Symptom
6. Surging
7. Spark knock
Problem parts
9) EGR valve
4) Knock sensor
7) EGR valve
EN(H6DO)(diag)-266
TRANSMISSION SECTION

of SUBARU vehicles.
CONTROL SYSTEMS
CS
4AT
(DIAGNOSTICS)
4AT(diag)
5AT
(DIAGNOSTICS)
5AT(diag)
MANUAL TRANSMISSION AND

DIFFERENTIAL
5MT
CLUTCH SYSTEM
CL

approval.
G2320GE5
CONTROL SYSTEMS
CS
1.
2.
3.
4.
5.
6.
7.
8.
9.
Page
Select Lever ................................................................................................7
Select Cable..............................................................................................12
AT Steering Shift Switch ...........................................................................16
Shift Lock Solenoid ...................................................................................18
MT Gear Shift Lever..................................................................................21
MT Drive Select Lever...............................................................................28
Drive Select Cable ....................................................................................30
General Description
CONTROL SYSTEMS
A: SPECIFICATION
Item
Swing torque of rod against lever
Specification
3.7 (0.38, 0.84) or less
N (kgf, lb)
B: COMPONENT
1. AT SELECT LEVER
(1)
(11)
(2)
(12)
(9)
(13)
(10)
(14)
(3)
(8)
(24)
(10)
(23)
(22)
(21)
(4)
T4
(5)
T2
(20)
(16)
(28)
(15)
(7)
(29)
(25)
T4
(31)
(30)
T1
(32)
(17)
(19)
(6)
(34)
(18)
T1
(26)
(27)
T3
(33)
CS-00370
CS-2
General Description
CONTROL SYSTEMS
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
Ring indicator
Front cover
Grip
Indicator cover ASSY
Blind
Guide plate
Pin
Clamp
Lever ASSY
Bushing
Rod
Spring
Arm
Spring pin
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
Shift lock solenoid UNIT

Plate
Grommet
Plate nut
Detent spring
Detent plate
Bushing
Packing
Rod
Spring
Bracket
Packing
Spacer
Arm ASSY
CS-3
(29)
(30)
(31)
(32)
(33)
(34)
Connector pin
Snap pin
Washer
Select cable
Nut A
Clamp

T1: 2.2 (0.22, 1.62)
T2: 6 (0.61, 4.4)
T3: 7.5 (0.76, 5.5)
T4: 18 (1.8, 13.3)
General Description
CONTROL SYSTEMS
2. 5MT GEAR SHIFT LEVER

(1)
(2)
(3)
T1
(16)
(26)
(4)
(17)
(19)
(7)
(19)
(24)
(3)
T2
(7)
(26)
(18) (26)
T1
T2
(6)
(7)
(7)
(19)
(7)
(7)
(8)
(5)
(9)
(12)
(10)
(11)
(13)
(14)
(20)
(15)
(25)
(21)
T2
T2
(23)
(22)
(26)
T2
CS-00267
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
Gear shift knob

Front cover ASSY
Clamp
Boot and insulator ASSY
Plate ASSY
Lever
Bushing
Lock wire
Snap ring
Bushing
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
O-ring
Spring pin
Bushing B
O-ring
Boot
Spring pin
Joint
Rod
Spacer
Bracket
CS-4
(21)
(22)
(23)
(24)
(25)
(26)
Washer
Stay
Cushion rubber
Boss
Bushing
Self-locking nut

T1: 12 (1.2, 8.9)
T2: 18 (1.8, 13.3)
General Description
CONTROL SYSTEMS
3. DRIVE SELECT LEVER

(8)
T2
(1)
T1
(7)
(2)
T1
(4)
(5)
(4)
(3)
(10)
(9)
(6)
T3
T2
(11)
(12)
T2
CS-00371
(1)
(2)
(3)
(4)
(5)
(6)
Cover
Knob
Lever ASSY
Bushing
Spacer
Spring
(7)
(8)
(9)
(10)
(11)
(12)
Plate ASSY
Bushing
Clevis pin
Snap pin
Cable
Clip
CS-5

T1: 4.5 (0.46, 3.3)
T2: 12 (1.2, 8.9)
T3: 27.5 (2.80, 20.3)
General Description
CONTROL SYSTEMS
C: CAUTION
Use SUBARU genuine fluid, grease etc. or
equivalent. Do not mix fluid, grease etc. with that of
another grade or from other manufacturers.
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 in a vice, place cushioning
material such as wood blocks, aluminum plate, or
cloth between the part and vice.
Before disconnecting electrical connectors, be
sure to disconnect the negative terminal from battery.
CS-6
Select Lever
CONTROL SYSTEMS
2. Select Lever
8) Raise the pawl of clamp to remove cable.
A: REMOVAL
3) Shift the select lever to N range.
5) Remove the rear exhaust pipe and muffler.
SOHC model
<Ref. to EX(H4SO 2.0)-11, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H4SO 2.0)-13, REMOVAL, Muffler.>
DOHC non-turbo model
Pipe.> <Ref. to EX(H6DO)-10, REMOVAL, Muffler.>
DOHC turbo model
<Ref. to EX(H4DOTC)-11, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-12, REMOVAL, Muffler.>
(A)
CS-00279
(A) Claw

10) Remove the console box. <Ref. to EI-53, REMOVAL, Console Box.>
11) Remove the harness clips from bracket.
CS-00372
AT-01331
12) Disconnect the connectors, and then remove

the four bolts to take out the select lever assembly
from vehicle body.
7) Remove the cable from arm assembly.

C
B
(B)
(A)
(A) Adjusting nut

(B) Arm ASSY
CS-00373
CS-00278
B: INSTALLATION
1) Set the select lever to vehicle body.
2) Tighten the four bolts to install the select lever to
vehicle body, and then connect the connector.
(1) Temporarily tighten the bolt A.
(2) Tighten the bolt B.
(3) Tighten the bolt A.
(4) Tighten the bolts C and D.
CS-7
Select Lever
CONTROL SYSTEMS
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
NOTE:
Inhibitor switch for 5AT model is not adjustable.
<Ref. to CS-15, ADJUSTMENT, Select Cable.>
<Ref. to 4AT-52, ADJUSTMENT, Inhibitor Switch.>
(1) Engine starts when the select lever is in P
and N range, but not in other range.
(2) Back-up light illuminates when the select lever is in R range, but not in other range.
(3) Select lever and indicator positions are
matched.
C
B
C: DISASSEMBLY
1) Remove the packing and plate.
CS-00373
3) Install the harness clips to bracket.
CS-00281
2) Remove the grip.
CS-00372
4) Install the console box. <Ref. to EI-53, INSTALLATION, Console Box.>

7) Shift the range select lever to N range.
8) Fix the cable to bracket. <Ref. to CS-13, INSTALLATION, Select Cable.>
9) Adjust the select cable position. <Ref. to CS-15,
ADJUSTMENT, Select Cable.>
10) After the completion of adjustment, confirm that
the select lever operates properly at all range positions.
12) Install the rear exhaust pipe and muffler.
SOHC model
Exhaust Pipe.> <Ref. to EX(H4SO 2.0)-13, INSTALLATION, Muffler.>
<Ref. to EX(H6DO)-8, INSTALLATION, Rear Exhaust Pipe.> <Ref. to EX(H6DO)-10, INSTALLATION, Muffler.>
DOHC turbo model
Exhaust Pipe.> <Ref. to EX(H4DOTC)-12, INSTALLATION, Muffler.>
13) Inspect the following items. When malfunctions
are found in the inspection, adjust the select cable
and inhibitor switch.
CS-00374
3) Insert a flat-tip screwdriver with thin tip under the

connector to disconnect each connector from plate
assembly.
CS-8
CS-00375
Select Lever
CONTROL SYSTEMS
4) Remove the indicator cover.
CS-00376
CS-00288
9) Remove the detent spring.
5) Remove the blind.
CS-00379
CS-00285
6) Remove the bolts, and then remove the guide

plate.
10) Remove the detent plate.
CS-00380
CS-00377
11) Remove the shift lock solenoid assembly.
7) Remove the clamp, spring, rod, packing and

bushing.
(E)
(D)
(C)
(B)
CS-00381
(A)
CS-00378
(A)
(B)
(C)
(D)
(E)
Clamp
Spring
Rod
Bushing
Plate
CS-9
Select Lever
CONTROL SYSTEMS
16) Pull out the arm assembly, and then remove

the select lever assembly to remove the arm bracket and bushing.
12) Raise the connector pawl.
(D)
(D)
(C)
(B)
(A)
CS-00292
13) Use a flat-tip screwdriver with thin tip to disconnect the connectors from terminals of SPORT
mode switch, shift lock solenoid assembly.
CS-00298
(A)
(B)
(C)
(D)
(A)
4 3
2 1
10 9 8 7 6 5
Arm ASSY
Select lever ASSY
Arm bracket
Bushing
17) Remove the rod and spring from arm bracket.

(A)
(B)
(C)
CS-00382
(B)
(A) Shift lock solenoid terminal

(B) SPORT mode switch terminal
14) Remove the grommet.

CS-00383
(A) Rod
(B) Spring
(C) Arm bracket
D: ASSEMBLY
CS-00296
15) Remove the spring pin.
1) Clean all the parts before assembly.

2) Apply grease [KOPR-KOTE (Part No.
003603001) or equivalent] to each parts. <Ref. to
CS-2, AT SELECT LEVER, COMPONENT, General Description.>
3) Assemble in the reverse order of disassembly.
NOTE:
When installing the guide plate, shift the select
lever to D range (normal mode position), care
should be taken in the following points.
Insert the protrusion (B) of guide plate into the
hole of shift lock solenoid assembly (A).
CS-00297
CS-10
Select Lever
CONTROL SYSTEMS
Insert the link (D) of shift lock release into the

link (C) of shift lock solenoid assembly.
a
(B)
(A)
b
(D)
(C)
CS-00384
Connect the switch and solenoid terminal to connector.
(B)
1
5
2
6
7
(C)
(A)
3 4
8 9 10
(D)
CS-00385
(A)
(B)
(C)
(D)
Shift lock solenoid (Color code: Blue and Red)

Shift lock solenoid (Color code: Black)
SPORT mode switch (Color code: White)
SPORT mode switch (Color code: Black)
4) After completion of installation, shift the select

lever from P range to D range, then check
whether the indicator and select lever matches,
whether the pointer and position mark matches and
what the operating force is.
E: INSPECTION
1) Inspect the removed parts by comparing with
new ones for deformation, damage and wear. Repair or replace if defective.
2) Confirm the select lever operating condition before assembly. Normal if it operates smoothly.
CS-11
Select Cable
CONTROL SYSTEMS
3. Select Cable
4AT
A: REMOVAL
5) Remove the front, center and rear exhaust pipes
and muffler. (SOHC and DOHC non-turbo model)
SOHC model
<Ref. to EX(H4SO 2.0)-7, REMOVAL, Front Exhaust Pipe.> <Ref. to EX(H4SO 2.0)-10, REMOVAL, Center Exhaust Pipe.> <Ref. to EX(H4SO 2.0)11, REMOVAL, Rear Exhaust Pipe.> <Ref. to
EX(H4SO 2.0)-13, REMOVAL, Muffler.>
Pipe.> <Ref. to EX(H6DO)-8, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H6DO)-10, REMOVAL,
Muffler.>
6) Remove the center and rear exhaust pipe and
muffler. (DOHC turbo model)
<Ref. to EX(H4DOTC)-6, REMOVAL, Center Exhaust Pipe.> <Ref. to EX(H4DOTC)-11, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)12, REMOVAL, Muffler.>
(A)
(D)
(B)
(C) (E)
CS-00036
(A)
(B)
(C)
(D)
(E)
Range select lever

Snap pin
Select cable
Bracket
Washer
5AT
(E)
(B)
(D)
(A)
(C)
CS-00327
(A)
(B)
(C)
(D)
(E)
AT-01331
8) Remove the snap pin and washer from range select lever.
Range select lever

Snap pin
Select cable
Bracket
Washer
9) Remove the plate assembly from transmission

case.
4AT
(A)
(C)
(B)
(A) Select cable

(B) Plate ASSY
(C) Bracket
CS-12
CS-00037
Select Cable
CONTROL SYSTEMS
4AT
5AT
(A)
(A)
T
(B)
(B)
CS-00039
CS-00328
(A) Select cable

(B) Plate ASSY
(A) Select cable

(B) Plate ASSY
5AT
10) Disconnect the cable from arm assembly.
(A)
(B)
(A)
(B)
CS-00278
CS-00328
(A) Adjusting nut

(B) Arm ASSY
(A) Select cable

(B) Plate ASSY
11) Raise the pawl of clamp to remove the cable

from bracket.
4) Install the washer and snap pin to range select

lever.
4AT
(A)
(D)
(B)
(A)
(C) (E)
CS-00279
CS-00036
(A) Pawl
12) Remove the select cable from plate assembly.
B: INSTALLATION
1) Install the select cable to plate assembly.
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
2) Install the select cable to range select lever.
3) Install the plate assembly to transmission.
Tightening torque:
T: 24.5 Nm (2.5 kgf-m, 18.1 ft-lb)
CS-13
(A)
(B)
(C)
(D)
(E)
Range select lever

Snap pin
Select cable
Bracket
Washer
Select Cable
CONTROL SYSTEMS
5AT
(E)
(B)
(D)
(A)
(C)
CS-00327
(A)
(B)
(C)
(D)
(E)
AT-01331
Range select lever

Snap pin
Select lever
Bracket
Washer
5) Install a new clump paying attention to the installing direction.
C
(A)
C
(B)
CS-00329
(A) Clamp
(B) Forward
9) Install the front, center and rear exhaust pipes

and muffler. (SOHC and DOHC non-turbo model)
SOHC model
Exhaust Pipe.> <Ref. to EX(H4SO 2.0)-10, INSTALLATION, Center Exhaust Pipe.> <Ref. to
EX(H4SO 2.0)-11, INSTALLATION, Rear Exhaust
Pipe.> <Ref. to EX(H4SO 2.0)-13, INSTALLATION, Muffler.>
<Ref. to EX(H6DO)-6, INSTALLATION, Front Exhaust Pipe.> <Ref. to EX(H6DO)-8, INSTALLATION, Rear Exhaust Pipe.> <Ref. to EX(H6DO)-10,
INSTALLATION, Muffler.>
10) Install the center and rear exhaust pipe and
muffler. (DOHC turbo model)
Exhaust Pipe.> <Ref. to EX(H4DOTC)-11, INSTALLATION, Rear Exhaust Pipe.> <Ref. to
EX(H4DOTC)-12, INSTALLATION, Muffler.>
C: INSPECTION
6) Insert the tip of inner cable into connector hole of

the select lever, and fix the cable to bracket.
CS-00330
7) Shift the select lever to N range, and then adjust the select cable position. <Ref. to CS-15, ADJUSTMENT, Select Cable.>
Check the removed cable and replace or adjust 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 the select lever from P to D range.
Check the existence of feel to contact the detents in
each range. If the detents cannot be felt or the position pointer is improperly aligned, adjust the cable.
6) Check if the starter motor rotates when the select lever is set to P range.
7) Check the back-up light illumination when the
select lever is in R range.
8) Check the parking lock operation when the select lever is in P range.
CS-14
Select Cable
CONTROL SYSTEMS
D: ADJUSTMENT
SOHC model
DOHC turbo model
5) Turn the adjusting nut B until it lightly touches

the connector.
(B)
(C)
(A)
(F)
(D)
(E)
(A)
(B)
(C)
(D)
(E)
(F)
CS-00041
Forward side
Select lever
Connector
Adjusting nut B
Contact point
Adjusting nut A
6) Set a spanner wrench to adjusting nut B so that

it does not rotate, and then tighten the adjusting nut
A.
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
AT-01331
4) Loosen the adjusting nuts on both sides.
(A)
(B)
CS-00042
(B)
(A)
(A) Adjusting nut A

(B) Adjusting nut B
CS-00040
(A) Adjusting nut A

(B) Adjusting nut B
7) After the completion of adjustment, confirm that

the select lever operates normally at all ranges.
CS-15
AT Steering Shift Switch

CONTROL SYSTEMS
4. AT Steering Shift Switch

A: REMOVAL
2) Set the tire to the straight-ahead position.
3) Remove the airbag module. <Ref. to AB-15, REMOVAL, Drivers Airbag Module.>
WARNING:
With the airbag module equipped, always refer
to Airbag System when performing the airbag
module repair service. <Ref. to AB-15, INSPECTION, Drivers Airbag Module.>
4) Remove the steering wheel. <Ref. to PS-20, REMOVAL, Steering Wheel.>
5) Remove the cover from steering wheel.
6) Remove each one of AT steering shift switch
mounting screw from the LH and RH side.
CS-00331
7) Remove the steering shift switch.
B: INSTALLATION
1) Clean all parts before installation.
3) After completion of installation, set the select lever to SPORT shift side and confirm that manual
mode 1 illuminates on the combination meter.
4) Operate the steering shift switch and confirm
that the 2 illuminates on combination meter.
CS-16
AT Steering Shift Switch

CONTROL SYSTEMS
C: INSPECTION
1 2 3 4 5
CS-00387
Step
SHIFT-UP SWITCH CONTINUITY CHECK.
1) Press the shift-up switch.
2) Measure the resistance between shift
switch connector terminals.
Terminals
No. 4 No. 3:
SHIFT-DOWN SWITCH CONTINUITY
CHECK.
1) Press the shift-down switch.
Terminals
No. 3 No. 2:
CHECK SHIFT SWITCH INSULATION.
1) Not to operate the shift switch.
Terminals
No. 3 No. 2:
No. 3 No. 4:
Check
?
Yes
Go to step 2.
No
Replace the steering shift switch.

?
Go to step 3.
Is the resistance 1 M?
Steering shift
switch is normal.
CS-17
Shift Lock Solenoid

CONTROL SYSTEMS
5. Shift Lock Solenoid
9) Press the select lever backward while lifting up

the detent spring and remove the shift lock solenoid
assembly.
A: REMOVAL
4) Remove the grip.
5) Remove the indicator cover.
(A)
(B)
CS-00391
(A) Detent spring

(B) Shift lock solenoid ASSY
10) Raise the connector pawl.

CS-00388
6) Remove the blind.

7) Remove the bolts, and then remove the guide
plate.
CS-00292
11) Use a flat-tip screwdriver with thin tip to disconnect the connectors from terminals of P range
switch and shift lock solenoid assembly.
CS-00377
8) Remove the connector from the plate assembly

using a flat-tip screwdriver.
(A)
4 3
2 1
10 9 8 7 6 5
CS-00392
(A) Shift lock solenoid terminal

CS-00390
B: INSTALLATION
NOTE:
Refer to COMPONENT for each tightening
torque. <Ref. to CS-2, COMPONENT, General Description.>
When installing the guide plate, shift the select
lever to D range (normal mode position), care
should be taken in the following points.
CS-18
Shift Lock Solenoid

CONTROL SYSTEMS
Insert the protrusion (B) of guide plate into the

hole of shift lock solenoid assembly (A).
Insert the link (D) of shift lock release into the
link (C) of shift lock solenoid assembly.
a
(B)
(A)
b
(D)
(C)
CS-00384
Connect the switch and solenoid terminal to connector.
(B)
1
5
2
6
(A)
3 4
8 9 10
CS-00393
(A) Shift lock solenoid (Color code: Blue and Red)

(B) Shift lock solenoid (Color code: Black)
CS-19
Shift Lock Solenoid

CONTROL SYSTEMS
C: INSPECTION
1
Step
Check
CHECK SHIFT LOCK SOLENOID.
Measure the resistance of shift lock solenoid
connector terminals.
Terminals
No. 4 No. 3:
Does the shift lock solenoid
Connect the battery to shift lock solenoid con- operate normally?
nector terminal, and then operate the solenoid.
Terminals
No. 3 (+) No. 4 ():
CS-20
Yes
Go to step 2.
No
Replace the shift
lock solenoid.
Normal operation
Replace the shift

lock solenoid.
MT Gear Shift Lever

CONTROL SYSTEMS
6. MT Gear Shift Lever

A: REMOVAL
3) Remove the gear shift knob.
5) Remove the clamp.

SOHC model
DOHC turbo model
<Ref. to EX(H4DOTC)-11, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-10, REMOVAL, Joint Pipe.>
CS-00311
6) Remove the boot and insulator assembly.
AT-01331
12) Remove the stay from transmission bracket.
CS-00312
(A)
7) Remove the harness clamp from plate.
(B)
CS-00050
(A) Stay
(B) Transmission bracket
13) Remove the rod from joint.

CS-00313
8) Remove the plate assembly from vehicle body.

(C)
(B)
(D)
(A)
(A)
(B)
CS-00051
(A) Stay
(B) Rod
CS-00314
CS-21
MT Gear Shift Lever

CONTROL SYSTEMS
14) Remove the cushion rubber from vehicle body.
NOTE:
Insert the rod and the stay, and then temporarily set
them onto transmission mount.
(A)
(B)
CS-00052
(A) Stay
(B) Cushion rubber
CS-00315

4) Mount the cushion rubber on the vehicle body.
15) Extract the spring pin and remove the joint.
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
(A)
(A)
(B)
(B)
CS-00053
(A) Joint
(B) Spring pin
CS-00052

17) Remove the gear shift lever.
(A) Stay
(B) Cushion rubber
5) Using new self-locking nuts, connect the rod to

the joint.
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
(A)
CS-00315
(B)
B: INSTALLATION
1) Install the joint to transmission and secure with
spring pin.
2) Insert the gear shift lever from the room side.
CS-00051
(A) Stay
(B) Rod
6) Using new self-locking nuts, connect the stay to

transmission bracket.
CS-22
MT Gear Shift Lever

CONTROL SYSTEMS
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
(5) Tighten the bolts (C) and (D).

(C)
(B)
(D)
(A)
(A)
(B)
CS-00314
10) Install the harness clamp to plate.

11) Install the boot and insulator assembly, and secure them with clamp.
CS-00050
(A) Stay
(B) Transmission bracket
CS-00312
12) Install the console box. <Ref. to EI-53, INSTALLATION, Console Box.>
AT-01331

SOHC model
<Ref. to EX(H6DO)-8, INSTALLATION, Rear Exhaust Pipe.> <Ref. to EX(H6DO)-10, INSTALLATION, Muffler.>
DOHC turbo model
9) Install the plate assembly to vehicle body.
C: DISASSEMBLY
1) Remove the lock wires.
(A)
CS-00316
(A) Lock wire
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
(1) Set the plate assembly to vehicle.
(2) Temporarily tighten the bolt (A).
(3) Tighten the bolt (B).
(4) Tighten the bolt (A).
CS-23
MT Gear Shift Lever

CONTROL SYSTEMS
2) Remove the rod from lever.
6) Remove the boot, bushing and snap ring from

gear shift lever.
(A)
(B)
(B)
(A)
(C)
(A)
(C)
CS-00317
CS-00320
(A) Rod
(B) Lever
(C) Stay
3) Separate the rod and inner boot.

4) Remove the snap ring from the stay.
(A) O-ring
(B) Bushing
(C) Snap ring
7) Remove the spring pin, and then remove the

bushing and snap ring.
(A)
(B)
(A)
CS-00318
CS-00060
(A) Snap ring

(A) Spring pin
(B) Bushing
5) Separate the gear shift lever and the stay.
8) Remove the boss from the joint.
CS-00319
CS-00322
CS-24
MT Gear Shift Lever

CONTROL SYSTEMS
2) Install the bushing and spacer to boss.
9) Remove the bushing and spacer from boss.

(A)
(A)
(B)
(B)
(A)
(A)
CS-00238
(A) Bushing
(B) Spacer
CS-00238
(A) Bushing
(B) Spacer
10) Remove the bushing and cushion rubber from

the stay.
3) Using new self-locking nuts, install the boss to

the joint.
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
(A)
(B)
(C)
CS-00058
(A) Bushing B
(B) Stay
(C) Cushion rubber
CS-00322
4) Install the snap ring to gear shift lever and install

the bushing.
D: ASSEMBLY
NOTE:
Clean all the parts before assembly.
Apply grease [KOPR-KOTE (Part No.
003603001) or equivalent] to each part.
1) Mount the bushing and cushion rubber on the
stay.
NOTE:
Apply grease to the bushing.
(A)
(B)
(A)
CS-00060
(B)
(A) Spring pin

(B) Bushing
CS-00061
(A) Bushing
(B) Cushion rubber
CS-25
MT Gear Shift Lever

CONTROL SYSTEMS
5) Apply grease to the bushing and O-ring, and

then install to the gear shift lever.
(A)
(B)
(A)
Tightening torque:
12 Nm (1.2 kgf-m, 8.9 ft-lb)
(C)
(B)
(A)
(C)
CS-00320
(A) O-ring
(B) Bushing
(C) Snap ring
CS-00317
(A) Rod
(B) Lever
(C) Stay
6) Apply sufficient grease into boss, and then install

the gear shift lever to the stay.
10) Install a new lock wire.
(A)
CS-00316
CS-00319
(A) Lock wire
7) Install the washer and snap ring.
NOTE:
Install the lock wire to the stay groove.
(A)
CS-00318
(A) Snap ring
8) Insert the gear shift lever and rod into boot hole.
9) Install the rod.
CS-26
MT Gear Shift Lever

CONTROL SYSTEMS
Bend the extra wire to same direction of lock wire

winding.
(A)
(A)
B
E: INSPECTION
1) Check the parts (bushing, cushion rubber, spacer, boot, stay and rod, etc.) for deformation, damage and wear. If necessary, repair or replace faulty
parts. Compare the removed parts with new ones
to judge if there are damages or not.
(B)
(B)
(C)
(F)
(A)
(C)
(A)
(C)
(A)
(C)
(D)
(B)
B-B
(B)
CS-00240
(A) Inner boot

(B) Lock wire
(C) Stay
(E)
CS-00323
(A)
(B)
(C)
(D)
(E)
(F)
Bushing
Cushion rubber
Spacer
Boot
Stay
Rod
2) Check the swing torque of rod linked with the

gear shift lever.
If the torque exceeds the specifications, replace the
bushing or retighten nuts.
Swing torque:
Less than 3.7 N (0.38 kgf, 0.84 lb)
(B)
(A)
CS-00116
(A) Pivot
(B) Swing torque
CS-27
MT Drive Select Lever

CONTROL SYSTEMS
7. MT Drive Select Lever
B: INSTALLATION
A: REMOVAL
1) Secure the drive select cable to the lever with

clip, and temporary tighten the flange nut.
1) Place the drive select lever in HI position.

2) Push the both sides of knob, and remove the
cover. (Rubber type)
(A)
(A)
(B)
CS-00397
(B)
(A) Flange nut

(B) Clip
CS-00395
2) Install the drive select lever to vehicle.
(A) Cover
(B) Knob
3) Insert a screwdriver with thin tip into the both

sides of knob, and push to remove the cover.
(Leather type)
4) Remove the bolt, and then remove the knob.
6) Remove the drive select lever from vehicle body.
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
CS-00396
3) Adjust the drive select cable. <Ref. to CS-31,

ADJUSTMENT, Drive Select Cable.>
C: DISASSEMBLY
CS-00396
7) Remove the flange nut and clip, and then remove the drive select cable.
1) Remove the bolt and nut.

2) Remove the lever and spring.
(A)
(B)
(A)
(B)
CS-00398
CS-00397
(A) Lever
(B) Spring
(A) Flange nut

(B) Clip
CS-28
MT Drive Select Lever

CONTROL SYSTEMS
3) Remove the bushing and spacer from plate assembly.
(B)
(A)
(A)
CS-00399
(A) Bushing
(B) Spacer
4) Remove the bushing from plate assembly.
CS-00400
D: ASSEMBLY
Tightening torque:
12 Nm (1.2 kgf-m, 8.9 ft-lb)
NOTE:
Refer to COMPONENT for greasing points. <Ref.
to CS-2, COMPONENT, General Description.>
2) Check the select lever for smooth operation.
E: INSPECTION
1) Check the select lever for smooth operation. If
not, check the transmission and drive select lever.
2) Transmission gear switches between HI and LO
positions normally. If not, adjust the drive select cable, and inspect the transmission.
3) Check that the drive select lever is not damaged.
Repair or replace if it is damaged.
CS-29
Drive Select Cable

CONTROL SYSTEMS
8. Drive Select Cable
8) Remove the clamp, and remove the drive select

cable from plate assembly.
A: REMOVAL
(A)
(B)
CS-00395
(A) Cover
(B) Knob

(Leather type)
7) Loosen the flange nut.
CS-00402
9) Remove the boot and insulator assembly.
CS-00312
10) Remove the air intake chamber and air intake

duct. <Ref. to IN(H4SO 2.0)-8, REMOVAL, Air Intake Chamber.> <Ref. to IN(H4SO 2.0)-9, REMOVAL, Air Intake Duct.>
11) Remove the snap pin and clevis pin.
(B)
(A)
CS-00401
CS-00403
(A) Snap pin

(B) Clevis pin
CS-30
Drive Select Cable

CONTROL SYSTEMS
12) Loosen the nut, and remove the cable from cable bracket.
D: ADJUSTMENT
(A)
(B)
CS-00404
13) Lift-up the vehicle, and then remove the cable

under vehicle.
CS-00395
(A) Cover
(B) Knob

(Leather type)
6) Loosen the flange nut.
CS-00405
B: INSTALLATION
NOTE:
Adjust the drive select cable. <Ref. to CS-31,
ADJUSTMENT, Drive Select Cable.>
Refer to COMPONENT for tightening torque.
<Ref. to CS-2, COMPONENT, General Description.>
Correctly insert the cable end bolt to slit of lever
arm.
C: INSPECTION
1) Check the transmission is set in HI or LO position according to the operation of drive select lever.
<Ref. to CS-31, ADJUSTMENT, Drive Select Cable.>
2) Check the cable for damage.
3) Check the cable for smooth operation. Replace
the cable if it does not operate smoothly.
CS-00401
7) Verify the transmission gear is set in HI position.

If not, pull the cable to set it in HI position.
8) Verify the select lever is set in HI position.
9) Tighten the flange nut with cable fixed.
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
CS-31

CONTROL SYSTEMS

A: INSPECTION
Symptom
Select lever
Possible cause
Starter does not run.
Back-up light does not illuminate.
Shift lock control system does not operate normally.
Manual mode is not engaged.
Drive select lever
Up-shift is not engaged at manual mode.

Down-shift is not engaged at manual mode.
Does not shift to HI or LO.
CS-32
Corrective action
Adjust the select cable and inhibitor switch, or
inspect circuit.
Adjust the select cable and inhibitor switch, or
inspect circuit.
Inspect shift lock circuit.
Adjust the mode switch and select lever, or inspect
circuit.
Check the shift-up switch and circuit.
Check the shift-down switch and circuit.
Adjust the drive select cable, or inspect transmission.
4AT
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.
Page
Differential Gear Oil...................................................................................33
Road Test..................................................................................................34
Stall Test ...................................................................................................35
Time Lag Test ...........................................................................................37
Line Pressure Test ....................................................................................38
Transfer Clutch Pressure Test ..................................................................39
Automatic Transmission Assembly ...........................................................40
Transmission Mounting System ................................................................48
Extension Case Oil Seal ...........................................................................50
Differential Side Retainer Oil Seal.............................................................51
Inhibitor Switch..........................................................................................52
Front Vehicle Speed Sensor .....................................................................55
Rear Vehicle Speed Sensor......................................................................58
Torque Converter Turbine Speed Sensor .................................................59
Control Valve Strainer ...............................................................................60
Control Valve Body ...................................................................................62
Air Bleeding of Control Valve ....................................................................65
ATF Filter ..................................................................................................66
Transmission Control Module (TCM) ........................................................67
Lateral G Sensor .......................................................................................68
ATF Cooler Pipe and Hose .......................................................................69
ATF Cooler (with Warmer Function) .........................................................74
Warmer Cock ............................................................................................78
Air Breather Hose......................................................................................80
Oil Charge Pipe.........................................................................................81
Torque Converter Clutch Assembly ..........................................................82
Extension Case .........................................................................................84
Transfer Clutch..........................................................................................88
Multi-plate Clutch ......................................................................................94
Rear Drive Shaft........................................................................................95
Reduction Driven Gear..............................................................................96
Reduction Drive Gear................................................................................98
Center Differential Carrier .......................................................................100
Parking Pawl ...........................................................................................102
Converter Case .......................................................................................103
Oil Pump Housing ...................................................................................105
Drive Pinion Shaft Assembly...................................................................110
Front Differential Assembly .....................................................................115
AT Main Case .........................................................................................121
Transmission Control Device ..................................................................142
General Description
5. PLANETARY GEAR AND PLATE
A: SPECIFICATION
1. TORQUE CONVERTER CLUTCH
Model
Type
Stall torque ratio
Nominal
mm (in)
diameter
Stall speed (at sea
level)
One-way clutch
2.0 L
2.5 L
Symmetric, 3 element, single stage,
2 phase torque converter
2.0 2.2
2.1 2.3
236 (9.29)
249 (9.69)
2,300 2,700
2,500 2,900
rpm
rpm
Sprague type one-way clutch
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

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
Model
Front sun gear
number of teeth
Front pinion number of teeth
Front internal gear
number of teeth
Rear sun gear
number of teeth
Rear pinion number of teeth
Rear internal gear
number of teeth
Drive plate number of high clutch
Drive plate number of low clutch
Drive plate number of reverse
clutch
Drive plate number of 2-4 brake
Drive plate number of low &
reverse brake
1st
2nd
3rd
4th
Rev
2.785
1.545
1.000
0.694
2.272
2.5 L
33
21
75
42
17
75
4
5
2
6. SELECTOR POSITION
P (Park)
R (Reverse)
4. TRANSMISSION GEAR RATIO
2.0 L
N (Neutral)
D (Drive)
SPORT mode
Manual mode (+)
Manual mode ()
Control method
4AT-2
Transmission in neutral, output member immovable, and engine start possible

Transmission in reverse for backing
Transmission in neutral and engine
start possible
4-forward automatic gear change
1st 2nd 3rd 4th
4-forward automatic gear change
1st 2nd 3rd 4th
4-forward manual gear change
(shift up)
1st 2nd 3rd 4th
4-forward manual gear change
(shift down)
1st 2nd 3rd 4th
Wire cable
General Description
7. HYDRAULIC CONTROL AND LUBRICATION
8. COOLING AND HARNESS

Cooling System
Inhibitor switch
Transmission harness
Electronic hydraulic control

[Four forward speed changes
Type
by electrical signals of vehicle
speed and accelerator (throttle)
opening]
SUBARU ATF or Idemitsu
Apolloil ATF HP, Castrol
Transmax J
Fluid
NOTE:
If the ATFs above are not available, use Dexron III.
8.4 8.7
2.0 L
(8.9 9.2, 7.4 7.7)
2 (US qt,
Fluid capacity
Imp qt)
9.3 9.6
2.5 L
(9.8 10.1, 8.2 8.4)
Forced feed lubrication with oil
Lubrication system
pump
Automatic transmission fluid
Oil
(above mentioned)
Liquid-cooled cooler
12 poles
20 poles
9. TRANSFER
Model
2.0 L
2.5 L
except for
VTD model
Multi-plate transfer (MPT)
Transfer type
Drive & driven
plate number of
transfer clutch
Control method
2.5 L
VTD model
Variable
torque distribution
(VTD)
3
Electronic hydraulic type

The same Automatic transmission fluid
used in automatic transmission
Lubricant
Reduction gear
ratio
1.000 (53/53)
10.FINAL REDUCTION
Model
Front final reduction gear ratio
Except for OUTBACK

4.111 (37/9)
OUTBACK
4.444 (40/9)
11.RECOMMENDED GEAR OIL
( C)
( F)
(1)
(2)
(3)
GL-5
(4)
-30 -26 -15 -5 0
-22 -15 5 23 32
Lubrication oil
15
59
25 30
77 86
90
85W
80W
75W -90
MT-00001
(1) Item
(2) Front differential gear oil
Front differential oil capacity
2 (US qt, Imp qt)
(3) API classification

1.1 1.3 (1.2 1.4, 1.0 1.1)
4AT-3
General Description
B: COMPONENT
1. TORQUE CONVERTER CLUTCH AND CASE
(2)
(1)
(4)
(19)
(3)
T4
T3
(16)
T2
(18)
(17)
T4
(5)
(15)
(6)
(7)
(14)
(8)
T1
T4
T4
(13)
T5
(12)
(9)
(10)
(11)
AT-02159
(1)
(2)
Pitching stopper bracket

O-ring
(3)
(4)

T1: 18 (1.8, 13.0)
(11)
(12)
Torque converter clutch ASSY

Drain plug
Differential oil level gauge
(13)
Gasket
T2: 23 (2.3, 16.7)
Stay
(14)
Oil seal
T3: 33 (3.4, 24.3)
(5)
(6)
Seal pipe
Oil pump shaft
(15)
(16)
Converter case
Harness stay
T4: 41 (4.2, 30.4)

T5: 44 (4.5, 32.5) (Aluminum gasket)
(7)
(8)
(9)
(10)
Clip
Oil drain pipe
Input shaft
O-ring
(17)
ATF cooler ASSY with warmer

function (if equipped)
(18)
(19)
Bracket (if equipped)

Clip (if equipped)
4AT-4
70 (7.1, 51.6) (Copper gasket)
General Description
2. OIL PUMP
AT-00003
(1)
(2)
(3)
(4)
Oil pump rotor

Oil pump cover
Seal ring
Thrust needle bearing
(11)
(12)
(13)
(14)
Gasket
O-ring
Test plug
Stud bolt
(21)
Lock nut
(5)
Drive pinion shaft
(15)
O-ring
T2: 13 (1.3, 9.4)
(6)
Roller bearing
(16)
O-ring
T3: 18 (1.8, 13.0)

T1: 7 (0.7, 5.1)
(7)
Shim
(17)
Oil seal retainer
T4: 25 (2.5, 18.1)
(8)
Oil pump housing
(18)
Oil seal
T5: 40 (4.1, 30)
(9)
(10)
Nipple
Air breather hose
(19)
(20)
O-ring
Drive pinion collar
T6: 42 (4.3, 31)

T7: 116 (11.8, 85)
4AT-5
General Description
3. TRANSMISSION CASE AND CONTROL DEVICE
(34)
(39)
T1
(1)
(33)
(32)
T4
(2)
T9
(36)
T3
(35)
T9
(5)
(3)
(38)
(6)
(7)
(31)
(37)
(4)
(41)
T9
(29)
T8
(8)
(40)
(31)
(9)
(27)
(28)
T10
(11)
(30)
(16)
(29)
T9
(13)
(28)
(14)
(28)
T5
(10)
(26)
(21)
(25)
T6
T9
(15)
(23)
(19)
T2
(20) (18)
(17)
(22)
(12)
T9
T9
(11)
(24)
T3
T9
(12)
T7
AT-02160
4AT-6
General Description
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
ATF level gauge

Oil charge pipe
O-ring
Straight pin
Return spring
Shaft
Parking pawl
Parking support
Bushing
Gasket
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
Oil pan
Magnet
Stud bolt (Short)
Stud bolt (Long)
Parking rod
Manual plate
Spring pin
Detention spring
Ball
Spring
(37)
(38)
(39)
(40)
Transmission case
Plate ASSY
Washer
Inlet pipe (Model with ATF cooler
with warmer function)
(41)
Outlet pipe (Model with ATF

cooler with warmer function)
(11)
Inlet pipe (Model without ATF

(29)
Gasket
T2: 5 (0.5, 3.6)
(30)
Outlet pipe (Model without ATF

T3: 6 (0.6, 4)

T1: 3.4 (0.35, 2.5)
(12)
Union screw
(13)
O-ring
(31)
Union screw
T4: 12 (1.2, 8.7)

T5: 13 (1.3, 10)
(14)
Test plug
(32)
Oil seal
T6: 14 (1.4, 10)
(15)
(16)
Oil filter
Oil filter stud bolt
(33)
(34)
Select lever
Inhibitor switch ASSY
T7: 18 (1.8, 13)

T8: 21 (2.1, 15.5)
(17)
Drain plug
(35)
Nipple
(18)
Gasket
(36)
Air breather hose
T9: 25 (2.5, 18.1)
4AT-7
T10: 44 (4.5, 32.5)
General Description
4. CONTROL VALVE AND HARNESS ROUTING
(2)
(1)
T1
(6)
(7)
(4)
(8)
(5)
(9)
(3)
T1
T1
(10)
T2
AT-01322
(1)
(2)
Stay
(6)
(7)
O-ring
Front vehicle speed sensor
(3)
O-ring
(8)
O-ring
(4)
(5)
O-ring
Torque converter turbine speed
sensor
(9)
(10)
Rear vehicle speed sensor

Control valve body

T1: 7 (0.7, 5.1)
T2: 8 (0.8, 5.8)
4AT-8
General Description
5. HIGH CLUTCH AND REVERSE CLUTCH
AT-00006
(1)
(2)
(3)
(4)
(5)
(6)
(7)
High clutch drum

Lip seal
D-ring
Reverse clutch piston
D-ring
D-ring
High clutch piston
(8)
(9)
(10)
(11)
(12)
(13)
(14)
Spring retainer
Cover
Snap ring
Driven plate (high clutch)
Drive plate (high clutch)
Retaining plate (high clutch)
Snap ring
4AT-9
(15)
(16)
(17)
(18)
(19)
(20)
(21)
Dish plate
Driven plate (reverse clutch)
Drive plate (reverse clutch)
Retaining plate (reverse clutch)
Snap ring
High clutch hub
General Description
6. PLANETARY GEAR AND 2-4 BRAKE

(5)
(4)
(3)
(2)
(13)
(1)
(12)
(11)
(10)
(9)
(8)
(7)
(6)
(19)
(18)
(16)
(17)
(16)
(17)
(16)
(15)
(14)
(24)
(26)
(23)
(25)
(22)
(21)
(20)
AT-00007
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)

Front sun gear
Snap ring
Front planetary carrier
Rear sun gear
Rear planetary carrier
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
Washer
Rear internal gear
Washer
Snap ring
Retaining plate
Drive plate
Driven plate
Pressure rear plate
4AT-10
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
Snap ring
Spring retainer
2-4 brake piston
D-ring
D-ring
2-4 brake piston retainer
2-4 brake seal
Leaf spring
General Description
7. LOW CLUTCH AND LOW & REVERSE BRAKE

(10) (11)
(9)
(8)
(7)
(5)
(6)
(4)
(3)
(3)
(4)
(2)
(1)
(16)
(15)
(14)
(13)
(12)
(21)
(23)
(22)
(20)
(19)
(18)
(30)
(17)
(29)
(28)
(27)
(28)
(27)
(24)
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
Snap ring
Retaining plate
Drive plate
Driven plate
Dish plate
Snap ring
Cover
Spring retainer
D-ring
Low clutch piston
D-ring
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(25)
(26)
AT-01278
Low clutch dram

Needle bearing
Snap ring
One-way clutch
Snap ring
Seal ring
Needle bearing
One-way clutch inner race
Socket bolt
Spring retainer
4AT-11
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
Return spring
Snap ring
Retaining plate
Leaf spring
Drive plate
Driven plate
Dish plate
Low & reverse brake piston

T: 25 (2.5, 18.1)
General Description
8. REDUCTION GEAR
(4)
(3)
(2)
(8)
(1)
(8)
(11)
(9)
(10)
(8)
(7)
(6)
(5)
AT-02161
(1)
(2)
(3)
(4)
(5)
Seal ring
Ball bearing
Reduction drive gear
Reduction drive shaft
Drive pinion shaft
(6)
(7)
(8)
(9)
(10)
Snap ring
Ball bearing
Snap ring
Reduction driven gear
Washer
4AT-12
(11)
Lock nut

T: 100 (10.2, 73.8)
General Description
9. REDUCTION GEAR WITH VTD
(7)
(4)
(3)
(11)
(6)
(2)
(10)
(5)
(4)
(9)
(3)
(8)
(23)
(1)
(22)
(21)
(19)
(20)
(19)
(17)
(18)
(16)
(15)
(14)
(13)
(12)
(32)
(31)
(29)
(30)
(27)
(27)
(28)
(25)
(26)
(27)
(24)
AT-02203
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
Ball bearing
Reduction drive gear
Washer
Needle bearing
Pinion gear
Carrier
Planetary pinion shaft
Snap ring
Seal ring
Intermediate shaft
Thrust washer
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
Rear drive shaft

Ball bearing
Multi-plate clutch (LSD) hub
Ball bearing
Revolution gear
Driven plate (Thicker)
Drive plate
Driven plate (Thinner)
Pressure plate
Rear drive shaft shim
Drive pinion shaft
4AT-13
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
Snap ring
Ball bearing
Snap ring
Lock washer
Lock nut
Gasket
Extension case

T: 100 (10.2, 73.8)
General Description
10.DIFFERENTIAL GEAR
(12)
(1)
(13)
(2)
(11)
(3)
(12)
(11)
(4)
(13)
(5)
T2
(10)
T1
T1
(10)
(6)
(9)
(7)
(8)
(7)
(8)
(6)
(9)
AT-00011
(1)
(2)
(3)
(4)
(5)
(6)
Hypoid driven gear

Pinion shaft
Differential case (RH)
Straight pin
Differential case (LH)
Taper roller bearing
(7)
(8)
(9)
(10)
(11)
(12)
Oil seal
O-ring
Differential side retainer
Lock plate
Washer
Differential bevel pinion
4AT-14
(13)
Differential bevel gear

T1: 25 (2.5, 18.1)
T2: 62 (6.3, 45.6)
General Description
11.TRANSFER AND EXTENSION CASE

(6)
(7)
(5)
(6)
(5)
(14)
(4)
(3)
(1)
(2)
(13)
(12)
(20)
T2
(11)
(19)
(18)
(10)
(9)
(8)
(21)
(15)
T1
(22)
T2
(17)
(16)
AT-01784
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)

Needle bearing
Snap ring
Pressure plate
Drive plate
Driven plate
Retaining plate
Snap ring
Transfer piston seal
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
Return spring
Transfer clutch piston
Rear drive shaft
Ball bearing
Seal ring
Gasket
Transfer clutch pipe
Extension case
Transmission hanger
4AT-15
(19)
(20)
(21)
(22)
Oil seal
Dust cover
Test plug
O-ring

T1: 13 (1.3, 9.4)
T2: 25 (2.5, 18.1)
General Description
12.TRANSFER AND EXTENSION CASE WITH VTD

(5)
(4)
(2)
(3)
(2)
(1)
T1
(20)
(19)
T3
(12)
(18)
(17)
(16)
(9)
T2
(15)
(14)
(11)
(10)
(13)
(8)
(7)
(6)
AT-00013
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)

Drive plate
Driven plate (Thinner)
Adjusting plate
Snap ring
Spring retainer
Plate
O-ring
(10)
Multi-plate clutch (LSD) piston

ASSY
(11)
(12)
(13)
(14)
(15)
(16)
(17)
D-ring
Gasket
Multi-plate clutch (LSD) pipe
Extension case
O-ring
Test plug
Oil seal
4AT-16
(18)
(19)
(20)
Dust cover
O-ring

T1: 7 (0.7, 5.1)
T2: 13 (1.3, 9.4)
T3: 25 (2.5, 18.1)
General Description
13.ATF COOLER WITH ATF WARMER FUNCTION
(2)
(3)
(3)
(6)
(1)
(3)
(3)
(3)
(3)
(8)
T
(4)
(7)
(3)
(5)
(3)
AT-03198
(1)
(2)
(3)
(4)
ATF cooler outlet hose

ATF cooler inlet hose
Hose clamp
ATF cooler ASSY
(5)
(6)
(7)
(8)
Engine coolant inlet pipe

Engine coolant outlet pipe
ATF cooler bracket
Clip
4AT-17

T: 23 (2.3, 16.6)
General Description
14.TRANSMISSION MOUNTING
(2)
T2
T2
T4
(1)
(3)
T3
T5
(4)
T1
T5
AT-00014
(1)
(2)
Pitching stopper
Rear cushion rubber
(3)
(4)
Crossmember
Stopper
4AT-18

T1: 35 (3.6, 26)
T2: 40 (4.1, 30)
T3: 50 (5.1, 37)
T4: 58 (5.9, 43)
T5: 70 (7.1, 51)
General Description
C: CAUTION
Do not place the oil pan with its inner side facing
upward until it is installed so as to prevent foreign
matter intrusion into valve body.
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.
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 bolts and nuts to the specified
torque.
points.
Apply gear oil or ATF onto sliding or revolution
surfaces before installation in view of components
usage.
Replace deformed or otherwise damaged snap
rings with new ones.
Before installing O-rings or oil seals, apply sufficient amount of ATF 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 vice, place cushioning material such as wood blocks, aluminum plate
or cloth between the part and the vice.
Avoid damaging the mating surface of the case.
Before applying liquid gasket, completely remove the old seal.
4AT-19
General Description
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
498575400
DESCRIPTION
OIL PRESSURE
GAUGE ASSY
REMARKS
Used for measuring oil pressure.
498897200
ADAPTER
Used for oil pump housing when measuring

reverse clutch pressure and line pressure.
498897700
ADAPTER SET
Used for measuring transfer clutch pressure.
498545400
FILTER WRENCH
Used for removing and installing ATF filter.
ST-498575400
ST-498897200
ST-498897700
ST-498545400
4AT-20
General Description
ILLUSTRATION
TOOL NUMBER
498277200
DESCRIPTION
STOPPER SET
REMARKS
Used for removing and installing automatic
transmission assembly to engine.
398527700
PULLER ASSY
Used for removing extension case roller bearing.

Used for removing extension oil seal.
Used for removing front differential side
retainer bearing outer race.
retainer oil seal.
498057300
INSTALLER
Used for installing extension oil seal.
ENGINE SUPPORT
ASSY
Used for supporting engine.

(1) ENGINE SUPPORT BRACKET
(41099AC010)
(1) ENGINE SUPPORT (41099AC020)
ST-498277200
ST-398527700
ST-498057300
41099AC000
ST41099AC000
4AT-21
General Description
ILLUSTRATION
TOOL NUMBER
498077000
DESCRIPTION
REMOVER
REMARKS
Used for removing differential taper roller bearing.
499247400
INSTALLER
Used for installing transfer outer snap ring.

Used with GUIDE (499257300).
499257300
SNAP RING
OUTER GUIDE
Used for installing transfer outer snap ring.

Used with INSTALLER (499247400).
499787000
WRENCH ASSY
Used for removing and installing differential side

retainer.
ST-498077000
ST-499247400
ST-499257300
ST-499787000
4AT-22
General Description
ILLUSTRATION
TOOL NUMBER
398437700
DESCRIPTION
DRIFT
REMARKS
Used for installing converter case oil seal.
398487700
INSTALLER
Used for installing front differential taper roller

bearing.
398673600
COMPRESSOR
Used for removing and installing clutch spring.
498255400
PLATE
Used for measuring backlash of hypoid gear.
ST-398437700
ST-398487700
ST-398673600
ST-498255400
4AT-23
General Description
ILLUSTRATION
TOOL NUMBER
399893600
DESCRIPTION
PLIERS
REMARKS
Used for removing and installing clutch spring.
498247001
MAGNET BASE
Used for measuring gear backlash.

Used with DIAL GAUGE (498247100).
498247100
DIAL GAUGE

Used with MAGNET BASE (498247001).
498517000
REPLACER
Used for removing front roller bearing.
ST-399893600
ST-498247001
ST-498247100
ST-498517000
4AT-24
General Description
ILLUSTRATION
TOOL NUMBER
398623600
DESCRIPTION
SEAT
REMARKS
Used for removing spring of transfer clutch piston.
499267300
STOPPER PIN
Used for installing inhibitor switch.
499787700
WRENCH
Used for removing and installing drive pinion lock

nut.
499787500
ADAPTER

nut.
ST-398623600
ST-499267300
ST-499787700
ST-499787500
4AT-25
General Description
ILLUSTRATION
TOOL NUMBER
398643600
DESCRIPTION
GAUGE
REMARKS
Used for measuring total end play, extension end
play and drive pinion height.
498627100
SEAT
Used for holding low clutch piston retainer spring

when installing snap ring.
499577000
GAUGE
Used for measuring mating surface of transmission to end of reduction gear.
398744300
PISTON GUIDE
Used for measuring height from mating surface of transmission case to pressure plate.
For VTD model
ST-398643600
ST-498627100
ST-499577000
ST-398744300
4AT-26
General Description
ILLUSTRATION
TOOL NUMBER
499737000
DESCRIPTION
PULLER
REMARKS
Used for removing reduction driven gear assembly.
499737100
PULLER SET
Used for removing reduction drive gear assembly.
498077600
REMOVER
Used for removing ball bearing.
498937110
HOLDER

nut.
ST-499737000
ST-499737100
ST-498077600
ST-498937110
4AT-27
General Description
ILLUSTRATION
TOOL NUMBER
498677100
DESCRIPTION
COMPRESSOR
REMARKS
Used for installing 2-4 brake snap ring.
498437000
HIGH CLUTCH PISTON GUIDE
Used for installing high clutch piston.
498437100
LOW CLUTCH PISTON GUIDE
Used for installing low clutch piston.
899580100
INSTALLER
Used for press-fitting of ball bearing for transfer

clutch.
ST-498677100
ST-498437000
ST-498437100
ST-899580100
4AT-28
General Description
ILLUSTRATION
TOOL NUMBER
28399SA010
DESCRIPTION
REMARKS
OIL SEAL PROTEC- Used for installing axle shaft.
TOR
ST28399SA010
18675AA000
DIFFERENTIAL OIL
SEAL INSTALLER
Used for installing differential side retainer oil

seal.
398497701
SEAT
Used for installing needle bearing.
899524100
PULLER SET
Used for bolt only.

Used with PULLER SET (499737100).
Used with PULLER (499737000).
(1) Puller
(2) Cap
ST18675AA000
ST-398497701
ST-899524100
4AT-29
General Description
ILLUSTRATION
TOOL NUMBER
499247300
DESCRIPTION
INSTALLER
REMARKS
Used for installing oil pump housing retainer oil
seal.
24082AA230
CARTRIDGE
22771AA030
SUBARU SELECT
MONITOR KIT

ST-499247300
ST24082AA230
ST22771AA030
2. GENERAL TOOL
TOOL NAME
Depth gauge
Thickness gauge
Micro meter
Spring balance
Circuit tester
TORX T70
Push/pull gauge
REMARKS
Used for measuring transmission end play.
Used for measuring clearance of clutch, brake and oil pump.
Used for measuring thickness of drive pinion.
Used for measuring starting torque of drive pinion.
Used for measuring resistance and voltage.
Used for removing and installing differential gear oil drain plug.
Used for measuring clutch piston stroke.
4AT-30

2. Automatic Transmission Fluid
B: REPLACEMENT
A: INSPECTION
1) Lift up the vehicle.

2) Remove the ATF drain plug to drain ATF.
NOTE:
The level of ATF varies with fluid temperature. Pay
attention to the ATF temperature when checking
ATF level.
3) After selecting all positions (P, R, N, D), set the
CAUTION:
Directly after the engine has been running, the
ATF is hot. Be careful not to burn yourself.
3) Check the condition of ATF. <Ref. to 4AT-32,
CONDITION CHECK, Automatic Transmission
Fluid.>
4) Tighten the ATF drain plug.
NOTE:
Use a new gasket.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
(A)
(B)
L
F
HOT
(A)
(C)
COLD
L
(B)
(B)
AT-01332
(C)
AT-01323
(A) Oil pan

(B) ATF drain plug
(A) ATF level gauge

(B) Upper level
(C) Lower level

6) Pour ATF from the oil charge pipe.
4) Make sure that ATF level is above the center of

upper level and lower level at HOT side.
5) If the ATF level is below the center between upper level and lower level, replenish a recommended ATF until the fluid level exceeds the center
between upper level and lower level.
Recommended fluid:
SUBARU ATF (Part No. K0410Y0700) or Idemitsu Apolloil ATF HP, Castrol Transmax
J.
CAUTION:
Use care not to exceed the upper limit level.
Be sure that the replenishment of ATF to the
upper level with the transmission cold will
cause overfilling of ATF and result in a transmission failure.
Make visual inspection for leaks from the inside of
transmission. If there are leaks, repair or replace
the gasket, oil seals, plugs or other parts.
Capacity:
NOTE:
Capacity when transmission is overhauled:

2.0 L model
8.4 8.7 2 (8.9 9.2 US qt, 7.4 7.7 Imp qt)
2.5 L model
9.3 9.6 2 (9.8 10.1 US qt, 8.2 8.4 Imp qt)
7) Bleed the air of control valve.
<Ref. to 4AT-65, Air Bleeding of Control Valve.>
8) Check the level and leaks of ATF.
4AT-31

C: CONDITION CHECK
NOTE:
When replacing ATF, check the inside condition of the transmission body by inspecting the drained ATF.
Fluid condition
Large amount of metallic pieces are
found.

Excessive wear of the internal of the transmission body.
Thick and varnish-form fluid.
Burned clutch and etc.
Clouded fluid or bubbles are found in

fluid.
Water mixed in fluid.
4AT-32
Corrective action
Replace ATF and check if AT operates
correctly.
Replace ATF and check AT itself and
vehicle for faulty.
Replace ATF and check the water entering point.
Differential Gear Oil

3. Differential Gear Oil

A: INSPECTION
proper orientation.
4) Remove the level gauge 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.
Tightening torque:
Aluminum gasket
44 Nm (4.5 kgf-m, 32.5 ft-lb)
Copper gasket
70 Nm (7.1 kgf-m, 51.6 ft-lb)
(A)
NOTE:
To prevent overfilling the differential gear oil, do not
add oil above the F line.
(B)
AT-02204
(A)
(B)
(A) Oil pan

(B) Differential gear oil drain plug
(A)
(C)

5) Pour gear oil into the gauge hole.
<Ref. to 4AT-3, RECOMMENDED GEAR OIL,
SPECIFICATION, General Description.>
PI-00183

1.1 1.3 2 (1.2 1.4 US qt, 1.0 1.1 Imp qt)
6) Check the level of the differential gear oil.
<Ref. to 4AT-33, INSPECTION, Differential Gear
Oil.>
(A) Oil level gauge

(B) Upper level
(C) Lower level
B: REPLACEMENT
2) Remove the differential gear oil drain plug using
TORX BIT T70, and drain the differential gear oil
completely.
CAUTION:
Directly after the engine has been running,
the differential gear oil is hot. Be careful not to
burn yourself.
Be careful not to spill the differential gear oil
on exhaust pipe to prevent it from emitting
smoke or fire. When the differential gear oil is
spilled on exhaust pipe, wipe it away completely.
3) Tighten the differential gear oil drain plug using
TORX BIT T70.
NOTE:
Use a new gasket.
4AT-33
Road Test
4. Road Test
A: INSPECTION
1. GENERAL PRECAUTION
Road tests should be conducted to properly diagnose the condition of the automatic transmission.
NOTE:
When performing the test, do not exceed posted
speed limit.
2. D RANGE SHIFT FUNCTION

Check shifting between 1st 2nd 3rd
4th while driving on general city streets.
3. D RANGE SHIFT SHOCK

Check the shock level when shifting up during normal driving.
Also when checking on the free roller, check with

depressing the foot brake lightly to make the checking easier, because the surface resistance will be
deficient.
2) Connect the Subaru Select Monitor.
3) Check the ATF temperature using Subaru Select
Monitor.
NOTE:
ATF temperature is between 50 100C (122
212F).
When the temperature is low, warm-up the ATF
by running the vehicle or etc.
4) Start the engine, so that the lock-up duty can be
read on data display of Subaru Select Monitor.
5) Drive the vehicle at a constant speed of 35 40
km/h (22 25 MPH).
6) Read the lock-up duty while vehicle is running.
Standard value:
25 45%
4. KICK-DOWN FUNCTION
Check kick-down for each gear. Also check the
kick-down shock level.
5. ENGINE BRAKE OPERATION
NOTE:
The value may be lower on the free roller.
Slip lock-up control is not operating when the
lock-up duty is less than 5%, or when the lock-up
duty goes down immediately after starts rising. On
these cases, improper ATF or deterioration of ATF
may be the cause. Check the amount of ATF or replace them, and then recheck it.
Check the 3rd gear engine brake when shifting

down from 4th to 3rd range while driving in 4th gear
of manual mode [50 60 km/h (31 37 MPH)].
Check the 2nd gear engine brake when shifting
down from 3rd to 2nd range while driving in 3rd
gear of manual mode [40 50 km/h (25 31
MPH)].
Check the 1st gear engine brake when shifting
down from 2nd to 1st range while driving in 2nd
gear of manual mode [20 30 km/h (12 19
MPH)].
7. P RANGE OPERATION
6. LOCK-UP FUNCTION
Check for noise and vibration while driving and during shifting.
Check that rpm does not change sharply when

the axle pedal is lightly depressed while driving on
flat roads at normal speed in D range.
Check slip lock-up with following procedure.
Subaru Select Monitor is needed for checking.
Before start checking, check that no DTC is displayed using Subaru Select Monitor. When DTC is
displayed, perform the collective action with DTC
and check that any more DTC is displayed, and
then start the checking.
1) Perform the check on flat and straight road or
free roller.
NOTE:
Slip lock-up does not operate when the vehicle is
lifted up, because of not occurring surface resistance.
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. NOISE AND VIBRATION
9. CLIMBING CONTROL FUNCTION

Check that the gear remains in 3rd when going
up a grade.
Check that the gear remains in 3rd when applying the brakes while going down a grade.
10.TRANSFER CLUTCH
Check tight corner braking when the vehicle started
with steering fully turned.
11.OIL LEAKS
After the driving test, inspect for oil leaks.
4AT-34
Stall Test
5. Stall Test
A: INSPECTION
NOTE:
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 2nd of manual mode.
Purposes of the stall test:
To check the operation of the automatic transmission clutch.
To check the operation of the torque converter
clutch.
To check engine performance.
1) Check that the throttle valve opens fully.
2) Check that the engine oil level is correct.
3) Check that the coolant level is correct.
4) Check that the ATF level is correct.
5) Check that the differential gear oil level is correct.
6) Increase ATF temperature to 70 80C (158
176F) by idling the engine for approximately 30
minutes (with select lever set to N or P).
7) Place the wheel chocks at the front and rear of
all wheels and engage the parking brake.
8) Move the manual linkage to ensure it operates
properly, and then set to the 2nd on manual mode.
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 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.
AT-02205
9) While depressing the brake pedal strongly, depress the accelerator pedal gradually.
10) When the engine speed is stabilized, record
that speed quickly and release the accelerator pedal.
11) Shift the select lever to N range, and cool
down the engine by idling it for more than one
minute.
12) If the stall speed in the 2nd of manual mode is
higher than specifications, low clutch slipping and
2-4 brake slipping may occur. To identify it, conduct
the same test as above in R range.
13) Perform the stall tests with the select lever in
D range.
4AT-35
Stall Test
Stall speed (at sea level):

2.0 L model:
2,300 2,700 rpm
2.5 L model:
2,600 2,900 rpm
Stall speed (at sea level)
Less than standard
Range
2nd on manual
mode, R
D
More than standard
R
2nd on manual
mode
Cause
Throttle valve not fully open
Erroneous engine operation
Torque converter clutchs one-way clutch slipping
Line pressure is too low
Low clutch slipping
One-way clutch malfunctioning
Reverse clutch slipping
Low & reverse brake slipping
Low clutch slipping
2-4 brake slipping
4AT-36
Time Lag Test

6. Time Lag Test

A: INSPECTION
NOTE:
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.
Perform the test at normal operation fluid temperature 70 80C (158 176F).
Be sure to allow a one minute interval between
tests.
Make three measurements and take the average
value.
1) Fully apply the parking brake.
Check the 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
If N D time lag is longer than specified:
Line pressure too low
Low clutch worn
One-way clutch not operating properly
D-ring worn
4) In the same manner, measure the time lag for
N R.
Time lag: Less than 1.5 seconds
If N R time lag is longer than specified:
Reverse clutch worn
Low & reverse brake worn
D-ring worn
4AT-37
Line Pressure Test

7. Line Pressure Test
ST2
A: MEASUREMENT
NOTE:
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 up-shift 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):
(1) Before measuring line pressure, jack-up all
the wheels.
(2) Maintain the temperature of ATF at approx.
70 80C (158 176F) during measurement.
(ATF will reach the above-mentioned temperature after idling the engine for approx. 30 minutes with the select lever in N or P.)
2) Line pressure measurement (under heavy load):
(1) Before measuring line pressure, apply both
the foot and parking brakes with all wheels
chocked (Same as for stall test conditions).
(2) Measure the line pressure when the select
lever is in R or 2nd of manual mode with engine under stall conditions.
(3) Measure the line pressure within 5 seconds
after shifting the select lever to each position. (If
the line pressure needs to be measured again,
allow the engine to idle and cool it down more
than 1 minute.)
(4) Maintain the ATF temperature at approx. 70
80C (158 176F) during measurement.
(ATF will reach the above-mentioned temperature after idling the engine for approx. 30 minutes with the select lever in N or P.)
3) Remove the test plug and install the ST instead.
ST 498897200
OIL PRESSURE GAUGE
ADAPTER
(A)
498575400
OIL PRESSURE GAUGE

ASSY
5) Check for duty ratio changes by adjusting the acceleration pedal position using Subaru Select Monitor.
Range position
Manual
mode (2nd)
AT-03205
(A) Test plug
4) Connect the ST1 with ST2.

ST1 498897200 OIL PRESSURE GAUGE
ADAPTER
4AT-38
Standard line pressure

Line presLine pressure
Throttle
sure duty
valve angle kPa (kg/cm2, psi)
ratio (%)
1,000 1,300
25 35
Full open
(10.2 13.3,
145 189)
1,500 1,850
15 25
Full open
(15.3 18.9,
217 268)
500 800
35 43
Full closed
(5.1 8.2,
73 116)
Transfer Clutch Pressure Test

8. Transfer Clutch Pressure

Test
Range
position
A: INSPECTION
Check the transfer clutch pressure in accordance
with the following chart in the same manner as with
line pressure. <Ref. to 4AT-38, Line Pressure
Test.>
ST 498897700
OIL PRESSURE ADAPTER
SET
ST 498575400
OIL PRESSURE GAUGE
ASSY
ON
Duty
ratio
(%)
95
Manual
mode
(2nd)
NOTE:
Before setting in FWD mode, install the spare
fuse on FWD mode switch. (MPT model)
MTP model
(A)
AT-00021
(A) Test plug
VTD model
(A)
AT-00022
(A) Test plug
If no oil pressure is produced or if it does not

change in AWD mode, the control valve body may
be malfunctioning. If oil pressure is produced in
FWD mode, the same problem as AWD mode occurs.
4AT-39
60
N or P
Acceleration pedal
position
(%)
Fully
opened:
100
Adjust
ON Duty
ratio to
60%.
Fully
closed: 0
Fully
closed: 0
Standard transfer clutch

pressure
kPa (kg/cm2, psi)
FWD
AWD mode
mode
1,000 1,200
(10.2 12.2,
145 174)
500 700
(5.1 7.1,
73 102)
0 (0, 0)
Automatic Transmission Assembly

9. Automatic Transmission Assembly

A: REMOVAL
2) Fully open the front hood and support with hood
stay.
Duct.>
Chamber.>
6) Remove the air cleaner case stay.

plate.
(1) Remove the V-belt covers.
(4) Insert the wrench to crank pulley bolt, and
then remove all the bolts with slightly rotating
crank pulley.
CAUTION:
Be careful not to drop bolts into torque converter clutch housing.
AT-00102
AT-01327
11) Install the ST to converter case.

ST 498277200
STOPPER SET
7) Disconnect the following connectors.

(1) Transmission harness connectors
ST
AT-00804
12) Remove the ATF level gauge.

AT-01328
(2) Transmission ground terminal

8) Remove the starter.
<Ref. to SC(H4SO 2.0)-6, REMOVAL, Starter.>
NOTE:
Plug the opening to prevent entry of foreign particles into transmission fluid.
AT-01330
AT-01329

4AT-40

14) Drain the engine coolant by approx. 2 2 (2.1

US qt, 1.8 Imp qt). (Model with ATF cooler with
warmer function)
15) Disconnect the ATF cooler inlet and outlet hoses from ATF cooler pipes.
18) Remove the warmer cock assembly. (Model

with ATF cooler with warmer function)
AT-02165
19) Remove the bracket for warmer cock assembly. (Model with ATF cooler with warmer function)
AT-02171
16) Disconnect each hose from warmer cock assembly.
AT-02166
AT-02163
17) Remove the ATF cooler with warmer function

from transmission body, and then secure it to vehicle body by wire, etc.. Select the place not to prevent transmission from being replaced. (Model with
ATF cooler with warmer function)
20) Remove the pitching stopper bracket.

21) Set the ST.
ST 41099AC000 ENGINE SUPPORT ASSEMBLY
ST
AT-02167
22) Remove the bolts which hold upper side of

AT-00106
AT-03199

4AT-41

25) Remove the front, center and rear exhaust

pipes and muffler.
<Ref. to EX(H4SO 2.0)-7, REMOVAL, Front Exhaust Pipe.> <Ref. to EX(H4SO 2.0)-11, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H4SO 2.0)13, REMOVAL, Muffler.>
32) Remove the bolt securing ball joint of front arm

to housing.
AT-00809
33) Pull out the front drive shaft from transmission.

(1) Using a tire lever or a pinch bar, etc., pull out
the front drive shaft until its joint facing to transmission can move smoothly.
AT-01331
NOTE:
Place cloth between tire lever or pinch bar and
transmission in order to avoid damaging the side
retainer of transmission.
(2) Hold the transmission side joint portion of
front drive shaft by hand and extract the housing
from the transmission by pressing it outside so
as not to stretch the boot.
34) Remove the bolts which hold the clutch housing cover.
35) Remove the bolts which hold lower side of

(A)
(B)
AT-01332
(A) Oil pan

(B) ATF drain plug
28) Disconnect the ATF cooler hoses from pipes of

transmission side, and remove the oil charge pipe.
(Model without ATF cooler with warmer function)
AT-00108
36) Place the transmission jack under transmission.

NOTE:
Make sure that the support plates of transmission
jack dont touch the oil pan.
AT-01333
29) Remove the propeller shaft.

<Ref. to DS-10, REMOVAL, Propeller Shaft.>
30) Remove the shift select cable.
<Ref. to CS-12, REMOVAL, Select Cable.>
31) Remove the brackets (two) which hold front
stabilizer.
4AT-42

37) Remove the transmission rear crossmember

from the vehicle.
ST
498277200
STOPPER SET
ST
AT-00103
AT-01334
38) Fully contract the engine support while lowering the transmission jack gradually, and tilt the engine backward.
4) Install the transmission onto engine.

(1) Lift up the transmission gradually using a
transmission jack.
NOTE:
Contract the support until the clearance between
front crossmember and torque converter case becomes approx. 10 mm (0.39 in).
39) Remove the transmission.
CAUTION:
Remove the transmission and torque converter
as a unit from engine.
AT-00109
(2) Engage them at splines.

(3) Turn the screws of engine support while
raising the transmission jack gradually, and tilt
the engine forward.
5) Install the 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)
AT-00109
40) Remove the rear cushion rubber from transmission assembly.
T2
T1
T2
B: INSTALLATION
1) Replace the differential side oil seal with a new
one.
NOTE:
When a new oil seal has been installed, the replacement is not required.
2) Install the rear cushion rubber to transmission
assembly.
Tightening torque:
39 Nm (4.0 kgf-m, 29 ft-lb)
AT-01335
6) Take off the transmission jack.

7) Tighten the bolts which hold the lower side of
4AT-43

Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
AT-00108
AT-00102
8) Screw the bolts for the clutch housing cover.

9) Lower the lift.
10) Connect the engine and transmission.
(1) Remove the ST from converter case.
(3) Fit the plug to service hole.

(4) Install the V-belt cover.
12) Remove the ST.
NOTE:
When removing the ST, be careful not to drop it into
converter case.
ST 498277200
STOPPER SET
(2) Install the starter.
<Ref. to SC(H4SO 2.0)-6, INSTALLATION,
Starter.>
(3) Tighten the bolts which hold the upper side
of transmission to engine.
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
ST
AT-02167
13) Install the warmer cock assembly bracket.

(Model with ATF cooler with warmer function)
Tightening torque:
16 Nm (1.6 kgf-m, 11.6 ft-lb)
AT-00106

(2) Insert the wrench to crank pulley bolt, and
then tighten all bolts while slightly rotating the
crank pulley.
AT-02166
14) Install the warmer cock assembly. (Model with

ATF cooler with warmer function)
4AT-44

Tightening torque:
T1: 6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
T2: 15 Nm (1.5 kgf-m, 10.8 ft-lb)
Tightening torque:
23 Nm (2.3 kgf-m, 16.6 ft-lb)
T2
T1
AT-02168
15) Connect each hose to warmer cock assembly.

(Model with ATF cooler with warmer function)
AT-02164
AT-02163
16) Install the pitching stopper bracket and bracket

(Model with ATF cooler with warmer function).
18) Connect the ATF cooler inlet and outlet hoses

to ATF cooler pipes. (Model with ATF cooler with
warmer function)
Tightening torque:
41 Nm (4.2 kgf-m, 30.4 ft-lb)
(A)
(B)
AT-02171
19) Install the throttle body. <Ref. to FU(H4SO

2.0)-10, INSTALLATION, Throttle Body.>
AT-02169
Tightening torque:
T1: 50 Nm (5.1 kgf-m, 37 ft-lb)
T2: 58 Nm (5.9 kgf-m, 43 ft-lb)
(A) Pitching stopper bracket

(B) Bracket (Model with ATF cooler with warmer
function)
17) Install the ATF cooler with warmer function to

transmission body. (Model with ATF cooler with
warmer function)
T2
T1
AT-01346
4AT-45


22) Replace the snap ring of front drive shaft with a
new one.
23) Apply grease to the oil seal lips.
24) Install the ST to side retainer.
ST 28399SA010 OIL SEAL PROTECTOR
Ensure the bushing and stabilizer have the same

identification colors when installing.
FS-00050
(1) Identification mark on stabilizer

(2) Bushing identification color
ST
AT-00110
25) Align the spline of front differential shaft to that

of differential bevel gear for insertion, and remove
them using ST.
26) Insert the front drive shaft into transmission securely by pressing the front housing from outside.
30) Always tighten the rubber bushing location

when wheels are in full contact with the ground and
vehicle is curb weight.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
31) Install the shift select cable onto select lever.
<Ref. to CS-13, INSTALLATION, Select Cable.>
32) Install the oil charge pipe, and connect the ATF
cooler hoses to pipe. (Model without ATF cooler
with warmer function)
AT-00111
27) Install the ball joint into housing.

28) Tighten the attachment bolts.
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
AT-01333
33) Install the oil charge pipe. (Model with ATF

34) Install the propeller shaft.
<Ref. to DS-11, INSTALLATION, Propeller Shaft.>
AT-00809
29) Install the stabilizer to crossmember.

NOTE:
Install the bushing (on front crossmember side)
while aligning it with the paint mark on stabilizer.
AT-01331
36) Install the rear exhaust pipe and muffler assembly.
4AT-46


Exhaust Pipe.>
39) Lower the lift.
40) Install the ATF level gauge.
AT-01330
41) Connect the following connectors.

(2) Transmission ground terminal
42) Install the air cleaner case stay.
Tightening torque:
16 Nm (1.6 kgf-m, 11.6 ft-lb)
<Ref. to IN(H4SO 2.0)-9, INSTALLATION, Air Intake Duct.>
45) Using a gauge hole, add the ATF until the fluid
level is found at the center between upper and lower levels of level gauge COLD side. <Ref. to 4AT31, Automatic Transmission Fluid.>
47) Check the level of differential gear oil. <Ref. to
4AT-33, Differential Gear Oil.>
48) Check the select lever operation.
<Ref. to 4AT-52, INSPECTION, Inhibitor Switch.>
49) Bleed the air of control valve. <Ref. to 4AT-65,
Air Bleeding of Control Valve.>
50) Check the ATF level. <Ref. to 4AT-31, Automatic Transmission Fluid.>
51) Execute the learning control promotion. <Ref.
to 4AT(diag)-19, FACILITATION OF LEARNING
CONTROL, OPERATION, Subaru Select Monitor.>
52) Perform the road test.
<Ref. to 4AT-34, Road Test.>
4AT-47
Transmission Mounting System

10.Transmission Mounting System
B: INSTALLATION
A: REMOVAL
1. PITCHING STOPPER
Tightening torque:
T1: 50 Nm (5.1 kgf-m, 37 ft-lb)
T2: 58 Nm (5.9 kgf-m, 43 ft-lb)

Chamber.>
1. PITCHING STOPPER
T1
T2
AT-01346
AT-01329
2. TRANSMISSION REAR CROSSMEMBER

& REAR CUSHION RUBBER
2) Jack-up the vehicle and support it with study
racks.
3) Remove the front, center, rear, exhaust pipes
and muffler.
<Ref. to EX(H4SO 2.0)-7, REMOVAL, Front Exhaust Pipe.> <Ref. to EX(H4SO 2.0)-11, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H4SO 2.0)13, INSTALLATION, Muffler.>
5) Set the transmission jack under the transmission. Make sure that the support plate of transmission jack does not touch the oil pan.
6) Remove the transmission rear crossmember.


1) Install the rear cushion rubber.
Tightening torque:
40 Nm (4.1 kgf-m, 29.5 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)
T2
T1
T2
AT-01335
AT-01334
7) Remove the rear cushion rubber.
3) Remove the transmission jack.

and muffler.
Exhaust Pipe.> <Ref. to EX(H4SO 2.0)-11, INSTALLATION, Rear Exhaust Pipe.> <Ref. to
EX(H4SO 2.0)-13, INSTALLATION, Muffler.>
4AT-48

C: INSPECTION
Repair or replace parts if the results of the inspection below are not satisfied.
1. PITCHING STOPPER
Make sure that the pitching stopper is not bent or
damaged. Ensure there are no cracks, hardening,
or damage on rubbers.

Make sure that the crossmember is not bent or
damaged. Ensure there are no cracks, hardening,
or damage on cushion rubbers.
4AT-49
Extension Case Oil Seal

11.Extension Case Oil Seal
13) Pour ATF into the oil charge pipe.
A: INSPECTION
Recommended fluid:
J.
Make sure that the ATF does not leak from the joint
of transmission and propeller shaft. If so, replace
the oil seal. <Ref. to 4AT-50, REPLACEMENT, Extension Case Oil Seal.>
B: REPLACEMENT
2) Clean the transmission exterior.
CAUTION:
NOTE:
Capacity:
15) Check the level and leaks of ATF. <Ref. to 4AT31, Automatic Transmission Fluid.>
NOTE:
Use a new gasket.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
(A)
(B)
AT-01332
(A) Oil pan

(B) ATF drain plug

7) Remove the propeller shaft. <Ref. to DS-10, REMOVAL, Propeller Shaft.>
8) Using the ST, remove the oil seal.
ST 398527700
PULLER ASSY
9) Using the ST, install the oil seal.
ST 498057300
INSTALLER
4AT-50
Differential Side Retainer Oil Seal

12.Differential Side Retainer Oil

Seal
A: INSPECTION
7) Using the ST, install the differential side retainer

by slightly tapping with hammer.
ST 18675AA000 DIFFERENTIAL SIDE OIL
SEAL INSTALLER
Check the leakage of gear oil from differential side

retainer oil seal part. If there is oil leakage, replace
the oil seal.
ST
B: REPLACEMENT
2) Remove the front and center exhaust pipe. <Ref.
to EX(H4SO 2.0)-7, REMOVAL, Front Exhaust
Pipe.>
TORX BIT T70, and drain the differential gear oil.
CAUTION:
burn yourself.
(A)
AT-00029
8) Apply gear oil to the oil seal lips.

9) Install the front drive shaft. <Ref. to DS-22, INSTALLATION, Front Drive Shaft.>
10) Install the front and center exhaust pipe. <Ref.
to EX(H4SO 2.0)-8, INSTALLATION, Front Exhaust Pipe.>
12) Pour the gear oil into the gauge hole.
1.1 1.3 2 (1.3 1.4 US qt, 1.0 1.1 Imp qt)
4AT-33, INSPECTION, Differential Gear Oil.>
(B)
AT-02204
(A) Oil pan

4) Tighten the differential gear oil drain plug.

NOTE:
Use a new gasket.
Tightening torque:
Aluminum gasket
44 Nm (4.5 kgf-m, 32.5 ft-lb)
Copper gasket
70 Nm (7.1 kgf-m, 51.6 ft-lb)
5) Separate the front drive shaft from transmission.
<Ref. to DS-22, REMOVAL, Front Drive Shaft.>
6) Remove the differential side retainer oil seal using a driver wrapped with vinyl tape or etc.
4AT-51
Inhibitor Switch
13.Inhibitor Switch
If there is continuity in one direction or in other

points, adjust the inhibitor switch. <Ref. to 4AT-52,
ADJUSTMENT, Inhibitor Switch.>
A: INSPECTION
When the 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 the inhibitor switch connector.
2) Check continuity in inhibitor switch circuits with
the select lever moved to each position.
(C)
(A)
(B)
(A)
NOTE:
Also check that continuity in ignition circuit does
not exist when the select lever is in R and D
ranges.
If the inhibitor switch is inoperative, check for
poor contact of connector on transmission side.
Signal sent to TCM
Ignition circuit
Back-up light circuit
Range
P
R
N
D
P/N
R
Pin No.
43
42
41
48
12 11
10 9
AT-02206
(A) Continuity does not exist.

(B) Continuity exists.
(C) 1.5
4) Repeat the above checks. If there are abnormalities, adjust the select cable. <Ref. to CS-15, ADJUSTMENT, Select Cable.>
B: ADJUSTMENT
1) Set the select lever to N range.
2) Loosen the three inhibitor switch securing bolts.
3) Insert the ST as vertical as possible into the
holes in the inhibitor switch lever and switch body.
ST 499267300
STOPPER PIN
(A)
ST
( 4 ) (3 ) (2 ) (1 )
( 8 ) (7 ) (6 ) (5 )
(12) (11) (10) (9 )
AT-00030
(A) Inhibitor switch connector
3) Check there is continuity at equal points when

the select lever is turned 1.5 in both directions
from N range.
AT-00032
4) Tighten the three inhibitor switch securing 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.
C: REMOVAL
2) Set the select lever to N range.
Chamber.>
4AT-52
Inhibitor Switch
10) Remove the three bolts which secure inhibitor

switch.
4) Disconnect the inhibitor switch connector.

(A)
(A)
AT-01350
AT-00036
5) Remove the inhibitor switch connector from stay.

8) Remove the snap pin and washers from range
select lever.
(A) Inhibitor switch
11) Shift the range select lever to parking position

(left side).
(A)
(A)
(B)
AT-00037
(C) (D)
(A) Range select lever
12) Remove the inhibitor switch from transmission.
AT-00034
(A)
(B)
(C)
(D)
Range select lever

Snap pin
Select cable
Washer
(A)
9) Remove the plate assembly from transmission

case.
AT-00038
(A)
13) Disconnect the inhibitor switch harness connector from inhibitor switch.
D: INSTALLATION
(B)
AT-00035
1) Connect the inhibitor switch harness connector

to inhibitor switch.
(A) Select cable

(B) Plate ASSY
4AT-53
Inhibitor Switch
2) Install the inhibitor switch to transmission case.
7) Install the snap pin washers to range select lever.
(A)
(A)
(B)
(C) (D)
AT-00038
AT-00034

(A)
(B)
(C)
(D)
3) Move the range select lever to neutral position.

4) Tighten the three inhibitor switch securing bolts
using ST.
ST 499267300
STOPPER PIN
Range select lever

Snap ring
Select cable
Washer

Exhaust Pipe.>
10) Install the inhibitor switch connector to the stay.
11) Connect the inhibitor switch connector.
Tightening torque:
3.5 Nm (0.36 kgf-m, 2.6 ft-lb)
ST
(A)
(A)
(B)
AT-00039

(B) Range select lever
AT-01350
5) Install the select cable to range select lever.

6) Install the plate assembly to transmission.
Tightening torque:
T: 25 Nm (2.5 kgf-m, 18.1 ft-lb)

13) Inspect the inhibitor switch. <Ref. to 4AT-52,
INSPECTION, Inhibitor Switch.>
(A)
(B)
AT-00040
(A) Select cable

(B) Plate ASSY
4AT-54
Front Vehicle Speed Sensor

14.Front Vehicle Speed Sensor

A: REMOVAL
Chamber.>
4) Disconnect the transmission connector.

<Ref. to EX(H4SO 2.0)-7, REMOVAL, Front Exhaust Pipe.> <Ref. to EX(H4SO 2.0)-11, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H4SO 2.0)13, REMOVAL, Muffler.>
12) Remove the shield cover.
NOTE:
Make sure that the support plates of transmission
jack does not touch the oil pan.
bolt.
(A)
AT-01337
(A) Transmission connector
5) Remove the pitching stopper. <Ref. to 4AT-48,

REMOVAL, Transmission Mounting System.>
6) Remove the transmission connector from the
stay.
CAUTION:
NOTE:
Use a new gasket.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
AT-00043
16) Lower the transmission jack.

NOTE:
Do not separate the transmission jack and transmission.
17) Remove the oil cooler inlet and outlet pipes.
NOTE:
When removing the outlet pipe, be careful not to
lose the ball and spring used with retaining screw.
18) Remove the front vehicle speed sensor and
torque converter turbine speed sensor.
(A)
(A)
(B)
(B)
AT-00044
AT-01332
(A) Front vehicle speed sensor

(B) Torque converter turbine speed sensor
(A) Oil pan

(B) ATF drain plug
4AT-55

19) Disconnect the connector from rear vehicle

speed sensor.
MPT model
B: INSTALLATION
1) Pass the harness assembly through the hole in
transmission case.
(A)
AT-02207
AT-00048
2) Connect the harness connector and transmission ground.
(A) Rear vehicle speed sensor
VTD model
Tightening torque:
8 Nm (0.8 kgf-m, 5.8 ft-lb)
(A)
(B)
(A)
AT-00117
AT-00050

21) Disconnect the harness connector and transmission ground terminal.
(A)
(A) Transmission ground

(B) Harness connector
3) Apply proper amount of liquid gasket to the entire oil pan mating surface.
Liquid gasket:
(B)
AT-00050

(B) Harness connector
22) Remove the harness assembly.
AT-00051
4) Apply liquid gasket fully to the three holes other

than screw holes on the transmission case
4AT-56

Liquid gasket:
AT-01339
5) Install the oil pan.

Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
6) Install the front vehicle speed sensor and torque
converter turbine speed sensor.
14) Install the transmission connector to the stay.

15) Install the pitching stopper. <Ref. to 4AT-48,
INSTALLATION, Transmission Mounting System.>
17) Fill the same amount of ATF drained.
19) Check the level of ATF. <Ref. to 4AT-31, Automatic Transmission Fluid.>
Tightening torque:
7 Nm (0.7 kgf-m, 5.1 ft-lb)
7) Connect the connector to rear vehicle speed
sensor.
8) Install the oil cooler pipe.
NOTE:
Use a copper washer.
Tightening torque:
T1: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
T2: 40 Nm (4.1 kgf-m, 30 ft-lb)
T3: 44 Nm (4.5 kgf-m, 32.5 ft-lb)
T2
T3
T1
AT-03072
9) Install the transmission rear crossmember bolt.

Tightening torque:
70 Nm (7.1 kgf-m, 51 ft-lb)
11) Install the shield cover.
and muffler. <Ref. to EX(H4SO 2.0)-8, INSTALLATION, Front Exhaust Pipe.> <Ref. to EX(H4SO
<Ref. to EX(H4SO 2.0)-13, INSTALLATION, Muffler.>
4AT-57
Rear Vehicle Speed Sensor

15.Rear Vehicle Speed Sensor
VTD model
A: REMOVAL
1) Set the vehicle on a lift, and then lift up the vehicle.
speed sensor.
MPT model
(A)
AT-00309
B: INSTALLATION
NOTE:
Replace O-ring with a new one.
AT-02207
Tightening torque:
7 Nm (0.7 kgf-m, 5.1 ft-lb)
VTD model
(A)
AT-00117
3) Remove the rear vehicle speed sensor.

MPT model
AT-01341
4AT-58
Torque Converter Turbine Speed Sensor

16.Torque Converter Turbine

Speed Sensor
A: REMOVAL
For removal procedure of torque converter turbine
speed sensor, refer to Front Vehicle Speed Sensor. <Ref. to 4AT-55, REMOVAL, Front Vehicle
Speed Sensor.>
B: INSTALLATION
For installation procedure of torque converter turbine speed sensor, refer to Front Vehicle Speed
Sensor. <Ref. to 4AT-56, INSTALLATION, Front
Vehicle Speed Sensor.>
4AT-59
Control Valve Strainer

17.Control Valve Strainer
11) Remove the control valve strainer tightening

bolt, and remove control valve strainer from the
control valve body.
A: REMOVAL
2) Disconnect the ground cable from the battery.
5) Remove the drain plug (ATF) to drain the ATF.
CAUTION:
The ATF will be extremely hot after driving. Be
careful not to receive burns.
AT-04597
B: INSTALLATION
1) Check the control valve body for dust and other
foreign matter.
2) Mount new control valve strainer to the control
valve body.
(1) Apply ATF to the entire perimeter of the Oring on the control valve strainer.
AT-03117
6) Perform replacement with a new gasket, and

tighten the drain plug (ATF).
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
CAUTION:
Be careful not to allow foreign matter such as
dust or dirt to enter the oil pan.
CAUTION:
Protect the O-ring from dust and dirt while applying ATF.
(2) Install the control valve strainer to the control valve body from the O-ring side.
CAUTION:
If the control valve strainer is pushed in at an
angle, the O-ring may be damaged. Be sure to
push in the control valve strainer straight to install.
(3) Tighten the three bolts.
Tightening torque:
10 Nm (1.0 kgf-m, 7.4 ft-lb)
AT-03118
8) Remove the magnet.

9) Clean the magnet.
10) Completely remove the remaining liquid gasket
on the transmission case and oil pan.
4AT-60
AT-04597
Control Valve Strainer

3) Attach the magnet at the specified position of the

oil pan.
7) Fill ATF from the oil charge pipe.

Recommended fluid:
<Ref. to 4AT-3, HYDRAULIC CONTROL AND
LUBRICATION, SPECIFICATION, General Description.>
Capacity:
Fill with the same amount of ATF as drained.
9) Check the ATF level. <Ref. to 4AT-31, Automatic Transmission Fluid.>
AT-02743
C: INSPECTION
Check the control valve strainer for holes, damages
or adhesion of dust and other foreign particles.
Liquid gasket:
or equivalent
AT-02742
5) Fill the three holes aside from the bolt holes in

the transmission case, with liquid gasket.
Liquid gasket:
or equivalent
AT-01339
6) Install the oil pan by equally tightening the bolts.

Tightening torque:
5 Nm (0.5 kgf-m, 3.7 ft-lb)
4AT-61
Control Valve Body

18.Control Valve Body

on transmission case and oil pan.
11) Disconnect the control valve connector.
A: REMOVAL
CAUTION:
AT-00058
12) Remove the oil cooler pipe.
AT-00055

NOTE:
Use a new gasket.
AT-00059
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
13) Remove the control valve body.
CAUTION:
Be sure to prevent the entering of dust and other foreign matters into oil pan.
NOTE:
Replace the control valve body as assembly, because it is non-disassemble part.
AT-01717
AT-00056
B: INSTALLATION
1) Check that the dust and other foreign matters
are not on control valve body.
2) Temporarily install the control valve body to
transmission.
3) Install the oil cooler pipe.
AT-00057
4AT-62
Control Valve Body

6) Attach the magnet at the specified position of oil

pan.
Tightening torque:
8 Nm (0.8 kgf-m, 5.8 ft-lb)
AT-00057
AT-00059
4) Tighten the bolts equally.
7) Apply liquid gasket to the oil pan.
Tightening torque:
8 Nm (0.8 kgf-m, 5.8 ft-lb)
Liquid gasket:
(A)
(2)
(2)
(2)
(2)
(1)
(1)
(2)
(2)
(2)
(2)
(2)
(2)
(2)
AT-00051
AT-01718
8) Fill liquid gasket to the holes except for bolt

holes (three) of transmission case.

Bolt length mm (in)
(1) 35 (1.38)
(2) 30 (1.18)
Liquid gasket:
5) Connect the control valve connector.
AT-01339
AT-00058
9) Install the oil pan with equally tighten the bolts.

Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
10) Fill ATF from oil charge pipe.
Recommended fluid:
J.
NOTE:
4AT-63
Control Valve Body

Capacity:
<Ref. to 4AT-31, Automatic Transmission Fluid.>
C: INSPECTION
Check that the holes, damages or other foreign
matters are not on each parts.
4AT-64
Air Bleeding of Control Valve

19.Air Bleeding of Control Valve

A: PROCEDURE
1) Lift up the vehicle with setting the select lever to
P range and applying the parking brake.
2) Connect the Subaru Select Monitor to the vehicle.
3) Using Subaru Select Monitor, check that the
DTC is not output.
ATF temperature is less than 60C (140F). <Ref.
to 4AT(diag)-17, OPERATION, Subaru Select
Monitor.>
5) Turn the Subaru Select Monitor switch to OFF.
6) Release the manual mode, and then turn the ignition switch to OFF.
7) Set the select lever to R range.
8) Depress the brake pedal fully until the air bleeding is completed.
10) Set the select lever to P range, and then wait
for more than 3 seconds.
11) Set the select lever to R range, and then wait
12) Set the select lever to N range, and then wait
13) Set the select lever to D range, and then wait
14) Set the select lever to N range, and then wait
15) Slowly depress the accelerator pedal fully.
16) Slowly release the accelerator pedal fully.
18) Set the select lever to D range.
19) Turn the Subaru Select Monitor switch to ON.
20) Select {Each System Check} in Main Menu
of Subaru Select Monitor.
screen, select Transmission. Air bleeding of control valve starts on transmission. At this time, the
SPORT indicator light in combination meter blinks
at 2 Hz. When the SPORT indicator light does not
blink, repeat the procedures from step 4).
22) Air bleeding of control valve is finished when
blinking of SPORT indicator light in combination
meter goes off from 2 Hz.
NOTE:
When blinking of SPORT indicator light changes
from 2 Hz to 4 Hz during air bleeding, repeat the
procedure from step 4).
23) Set the select lever to N range, and then turn
the ignition switch to OFF.
24) Set the select lever to P range, and then finish
the air bleeding.
4AT-65
ATF Filter
20.ATF Filter
A: REMOVAL
NOTE:
The ATF filter is maintenance free.
2) Using the ST, remove the ATF filter.
ST 498545400
OIL FILTER WRENCH
(A)
ST
AT-00091
(A) ATF filter
B: INSTALLATION
1) Apply a thin coat of ATF to the oil seal part of
new ATF filter.
2) Install the ATF filter. Turn it by hand, being careful not to damage oil seal.
3) Tighten the ATF filter using ST.
Calculate the ATF filter tightening torque using following formula.
T2 = L2/(L1 + L2) T1
T1: 14 Nm (1.4 kgf-m, 10.1 ft-lb)
[Required torque setting]
T2: Tightening torque
L1: ST length 78 mm (3.07 in)
L2: Torque wrench length
Example:
Torque wrench length
mm (in)
100 (3.94)
150 (5.91)
200 (7.87)
Tightening torque
Nm (kgf-m, ft-lb)
7.7 (0.79, 5.7)
9.0 (0.92, 6.7)
10 (1.0, 7.2)
NOTE:
Install the ST straightly to converter case.
ST 498545400
OIL FILTER WRENCH
4) Fill the ATF.
5) Inspect the level of ATF. <Ref. to 4AT-31, Automatic Transmission Fluid.>
C: INSPECTION
Check for rust, hole, ATF leaks, and other damage.
4AT-66
Transmission Control Module (TCM)

21.Transmission Control Module (TCM)
B: INSTALLATION
1) Install the TCM.
LHD model
A: REMOVAL
2) Remove the lower cover and the connector.
3) Replace the body integrated unit. <Ref. to SL45, REMOVAL, Body Integrated Module.>
4) Disconnect the connector from TCM.
LHD model
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
(A)
(B)
(A)
AT-02170
(B)
(A) Transmission control module (TCM)

(B) Brake pedal
AT-02170
RHD model
Tightening torque:
18 Nm (1.8 kgf-m, 13 ft-lb)

(B) Brake pedal
RHD model
(B)
(B)
(A)
(A)
5) Remove the TCM.

(B) Steering column
AT-01342

(B) Steering column
AT-01342
2) Connect the connector to TCM.

4) Execute the learning control promotion. <Ref. to
4AT(diag)-19, FACILITATION OF LEARNING
4AT-67
Lateral G Sensor
22.Lateral G Sensor
RHD model
A: REMOVAL
Tightening torque:
T1: 7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
T2: 24.5 Nm (2.5 kgf-m, 18.1 ft-lb)

2) Disconnect the connector from lateral G sensor.
LHD model
T2
T1
AT-01719
AT-02181
RHD model
AT-01343
3) Remove the lateral G sensor.
B: INSTALLATION
LHD model
Tightening torque:
24.5 Nm (2.5 kgf-m, 18.1 ft-lb)
AT-02181
4AT-68
ATF Cooler Pipe and Hose

23.ATF Cooler Pipe and Hose
When hard to remove the hose, wrap the hose

with cloth to prevent from damaging, and then turn
with pliers and pull out with hand straightly.
A: REMOVAL
1. MODEL WITHOUT ATF COOLER WITH
WARMER FUNCTION
5) Remove the radiator under cover.
AT-01333
8) Disconnect the ATF cooler pipe from frame.
AT-01344

NOTE:
Do not use a screwdriver or other pointed tools.
AT-01347

AT-01345
7) Disconnect the ATF cooler hoses from pipes.

NOTE:
4AT-69

NOTE:
When disconnecting the outlet pipe, be careful not
to lose the ball and spring used with retaining
screw.
6) Remove the ATF cooler assembly from transmission body, and put it aside.
(A)
(B)
AT-01348
(A) Inlet pipe

(B) Outlet pipe
2. MODEL WITH ATF COOLER WITH

WARMER FUNCTION
3) Disconnect the transmission harness connector
and remove it from stay.
4) Remove the harness bracket.
AT-03199
7) Remove the oil charge pipe. <Ref. to 4AT-81,

REMOVAL, Oil Charge Pipe.>
8) Remove the air breather hose. <Ref. to 4AT-80,
REMOVAL, Air Breather Hose.>
AT-02179
5) Disconnect the inlet and outlet hoses.
(A)
(B)
AT-02180
(A) Inlet hose

(B) Outlet hose
4AT-70

2) Install the ATF cooler pipe to frame.

CAUTION:
When disconnecting the outlet pipe, be careful
not to lose the ball and spring used with retaining screw.
(A)
(B)
(B)
(A)
AT-01347
3) Connect the ATF cooler hose to pipe on 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.
AT-01870
(A) ATF cooler outlet pipe

(B) ATF cooler inlet pipe
B: INSTALLATION
1. MODEL WITHOUT ATF COOLER WITH
WARMER FUNCTION
1) Install the oil cooler inlet pipe and outlet pipe with
new washer.
Tightening torque:
T1: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
T2: 40 Nm (4.1 kgf-m, 30 ft-lb)
T3: 44 Nm (4.5 kgf-m, 32.5 ft-lb)
AT-01333
4) Connect the ATF cooler hose to pipe on radiator

side.
NOTE:
T2
T3
T1
AT-03072
4AT-71

2. MODEL WITH ATF COOLER WITH

WARMER FUNCTION
1) Install the ATF cooler inlet pipe and outlet pipe.
NOTE:
Use new washers.
Tightening torque:
T1: 45 Nm (4.6 kgf-m, 33.2 ft-lb)
T2: 40 Nm (4.1 kgf-m, 30 ft-lb)
T3: 21 Nm (2.1 kgf-m, 15.5 ft-lb)
T4: 41 Nm (4.2 kgf-m, 30.4 ft-lb)
AT-01345
5) Install the radiator under cover.

Tightening torque:
4.9 Nm (0.5 kgf-m, 3.6 ft-lb)
T4
T2
T3
AT-01344

7) Install the battery.
8) Fill the ATF. <Ref. to 4AT-31, Automatic Transmission Fluid.>
NOTE:
Make sure there are no ATF leaks in joints between
the transmission, radiator, pipes, and hoses.
4AT-72
T3
T1
AT-03131

2) Install the ATF cooler assembly to transmission.
5) Install the harness bracket.
Tightening torque:
23 Nm (2.3 kgf-m, 16.6 ft-lb)
Tightening torque:
T1: 16 Nm (1.6 kgf-m, 11.6 ft-lb)
T2: 36 Nm (3.6 kgf-m, 26.0 ft-lb)
T1
T2
AT-02208
6) Install the inhibitor switch and transmission harness connector to the stay, and then connect the
harness connector.
7) Install the air breather hose. <Ref. to 4AT-80, INSTALLATION, Air Breather Hose.>
8) Install the air intake chamber. <Ref. to IN(H4SO
2.0)-8, INSTALLATION, Air Intake Chamber.>
AT-03199
C: INSPECTION
3) Install the oil charge pipe. <Ref. to 4AT-81, INSTALLATION, Oil Charge Pipe.>
4) Connect the inlet and outlet hoses.
(A)
(B)
AT-02180
Repair or replace any defective hoses, pipes,

clamps, and washers found in 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 installed by pressing
with your fingernail.
5) Check for peeling, cracks and deformation at the
tip of the hose.
(A) Inlet hose

(B) Outlet hose
4AT-73
ATF Cooler (with Warmer Function)

24.ATF Cooler (with Warmer

Function)
7) Disconnect the engine coolant inlet hose from

cylinder block.
A: REMOVAL
1) Drain the engine coolant. <Ref. to CO(H4SO
2.0)-13, REPLACEMENT, Engine Coolant.>
3) Disconnect the engine harness, and then remove the engine harness connector from engine
harness bracket.
4) Remove the engine harness bracket.
AT-02173
8) Remove the ATF cooler assembly from transmission.
AT-02179
5) Disconnect the ATF cooler hose from the pipe

on transmission side.
AT-02171
6) Disconnect the engine coolant outlet hose from

warmer cock assembly.
AT-02172
4AT-74
AT-03199

B: INSTALLATION
1) Install the ATF cooler assembly to transmission.
4) Connect the ATF cooler hose to pipe on transmission side.
Tightening torque:
23 Nm (2.3 kgf-m, 16.6 ft-lb)
AT-02171
5) Install the engine harness bracket.

Tightening torque:
T1: 16 Nm (1.6 kgf-m, 11.6 ft-lb)
T2: 36 Nm (3.6 kgf-m, 26.0 ft-lb)
T1
T2
AT-03199
2) Connect the engine coolant inlet hose to cylinder

block.
AT-02208
6) Install the harness connector to bracket, and

then connect the harness.
8) Fill the engine coolant. <Ref. to CO(H4SO 2.0)13, REPLACEMENT, Engine Coolant.>
AT-02173
3) Connect the engine coolant outlet hose to warmer cock assembly.
AT-02172
4AT-75

C: DISASSEMBLY
D: ASSEMBLY
1) Remove each hose from ATF cooler.
1) Install the clip to bracket.
(A)
(D)
(B)
(C)
AT-03201
2) Install the bracket.

Tightening torque:
23 Nm (2.3 kgf-m, 16.6 ft-lb)
(C)
AT-02174
(A)
(B)
(C)
(D)

Engine coolant inlet hose
Engine coolant outlet hose
AT-03200
2) Remove the bracket from ATF cooler.
AT-03200
3) Remove the clip from bracket.
AT-03201
4AT-76

3) Install each hose to ATF cooler.

NOTE:
Pay attention to the orientation of hose.
(A)
(D)
(B)
(C)
(C)
AT-02174
(A)
(B)
(C)
(D)

Engine coolant inlet hose
Engine coolant outlet hose
E: INSPECTION
clamps and washers found from the inspection below.
1) Check each connection for ATF or engine coolant leakage.
2) Check the clamp for deformation.
surface and other damage.
5) Check the end of each hose for peeling, cracks
and deformation.
6) Check the ATF cooler for damage.
4AT-77
Warmer Cock
25.Warmer Cock
B: INSTALLATION
A: REMOVAL
1) Install the bracket, and then install the throttle

body.

2) Remove all hoses from warmer cock.
Tightening torque:
16 Nm (1.6 kgf-m, 11.6 ft-lb)
AT-02166
AT-02163
2) Install the warmer cock.
3) Remove the warmer cock.
Tightening torque:
T1: 6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
T2: 15 Nm (1.5 kgf-m, 10.8 ft-lb)
T2
AT-02165
T1
4) Remove the throttle body as necessary, and

then remove the bracket.
AT-02168
3) Connect the hoses to warmer cock.
AT-02166
AT-02163

4AT-78
Warmer Cock
C: DISASSEMBLY
Remove the bolt on warmer cock, and remove the
thermostat.
AT-02177
D: ASSEMBLY
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
E: INSPECTION
Inspection method
During the test, agitate the water for even temperature distribution. The measurement should conform to the specification.
69 73C (156 163F)
Fully opens:
84C (183F)
Valve lift:
(A)
(B)
CO-00033
(A) Thermometer
(B) Thermostat
4AT-79
Air Breather Hose

26.Air Breather Hose

A: REMOVAL
Chamber.>
2) Disconnect the air breather hose.
AT-00099
(A) Air breather hose (Transmission case)

(B) Air breather hose (Oil pump housing)
B: INSTALLATION
1) Install the air breather hose.
AT-00099

(B) Air breather hose (Oil pump housing)

C: INSPECTION
Make sure the hose is not cracked or clogged.
4AT-80
Oil Charge Pipe

27.Oil Charge Pipe
B: INSTALLATION
A: REMOVAL
1) Install the oil charge pipe with a new O-ring applied with ATF.
Model with ATF cooler with warmer function

Chamber.>
2) Remove the oil charge pipe, and then remove
the O-ring from flange side.
Model with ATF cooler with warmer function
Tightening torque:
41 Nm (4.2 kgf-m, 30.4 ft-lb)
(A)
(A)
(B)
AT-02178
(B)
(A) Oil level gauge

(B) Oil charge pipe
AT-02178
(A) Oil level gauge

(B) Oil charge pipe
Model without ATF cooler with warmer function
Model without ATF cooler with warmer function
Tightening torque:
41 Nm (4.2 kgf-m, 30.4 ft-lb)
(A)
(A)
(B)
(B)
AT-03202
AT-03202
(A) Oil level gauge

(B) Oil charge pipe
(A) Oil level gauge

(B) Oil charge pipe

C: INSPECTION
Make sure the oil charge pipe is not deformed or
damaged.
4AT-81
Torque Converter Clutch Assembly

28.Torque Converter Clutch Assembly

A: REMOVAL
1) Remove the transmission assembly from vehicle. <Ref. to 4AT-40, REMOVAL, Automatic Transmission Assembly.>
2) Pull out the torque converter clutch and oil pump
shaft horizontally.
NOTE:
Be sure not to scratch the inside of bushing in oil
pump shaft.
B: INSTALLATION
1) Install the shaft to the converter case when oil
pump shaft is removed.
2) Install the oil pump shaft to torque converter
clutch, and then make sure that the clip is secured
on groove.
3) Apply ATF to O-ring and insert the input shaft
with rotating it by hand lightly.
Normal protrusion A:
50 55 mm (1.97 2.17 in)
AT-00291
AT-00113
3) Remove the input shaft.

NOTE:
When removing the torque converter clutch assembly, the input shaft is also removed.
4) With holding the torque converter clutch assembly by hands, carefully install to the converter case.
Take care not to damage the bushing. Do not contact the oil pump shaft bush with starter shaft part of
oil pump cover inappropriately.
5) Lightly rotating the shaft by hands to engage the
spline securely, and then check it is within the dimension A.
Dimension A:
2.0 L model
1.1 1.3 mm (0.043 0.051 in)
(A)
AT-00114
4) Remove the oil pump shaft from the torque converter clutch as necessary.
AT-01352
(A) Dimension A
4AT-82
Torque Converter Clutch Assembly

2.5 L model
2.7 2.9 mm (0.106 0.114 in)
(A)
AT-00311
(A) Dimension A
6) Install the transmission assembly into vehicle.

<Ref. to 4AT-43, INSTALLATION, Automatic
C: INSPECTION
Make sure the ring gear and protrusion of torque
converter clutch end are not deformed or damaged.
4AT-83
Extension Case
29.Extension Case
4) Tighten bolts to secure extension case.
A: REMOVAL
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
1) Remove the transmission assembly.

<Ref. to 4AT-40, REMOVAL, Automatic Transmission Assembly.>
MPT model
(A)
AT-00118
5) Install the rear vehicle speed sensor.

Tightening torque:
7 Nm (0.7 kgf-m, 5.1 ft-lb)
MPT model
AT-02207
(A)
VTD model
(A)
AT-02207

AT-00117
VTD model
3) Separate the transmission case and extension

case part.
(A)
AT-00117
6) Install the transmission assembly.

AT-00118
B: INSTALLATION
1) Attach the selected thrust needle bearing to the
end surface of reduction drive gear with vaseline.
NOTE:
Install the thrust needle bearing in correct direction.
2) Install a new gasket.
3) Install the extension case to transmission case.
4AT-84
Extension Case
C: DISASSEMBLY
2. VTD MODEL
1. MPT MODEL
1) Remove the snap ring using ST1, ST2, ST3 and

a press.
ST1 398673600 COMPRESSOR
ST2 498627100 SEAT
ST3 398663600 PLIERS
1) Take out the transfer clutch by lightly tapping the

end of rear drive shaft.
NOTE:
Be careful not to damage the oil seal of extension
case.
ST1
ST2
ST3
(A)
(B)
AT-00121
2) Remove the test plug.

AT-00119
(A)
(A) Extension case

(B) Transfer clutch
2) Remove the transfer clutch pipe without deforming the pipe.

(A)
(B)
AT-00122
(B)
(A) Extension case

(B) Test plug
3) Remove the clutch piston using compressed air.

AT-00120
(A) Extension case

(B) Transfer clutch pipe
3) Remove the dust cover from extension case.

4) Remove the oil seal from extension case.
AT-00123
4AT-85
Extension Case
4) Remove transfer clutch pipe without deforming

the pipe.
Press-fit the clutch assembly to bottom of bearing shoulder completely.
(A)
(B)
AT-00124
AT-00125

(A) Transfer clutch

(B) Extension case
D: ASSEMBLY
2. VTD MODEL
1. MPT MODEL
1) Press-fit new oil seal using ST and press.
ST 498057300
INSTALLER
2) Press-fit the dust cover.
3) Install the transfer clutch pipe to extension case
without deforming the pipe.
1) Press new oil seal using ST and press.

ST 498057300
INSTALLER
3) Install the transfer clutch pipe to extension case
without deforming the pipe.
(A)
(B)
AT-00124
AT-00120
4) Apply ATF to a new O-ring and install the test

plug.
(A) Extension case

(B) Transfer pipe
4) Install the transfer clutch assembly to the case.
Tightening torque:
13 Nm (1.3 kgf-m, 9.4 ft-lb)
NOTE:
Be careful not to damage the seal ring.
(A)
(B)
AT-00122
(A) Test plug

(B) Extension case
4AT-86
Extension Case
5) Insert the multi-plate clutch, drive plates, driven

plates, and spring retainer.
(A)
(B)
AT-00126
(A) Spring retainer

(B) Multi-plate clutch (LSD) piston assembly
6) Install the snap ring using special tools 1, 2, and

3.
ST2 498627100 SEAT
ST3 398663600 PLIERS
ST1
ST2
ST3
AT-00121
E: INSPECTION
Spray compressed air, and make sure the transfer pipe and extension case routes are not clogged
and have no leaks.
Measure the extension end play and adjust it to
within specifications.
MPT model
<Ref. to 4AT-91, MP-T MODEL, ADJUSTMENT, Transfer Clutch.>
VTD model
<Ref. to 4AT-92, VTD MODEL, ADJUSTMENT,
Transfer Clutch.>
4AT-87
Transfer Clutch
30.Transfer Clutch
C: DISASSEMBLY
A: REMOVAL
1) Remove the seal ring.
2) Remove the extension case, and then remove
the transfer clutch. <Ref. to 4AT-84, REMOVAL,
Extension Case.> <Ref. to 4AT-85, DISASSEMBLY, Extension Case.>
B: INSTALLATION
1) Select the thrust needle bearing. <Ref. to 4AT91, ADJUSTMENT, Transfer Clutch.>
2) Install the transfer clutch assembly to the case.
AT-00127
(A) Seal ring

(B) Transfer clutch
2) Remove the ball bearing using ST and press.

ST 498077600
REMOVER
(A)
(B)
AT-00125
(A) Transfer clutch

(B) Extension case
AT-00128
3) Tighten the bolts to secure the case.
3) Remove the snap ring, and then take out the

pressure plate, drive plate and driven plate.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
AT-00129
AT-00118

(A) Snap ring

(B) Transfer clutch
4) Using the ST1, ST2 and ST3, remove the snap

ring, and then take out the return spring and transfer clutch piston seal.
4AT-88
Transfer Clutch
ST1 399893600
ST2 398673600
ST3 398623600
2) Install the return spring to transfer clutch piston.
PLIERS
COMPRESSOR
SEAT
(A)
ST1
ST2
(A)
ST3
(B)
(B)
AT-00133
(A) Return spring

(B) Rear drive shaft
AT-00130
(A) Snap ring

(B) Transfer piston seal
3) Apply ATF to the lip of transfer clutch piston seal

and install it.
5) Apply compressed air to the rear drive shaft to

remove transfer clutch piston.
(B)
(A)
AT-00134
(A) Transfer clutch piston seal

AT-00131
D: ASSEMBLY
4) Install the ST to the rear drive shaft.

ST 499257300
SNAP RING OUTER GUIDE
1) Install the transfer clutch piston.
ST
(A)
(B)
(A)
AT-00132
AT-00135
(A) Transfer clutch piston

(A) Transfer clutch
4AT-89
Transfer Clutch
5) Install the snap ring to ST.

ST 499257300
SNAP RING OUTER GUIDE
(A)
8) Apply compressed air to see if the assembled

parts move smoothly.
ST
(B)
AT-00139
AT-00136
(A) Snap ring

(B) Transfer clutch
6) Install the snap ring to rear drive shaft using ST1

and ST2.
ST1 499257300 SNAP RING OUTER GUIDE
ST2 499247400 INSTALLER
9) Check clearance between snap ring and pressure plate. <Ref. to 4AT-91, INSPECTION, Transfer Clutch.>
10) Press-fit new ball bearing using ST.
ST 899580100
INSTALLER
ST
ST2
(A)
(A)
ST1
AT-00140
(B)
(A) Ball bearing
AT-00137
11) Apply vaseline to a new seal ring and attach to

the seal ring groove of the shaft.
(A) Snap ring

(B) Transfer clutch
7) Install the driven plate, drive plate, pressure

plate and snap ring.
NOTE:
While installing the seal ring, not to expand the seal
ring excessively.
(A)
(B)
(A)
AT-00138
(A) Snap ring
(A) Seal ring

(B) Transfer clutch
4AT-90
AT-00141
Transfer Clutch
12) Install the transfer clutch assembly without

damaging seal ring.
(A)
(B)
AT-00125
4) Check that the tight corner braking does not occur when the vehicle is started with steering wheel
held at fully turned position. If tight corner braking
occurs, perform the following procedures.
(1) With the steering wheel held at fully turned
position, drive the vehicle in D range and with
vehicle speed at approx. 5 km/h (3 MPH) in both
clockwise and counterclockwise directions for
approx. ten times each, while repeating acceleration and braking intermittently.
(2) If the tight corner braking still persists, drive
the vehicle again in a circle for several laps.
F: ADJUSTMENT
(A) Transfer clutch

(B) Extension case
1. MP-T MODEL
E: INSPECTION
Inspect the drive plate facing for wear and damage.
Inspect the snap ring for wear, return spring for
permanent distortion, breakage and deformation.
Inspect the D-ring for damage.
Inspect the extension end play and adjust it to
within specifications. <Ref. to 4AT-91, ADJUSTMENT, Transfer Clutch.>
1) Check clearance between snap ring and pressure gauge.
2) Before measuring clearance, place the same
thickness of shim on both sides to prevent pressure
plate from tilting.
3) If the clearance is not within specification, adjust
it by selecting a suitable pressure plate on transfer
clutch piston side.
Initial standard:
0.7 1.1 mm (0.028 0.043 in)
1) Measure the depth A from the end of extension

case to the end of rear drive shaft using ST.
ST 398643600
GAUGE
ST
A
AT-01029
2) Measure the height B from the transmission

case mating surface to the end of ST using ST1
and ST2.
ST1 398643600 GAUGE
ST2 499577000 GAUGE
ST2
Limit thickness:
1.6 mm (0.063 in)
ST1
AT-02210
AT-00142
Part number
31593AA151
31593AA161
31593AA171
31593AA181
Pressure plate
Thickness mm (in)
3.3 (0.130)
3.7 (0.146)
4.1 (0.161)
4.5 (0.177)
4AT-91
Transfer Clutch
3) Calculation formula:
2. VTD MODEL
NOTE:
Calculate T:
T = A B + 35.4 mm
[T = A B + 1.3937 in]
T: Thrust needle bearing thickness
A: Depth from mating surface of extension case to
end of surface of rear drive shaft ball bearing outer
race
B: Height from mating surface of transmission case
to end of ST
Example:
When A = 33.6 mm (1.3228 in), B = 65.05 mm
(2.5610 in)
T = 33.6 65.05 + 35.4 = 3.95
[T = 1.3228 2.5610 + 1.3937 = 0.1555]
After calculation, the value of T becomes 3.95,
therefore select bearing thickness of 3.8 mm (0.150
in).
1) Insert the rear drive shaft into the reduction drive

gear and center differential assembly.
NOTE:
Calculation formula for T is applied when measuring using ST (398643600 GAUGE, 499577000
GAUGE). When not using the ST,
T = (A + 0.45 mm) (B ) H
[T = (A + 0.0177 in) (B ) H]
is applied.
end of surface of rear drive shaft ball bearing outer
race
to end of substitution as ST
: Tool thickness used when measuring A
: Tool thickness used when measuring B
0.45: Gasket thickness (mm)
0.0177: Gasket thickness (in)
H: Shim clearance
(A)
(B)
AT-02211
(A) Rear drive plate

(B) Center differential carrier
2) Using the ST, measure the depth A, which is

from mating surface of extension case to rear drive
shaft ball bearing outer ring contact surface.
ST 398643600
GAUGE
ST
AT-01031
3) Using the ST, measure the height B from the

mating surface of transmission case to rear drive
shaft ball bearing.
ST 398643600
GAUGE
ST

Part No.
Thickness mm (in)
806536020
3.8 (0.150)
806535030
4.0 (0.157)
806535040
4.2 (0.165)
806535050
4.4 (0.173)
806535060
4.6 (0.181)
806535070
4.8 (0.189)
806535090
5.0 (0.197)
B
AT-01032
4AT-92
Transfer Clutch
NOTE:
Calculate T:
When the clearances are 0.05 mm (0.0020 in), select up to four adjusting shims from the table, suitable for clearance value.
When clearances are 0.05 mm (0.0020 in)
T = A B + 0.40 mm
[T = A B + 0.0157 in]
When clearances are 0.25 mm (0.0098 in)
T = A B + 0.20 mm
[T = A B + 0.0079 in]
T: Shim clearance
rear drive shaft ball bearing outer ring contact surface
to ball bearing end of rear drive shaft
T: Shim thickness
0.05 0.25 mm (0.0020 0.0098 in)
Example:
When A = 90.50 mm (3.5630 in), B = 90.35 mm
(3.5571 in)
Calculation when clearance is 0.05 mm (0.0020 in)
T = 90.50 90.35 + 0.4 = 0.55
[T = 3.5630 3.5571 + 0.0157 = 0.0216]
T = 90.50 90.35 + 0.2 = 0.35
[T = 3.5630 3.5571 + 0.0079 = 0.0138]
NOTE:
Calculation formula for T above is applied when
measuring using ST (398643600 GAUGE). When
not using the ST,
T = (A + 0.45 mm) (B ) H
[T = (A + 0.0177 in) (B ) H]
is applied.
rear drive shaft ball bearing outer ring contact surface
to rear drive shaft ball bearing end surface
H: Shim clearance
After calculation, the value of T becomes between
0.35 mm (0.0138 in) and 0.55 mm (0.0216 in),
therefore select two shims with thickness of 0.2 mm
(0.010 in) or one shim with thickness of 0.5 mm
(0.020 in).
4AT-93
Part No.
33281AA001
33281AA011
Adjustment shim
Thickness mm (in)
0.2 (0.008)
0.5 (0.020)
Multi-plate Clutch
31.Multi-plate Clutch
T = A B + 0.45 mm
[T = A B + 0.0177 in]
A: REMOVAL
Remove the multi-plate clutch following the same
instructions as for the extension case. <Ref. to
4AT-84, REMOVAL, Extension Case.>
B: INSTALLATION
Install the multi-plate clutch following the same instructions as for the extension case. <Ref. to 4AT84, INSTALLATION, Extension Case.>
C: INSPECTION
Make sure the snap ring is not worn and the return spring has no permanent distortion, damage,
or deformation.
Inspect the lathe cut seal ring for damage.
Measure the multi-plate clutch clearance and adjust it to within the specification range. <Ref. to
4AT-94, ADJUSTMENT, Multi-plate Clutch.>
D: ADJUSTMENT
1) Assemble the drive plate and driven plate to center differential carrier.
2) Using the ST, measure the depth A from mating surface of extension case to multi-plate clutch
piston.
ST 398643600
GAUGE
NOTE:
GAUGE). When not using the ST,
T = (A + 0.45 mm) (B )
[T = (A + 0.0177 in) (B )]
is applied.
A: Depth from the end of the substitute as ST to
multi-plate clutch piston
to end of substitution as ST
Measure the thickness of multi-plate clutch piston driven and drive plate to find the clearance between measurement value and T.
Initial specification:
0.2 0.6 mm (0.008 0.024 in)
Service limit:
1.6 mm (0.063 in)
If the clearance exceeds the limit, replace the plate
set (drive and driven). Select a driven plate of multiplate clutch piston so that the clearance becomes
within specification.
ST
Driven plate
Part No.
31589AA041
31589AA050
31589AA060
31589AA070
AT-01031
3) Using the ST, measure the height B from transmission case mating surface to end of ST.
ST 398744300
PISTON GUIDE
ST
AT-01033
4AT-94
Thickness mm (in)
1.6 (0.063)
2.0 (0.079)
2.4 (0.094)
2.8 (0.110)
Rear Drive Shaft

32.Rear Drive Shaft
2) Using a press, remove the front and rear side

ball bearings and clutch hub.
A: REMOVAL
1) Remove the transmission assembly. <Ref. to
4AT-40, REMOVAL, Automatic Transmission Assembly.>
2) Remove the rear wheel speed sensor, and separate the extension case from transmission case.
<Ref. to 4AT-84, REMOVAL, Extension Case.>
3) Pull out the rear driveshaft from center differential assembly.
(B)
(A)
(C)
AT-00151
(A)
(A) Rear ball bearing

(B) Rear driveshaft
(C) Clutch hub
D: ASSEMBLY
(B)
NOTE:
Use a new revolution gear and ball bearings.
Make sure the clutch hub is in the correct direction.
AT-02211
(A) Rear driveshaft

(B)
4) Remove the drive plate and driven plate.
B: INSTALLATION
1) Select the appropriate shim. <Ref. to 4AT-92,
VTD MODEL, ADJUSTMENT, Transfer Clutch.>
2) Install the drive plate and driven plate.
3) Insert the rear driveshaft into center differential
assembly.
4) Combine the transmission case and extension
case. Install the rear wheel speed sensor. <Ref. to
4AT-84, INSTALLATION, Extension Case.>
5) Install the transmission assembly. <Ref. to 4AT43, INSTALLATION, Automatic Transmission Assembly.>
(A)
(D)
AT-00152
(A)
(B)
(C)
(D)
C: DISASSEMBLY
1) Using a press, remove the revolution gear.
(C)
Front side
Clutch hub
Rear side
Revolution gear
E: INSPECTION
Inspect the parts to make sure there are no
holes, cuts, and that they are not dusty.
Inspect the extension end play, and adjust it to
within the standard value. <Ref. to 4AT-92, VTD
MODEL, ADJUSTMENT, Transfer Clutch.>
(A)
AT-00149
(A) Revolution gear
4AT-95
Reduction Driven Gear

33.Reduction Driven Gear
3) Remove the rear drive shaft. <Ref. to 4AT-95,

REMOVAL, Rear Drive Shaft.>
4) Set the range select lever to P.
5) Straighten the staked portion, and remove the
lock nut.
A: REMOVAL
1. MPT MODEL
2) Remove the rear vehicle speed sensor, and then
separate the extension case from transmission
case. <Ref. to 4AT-84, REMOVAL, Extension
Case.>
3) Set the select lever to P range.
4) Remove the caulking part, and then remove the
lock nut.
AT-00155
6) Using the ST1 and ST2, extract the reduction

driven gear.
ST1 499737000 PULLER
ST2 899524100 PULLER SET
7) Pull out the center differential assembly. <Ref. to
4AT-100, REMOVAL, Center Differential Carrier.>
(B)
(A)
B: INSTALLATION
1. MPT MODEL
AT-02212
(A) Reduction driven gear

(B) Reduction drive gear

driven gear.

2) Using a plastic hammer, install the reduction
driven gear assembly and new washer, and tighten
new drive pinion lock nut.
Tightening torque:
100 Nm (10.2 kgf-m, 73.8 ft-lb)
(B)
(B)
(A)
ST2
ST1
(A)
AT-02212
AT-00154


2. VTD MODEL
2) Remove rear vehicle speed sensor, and separate the extension case from transmission case.
3) After tightening, stake the lock nut securely.

4) Combine the transmission case with extension
case, and then install the rear vehicle speed sensor. <Ref. to 4AT-84, INSTALLATION, Extension
Case.>
4AT-96

2. VTD MODEL
2) Using a plastic hammer, install the reduction
driven gear assembly.
3) Using a plastic hammer, install the center differential assembly.
4) Install a new self-lock nut and a washer.
2) Remove the ball bearing from reduction driven

gear using ST.
ST 498077600
REMOVER
(A)
ST
Tightening torque:
100 Nm (10.2 kgf-m, 73.8 ft-lb)
AT-00157
(A) Ball bearing
3) Remove the snap ring from reduction driven

gear.
D: ASSEMBLY
AT-00155
5) After tightening, stake the lock nut securely.

6) Insert the rear drive shaft assembly. <Ref. to
4AT-95, INSTALLATION, Rear Drive Shaft.>
case, and install the rear vehicle speed sensor.
<Ref. to 4AT-84, INSTALLATION, Extension
Case.>
8) Install the transmission assembly to vehicle.
1) Install the snap ring to reduction driven gear.

2) Install the new ball bearing to reduction driven
gear using press.
(A)
C: DISASSEMBLY
AT-00158

gear.
(A) Ball bearing
(A)
(A)
AT-00156
(A) Snap ring
AT-00156
(A) Snap ring
E: INSPECTION
Make sure the ball bearing and gear is not deformed or damaged.
4AT-97
Reduction Drive Gear

34.Reduction Drive Gear
C: DISASSEMBLY
A: REMOVAL
1) Take out the seal ring.
Case.>
3) Remove the reduction driven gear. <Ref. to 4AT96, REMOVAL, Reduction Driven Gear.>
4) Using the ST, extract the reduction drive gear.
(A)
(B)
AT-00161
(A) Seal ring

(B) Reduction drive shaft
(A)
2) Remove the ball bearing using ST.

ST 498077600
REMOVER
ST1
(A)
ST
ST2
AT-00159
(B)
(A) Reduction drive gear
B: INSTALLATION
AT-00162
1) Install the reduction drive gear assembly.

NOTE:
Press-fit it to the bottom of bearing shoulder completely.
(A) Ball bearing

3) Using the press, remove the reduction drive

gear.
(A)
(A)
AT-02213
AT-00163
2) Install the reduction driven gear. <Ref. to 4AT96, INSTALLATION, Reduction Driven Gear.>
Case.>
D: ASSEMBLY
1) Press-fit the reduction drive gear to shaft.
2) Press-fit the new ball bearing into reduction drive
gear.
3) Apply vaseline to the outer surface of seal ring
and shaft groove.
4AT-98

4) Apply ATF to new seal rings and install them.
(A)
(B)
AT-00161
(A) Seal ring

(B) Reduction drive shaft
E: INSPECTION
Rotate the bearing by hand, make sure it rotates
smoothly.
Check that the holes, damages or other foreign
matters are not on each parts.
4AT-99
Center Differential Carrier

35.Center Differential Carrier
C: DISASSEMBLY
A: REMOVAL
1) Remove the seal rings.
2) Remove the rear wheel speed sensor, and separate the extension case from transmission case.
3) Pull out the rear driveshaft. <Ref. to 4AT-95, REMOVAL, Rear Drive Shaft.>
4) Using the STs, pull out the center differential carrier assembly.
(A)
AT-00166
(A) Seal ring
2) Using a press and the ST, remove the ball bearing.

ST 498077600
REMOVER
ST1
ST2
AT-00164
5) Pull out the shim(s) from transmission case.
B: INSTALLATION
1) Install the center differential assembly with the
shim(s).
NOTE:
Insert the center differential assembly and shim(s)
completely into bearing shoulder bottom.
AT-00167
3) Remove the snap ring, and pull out the shaft

from center differential assembly.
(A)
(B)
AT-00168
(A) Snap ring

(B) Shaft
AT-00165
2) Insert the rear driveshaft. <Ref. to 4AT-95, INSTALLATION, Rear Drive Shaft.>
3) Connect the transmission case and extension
case, and install the rear wheel speed sensor.
<Ref. to 4AT-84, INSTALLATION, Extension
Case.>
4) Install the transmission assembly onto vehicle.
4AT-100

4) Remove the thrust washers, pinion gears, and

washers from center differential assembly.
(A)
AT-00169
(A) Pinion gear
5) Pull out the intermediate shaft and thrust bearing.
D: ASSEMBLY
1) Install the thrust washer onto intermediate shaft.
2) Install the thrust bearing onto the intermediate
shaft.
3) Install the pinion gears and washers.
4) Insert the shaft into center differential assembly.
6) Using a press, install a new ball bearing into center differential assembly.
ST 498077000
REMOVER
(A)
ST
(B)
AT-00170
(A) Plate
7) Apply vaseline onto the seal ring outer surface

and shaft grooves.
8) Install new seal rings.
E: INSPECTION
Check all the parts for hole, score, or dirt.
Check the play of the extension end, and if necessary, adjust it. <Ref. to 4AT-92, VTD MODEL,
ADJUSTMENT, Transfer Clutch.>
4AT-101
Parking Pawl
36.Parking Pawl
A: REMOVAL
Case.>
3) Remove the reduction drive gear. (MP-T model)
<Ref. to 4AT-98, REMOVAL, Reduction Drive
Gear.>
4) Remove the center differential carrier. (VTD
model) <Ref. to 4AT-100, REMOVAL, Center Differential Carrier.>
5) Remove the parking pawl, return spring and
shaft.
(A)
4) Install the extension case and rear vehicle speed

sensor. <Ref. to 4AT-84, INSTALLATION, Extension Case.>
5) Install the transmission assembly into the vehicle. <Ref. to 4AT-43, INSTALLATION, Automatic
C: INSPECTION
Make sure that the tab of parking pawl on reduction
gear is not worn or otherwise damaged.
(B)
AT-02214
(A) Return spring

(B) Parking pawl
B: INSTALLATION
1) Install the parking pawl, return spring and shaft.
(A)
(B)
AT-02214
(A) Return spring

(B) Parking pawl
2) Install the reduction drive gear. (MP-T model)

<Ref. to 4AT-98, INSTALLATION, Reduction Drive
Gear.>
3) Install the center differential carrier. (VTD model)
<Ref. to 4AT-100, INSTALLATION, Center Differential Carrier.>
4AT-102
Converter Case
37.Converter Case
Be careful not to loosen the rubber seal.
A: REMOVAL
2) Pull out the torque converter clutch assembly.
<Ref. to 4AT-82, REMOVAL, Torque Converter
Clutch Assembly.>
AT-03203
9) Remove the seal pipe.
AT-00114
4) Lift up the lever on the rear side of connector,

and then disconnect it from the stay.
5) Disconnect the inhibitor switch connector from
the stay.
AT-00176
(A) Seal pipe

(B)
(A)
10) Remove the differential assembly. <Ref. to

4AT-115, REMOVAL, Front Differential Assembly.>
11) Remove the oil seal from converter case.
B: INSTALLATION
1) Check the appearance of each component and
clean them.
2) Press-fit the oil seal to converter case using ST.
ST 398437700
DRIFT
AT-01351

(B) Inhibitor switch connector

<Ref. to 4AT-69, REMOVAL, ATF Cooler Pipe and
Hose.>
8) Remove the converter case aligning bolt, and
then separate the transmission case and converter
case by lightly tapping with plastic hammer.
NOTE:
Be careful not to damage the oil seal and bush inside the converter case by the oil pump cover.
AT-00177
3) Install the differential assembly to case. <Ref. to

4AT-115, INSTALLATION, Front Differential Assembly.>
4) Install the left and right side retainers. <Ref. to
4AT-119, ADJUSTMENT, Front Differential Assembly.>
4AT-103
Converter Case
5) Install the new seal pipe to converter case.
8) Install the converter case assembly without

damaging bushing and oil seal.
Tightening torque:
41 Nm (4.2 kgf-m, 30.4 ft-lb)
AT-00176
(A) Seal pipe
6) Install the rubber seal to converter case.
AT-03203
9) Insert the inhibitor switch and transmission connector to the stay.

10) Install the air breather hose. <Ref. to 4AT-80,
INSTALLATION, Air Breather Hose.>
11) Install the oil cooler pipe. <Ref. to 4AT-71, INSTALLATION, ATF Cooler Pipe and Hose.>
12) Install the oil charge pipe with O-ring. <Ref. to
4AT-81, INSTALLATION, Oil Charge Pipe.>
13) Insert the input shaft with rotating it by hand
lightly, and then check the protrusion amount.
(A)
AT-00178
50 55 mm (1.97 2.17 in)
(A) Rubber seal
7) Apply proper amount of liquid gasket to the entire matching surface of converter case.
Liquid gasket:
(B)
AT-03204
(A)
AT-00179
(A) THREE BOND 1215

(B) Rubber seal
14) Install the torque converter clutch assembly.

<Ref. to 4AT-82, INSTALLATION, Torque Converter Clutch Assembly.>
C: INSPECTION
Measure the backlash, and then adjust it within
specification. <Ref. to 4AT-113, ADJUSTMENT,
Drive Pinion Shaft Assembly.>
4AT-104
Oil Pump Housing

38.Oil Pump Housing
14) Place two wooden blocks on the workbench,

and stand the transmission case with its rear end
facing down.
A: REMOVAL
Clutch Assembly.>
NOTE:
Be careful not to scratch the rear mating surface
of transmission case.
Note that the parking rod and drive pinion protrudes from mating surface.
55mm
(2.17in)
AT-00181
AT-00114
4) Lift up the lever on the rear side of transmission

harness connector, and then remove it from stay.
Hose.>
8) Separate the converter case and transmission
case part. <Ref. to 4AT-103, REMOVAL, Converter
Case.>
case part. <Ref. to 4AT-84, REMOVAL, Extension
Case.>
10) Remove the reduction drive gear. (MP-T model) <Ref. to 4AT-98, REMOVAL, Reduction Drive
Gear.>
12) Remove the reduction driven gear. <Ref. to
4AT-96, REMOVAL, Reduction Driven Gear.>
13) Loosen the oil pump housing mounting bolts.
15) Remove the oil pump housing and adjusting

thrust washer.
(A)
AT-00182
(A) Oil pump housing
B: INSTALLATION
1) Secure the oil pump housing with two nuts and a
bolt.
Tightening torque:
42 Nm (4.3 kgf-m, 31 ft-lb)
(A)
AT-01035
(A) Oil pump housing

AT-01034
4AT-105
Oil Pump Housing

2) Install the converter case assembly into transmission case assembly. <Ref. to 4AT-82, INSTALLATION, Torque Converter Clutch Assembly.>
Gear.>
Case.>
(B)

C: DISASSEMBLY
1. OIL PUMP COVER
1) Remove four seal rings.
(A)
AT-00189
(A)
(A) Seal ring
2) Remove the cover by lightly tapping the end of

stator shaft.
(B)
(A)
AT-01351

9) Install the oil charge pipe with a O-ring. <Ref. to
AT-00190
(A) Oil pump cover

(B) Oil pump housing
3) Remove the inner and outer rotor.
50 55 mm (1.97 2.17 in)
(B)
(A)
AT-01036
AT-03204

4AT-106
(A) Inner rotor

(B) Outer rotor
Oil Pump Housing

2. OIL SEAL RETAINER
D: ASSEMBLY
1) Remove the oil seal retainer.
1. OIL PUMP COVER

1) Install the oil pump rotor assembly to oil pump
housing.
(B)
(B)
(A)
(A)
AT-00183
(A) Oil seal retainer

(B) Drive pinion shaft
AT-01036
2) Remove the O-ring.
(A) Inner rotor

(B) Outer rotor
2) Align both pivots with the pivot holes of cover,

and then install the oil pump cover being careful not
to apply excessive force to the pivots.
(A)
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
(B)
(A)
AT-00186
(A) O-ring
3) Remove the oil seal from oil seal retainer.

(A)
AT-00190
(A) Oil pump cover

(B) Oil pump housing
3) After assembling, turn the oil pump shaft to

check the smooth rotation of rotor.
(B)
AT-00185
(A) Oil seal

(B) Oil seal retainer
4AT-107
Oil Pump Housing

4) Apply vaseline to the oil seal retainer and new

seal rings, and install them. After installing, adjust
the tooth contact and backlash of drive pinion.
<Ref. to 4AT-109, ADJUSTMENT, Oil Pump Housing.>
3) Install the oil seal and secure it using three bolts

being careful not to damage oil seal lip.
Tightening torque:
7 Nm (0.7 kgf-m, 5.1 ft-lb)
(A)
(B)
(B)
(A)
AT-00183
AT-01307
(A) Oil seal retainer

(B) Drive pinion shaft
(A) Seal ring (Black)

(B) Seal ring (Brown)
E: INSPECTION
2. OIL SEAL RETAINER

1) Apply ATF to new oil seals (two), and install
them to the oil seal retainer in proper direction using ST.
ST 499247300
INSTALLER
(A)
1) Check the seal ring and oil seal for breaks and
damages.
2) Check other parts for dents or abnormalities.
3) Selection of oil pump rotor assembly
(1) Tip clearance
Install the inner rotor and outer rotor to oil pump.
With rotor gears facing each other, measure the
crest-to-crest clearance.
Tip clearance:
0.02 0.15 mm (0.0008 0.0059 in)
(A)
(C)
(B)
AT-00185
(A) Oil seal

(B) Oil seal retainer
(B)
2) Apply ATF to a new O-ring and install it to the oil

seal retainer. Install the seal to oil pump housing
bore.
AT-01038
(A) Thickness gauge

(B) Inner rotor
(C) Outer rotor
(A)
AT-00186
(A) O-ring
4AT-108
Oil Pump Housing

(2) Side clearance

Set a depth gauge to oil pump housing, then
measure the oil pump housing-to-rotor clearance.
ST
398643600
GAUGE
ST
Side clearance:
0.02 0.04 mm (0.0008 0.0016 in)
(A)
(C)
AT-00195
3) Calculation of total end play

Select the suitable bearing race from among those
listed in this table so that clearance C to be within
0.25 to 0.55 mm (0.0098 to 0.0217 in).
C = (L + G) 2
(B)
AT-01039
(A) Depth gauge

(B) Inner rotor
(C) Outer rotor
L
G
(3) If the depth and/or side clearance are not

within the specifications, replace the rotor assembly.
Part number
15008AA060
15008AA070
15008AA080
Clearance between concave portion of high

clutch and end of clutch drum support
Length from case mating surface to concave
portion of high clutch
Gasket thickness [0.28 mm (0.0110 in)]
Height from housing mating surface to upper
surface of clutch drum support
Oil pump rotor ASSY

Thickness mm (in)
11.37 11.38 (0.4476 0.4480)
11.38 11.39 (0.4480 0.4484)
11.39 11.40 (0.4484 0.4488)
Measure the total end play and adjust it within

specifications. <Ref. to 4AT-109, ADJUSTMENT, Oil Pump Housing.>
F: ADJUSTMENT
AT-00196
1) Using the ST, measure the length L, which is

from the mating surface of transmission to the recessed portion of high clutch drum.
ST 398643600
GAUGE

Part number
Thickness mm (in)
806528050
4.1 (0.161)
806528060
4.3 (0.169)
806528070
4.5 (0.177)
806528080
4.7 (0.185)
806528090
4.9 (0.193)
806528100
5.1 (0.201)
ST
L
AT-00194
2) Using the ST, measure the length from oil pump

housing mating surface to the top surface of oil
pump cover with thrust needle bearing.
4) After completing the end play adjustment, insert

the bearing race in recess of the high clutch. Install
the thrust needle bearing to oil pump cover using
vaseline.
5) After correctly install the new gasket to the case
mating surface, carefully install the oil pump housing assembly. Be careful to avoid hitting the drive
pinion against the inside of case.
6) Install both parts with dowel pins aligned. Make
sure no clearance at mating surface.
4AT-109
Drive Pinion Shaft Assembly

39.Drive Pinion Shaft Assembly

A: REMOVAL
14) Remove the drive pinion shaft mounting bolt

and remove the drive shaft assembly from oil pump
housing.
Clutch Assembly.>
AT-01252
B: INSTALLATION
1) Assemble the drive pinion assembly to oil pump
housing.
AT-00114
4) Lift up the lever on rear side of transmission harness connector, and then disconnect it from the
stay.
the stay.
6) Disconnect the air breather hose. <Ref. to 4AT80, REMOVAL, Air Breather Hose.>
Hose.>
Case.>
case part. <Ref. to 4AT-84, REMOVAL, Extension
Case.>
11) Remove the reduction drive gear. (MP-T model) <Ref. to 4AT-98, REMOVAL, Reduction Drive
Gear.>
13) Remove the reduction driven gear. <Ref. to
4AT-96, REMOVAL, Reduction Driven Gear.>
NOTE:
Be careful not to bend the shim.
Be careful not to press-fit the pinion into housing
bore.
Tightening torque:
40 Nm (4.0 kgf-m, 30 ft-lb)
AT-01252
2) Combine the torque converter case with transmission case. <Ref. to 4AT-103, INSTALLATION,
Converter Case.>
Gear.>
6) Combine the transmission case with the extension case, and then install the rear vehicle speed
sensor. <Ref. to 4AT-84, INSTALLATION, Extension Case.>
8) Install the oil cooler inlet and outlet pipes. <Ref.
to 4AT-71, INSTALLATION, ATF Cooler Pipe and
Hose.>
9) Install the oil charge pipe with O-ring.
4AT-110


3) Separate the roller bearing and outer race from

shaft using press.
50 55 mm (1.97 2.17 in)
(A)
AT-00198
(A) Outer race

AT-03204

4) Separate the front roller bearing from shaft using

a press and ST.
ST 498517000
REPLACER
(A)
C: DISASSEMBLY
ST
1) Remove the caulking part of lock nut, and then

remove the lock nut with holding the rear spline part
of shaft using ST1 and ST2. Pull out the drive pinion collar.
ST1 498937110 HOLDER
ST2 499787700 WRENCH
ST3 499787500 ADAPTER
AT-00199
(A) Front roller bearing
D: ASSEMBLY
1) Measure the dimension A of drive pinion shaft
ST 398643600
GAUGE
ST3
ST2
ST1
AT-00197
4AT-111
AT-00200

2) Using a press, press-fit the new roller bearing

into specified position.
NOTE:
If excessive force is applied to roller bearing, the
roller bearing will not turn easily.
NOTE:
Install the ST2 to torque wrench as straight as possible.
ST3
ST2
(A)
L1 [m (in)]
L2 [m (in)]
(B)
ST1
AT-00202
6) Measure the starting torque of bearing. Make

sure the starting torque is within the specified
range. If the torque is not within specified range, replace the roller bearing.
AT-00201
(A) Drive pinion shaft

(B) Roller bearing
3) After applying ATF to a new O-ring and fitting it

to the shaft, attach the drive pinion collar to shaft.
4) Install the lock washer to drive pinion shaft in
proper direction.
5) Tighten the new lock nuts using ST1, ST2 and
ST3.
Calculate the lock washer and lock nut specifications using following formula.
T2 = L2/(L1 + L2) T1
T1: 116 Nm (11.8 kgf-m, 85.3 ft-lb)
L1: ST2 length 0.072 m (2.83 in)
Example:
m (in)
0.4 (15.75)
0.45 (17.72)
0.5 (19.69)
0.55 (21.65)
ST1
ST2
ST3
498937110
499787700
499787500
Starting torque:
7.6 38.1 N (0.776 3.88 kgf, 1.7 8.6 lb)
AT-00203
7) Stake the lock nut at two points.

8) Measure the dimension B of drive pinion shaft
ST 398643600
GAUGE
Tightening torque
Nm (kgf-m, ft-lb)
98 (10.0, 72)
100 (10.2, 73.8)
101 (10.3, 74.5)
102 (10.4, 75)
HOLDER
WRENCH
ADAPTER
B
AT-00204
9) Calculate the thickness t (mm) of drive pinion

shim.
t = 6.5 0.0625 (B A)
10) Select three or less shims from following table.
4AT-112

Drive pinion shim
Part number
Thickness mm (in)
31451AA050
0.150 (0.0059)
31451AA060
0.175 (0.0069)
31451AA070
0.200 (0.0079)
31451AA080
0.225 (0.0089)
31451AA090
0.250 (0.0098)
31451AA100
0.275 (0.0108)
E: INSPECTION
Make sure that all component parts are free of
harmful cut, gouges, and other faults.
Adjust the teeth alignment. <Ref. to 4AT-113,
ADJUSTMENT, Drive Pinion Shaft Assembly.>
5) Apply red lead evenly to the surfaces of three or

four teeth on crown gear. Rotate the drive pinion in
the forward and reverse directions for several
times. Remove the oil pump housing, and check
the tooth contact pattern.
If the tooth contact is improper, readjust the backlash or shim thickness. <Ref. to 4AT-119, ADJUSTMENT, Front Differential Assembly.>
Correct tooth contact
Checking item: Tooth contact pattern is slightly
shifted toward to toe side under no-load
rotation. [When loaded, contact pattern moves
toward heel.]
(A)
F: ADJUSTMENT
1) Remove the liquid gasket completely.
2) Install the oil pump housing assembly to converter case, and secure them with tightening four bolts
evenly.
(B)
NOTE:
Use an old gasket or an aluminum washer so as not
to damage the mating surface of housing.
AT-00207
Tightening torque:
41 Nm (4.2 kgf-m, 30.4 ft-lb)
(A) Toe side

(B) Heel side
Face contact
Checking item: Backlash is too large.
Contact pattern
AT-00205
3) Rotate the drive pinion several times using ST1

and ST2.
ST2
AT-00208
Corrective action: Increase thickness of pinion

height adjusting washer in order to bring drive pinion close to driven gear.
ST1
AT-00206
4) Adjust backlash between drive pinion and crown

gear. <Ref. to 4AT-119, ADJUSTMENT, Front Differential Assembly.>
4AT-113
AT-00212

Heel contact (outside end contact)

Checking item: Contact area is small.
Contact pattern
Flank contact
Checking item: Backlash is too small.
Contact pattern
AT-00209
AT-00211
Corrective action: Reduce thickness of pinion

height adjusting washer in order to bring drive pinion away from driven gear.

height adjusting washer in order to bring drive pinion close to driven gear.
AT-00213
AT-00212
6) If tooth contact is correct, mark the retainer position and loosen it. After fitting a new O-ring and oil
seal, screw in the retainer to the marked position.
Tighten the lock plate with specified torque.
Toe contact (inside end contact)

Contact pattern
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
(A)
AT-00210

AT-00214
(A) Lock plate
AT-00213
4AT-114
Front Differential Assembly

40.Front Differential Assembly
B: INSTALLATION
A: REMOVAL
1) When installing the differential assembly to

case, be careful not to damage the inside of case
(particularly, the differential side retainer mating
surface).
Clutch Assembly.>
(A)
AT-00215
(A) Differential assembly
AT-00114
4) Lift up the lever on rear side of transmission harness connector, and then remove it from the stay.
5) Remove the inhibitor switch from the stay.
Hose.>
case. <Ref. to 4AT-103, REMOVAL, Converter
Case.>
9) Remove the seal pipe.
10) Remove the differential side retainers using
ST.
NOTE:
Hold the differential case assembly by hand to
avoid damaging retainer mounting hole of converter case.
ST 499787000
WRENCH ASSY
11) Remove the differential assembly without damaging installation part of retainer.
2) Install the O-ring to left and right side retainer.

3) Install the side retainers using ST. <Ref. to 4AT119, ADJUSTMENT, Front Differential Assembly.>
ST 499787000
WRENCH ASSY
4) Adjust the front differential backlash. <Ref. to
5) Install the lock plate.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
(A)
AT-00214
(A) Lock plate
6) Install the new seal pipe to converter case.
AT-00176
(A) Seal pipe
4AT-115

7) Install the converter case to transmission case.

<Ref. to 4AT-103, INSTALLATION, Converter
Case.>
(B)
C: DISASSEMBLY
1. DIFFERENTIAL CASE ASSEMBLY
1) Remove taper roller bearing using ST and press.
ST 498077000
REMOVER
(A)
AT-01351
AT-00216
2) Secure the case in a vise and remove the hypoid

driven gear tightening bolts, then separate the hypoid driven gear, case (RH) and case (LH).

(A)
(B)
50 55 mm (1.97 2.17 in)
(C)
AT-00217
(A) Hypoid driven gear

(B) Differential case (RH)
(C) Differential case (LH)
3) Pull out the straight pin and shaft, and then remove the differential bevel gear, washer and differential bevel pinion.
AT-03204

(A)
(A) Differential case (RH)
4AT-116
AT-00218

2. SIDE RETAINER
ST
398527700
PULLER ASSY
NOTE:
After adjusting the drive pinion backlash and tooth
contact, remove and install the oil seal and O-ring.
AT-00222
(A) Shaft
(B) Claw
5) Restore the removed claws to original position,

and install the pin and split pin.
6) Hold the shaft of ST to avoid removing from side
retainer, and then remove the bearing outer race.
ST 398527700
PULLER ASSY
AT-00219
NOTE:
Replace the bearing inner and outer races as a single unit.
AT-00220
3) Remove the split pin, and then remove the claw.

ST 398527700
PULLER ASSY
AT-00223
(A) Shaft
(B) Side retainer
AT-00221
(A) Claw
(B) Split pin
(C) Pin
4) Attach two claws to the outer race, and set the

ST to side retainer.
4AT-117

D: ASSEMBLY
Fix the bevel pinion gear in place with a screwdriver or similar tool when measuring.

1) Install the washer, differential bevel gear and differential bevel pinion in differential case (RH). Insert the pinion shaft.
2) Install the straight pin in reverse direction.
Standard value:
0.13 0.18 mm (0.0051 0.0071 in)
ST1
ST2
AT-00224
(A)
(3) If the backlash is not within specified, select

a washer from the table below.
AT-00218
Washer
3) Install the washer and differential bevel gear to

differential case (LH). Put the differential case (RH)
on the case, and then combine the both cases.
4) Install the hypoid driven gear and secure by
tightening the bolt.
Tightening torque:
62 Nm (6.3 kgf-m, 45.6 ft-lb)
Part number
803038021
803038022
803038023
Thickness mm (in)
0.95 (0.037)
1.00 (0.039)
1.05 (0.041)
6) Using the ST, install the taper roller bearing.

ST 398487700
DRIFT
(A)
(B)
(C)
AT-00225
(A) Taper roller bearing
AT-00217
2. SIDE RETAINER

5) Measurement of backlash (Selection of washer)

(1) Install the SUBARU genuine axle shaft to
differential case.
Parts No. 38415AA070 AXLE SHAFT
(2) Measure the gear backlash using ST1 and
ST2, and then insert the ST2 from the access
window of case.
ST1 498247001 MAGNET BASE
ST2 498247100 DIAL GAUGE
1) Install the bearing outer race to side retainer.

2) Install a new oil seal using ST and hammer.
SEAL INSTALLER
NOTE:
Measure the backlash by applying a pinion tooth
between two bevel gear teeth.
4AT-118
ST
AT-00226

3) Apply gear oil to a new O-ring and install it.
Tightening torque:
41 Nm (4.2 kgf-m, 30.4 ft-lb)
AT-00219
E: INSPECTION
AT-00205
Check each component for scratches, damage

and other faults.
specification.
<Ref. to 4AT-119, ADJUSTMENT, Front Differential Assembly.>

and ST2.
ST2
F: ADJUSTMENT
1) Using the ST, screw-in the retainer until light
contact is felt.
ST1
NOTE:
Screw-in the RH side slightly deeper than the LH
side.
ST 499787000
WRENCH ASSY
AT-00206
ST
AT-00227
2) Remove the oil pump housing.

3) Remove the liquid gasket completely.
4) Install the oil pump housing assembly to converter case, and secure them with tightening four bolts
evenly.
NOTE:
Use an old gasket or an aluminum washer so as not
to damage the mating surface of housing.
4AT-119

6) Tighten the retainer LH until contact is felt while

rotating the shaft. Then loosen the retainer RH.
Keep tightening the retainer LH, and loosening the
retainer RH until the pinion shaft cannot be turned.
This is the zero state.
9) Turn the drive pinion several times with ST1 and

check to see if the backlash is within the specified
value with ST2, ST3, ST4 and ST5.
ST5 498255400 PLATE
Backlash:
0.13 0.18 mm (0.0051 0.0071 in)
ST1
ST4
(A)
AT-00229
ST5
(A) Retainer
7) After the zero state is established, back off the

retainer LH 3 notches and secure it with the lock
plate. Then back off the retainer RH and retighten
until it stops. Rotate the drive pinion few times.
Tighten the retainer RH 1-3/4 notches further. This
sets the preload. Finally, secure the retainer with its
lock plate.
ST2
ST3
AT-00231
10) Adjust the tooth contact between front differential and drive shaft. <Ref. to 4AT-113, ADJUSTMENT, Drive Pinion Shaft Assembly.>
(A)
AT-00214
(A) Lock plate
NOTE:
Turning the retainer by one tooth changes the
backlash about 0.05 mm (0.0020 in).
0.05 mm
(0.0020 in)
AT-00230
8) Install the SUBARU genuine axle shaft to both

side of front differential part.
4AT-120
AT Main Case
41.AT Main Case
12) Take out the high clutch hub and thrust bearing.
A: REMOVAL
Clutch Assembly.>
(A)
(B)
AT-00233
(A) High clutch hub

(B) Thrust needle bearing
13) Take out the front sun gear and thrust needle
bearing.
(A)
AT-00114

harness connector, and then disconnect it from the
stay.
the stay.
Hose.>
Case.>
10) Remove the oil pump housing.
<Ref. to 4AT-105, REMOVAL, Oil Pump Housing.>
11) Take out the high clutch, thrust needle bearing
and reverse clutch assembly.
(B)
AT-00251
(A) Front sun gear

14) Pull out the leaf spring without folding.

NOTE:
Remove it while pressing down on lower leaf
spring.
(A)
(A)
(B)
(B)
AT-00252
(A) Leaf spring

(B) Retaining plate
AT-00232
(A) High clutch and reverse clutch ASSY

4AT-121
AT Main Case
15) Remove the snap ring and thrust needle bearing.

(A)
(A)
(B)
(B)
AT-00285
AT-00253
(A) Snap ring

(B) 2-4 brake piston
(A) Snap ring

20) Take out the 2-4 brake return spring.
16) Take out the retaining plate, drive plate and

driven plate of 2-4 brake.
AT-00286
21) Remove the 2-4 brake piston and piston retainer without damaging.
AT-00254
17) Take out the thrust needle bearing, planetary

gear assembly and low clutch assembly.
(A)
(B)
AT-00287
(A) 2-4 brake piston

(B) 2-4 brake piston retainer
AT-00255
18) Remove the 2-4 brake seal.
AT-02215
4AT-122
AT Main Case
22) Pull out the leaf spring without folding.
26) Remove the spring retainer.
(A)
AT-00293
AT-00302
27) Take out the return spring.
(A) Leaf spring

(A)
AT-00301
28) Apply compressed air.

AT-00294
(A) Snap ring
24) Take out the retaining plate, drive plate, driven

plate and dish plate.
AT-00297
29) Take out the low & reverse piston.
AT-00295
25) Turn the transmission case upside down, and

then take out the socket bolts while holding the
one-way clutch inner race with hand.
AT-00300
AT-00296
4AT-123
AT Main Case
B: INSTALLATION
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
1) Install the low & reverse brake piston.

NOTE:
Be careful not to damage the lip seal.
Apply ATF to the lip.
AT-00296
6) Place the front side of transmission body up.

7) Install the thrust needle bearing.
8) Place the dish plate, driven plate, drive plate and
retaining plate neatly in this order on surface table.
9) Set the micro gauge to clutch, and read its scale.
AT-00300
2) Install the return spring.
NOTE:
The value, which is read in the gauge at this time, is
zero point.
10) Scale and record the weight Z of a flat board
which will be put on plates.
NOTE:
Use a stiff flat board which does not bend against
load.
Use a flat board of its weight less than 83 N (8.5
kgf, 18.7 lb).
11) Put the flat board on retaining plate.
AT-00301
3) Install the spring retainer.
AT-00302
AT-01720
4) Install the one-way clutch inner race, spring retainer and return spring.
5) Tighten the socket bolts evenly from the rear
side of transmission case.
12) Using the following formula, calculate N indicated on the push/pull gauge.
N = 83 N (8.5 kgf, 18.7 lb) Z
N: Value indicated on push/pull gauge
83 N (8.5 kgf, 18.7 lb): Load applied to clutch plate
Z: Flat board weight
13) Press the center of retaining plate applying
force of N with push/pull gauge, and then measure
and record the height A. Make more than three
measurements at even distance and take the average value.
4AT-124
AT Main Case
NOTE:
If three points, measure the height every 120. If
four points, measure the height every 90.
15) Apply compressed air intermittently to check for

operation.
AT-00297
16) Place the same thickness of shim on both sides

to prevent the plate from tilting, and then measure
and record the clearance B.
NOTE:
Do not press the shim downward with excessive
force, or else the waveform of drive plates will be
broken down.
(D)
(B)
(C)
(A)
AT-01721
(A)
(B)
(C)
(D)
Dish plate
Driven plate
Drive plate
Retaining plate
AT-02216
14) Installation of the low & reverse brake:

Install the dish plate, driven plate and retaining
plate, and then secure them with snap ring.
NOTE:
Pay attention to the orientation of dish plate.
(A)
17) Piston stroke calculation

Select the retaining plate within the specification by
calculating with A and B dimensions which have
been recorded before. If the calculated value exceeds the service limit, replace the drive plate with
a new one and adjust it within the specitication.
T=A+B
T: Piston stroke
A: Collapse amount of drive plate
B: Clearance between retaining plate and snap ring
Initial standard:
2.15 2.65 mm (0.085 0.104 in)
Limit thickness:
2.95 mm (0.116 in)
AT-00294
(A) Snap ring
4AT-125
AT Main Case
Part number
31667AA420
31667AA320
31667AA330
31667AA340
31667AA350
31667AA360
31667AA370
31667AA380
21) Position the snap ring in transmission. Using

the ST, press the snap ring into specified place.
ST 498677100
COMPRESSOR
Retaining plate
Thickness mm (in)
3.8 (0.150)
4.1 (0.161)
4.4 (0.173)
4.7 (0.185)
5.0 (0.197)
5.3 (0.209)
5.6 (0.220)
5.9 (0.232)
ST
18) Install the leaf spring of low & reverse brake.

AT-00289
(A)
22) Install the planetary gear and low clutch assembly to transmission case.
Install carefully while slowly rotating the low clutch
and planetary gear assembly paying special attention not to damage the seal ring.
AT-00293
(A) Leaf spring
19) Install the 2-4 brake piston and 2-4 brake retainer by aligning the holes of 2-4 brake retainer
and hole of transmission case.
AT-00255
(A)
23) Place the dish plate, driven plate, drive plate

and retaining plate neatly in this order on surface
table.
24) Set the micro gauge to clutch, and read its
scale.
NOTE:
zero point.
(B)
AT-00287

20) Install 2-4 brake piston return spring to transmission case.
NOTE:
load.
Use a flat board of its weight less than 100 N
(10.2 kgf, 22.5 lb).
AT-00286
4AT-126
AT Main Case
29) Install the pressure plate, drive plate, driven

plate, retaining plate and snap ring.
AT-01720
N = 100 N (10.2 kgf, 22.5 lb) Z
100 N (10.2 kgf, 22.5 lb): Load applied to clutch
plate
NOTE:
AT-00254
30) Install a new 2-4 brake oil seal to transmission

case.
AT-02215
31) After all 2-4 brake component parts have been

installed, blow air intermittently and confirm the operation of brake.
AT-00290
32) Measure and record the clearance B between

the retaining plate and snap ring.
A
(C)
B
(B)
(A)
AT-01723
(A) Driven plate

(B) Drive plate
(C) Retaining plate
AT-01724
4AT-127
AT Main Case

been recorded before. If the calculated value exceeds the usage limit, replace the drive plate with a
new one and adjust it within the specitication.
T=A+B
T: Piston stroke
35) Install the thrust needle bearing in correct direction.

(E)
(D)
(B)
2.0 L SOHC model:

Initial standard:
1.4 1.8 mm (0.055 0.071 in)
Limit thickness:
1.95 mm (0.077 in)
AT-02217
(A)
(B)
(C)
(D)
(E)
Except for 2.0 L SOHC model:

Initial standard:
1.7 2.1 mm (0.067 0.083 in)
Limit thickness:
2.3 mm (0.091 in)
Part number
31567AA991
31567AB001
31567AB011
31567AB021
31567AB031
31567AB041
(C)
(A)
Snap ring
Upside
Downside
Outside
36) Install the front sun gear and thrust needle

bearing.
Retaining plate
Thickness mm (in)
5.6 (0.220)
5.8 (0.228)
6.0 (0.236)
6.2 (0.244)
6.4 (0.252)
6.6 (0.260)
(A)
(C)
(E)
(D)
(B)
34) Be careful not to mistake the location of the leaf

spring to be inserted.
AT-02218
(A)
(B)
(C)
(D)
(E)
(A)
Front sun gear

Upside
Downside
Outside
37) Install the high clutch hub.

Attach the thrust needle bearing to hub using vaseline, and then install the hub by correctly engaging
the splines of the front planetary carrier.
(B)
AT-00252
(A) Leaf spring

(B) Retaining plate
4AT-128
AT Main Case
38) Install the thrust needle bearing in proper direction.

(C)
(E)
(D)
(B)
42) Install the oil pump housing assembly with a

new gasket. <Ref. to 4AT-105, Oil Pump Housing.>
43) Install the converter case assembly into transmission case assembly. <Ref. to 4AT-103, INSTALLATION, Converter Case.>
44) Insert the inhibitor switch and transmission
connector to the stay.
(B)
(A)
(A)
AT-02219
(A)
(B)
(C)
(D)
(E)
High clutch hub

Upside
Downside
Outside
AT-01351
39) Install the high clutch assembly.

(A)
50 55 mm (1.97 2.17 in)
AT-00235
(A) High clutch and reverse clutch ASSY
40) Adjust the total end play. <Ref. to 4AT-109, ADJUSTMENT, Oil Pump Housing.>
(A)
(C)
(B)
(E)
(D)
AT-03204
AT-02220
(A)
(B)
(C)
(D)
(E)

High clutch and reverse clutch ASSY

Upside
Downside
Outside
4AT-129
AT Main Case
C: DISASSEMBLY
4) Take out the clutch cover, spring retainer, high

clutch piston and reverse clutch piston.
1) Remove the snap ring, and then take out the retaining plate, drive plate and driven plate.
(A)
(B)
(A)
(C)
AT-00239
(A) Reverse clutch piston

(B) Cover
(C) Return spring
AT-00236
(A) Snap ring
2) Remove the snap ring, and then take out the retaining plate, drive plate and driven plate.
5) Remove the seal ring and lip seal from the high
clutch piston and reverse clutch piston.
(A)
(A)
(B)
AT-00240
AT-00237
(A) High clutch piston

(B) Reverse clutch piston
(A) Snap ring
3) Using the ST1 and ST2, remove the snap ring.

ST2 498627100 SEAT
2. PLANETARY GEAR AND LOW CLUTCH

1) Remove the snap ring from low clutch drum.
ST1
(A)
(A)
ST2
(B)
AT-00259
AT-00238
(A) Snap ring

(B) Low clutch dram
(A) Snap ring
4AT-130
AT Main Case
2) Take out the front planetary carrier.
5) Take out the rear internal gear.
(A)
(A)
(B)
(B)
AT-00260
AT-00263
(A) Front planetary carrier

(B) Low clutch dram
(A) Rear internal gear

(B) Low clutch dram
3) Take out the rear sun gear.
6) Remove the snap ring from low clutch drum.

(A)
(A)
(B)
(B)
AT-00261
AT-00264
(A) Rear sun gear

(B) Rear planetary carrier
(A) Snap ring

(B) Low clutch dram
4) Take out the rear planetary carrier, washer and

thrust needle bearing.
7) Compress the spring retainer, and remove the

snap ring from low clutch drum using ST1 and ST2.
ST1 498627100 SEAT
(A)
ST2
ST1
(B)
AT-00262
(A)
(A) Rear planetary carrier

(B) Low clutch dram
(B)
AT-00265
(A) Snap ring

(B) Low clutch dram
8) Remove the one-way clutch. <Ref. to 4AT-121,

REMOVAL, AT Main Case.>
4AT-131
AT Main Case
9) Install the one-way clutch inner race to low

clutch drum, and then apply compressed air to remove the low clutch piston.
3. 2-4 BRAKE
Separate the 2-4 brake piston and piston retainer.
(B)
(A)
(A)
(B)
AT-00288
AT-00266

(A) Apply compressed air.

(B) One-way clutch inner race
10) Remove the one-way clutch inner race.

11) Remove the one-way clutch after taking out the
snap ring.
(A)
4. ONE-WAY CLUTCH INNER RACE

(C)
(A)
(B)
(B)
AT-00298
AT-00267
(A) One-way clutch inner race

(B) Seal ring
(A) Snap ring

(B) Plate
(C) One-way clutch
2) Remove the needle bearing using ST.

ST 398527700
PULLER ASSY
12) Remove the needle bearing after taking out the

snap ring.
5. ONE-WAY CLUTCH OUTER RACE

1) Remove the one-way clutch after taking out the
snap ring.
(B)
(A)
(A)
(C)
(B)
AT-00268
(A) Needle bearing

(B) Snap ring
AT-00267
(A) Snap ring

(B) Plate
(C) One-way clutch
4AT-132
AT Main Case
2) Remove the needle bearing after taking out the

snap ring.
4) Install the spring retainer to high clutch piston.
(A)
(B)
(A)
(B)
AT-00242
AT-00268
(A) Spring retainer

(B) High clutch drum
(A) Needle bearing

(B) Snap ring
D: ASSEMBLY
5) Install the ST to high clutch piston.

ST 498437000
HIGH CLUTCH PISTON
GUIDE
1) Install the seal ring and lip seal to the high clutch
piston and reverse clutch piston.
2) Install the high clutch piston to reverse clutch
piston.
ST
(A)
AT-00243
6) Install the cover to high clutch piston without

folding the high clutch piston seal.
7) Install the snap ring using ST1 and ST2.
ST2 498627100 SEAT
ST3 498437000 HIGH CLUTCH PISTON
GUIDE
(B)
AT-00240
(A) High clutch piston

(B) Reverse clutch piston
3) Install the reverse clutch piston to high clutch

drum. Align the groove on reverse clutch piston
with the groove on high clutch drum during installation.
ST1
ST3
(A)
ST2
AT-00244
(B)
AT-00241
(A) Reverse clutch piston

(B) High clutch drum
8) Place the dish plate, driven plate, drive plate and

retaining plate neatly in this order on surface table.
9) Set the micro gauge to clutch, and read its scale.
NOTE:
zero point.
4AT-133
AT Main Case
NOTE:
load.
(25.5 kgf, 56.2 lb).
NOTE:
AT-01720
N = 250 N (25.5 kgf, 56.2 lb) Z
plate
(C)
(B)
(A)
AT-01725
(A) Driven plate

(B) Drive plate
(C) Retaining plate
14) Install the thickest driven plate to piston side,

and then install the driven plate, drive plate, retaining plate to high clutch drum.
AT-00245
15) Install the snap ring to high clutch drum.
4AT-134
AT Main Case

operation.
19) Place the dish plate, driven plate, drive plate

and retaining plate neatly in this order on surface
table.
20) Set the micro gauge to clutch, and read its
scale.
NOTE:
zero point.
AT-00246

the retaining plate and snap ring. (High clutch)
At this time, do not press down the retaining plate.
B
NOTE:
load.
(15.3 kgf, 33.7 lb).
(A)
AT-01726
AT-01720
(A) Thickness gauge

T=A+B
T: Piston stroke
Initial standard:
2.0 2.3 mm (0.079 0.091 in)
N = 150 N (15.3 kgf, 33.7 lb) Z
plate
Limit thickness:
2.6 mm (0.102 in)
High clutch retaining plate
Part number
Thickness mm (in)
31567AA710
4.7 (0.185)
31567AA720
4.8 (0.189)
31567AA730
4.9 (0.193)
31567AA740
5.0 (0.197)
31567AA670
5.1 (0.201)
31567AA680
5.2 (0.205)
31567AA690
5.3 (0.209)
31567AA700
5.4 (0.213)
4AT-135
AT Main Case
NOTE:

the retaining plate and snap ring. (Reverse clutch)
At this time, do not press down the retaining plate.
(A)
B
AT-01728
(A) Thickness gauge

T=A+B
T: Piston stroke
(C)
(B)
(A)
AT-01727
(A) Driven plate

(B) Drive plate
(C) Retaining plate
Initial standard:
1.1 1.4 mm (0.043 0.055 in)
25) Install the driven plate, drive plate, retaining

plate and snap ring.
Limit thickness:
1.6 mm (0.063 in)
Reverse clutch retaining plate
Part number
Thickness mm (in)
31567AA910
4.0 (0.157)
31567AA920
4.2 (0.165)
31567AA930
4.4 (0.173)
31567AA940
4.6 (0.181)
31567AA950
4.8 (0.189)
31567AA960
5.0 (0.197)
31567AA970
5.2 (0.205)
31567AA980
5.4 (0.213)
AT-00247

operation.
AT-00248
4AT-136
AT Main Case

1) Apply ATF to D-ring and install it to low clutch
piston.
2) Install the low clutch piston to low clutch drum.
ST1
ST2
ST3
498627100
398673600
498437100
SEAT
COMPRESSOR
LOW CLUTCH PISTON
GUIDE
ST2
(A)
ST3
ST1
(B)
AT-00272
AT-00269
6) Install the dish plate, driven plate and retaining

plate, and then secure them with snap ring.
(A) Low clutch piston

(B) Low clutch dram
(A)
3) Install the spring retainer to low clutch piston.
(C)
(A)
(D)
(B)
AT-02221
(B)
(A)
(B)
(C)
(D)
AT-00270
(A) Spring retainer

(B) Low clutch dram
Snap ring
Low clutch dram
Dish plate
Low clutch piston side
7) Check the low clutch for operation.

(1) Remove the one-way clutch. <Ref. to 4AT121, REMOVAL, AT Main Case.>
(2) Set the one-way clutch inner race, and apply
compressed air for checking.
4) Install the ST to low clutch drum.

ST 498437100
LOW CLUTCH PISTON
GUIDE
ST
(A)
(B)
AT-00271
5) Set the cover on the piston with a press using

ST1 and ST2, and attach the snap ring. At this time,
be careful not to fold the cover seal during installation.
AT-00274
(A) Apply compressed air.

(B) Low clutch dram
8) Check the low clutch clearance.

(1) Place the same thickness of shim on both
sides to prevent pressure plate from tilting.
4AT-137
AT Main Case
(2) Check the clearance between retaining

plate and low clutch operation.
10) Install the rear internal gear.
Initial standard:
0.7 1.1 mm (0.028 0.043 in)
(A)
Limit thickness:
1.5 mm (0.059 in)
(A)
(B)
AT-00276

(B) Low clutch dram
(B)
AT-00283
(A) Thickness gauge

(B) Low clutch dram
(A)
(C)
(D)
If the clearance is out of specification, select a

suitable retaining plate.
Part number
31567AB050
31567AB060
31567AB070
31567AB080
31567AB090
(B)
Retaining plate
Thickness mm (in)
3.8 (0.150)
4.0 (0.157)
4.2 (0.165)
4.4 (0.173)
4.6 (0.181)
AT-02222
(A)
(B)
(C)
(D)
9) Install the washer to rear internal gear.
(A)
(B)

Low clutch dram
Rear planetary carrier side
Low clutch piston side
12) Install the washer by aligning protrusion of

washer and hole of rear planetary carrier.
(A)
(B)
AT-00275

(B) Washer
AT-00278
(A) Washer
4AT-138
AT Main Case
13) Install the rear planetary carrier to low clutch

drum.
(A)
(A)
(C)
(D)
(B)
(B)
AT-00262
AT-00280
(A) Rear planetary carrier

(B) Low clutch dram
(A)
(B)
(C)
(D)

(A)

Front planetary carrier
Rear sun gear side
Front planetary carrier side
17) Install the front planetary carrier to low clutch

drum.
(B)
(A)
(B)
AT-02223
(A) Rear sun gear side

(B) Rear planetary carrier side
AT-00260
(A) Front planetary carrier

(B) Low clutch dram
15) Install the rear sun gear in proper direction.
18) Install the snap ring to low clutch drum.
(A)
(A)
(B)
(B)
AT-00261
(A) Rear sun gear

AT-00281
(A) Snap ring

(B) Front planetary carrier
4AT-139
AT Main Case
19) Install the needle bearing, and then secure with

the snap ring.
(B)
(A)
4. ONE-WAY CLUTCH INNER RACE

1) Install the needle bearing to inner race using ST
and press.
ST 398497701
SEAT
ST
AT-00268
(A) Needle bearing

(B) Snap ring
AT-00299
20) Install the one-way clutch and one-way clutch

inner race, and then secure with the snap ring.
21) Set the inner race. Make sure that the clutch
locks in the clockwise direction and rotates freely in
the counterclockwise direction.
2) Apply vaseline to the groove of inner race and

seal ring.
3) Install two seal rings to one-way clutch inner
race.
(A)
(A)
(B)
(B)
AT-00282
AT-00298
(A) One-way clutch inner race

(B) Seal ring
(A) Locked
(B) Free
5. ONE-WAY CLUTCH OUTER RACE
3. 2-4 BRAKE
1) Apply ATF to D-ring, and install it to 2-4 brake
piston.
2) Install the 2-4 brake piston to 2-4 brake piston
retainer.
(A)
1) Install the needle bearing, and then secure with

the snap ring.
(B)
(A)
(B)
AT-00268
(A) Needle bearing

(B) Snap ring
AT-00288

2) Install the one-way clutch and one-way clutch inner race, and then secure with the snap ring.
4AT-140
AT Main Case
3) Set the inner race. Make sure that the clutch

locks in the clockwise direction and rotates freely in
the counterclockwise direction.
(A)
4. ONE-WAY CLUTCH
Make sure the snap ring is not worn and the seal
rings are not deformed.
specifications. <Ref. to 4AT-109, ADJUSTMENT,
Oil Pump Housing.>
5. LOW & REVERSE BRAKE
(B)

Drive plate facing for wear and damage
Driven plate for discoloration (burned color)
Snap ring for wear and spring retainer for deformation
AT-00282
(A) Locked
(B) Free
E: INSPECTION
Snap ring for wear, return spring for setting and
breakage, and snap ring retainer for deformation
Lip seal and D-ring for damage
Piston and drum check ball for operation
Adjust the total end play. <Ref. to 4AT-109, ADJUSTMENT, Oil Pump Housing.>

Snap ring for wear, return spring for setting and
breakage, and spring retainer for deformation
Piston check ball for operation
Oil Pump Housing.>
3. 2-4 BRAKE
Snap ring for wear and spring retainer for deformation
Oil Pump Housing.>
4AT-141
Transmission Control Device

42.Transmission Control Device

A: REMOVAL
NOTE:
Be careful not to damage the lips of press-fitted oil
seal in the case.
Clutch Assembly.>
harness connector, and then remove it from stay.
7) Wrap vinyl tape around the nipple attached to
the air breather hose.
9) Remove the inhibitor switch.
(A)
(C)
(B)
(D)
AT-02225
(A)
(B)
(C)
(D)
Bolt
Range select lever
Manual plate
Parking rod
13) Remove the detention spring.
AT-00304
10) Remove the control valve body assembly.

<Ref. to 4AT-62, REMOVAL, Control Valve Body.>
11) Pull out the straight pin of manual plate.
AT-00307
B: INSTALLATION
1) Install the detention spring to transmission case.
Tightening torque:
6 Nm (0.6 kgf-m, 4.3 ft-lb)
AT-02224
12) Remove the bolts securing select lever, and

then remove the select lever, manual plate and
parking rod.
AT-00307
2) Insert the select lever, and then tighten the bolt.
4AT-142

Tightening torque:
6 Nm (0.6 kgf-m, 4.3 ft-lb)

(B)
(A)
AT-01351
AT-00308
3) Insert the manual plate and parking rod.

(A)

(C)
(B)
(D)
50 55 mm (1.97 2.17 in)
AT-02225
(A)
(B)
(C)
(D)
Bolt
Range select lever
Manual plate
Parking rod
4) Insert a new straight pin to manual plate.

AT-03204

C: INSPECTION
AT-02224
5) Install the oil pan and control valve assembly.

<Ref. to 4AT-62, INSTALLATION, Control Valve
Body.>
6) Turn over the transmission case to its original
position.
7) Install the pitching stopper bracket.
Make sure the manual lever and detention spring

are not worn or otherwise damaged.
Tightening torque:
41 Nm (4.2 kgf-m, 30.4 ft-lb)
8) Install and adjust the inhibitor switch. <Ref. to
4AT-52, Inhibitor Switch.>
4AT-143

4AT-144
(DIAGNOSTICS)
4AT(diag)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Page
Transmission Control Module (TCM) I/O Signal .......................................14
Inspection Mode........................................................................................21
SPORT Indicator Light Display .................................................................23
Diagnostic Procedure for Subaru Select Monitor Communication ............27
Diagnostic Procedure without Diagnostic Trouble Code (DTC) ..............123
Diagnostics with Phenomenon................................................................138

AUTOMATIC TRANSMISSION (DIAGNOSTICS)

A: PROCEDURE
1
Step
CHECK PRE-INSPECTION.
1) Ask the customer when and how the trouble occurred using the interview checklist.
<Ref. to 4AT(diag)-4, Check List for Interview.>
2) Before performing diagnosis, inspect the
following items which might influence the AT
problems.
General inspection <Ref. to 4AT(diag)-5,
INSPECTION, General Description.>
Disconnection of harness connector
Visual check for harness damage
Oil Leaking
Stall speed test <Ref. to 4AT-35, Stall Test.>
Line pressure test <Ref. to 4AT-38, Line
Pressure Test.>
Transfer clutch pressure test <Ref. to 4AT39, Transfer Clutch Pressure Test.>
Time lag test <Ref. to 4AT-37, Time Lag
Test.>
Road test <Ref. to 4AT-34, Road Test.>
Inhibitor switch <Ref. to 4AT-52, Inhibitor
Switch.>
CHECK SPORT INDICATOR LIGHT.
After starting the engine, wait for at least 2 seconds.
2) Check the SPORT indicator light.
<Ref. to 4AT(diag)-24, INSPECTION, SPORT
Indicator Light Display.>
3) After the ignition switch is turned to ON,
wait for at least 2 seconds.
CHECK INDICATION OF DTC.
Display DTC.
Check
Yes
Is the unit that might influence Go to step 2.
the AT problem normal?
No
Repair or replace
each item.
Does the SPORT indicator

light blink?
Go to step 4.
Go to step 3.

light blink?
Go to step 4.
Go to step 5.
Is DTC displayed?
Go to step 6.
Go to step 5.
NOTE:
If the communication function of Subaru Select
Monitor cannot be executed normally, check
communication circuit. <Ref. to 4AT(diag)-27,
COMMUNICATION FOR INITIALIZING IMPOSSIBLE, Diagnostic Procedure for Subaru
Select Monitor Communication.>
PERFORM GENERAL DIAGNOSTICS.
Is DTC displayed?
1) Inspect using Diagnostic Procedure without Diagnostic Trouble Code (DTC). <Ref. to
4AT(diag)-123, Diagnostic Procedure without
2) Inspect using General Diagnostic Chart.
<Ref. to 4AT(diag)-138, Diagnostics with Phenomenon.>
4AT(diag)-21, Inspection Mode.>
4) Display DTC.
4AT(diag)-2
NOTE:
Record all DTC.
Go to step 6.
Finish the diagnosis.

Step
Check
PERFORM DIAGNOSIS.
Is DTC displayed?
1) Inspect using the Diagnostic Procedure
with Diagnostic Trouble Code (DTC). <Ref. to
4AT(diag)-34, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
NOTE:
For DTC table, refer to List of Diagnostic Trouble Code (DTC). <Ref. to 4AT(diag)-32, List of
2) Repair the trouble cause.
3) Perform the clear memory mode.
5) Display DTC.
4AT(diag)-3
Yes
No
Inspect using
Finish the diagnoDiagnostic Proce- sis.
dure with Diagnostic Trouble Code
(DTC). <Ref. to
4AT(diag)-34,
(DTC).>


A: CHECK
NOTE:
Customers name
Date of sale
Date of repair
Trans. model
Odometer reading
Frequency
Weather
Place

Vehicle speed
AT warning light (SPORT indicator
light)
Select lever position
Driving condition
SPORT mode
Symptom
Transmission
V.I.N.
km (miles)
Continuous Intermittent (
times a day)
Fine Cloudy Rainy Snowy
Others
(
)
Highland Suburbs Inner city Uphill
Others
(
)
Hot Warm Cool Cold
Rough road
km/h (MPH)
Blinks continuously
Not blink
P R N D SPORT mode
Not affected
At starting
While idling
At racing
When accelerating
While cruising
When decelerating
While turning ( RH / LH)
ON OFF
No up-shift
No down-shift
No kick down
Vehicle does not move ( Any position Particular position)
Lock-up malfunction
Noise or vibration
Shift shock or slip
Select lever does not move
Others
(
)
4AT(diag)-4
General Description
3. ATF LEVEL
A: CAUTION
Make sure that ATF level is within the specification.

CAUTION:
All airbag system wiring harnesses and connectors are colored yellow. Do not use an electric test equipment on these circuits.
wiring harness when performing diagnostics or
servicing the TCM.
MEASUREMENT
When measuring the 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 a pin of more
than 0.65 mm (0.026 in) diameter.
(C)
(D)
L
F
HOT
(A)
(E)
COLD
L
SUPPLEMENTAL
RESTRAINT
SYSTEM
AIRBAG
The airbag system wiring harness is routed near
the TCM.
(B)
(C)
(D)
PI-00105
(A)
(B)
(C)
(D)
(E)
B: INSPECTION
Level gauge
HOT side
Upper level
Lower level
COLD side
1. BATTERY
4. FRONT DIFFERENTIAL OIL LEVEL
Measure the battery voltage and specific gravity of

electrolyte.
Make sure the front differential oil level is within the

specification. <Ref. to 4AT-33, INSPECTION, Differential Gear Oil.>
Standard voltage: 12 V or more

Specific gravity: More than 1.260
2. TRANSMISSION GROUND
Make sure that the ground terminal bolt is tightened

securely.
Chassis side
(A)
(B)
Tightening torque:
13 Nm (1.3 kgf-m, 9.4 ft-lb)
AT-00317
(A) Upper level

(B) Lower level
AT-01464
4AT(diag)-5
General Description
5. OPERATION OF SHIFT SELECT LEVER

Make sure there is no noise, dragging or contact
pattern in each select lever range.
WARNING:
Stop the engine while checking operation of the
selector lever.
AT-02048
C: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
24082AA230
DESCRIPTION
CARTRIDGE
REMARKS
22771AA030
SUBARU SELECT
MONITOR KIT

ST24082AA230
ST22771AA030
2. GENERAL TOOL
TOOL NAME
Circuit tester
Oscilloscope
REMARKS
Used for measuring resistance, voltage and current.
Used for measuring sensor.
4AT(diag)-6


A: LOCATION
1. CONTROL MODULE
LHD model
(1)
(5)
(3)
(4)
(2)
AT-01873
(1)
(2)

SPORT indicator light (AT warning
light)
(3)
Transmission control module

(TCM)
4AT(diag)-7
(4)
(5)
Data link connector

Body integrated unit

(1)
(2)
AT-01470
AT-01874
(4)
(3)
AT-01875
(5)
AT-01876
4AT(diag)-8
AT-01877

RHD model
(3)
(2) (4)
(5)
(1)
AT-01467
(1)
(2)

light)
(3)

(TCM)
4AT(diag)-9
(4)
(5)
Data link connector


(1)
(2)
AT-01468
AT-01470
(4)
(3)
AT-01469
(5)
AT-01472
4AT(diag)-10
AT-01471

2. SENSOR
LHD model
(3)
(6)
(5) (1) (2)
(7)
(4)
AT-01878
RHD model
(3) (1) (6)
(5)
(2)
(7)
(4)
AT-01879
(1)
(2)
(3)
Throttle position sensor

Inhibitor switch
(4)
(5)

sensor
4AT(diag)-11
(6)
(7)
ATF temperature sensor

Lateral G sensor

Model without vehicle dynamics control (VDC)
(2)
(4)
(1)
AT-00375
AT-01474
Model with vehicle dynamics control (VDC)

(2)
(4)
(3)
AT-01880
AT-00330
(5)
(6)
AT-00378
AT-00331
LHD model
RHD model
(7)
(7)
AT-01882
4AT(diag)-12
AT-01475

3. SOLENOID
(7)
(1)
(2)
(6)
(3)
(5)
(4)
AT-00379
(1)
(2)
(3)
Line pressure linear solenoid

High clutch duty solenoid
2-4 brake duty solenoid
(4)
(5)
(6)
(2) (3)
(4)
(7) (6)
(5)
Low & reverse duty solenoid

Low clutch duty solenoid
Transfer duty solenoid
(1)
AT-00380
4AT(diag)-13
(7)
Lock-up duty solenoid
Transmission Control Module (TCM) I/O Signal

5. Transmission Control Module (TCM) I/O Signal

To
To
B54
7 6 5 4 3
2 1
16 15 14 13 12 11 10 9 8
24 23 22 21 20 19 18 17
B55
9 8 7 6 5 4 3
2 1
21 20 19 18 17 16 15 14 13 12 11 10
31 30 29 28 27 26 25 24 23 22
AT-01476
Check with ignition switch ON.

Item
Connector
No.
B55
ACC power supply
B55
Ignition power supply
B55
Terminal No.
27
28
29
16
21
31
P range
switch
B54
N range
switch
B54
22
R range
switch
B54
14
D range
switch
B54
Accelerator pedal position

sensor
B54
19
Accelerator pedal position

sensor power supply
B54
10
B54
21
Inhibitor
switch
B54
24
Measuring conditions
Voltage (V)
Resistance
to chassis
ground ()
Ignition switch OFF
10 13
Ignition switch ACC
10 13
Ignition switch ON (with

engine OFF)
10 13
Selector lever in P range

Select lever in any other
than P range (except N
range)
Selector lever in N range
Selector lever in any other
than N range
Selector lever in R range
than R range
Selector lever in D range
than D range
Throttle fully closed.
Throttle fully open.
engine OFF)
ATF temperature 20C
(68F)
ATF temperature 80C
(176F)
Vehicle speed at least 20
km/h (12 MPH)
4AT(diag)-14
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 0.2

4.6 or less
4.6 5.4
3.5 4.3
3.9 k 4.7 k
1.5 1.9
500 600
More than 2 (AC range)

Item
Connector
No.
Terminal No.
B54
Torque converter turbine

speed sensor
B54
Engine speed signal
B54
B54
13
20
Voltage (V)
Vehicle stopped
Vehicle speed at least 20
km/h (12 MPH)
Engine idling after warmup (D range)
Engine idling after warmup (N range)
engine OFF)
Ignition switch ON (engine
ON)
engine OFF)
Throttle fully closed in R
range after warm-up.
engine OFF)
Throttle fully open in R
range after warm-up.
When lock up occurs.
When lock up is released.
P or N range
1st gear
P or N range
2nd or 4th gear
3rd or 4th gear
P or N range
1st or 2nd gear
P or N range
P or N range
Driving at 1st on manual
mode (15 km/h (9.3 MPH)
or more)
0
Resistance
to chassis
ground ()
450 750
0
450 750
Less than 1
3.7 7.5
4.0 8.0
1.0 5.1
More than 10.5
Less than 1
Less than 1
1.7 4.0
More than 10.5
Less than 1
Less than 1
More than 10.5
Less than 1
More than 10.5
More than 10.5
B55
B55
B55
B55
B55
B55
B54
15
Less than 1
B54
24
Less than 1
B54
16
Less than 1
17
2
3
8
19
9
Less than 1
Sensor ground line 3

Sensor ground line 4
B54
B55
B55
B54
B55
B54
0
0
Less than 1
Less than 1
More than 10.5
Range lock signal
B55
18
Vehicle speed in D range

0 km/h (0 MPH)
Vehicle speed in D range
20 km/h (12 MPH)

ground
ground
Torque converter turbine
speed sensor ground
System ground circuit
Data link signal (Subaru

Select Monitor)
B55
12
4AT(diag)-15
5 10
2.0 6.0
2.0 6.0
2.0 6.0
2.0 6.0
2.0 6.0
2.0 6.0
7 18
Less than 1

Connector
No.
Terminal No.
Voltage (V)
Resistance
to chassis
ground ()
B54
Ignition switch ON
Pulse signal
B54
12
Ignition switch ON
Pulse signal
FWD switch
B55
17
10.5 or more
1 or less
Lateral G sensor
B54
11
Fuse removed
Fuse installed
Ignition switch ON (Lateral
G sensor in horizontal
position)
2.0 3.0
Lateral G sensor power supply
B54
Ignition switch ON
4.75 5.25
Item
CAN communication signal
(+)
()
4AT(diag)-16


A: OPERATION
(DTC)
NOTE:
Do not connect scan tools except for Subaru Select
Monitor.
1) Prepare the Subaru Select Monitor kit.

(A)
AT-00341
AT-00338

Monitor.
<Ref. to 4AT(diag)-6, PREPARATION TOOL, General Description.>
AT-00339

connector.
(1)
AT-01712

connector.
(A) Power switch

screen, select the {Transmission} and press the
[YES] key.
8) Press the [YES] key after the information of
transmission type is displayed.
9) On the Transmission Diagnosis display
screen, select the {Diagnosis Code(s) Display} and
press [YES] key.
NOTE:
For details concerning operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MANUAL.
Diagnostic Trouble Code (DTC). <Ref. to 4AT(diag)-32, List of Diagnostic Trouble Code (DTC).>
2. READ CURRENT DATA

[YES] key.
screen, select the {Current Data Display & Save}
screen, select the {Data Display} and press the
[YES] key.
6) Using the scroll key, scroll the display screen up
or down until the desired data is shown.
4AT(diag)-17


Item
Battery voltage
Rear vehicle speed sensor signal
Front vehicle speed sensor signal
Engine speed signal
Automatic transmission fluid temperature signal
Accelerator pedal position sensor
Gear position
Line pressure control duty ratio
Lock up clutch control duty ratio
Transfer clutch control duty ratio
Accelerator pedal position sensor power supply
Torque converter turbine speed signal
2-4 Brake timing pressure control duty ratio
Low clutch duty ratio
High clutch duty ratio
Low & reverse brake duty ratio
Throttle position
FWD switch signal
Anti lock brake system signal
Parking range signal
Neutral range signal
Reverse range signal
Drive range signal
Automatic transmission diagnosis light output signal
Cruise control signal
AT OIL TEMP warning light
Up-shift signal
Down shift signal
Tip signal
Shift lock solenoid signal
Lateral G sensor
Display
Battery Voltage
Rear Wheel Speed
Front Wheel Speed
Engine speed
ATF Temp.
Throttle Sensor Voltage
Gear position
Line pressure duty
L/U Duty
AWD duty
Throttle sensor power supply
Turbine Revolution Speed
2-4 B Pressure Duty
L/C Duty
H/C Duty
L&R/B Duty
Throttle opening angle
FWD SW
Stop Light SW
ABS signal
P range
N range
R Range
D Range
Diagnosis Lamp
Cruise control signal
ATF Temperature Lamp
UP SW
Down SW
Tip mode SW
Shift lock solenoid
Lateral G sensor
Unit of measure
V
km/h or MPH
km/h or MPH
rpm
C or F
V
%
%
%
V
rpm
%
%
%
%
%
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
V
NOTE:
4AT(diag)-18

3. CLEAR MEMORY MODE

[YES] key.
screen, select the {Clear Memory} and press the
[YES] key.
NOTE:
When {Clear Memory 2} is selected and executed,
DTC and learned control memory is cleared. If
Clear Memory 2 has been performed, execute the
learning control. <Ref. to 4AT(diag)-19, FACILITATION OF LEARNING CONTROL, OPERATION,
Subaru Select Monitor.>
4. FACILITATION OF LEARNING CONTROL

1) Shift the select lever to P range, and apply
parking brake.
connector, and then turn the ignition switch to ON.
4) Perform the {Clear Memory 2} using Subaru Select Monitor. <Ref. to 4AT(diag)-19, CLEAR MEMORY MODE, OPERATION, Subaru Select
Monitor.>
DTC is not output. <Ref. to 4AT(diag)-17, READ
DIAGNOSTIC TROUBLE CODE (DTC), OPERATION, Subaru Select Monitor.>
6) Warm-up the engine until the ATF temperature
which is displayed on the Subaru Select Monitor
reaches 60 90C (140 194F). <Ref. to
7) Shift the select lever to R range.
8) Turn all switches including headlight, air conditioner, seat heater, rear defogger and etc. to OFF.
9) Wait for 30 seconds with turning ignition key to
OFF until ACC goes OFF.
10) Depress the brake pedal fully until the facilitation of learning control is completed when the
Communication Failed! is displayed on Subaru
Select Monitor.
12) Check that the Subaru Select Monitor is returned to normal operation.
13) Shift the select lever to P range, and then wait
14) Shift the select lever to R range, and then wait
15) Shift the select lever to N range, and then wait

16) Shift the select lever to D range, and then wait
17) Shift the select lever to N range, and then wait
18) Slowly depress the accelerator pedal fully.
19) Slowly release the accelerator pedal fully.
20) Start the engine, and idle it.
21) Shift the select lever to D range.
22) Start the facilitation of learning control. At this
time, the SPORT indicator light in the combination
meter start blinking at 2 Hz. When the SPORT indicator light does not blink, turn the ignition switch to
OFF and repeat the procedures from step 4). When
the SPORT indicator light stop blinking at 2 Hz and
goes OFF, facilitation of learning control is completed.
NOTE:
When blinking of SPORT indicator light changes
from 2 Hz to 4 Hz during facilitation of learning control, repeat the procedure from step 4).
23) Shift the select lever to N range, and then turn
24) Shift the select lever to P range to complete
the facilitation of learning control.
4AT(diag)-19


Code (DTC)
A: OPERATION
Refer to Subaru Select Monitor for information
about how to display DTC. <Ref. to 4AT(diag)-17,
OPERATION, Subaru Select Monitor.>
For details concerning DTCs, refer to List of Diagnostic Trouble Code (DTC). <Ref. to 4AT(diag)32, List of Diagnostic Trouble Code (DTC).>
NOTE:
DTC can not be read by SPORT indicator light.
4AT(diag)-20
Inspection Mode
8. Inspection Mode
A: PROCEDURE
WARNING:
Observe the traffic law during actual driving.
1) Shift the select lever to D range, and then drive
the vehicle at 60 km/h (37 MPH) for at least 10 seconds.
2) Drive the vehicle with manual mode.
4AT(diag)-21
Clear Memory Mode

9. Clear Memory Mode

A: OPERATION
about how to clear DTC.
<Ref. to 4AT(diag)-19, CLEAR MEMORY MODE,
4AT(diag)-22
SPORT Indicator Light Display

10.SPORT Indicator Light Display

A: OPERATION
When any on-board diagnostics item is malfunctioning, the display on the SPORT 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 unit can be determined by a DTC during the on-board diagnostics operation. Problems
which occurred previously can also be identified through the memory function. If the SPORT indicator light
does not show a problem (although a problem is occurring), the problem can be determined by checking the
performance characteristics of each sensor using Subaru Select Monitor. Indicator light signal patterns are
(A)
(1)
(2)
(B)
(1)
(3)
(2)
(4)
(C)
(1)
(3)
(2)
(5)
(D)
(1)
(3)
(2)
(7)
(6)
AT-01109
(A)
(B)
Ignition switch (Engine OFF)

Normal (Engine ON)
(C)
Faulty (Engine ON)
(D)
Normal (SPORT mode ON)
(1)
(2)
(3)
ON
OFF
2 seconds
(4)
(5)
(6)
0.25 seconds
Blink
SPORT mode ON
(7)
SPORT mode OFF
Perform the inspection when the SPORT indicator light does not operate correctly. <Ref. to 4AT(diag)-24, INSPECTION, SPORT Indicator Light Display.>
4AT(diag)-23

B: INSPECTION
DIAGNOSIS:
SPORT indicator light circuit is open or shorted.
TROUBLE SYMPTOM:
When the ignition switch is turned to ON (engine OFF), SPORT indicator light does not illuminate.
WIRING DIAGRAM:
LHD model
IGNITION
SWITCH
SBF-7
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
No.5
SBF-1
i10
i77
A:
BATTERY
1 2 3 4 5 6 7 8 9 10 11 12
SPORT
COMBINATION
METER
i84
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
i10
21
22
B: B280
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
i84
B: B280
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
BODY INTEGRATED UNIT
B20
B30
B352
B355
1 2 3 4
5 6 7 8
JOINT
CONNECTOR
B352
B54
B355
12
JOINT
CONNECTOR
A:
B54
i77
A27
A26
JOINT
CONNECTOR
TCM
AT-01883
4AT(diag)-24

RHD model
IGNITION
SWITCH
SBF-7
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
No.5
SBF-1
i10
i77
A:
BATTERY
1 2 3 4 5 6 7 8 9 10 11 12
SPORT
COMBINATION
METER
i84
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
i10
21
22
B: B280
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
B: B280
B54
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24

B352
B30
B20
i84
1 2 3 4
5 6 7 8
JOINT
CONNECTOR
4
9
B54
B53
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
JOINT
CONNECTOR
B53
12
10
2
18
19
B352
A:
i77
A27
A26
JOINT
CONNECTOR
TCM
AT-01884
4AT(diag)-25

Step
Check
light illuminate?
Yes
Go to step 2.

After the ignition switch is ON, wait for at least
2 seconds.
Start the engine.

light illuminate?
Go to step 3.
CHECK SUBARU SELECT MONITOR COMMUNICATION.

Connect the Subaru Select Monitor to data link
connector.
CHECK TCM.
Display the current data of TCM using Subaru
Select Monitor.
CHECK BODY INTEGRATED UNIT.

Display the current data of body integrated unit
using Subaru Select Monitor. <Ref. to
LAN(diag)-14, OPERATION, Subaru Select
Monitor.>
CHECK TCM.
2) Display the current data of TCM using Subaru Select Monitor. <Ref. to 4AT(diag)-17,
Monitor.>

light go off?
No
Perform the selfdiagnosis of combination meter.
Go to step 4.
Normal. Return to Go to step 7.

Basic Diagnostic
Procedure. <Ref.
to 4AT(diag)-2,
Basic Diagnostic
Procedure.>
Is the communication between Go to step 5.
Check the power
Subaru Select Monitor and
supply ground cirTCM normal?
cuit of TCM and
Subaru Select
Monitor communication. <Ref. to
4AT(diag)-27,
Diagnostic Procedure for Subaru
Select Monitor
Communication.>
Is the Diagnosis light output Go to step 6.
Replace the TCM.
signal ON?
<Ref. to 4AT-67,
Transmission Control Module
(TCM).>
Is the SPORT light input sig- Replace the com- Check DTC of
nal Illuminate?
bination meter
body integrated
assembly. <Ref. to unit. <Ref. to
IDI-16, Combina- LAN(diag)-14,
tion Meter.>
OPERATION,
Subaru Select
Monitor.>
Is the Diagnosis light output Replace the TCM. Go to step 8.
signal ON?
<Ref. to 4AT-67,
(TCM).>
Is the SPORT light input sig- Check DTC of
Perform the selfnal Illuminate?
body integrated
diagnosis for comunit. Perform the bination meter.
diagnosis accord- <Ref. to IDI-3,
ing to DTC. <Ref. INSPECTION,
to LAN(diag)-14, Combination
OPERATION,
Meter System.>
Subaru Select
Monitor.>
4AT(diag)-26
Diagnostic Procedure for Subaru Select Monitor Communication

11.Diagnostic Procedure for Subaru Select Monitor Communication

A: COMMUNICATION FOR INITIALIZING IMPOSSIBLE
DIAGNOSIS:
Faulty harness connector
TROUBLE SYMPTOM:
Subaru Select Monitor communication failure
WIRING DIAGRAM:
LHD model
BATTERY
B11
3 4
8
6 7
9 10
11 12
14 15
13
16
17 18
19 20
1
SBF-7
NO.12
SBF-1
NO.13
B40
1 2 3 4 5 6 7 8
IGNITION
SWITCH
B40
9 10 11 12 13 14 15 16
1
10
NO.12
12
13
JOINT
CONNECTOR
JOINT
CONNECTOR
36
TCM
B21
1 2
3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26
27 28
29 30 31
B3
B2
A17
B54
B: B55
E2
A8
A:
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21
22 23 24
B12
B: B55
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
B122
13
B31
3
B21
A: B54
1 2 3 4
5 6 7 8
19
18
16
B122
JOINT
CONNECTOR
B11
T4
B21
8
20
B53
19
15
B29
14
B28
B53
B27
B53
DATA LINK
CONNECTOR
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 45
46 47
48 49 50 51 52 53 54
TRANSMISSION
AT-01885
4AT(diag)-27

RHD model
BATTERY
SBF-1
NO.13
NO.12
SBF-7
IGNITION
SWITCH
B40
1
10
NO.12
DATA LINK
CONNECTOR
12
A17
B2
B3
17
15
14
25E : B138
O25 :
36
A8
TCM
JOINT
CONNECTOR
B: B55
16
A: B54
B12
B31
B21
B29
B28
B27
13
JOINT
CONNECTOR
B21
E2
B53
B83
20
19
25E : 2.5 L EK MODEL

B11
O25 : EXCEPT 2.5 L EK MODEL
T4
E
E
B11
1
5
TRANSMISSION
B40
B53
B21
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
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
B21
3 4
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
9 10 11 12 13 14 15 16
A:
B83
B:
B54
B55
B138
1 2 3 4
5 6 7 8
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21
22 23 24
1 2
3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26
27 28
29 30 31
4AT(diag)-28
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
AT-01886

Step
Check
Yes
CHECK SUBARU SELECT MONITOR POW- Is the voltage more than 10 V? Go to step 2.
ER SUPPLY CIRCUIT.
Measure the voltage between data link connector and chassis ground.
CHECK SUBARU SELECT MONITOR

GROUND CIRCUIT.
2) Measure the resistance of harness connector between data link connector and ECM.
GROUND CIRCUIT.
between data link connector and chassis
ground.
CHECK ENGINE GROUND CIRCUIT.
Check engine ground circuit. <Ref. to
4AT(diag)-92, DTC P1708 THROTTLE POSITION SENSOR CIRCUIT LOW INPUT, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
CHECK COMMUNICATION OF SUBARU SELECT MONITOR.
2) Using the Subaru Select Monitor, check
whether communication to transmission systems can be executed normally.
2) Disconnect the TCM connector.
3) Check whether communication to engine
systems can be executed normally.
2) Connect the TCM connector.
3) Disconnect the ECM connector.
4) Check whether communication to transmission systems can be executed normally.
CHECK HARNESS CONNECTOR BETWEEN
EACH CONTROL UNIT AND DATA LINK
CONNECTOR.
2) Disconnect the TCM and ECM connector.
3) Measure the resistance between TCM connector and chassis ground.
No
Repair the harness connector
and connector
between battery
and data link connector, and poor
contact in coupling connector.
Repair the open
circuit in harness
between data link
connector and
ECM.

?
Go to step 3.

M?
Go to step 4.
Repair the short

circuit in harness
between data link
connector and
ground terminal.
Is the engine ground circuit

normal?
Go to step 5.
Repair the ground

circuit of ECM.
Are the name of system disGo to step 10.

played on Subaru Select Monitor?
Go to step 6.
Are the name of system disGo to step 8.

Go to step 7.
Are the name of system disInspect the ECM.

Go to step 8.

M?
Check harness
and connector
between each control unit and data
link connector.
4AT(diag)-29
Go to step 9.

10
11
12
13
14
15
16
17
Step
CHECK OUTPUT SIGNAL FOR TCM.
2) Measure the voltage between TCM and
chassis ground.
TCM AND DATA LINK CONNECTOR.
Measure the resistance between TCM connector and data link connector.
(B55) No. 12 (B40) No. 10:
CHECK INSTALLATION OF TCM CONNECTOR.
Turn the ignition switch to OFF.
CHECK TRANSMISSION HARNESS CONNECTOR.
Check
Yes
No
Check harness
Go to step 10.
and connector
link connector.

?
Go to step 11.
Is TCM connector inserted into Go to step 12.

TCM?
Connect the TCM

connector to TCM.
Is the transmission harness

connector connected to bulkhead harness connector?
Connect the bulkhead harness connector to

transmission harness connector.
Go to step 14.
CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in control

unit power supply and data link
connector?
CHECK POWER SUPPLY OF TCM.
3) Measure the voltage between TCM connector and chassis ground.
CHECK FUSE (No. 12).
Is the fuse (No. 12) blown?
2) Remove the fuse (No. 12).
CHECK IGNITION POWER SUPPLY CIRCUIT.

1) Turn the ignition switch to ON (engine
OFF).
2) Measure the ignition power supply voltage
between TCM connector and chassis ground.
Remove the fuse (No. 12).
Repair the harness and connector between TCM

and data link connector.
Is the fuse (No. 12) blown?
4AT(diag)-30
Go to step 13.
Repair the poor

contact.
Go to step 16.
Go to step 15.
Replace the fuse

(No. 12). If the
replaced fuse (No.
12) blown out easily, repair the short
circuit in harness
between fuse (No.
12) and TCM.
Go to step 18.
Repair the open

circuit in harness
between fuse (No.
12) and TCM, or
fuse (No. 12) and
battery, and poor
Go to step 17.
Replace the fuse

(No. 12). If the
replaced fuse (No.
12) blown out easily, repair the short
circuit in harness
between fuse (No.
12) and TCM.
Repair the open

circuit in harness
between fuse (No.
12) and TCM, or
fuse (No. 12) and
battery, and poor

18
19
20
Step
TCM AND TRANSMISSION.
2) Disconnect the connector from TCM and
transmission.
between TCM and transmission connector.
(B54) No. 8 (B11) No. 19:
(B54) No. 17 (B11) No. 19:
(B55) No. 2 (B11) No. 20:
(B55) No. 3 (B11) No. 20:
TRANSMISSION AND TRANSMISSION
GROUND.
transmission and transmission ground.
(T4) No. 19 Transmission ground:
Check
?
Yes
Go to step 19.
No
Repair the open
circuit in harness
between TCM and
transmission harness connector,
and poor contact
in connector.

?
Go to step 20.
Repair the open

circuit in harness
between transmission and transmission ground.
Is there poor contact in TCM

Repair the conpower supply, ground and data nector.
link connector?
4AT(diag)-31
Replace the TCM.

<Ref. to 4AT-67,
(TCM).>


A: LIST
DTC
Item
Content of diagnosis
P0705
Transmission Range
Sensor Circuit (PRNDL
INPUT)
Inhibitor switch malfunction short

circuit
P0712
Transmission Fluid Temperature Sensor Circuit

Low Input
ATF temperature sensor is faulty

or input signal circuit is open.
P0713

High Input
ATF temperature sensor is faulty

or input signal circuit is shorted.
P0715
Torque Converter Turbine Speed Signal Circuit Malfunction

sensor malfunction, short input
signal circuit
P0719
Torque Converter/Brake
Switch B Circuit Low
Brake switch malfunction, open

input signal circuit
P0720
AT Vehicle Speed Sensor Circuit Malfunction
Front vehicle speed sensor malfunction, open or short input signal circuit
P0724
Switch B Circuit High
Brake switch malfunction, short

input signal circuit
P0725
Engine Speed Input Circuit Malfunction
Open or short engine speed output signal circuit
P0731
Gear 1 Incorrect Ratio
P0732
P0733
P0734
P0736
Reverse Incorrect Ratio
P0741
Torque Converter Clutch

Circuit Performance or
Stuck Off
Lock-up clutch is faulty or valve is

stuck.
P0743

Circuit Electrical
Lock-up solenoid is faulty or output signal circuit is open or

shorted.
Vehicle sensor, torque converter

turbine speed sensor, or control
valve malfunction
valve malfunction
valve malfunction
valve malfunction
valve malfunction
4AT(diag)-32
Reference target
<Ref. to 4AT(diag)-34, DTC P0705 TRANSMISSION RANGE SENSOR CIRCUIT (PRNDL
INPUT), Diagnostic Procedure with Diagnostic
<Ref. to 4AT(diag)-42, DTC P0712 TRANSMISSION FLUID TEMPERATURE SENSOR
CIRCUIT LOW INPUT, Diagnostic Procedure
CIRCUIT HIGH INPUT, Diagnostic Procedure
<Ref. to 4AT(diag)-48, DTC P0715 INPUT/
TURBINE SPEED SENSOR CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to 4AT(diag)-50, DTC P0719 TORQUE
CONVERTER/BRAKE SWITCH B CIRCUIT
LOW, Diagnostic Procedure with Diagnostic
<Ref. to 4AT(diag)-53, DTC P0720 OUTPUT
SPEED SENSOR CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
HIGH, Diagnostic Procedure with Diagnostic
<Ref. to 4AT(diag)-59, DTC P0725 ENGINE
SPEED INPUT CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to 4AT(diag)-61, DTC P0731 GEAR 1
INCORRECT RATIO, Diagnostic Procedure
<Ref. to 4AT(diag)-62, DTC P0736 REVERSE
CONVERTER CLUTCH CIRCUIT PERFORMANCE OR STUCK OFF, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
CONVERTER CLUTCH CIRCUIT ELECTRICAL, Diagnostic Procedure with Diagnostic

DTC
Item
Line pressure linear solenoid is
faulty or output signal circuit is
open or shorted.
P0748
Pressure Control Solenoid A Electrical
P0753
Shift Solenoid A Electrical
P0758
Shift Solenoid B Electrical
P0763
Shift Solenoid C Electrical
P0768
Shift Solenoid D Electrical
P0801
Reverse Inhibit Control

Circuit
P1706

(Rear Wheel)
Rear vehicle speed sensor is

faulty or input signal circuit is
open or shorted.
P1707
AT AWD Solenoid Valve
Transfer duty solenoid is faulty or

output signal circuit is open or
shorted.
P1708

Circuit Low Input
Accelerator pedal position sensor is faulty or input signal circuit

is open.
P1709

Circuit High Input

is shorted.
P1714

Power Supply Circuit

is open or shorted.
P1718
CAN Communication
Circuit
CAN communication circuit is

open or shorted.
P1760
Lateral Acceleration
Sensor Performance
Problem
Lateral G sensor is faulty.
P1761
Sensor Circuit Low
Lateral G sensor is faulty or input

signal circuit is open.
P1762
Sensor Circuit High

signal circuit is shorted.
P1817
Sports Mode Switch Circuit
manual mode switch is faulty or

input signal circuit is open or
shorted.
Low clutch duty solenoid is faulty

or output signal circuit is open or
shorted.
2-4 brake duty solenoid is faulty
shorted.
High clutch duty solenoid is faulty
shorted.
Low & reverse clutch duty solenoid is faulty or output signal circuit is open or shorted.
Range lock solenoid is faulty or
shorted.
4AT(diag)-33
Reference target
<Ref. to 4AT(diag)-68, DTC P0748 PRESSURE CONTROL SOLENOID A ELECTRICAL, Diagnostic Procedure with Diagnostic
<Ref. to 4AT(diag)-71, DTC P0753 SHIFT
SOLENOID A ELECTRICAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
SOLENOID B ELECTRICAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
SOLENOID C ELECTRICAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
SOLENOID D ELECTRICAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
INHIBIT CONTROL CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to 4AT(diag)-86, DTC P1706 AT VEHICLE SPEED SENSOR CIRCUIT MALFUNCTION (REAR WHEEL), Diagnostic Procedure
<Ref. to 4AT(diag)-89, DTC P1707 AT AWD
SOLENOID VALVE CIRCUIT MALFUNCTION, Diagnostic Procedure with Diagnostic
<Ref. to 4AT(diag)-92, DTC P1708 THROTTLE
POSITION SENSOR CIRCUIT LOW INPUT,
Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
<Ref. to 4AT(diag)-98, DTC P1709 THROTTLE
POSITION SENSOR CIRCUIT HIGH INPUT,
Code (DTC).>
<Ref. to 4AT(diag)-104, DTC P1714 THROTTLE POSITION SENSOR POWER SUPPLY
CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to 4AT(diag)-109, DTC P1718 CAN
COMMUNICATION CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to 4AT(diag)-110, DTC P1760 LATERAL
ACCELERATION SENSOR PERFORMANCE
PROBLEM, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
ACCELERATION SENSOR CIRCUIT LOW,
Code (DTC).>
ACCELERATION SENSOR CIRCUIT HIGH,
Code (DTC).>
<Ref. to 4AT(diag)-119, DTC P1817 SPORTS
MODE SWITCH CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>


A: DTC P0705 TRANSMISSION RANGE SENSOR CIRCUIT (PRNDL INPUT)
Inhibitor switch is faulty.
More than 2 range signal is input.
TROUBLE SYMPTOM:
Shift characteristics are erroneous.
Range position of select lever and AT select lever position indicator light on the combination meter is not
matched.
4AT(diag)-34

WIRING DIAGRAM:
LHD model
No.5
BATTERY
i10
SBF-7
SBF-1
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
COMBINATION
METER
P
i10
i77
22
7
8
A26
21
2
A27
1 2 3 4 5 6 7 8 9 10 11 12
JOINT
CONNECTOR
BODY INTEGRATED
UNIT
B30
7
B: B280
JOINT
CONNECTOR
JOINT
CONNECTOR
B355
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
B54
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
B12
1 2 3 4
5 6 7 8
9 10 11 12
12
B: B280
B352
B20
5
1
2
5
i84
TCM
14
22
10
B54
5
i84
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
i77
A:
B12
A:
T7
1 2 3 4 5 6
7 8 9 10 11 12
T3
INHIBITOR
SWITCH
R
N
B352
B355
T7
D
5
1 2 3 4
5 6 7 8
T3
B12
E
AT-01888
4AT(diag)-35

RHD model
No.5
BATTERY
SBF-7
SBF-1
i10
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
COMBINATION
METER
i10
21
22
i77
1 2 3 4 5 6 7 8 9 10 11 12
JOINT
CONNECTOR
A27
A26
B30
8
A:
B20
i84
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
i77
A:
i84
B: B280
B: B280
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
JOINT
CONNECTOR
B352
B352
10
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
B54
8
3
1
10
22
2
8
5
3
9
14
B53
B53
TCM
B54
B12
JOINT
CONNECTOR
12
18
19
1 2 3 4
5 6 7 8
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
T3
B12
INHIBITOR
SWITCH
R
N
T7
1 2 3 4
5 6 7 8
9 10 11 12
T7
4
T3
B12
1 2 3 4 5 6
7 8 9 10 11 12
E
AT-02356
Step
CHECK INDICATOR LIGHT.
2) Shift the select lever to P range.
Check
Yes
Does the P range indicator
Go to step 2.
light on combination meter illuminate?
Does the R range indicator
Go to step 26.
4AT(diag)-36
No
Go to step 12.
Go to step 3.

10
11
12
13
Step
Check
Yes
Does the N range indicator
Go to step 33.
Does the D range indicator
Go to step 40.
CHECK P RANGE SWITCH.
Does the P range LED of
Go to step 19.
1) Connect the Subaru Select Monitor to data Subaru Select Monitor illumilink connector.
nate?
Does the R range indicator
Go to step 8.
CHECK R RANGE SWITCH.
Does the R range LED of
Go to step 23.
Subaru Select Monitor illuminate?
Does the P range indicator
Go to step 10.
Shift the select lever to the N range.
Go to step 30.
CHECK N RANGE SWITCH.
Does the N range LED of
Does the D range indicator
Even if the SPORT
Shift the select lever to D range.
light on combination meter illu- indicator light is
minate?
blinking, the circuit has returned
to normal condition at this time. A
temporary poor
contact of connector or harness may
be the cause.
Repair the harness or connector
in TCM and transmission.
CHECK D RANGE SWITCH.
Does the D range LED of
Go to step 37.
CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 1
Go to step 13.
INHIBITOR SWITCH AND CHASSIS
?
GROUND.
2) Disconnect the connector from inhibitor
switch.
between inhibitor switch and chassis ground.
(T7) No. 5 Chassis ground:
Go to step 14.
TCM AND INHIBITOR SWITCH.
?
inhibitor switch.
between TCM and inhibitor switch connector.
(B54) No. 5 (T7) No. 9:
4AT(diag)-37
No
Go to step 4.
Go to step 5.
Go to step 6.
Go to step 7.
Go to step 20.
Go to step 9.
Go to step 27.
Go to step 11.
Go to step 34.
Repair the open

circuit in harness
between inhibitor
switch connector
and chassis
ground, and poor
Repair the open

circuit in harness
between TCM and
inhibitor switch
connector, and
poor contact in
coupling connector.

14
15
16
17
18
19
20
21
Step
CHECK INPUT SIGNAL FOR TCM.
2) Connect the connector to TCM and inhibitor
switch.
chassis ground.
1) Shift the select lever to any range other
than P.
chassis ground.
Read the data of the inhibitor switch from Subaru Select Monitor. <Ref. to LAN(diag)-14,
Check DTC of body integrated unit.
Check
Yes
Go to step 15.
No
Go to step 41.
Go to step 41.
Replace the TCM.

<Ref. to 4AT-67,
(TCM).>
Is 7 displayed?
Go to step 17.
Check the body

integrated unit.
Is DTC of CAN communication Perform the diag- Go to step 18.

displayed?
nosis according to
DTC.
Is the P range indicator light Go to step 41.
Replace the comCheck the P range indicator light. <Ref. to
OK?
bination meter
IDI-3, INSPECTION, Combination Meter Sysassembly. <Ref. to
tem.>
Go to step 42.
Repair the ground
M?
short circuit in P
range circuit.
2) Disconnect the connectors from TCM,
inhibitor switch and combination meter.
Go to step 21.
Repair the open
?
circuit in harness
between TCM and
inhibitor switch
inhibitor switch.
connector, and
poor contact in
coupling connecConnector & terminal
tor.
(B54) No. 14 (T7) No. 8:
Go to step 22.
Go to step 41.
switch.
chassis ground.
4AT(diag)-38

22
23
24
25
26
27
28
29
30
Step
1) Shift the select lever to other than R
range.
chassis ground.
Read the data of shift position from Subaru
Select Monitor. <Ref. to LAN(diag)-14, OPERATION, Subaru Select Monitor.>
Check
Yes
Go to step 41.
No
Replace the TCM.
<Ref. to 4AT-67,
(TCM).>
Is 6 displayed?
Go to step 24.
Check the body

integrated unit.

displayed?
nosis according to
DTC.
Is the R range indicator light Go to step 41.
Replace the comCheck the R range indicator light. <Ref. to
OK?
bination meter
tem.>
CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1 Go to step 41.
Repair the ground
M?
short circuit in R
range circuit.
Go to step 28.
Repair the open
?
circuit in harness
between TCM and
inhibitor switch
inhibitor switch.
connector, and
poor contact in
tor.
(B54) No. 22 (T7) No. 10:
Go to step 29.
Go to step 41.
switch.
chassis ground.
Replace the TCM.
1) Shift the select lever to other than N
<Ref. to 4AT-67,
range.
Transmission Con2) Measure the voltage between TCM and
trol Module
chassis ground.
(TCM).>
Is 5 displayed?
Go to step 31.
Check the body
Read the data of shift position from Subaru
integrated unit.
4AT(diag)-39

31
32
33
34
35
36
37
38
39
Step
Check
Yes
No
displayed?
nosis according to
DTC.
Is the N range indicator light Go to step 41.
Replace the comCheck the N range indicator light. <Ref. to
OK?
bination meter
tem.>
Repair the ground
M?
short circuit in N
range circuit.
Go to step 35.
Repair the open
?
circuit in harness
between TCM and
inhibitor switch
inhibitor switch.
connector, and
poor contact in
tor.
(B54) No. 4 (T7) No. 3:
Go to step 36.
Go to step 41.
switch.
chassis ground.
Replace the TCM.
1) Shift the select lever to other than D
<Ref. to 4AT-67,
range.
Transmission Con2) Measure the voltage between TCM and
trol Module
chassis ground.
(TCM).>
Is 4 displayed?
Go to step 38.
Check the body
Read the data of inhibitor switch from Subaru
integrated unit.
displayed?
nosis according to
the DTC.
Is the D range indicator light Go to step 41.
Replace the comCheck the D range indicator light. <Ref. to
OK?
bination meter
tem.>
4AT(diag)-40

40
41
42
Step
Check
CHECK HARNESS CONNECTOR BETWEEN Is the resistance more than 1
M?
CHECK POOR CONTACT.
Is there poor contact in inhibitor switch circuit?
Is the inhibitor switch in normal
position?
4AT(diag)-41
Yes
Go to step 41.
No
Repair the ground
short circuit in D
range circuit.
Repair the poor

contact.
Replace the TCM.
<Ref. to 4AT-67,
(TCM).>
Go to step 42.
Adjust inhibitor
switch and select
cable. <Ref. to
4AT-52, Inhibitor
Switch.> and <Ref.
to CS-12, Select
Cable.>

B: DTC P0712 TRANSMISSION FLUID TEMPERATURE SENSOR CIRCUIT LOW

INPUT
Input signal circuit of TCM to ATF temperature sensor is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
AT2
1 2
3 4
B11
B54
TCM
3 4
8
6 7
9 10
11 12
14 15
13
16
17 18
19 20
1
21
B54
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21
22 23 24
15
11
B11
ATF TEMPERATURE
SENSOR
T4
AT2
TRANSMISSION
AT-02227
4AT(diag)-42

Step
TCM AND ATF TEMPERATURE SENSOR.
2) Disconnect the connector from transmission and TCM.
(B54) No. 21 (B11) No. 11:
TCM and transmission connector.
(B54) No. 9 (B11) No. 15:
CHECK ATF TEMPERATURE SENSOR.
2) Connect the connectors to transmission
and TCM.
3) Turn the ignition switch to ON and start
engine.
4) Warm-up the transmission until the ATF
temperature reaches to 80C (176F).
NOTE:
If the ambient temperature is below 0C (32F),
drive the vehicle until the ATF reaches its operating temperature.
5) Disconnect the connector from transmission.
6) Measure the resistance between transmission connector terminals.
(T4) No. 11 No. 15:
Measure the resistance between transmission
(T4) No. 11 No. 15:
CHECK INPUT SIGNAL FOR TCM USING
SUBARU SELECT MONITOR.
1) Connect the connector to transmission.
link connector.
OFF).
4) Read the data of ATF temperature using
CHECK POOR CONTACT.
Check
?
Yes
Go to step 2.
No
Repair the open
circuit in harness
between TCM and
transmission connector.

?
Go to step 3.
Repair the open

circuit in harness
between TCM and
Is the resistance 500 600

?
Go to step 4.
Go to step 7.
Does the resistance value

Go to step 5.
increase while the ATF temperature decreases?
Go to step 7.
Does the ATF temperature

gradually decrease?
Is there poor contact in ATF

temperature sensor circuit?
4AT(diag)-43
Even if the SPORT Go to step 6.

indicator light is
temporary poor
be the cause.
Repair the harness or contact in
the ATF temperature sensor and
Repair the poor
Replace the TCM.
contact.
<Ref. to 4AT-67,
(TCM).>

Step
Check
TRANSMISSION AND ATF TEMPERATURE ?
SENSOR.
3) Remove the transmission connector from
bracket.
4) Lift-up the vehicle and support with rigid
racks.
Yes
Go to step 8.
No
Repair the open
circuit in harness
between ATF temperature sensor
and transmission
connector.

?
Go to step 9.
Repair the open

circuit in harness
and transmission
connector.

M?
Go to step 10.
Repair the short

circuit in harness
and transmission
connector.

M?
Replace the control valve body.

<Ref. to 4AT-62,
Control Valve
Body.>
Repair the short

circuit in harness
and transmission
connector.
NOTE:
Raise all wheels off floor.
5) Drain the ATF.
10
CAUTION:
Do not drain the ATF until it cools down.
6) Remove the oil pan, and disconnect the
connector from control valve.
between ATF temperature sensor and transmission connector.
(T4) No. 11 (AT2) No. 1:
TRANSMISSION AND ATF TEMPERATURE
SENSOR.
ATF temperature sensor and transmission connector.
(T4) No. 15 (AT2) No. 3:
SENSOR.
transmission connector and transmission
ground.
SENSOR.
ground.
4AT(diag)-44

C: DTC P0713 TRANSMISSION FLUID TEMPERATURE SENSOR CIRCUIT HIGH

INPUT
Input signal circuit of TCM to ATF temperature sensor is shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
AT2
1 2
3 4
B11
B54
TCM
3 4
8
6 7
9 10
11 12
14 15
13
16
17 18
19 20
1
21
B54
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21
22 23 24
15
11
B11
ATF TEMPERATURE
SENSOR
T4
AT2
TRANSMISSION
AT-02227
4AT(diag)-45

Step
3) Measure the resistance between TCM connector terminals.
(B54) No. 21 No. 9:
TCM connector and chassis ground.
CHECK HARNESS.
Measure the resistance between TCM connector terminals while shaking the harness.
(B54) No. 21 No. 9:
(T4) No. 11 No. 15:
Check
500 ?
Yes
Go to step 2.
No
Go to step 4.

M?
Go to step 3.
Go to step 4.
Does the resistance change?
Go to step 4.

M?
Go to step 5.
Replace the TCM.

<Ref. to 4AT-67,
(TCM).>
Repair the short
circuit in harness
between TCM and
transmission harness.

M?
Go to step 6.

500 ?

indicator light is
temporary short
circuit of connector
or harness may be
the cause. Repair
the harness or
connector.
4AT(diag)-46
Repair the short

circuit in harness
between TCM and
transmission harness.

Step
CHECK TRANSMISSION HARNESS.
1) Lift-up the vehicle and place it on rigid
racks.
2) Drain the ATF.
NOTE:
4) Disconnect the harness connector from
control valve.
5) Measure the resistance between ATF temperature sensor connector terminals
6) Measure the resistance between transmission connector and transmission ground.
CHECK TRANSMISSION HARNESS.
connector and transmission ground,
Measure the resistance between control valve
connector terminals
Terminal
No. 1 No. 3:
Check
M?
Yes
Go to step 8.
No
Replace the transmission harness.

M?
Go to step 9.
Replace the transmission harness.

500 ?
Even if the SPORT

indicator light is
temporary short
or harness may be
the cause. Repair
the harness or
connector.

<Ref. to 4AT-62,
Control Valve
Body.>
4AT(diag)-47

D: DTC P0715 INPUT/TURBINE SPEED SENSOR CIRCUIT

Input signal circuit of TCM is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B11
1
B54
TCM
3 4
6 7
8
9 10
11 12
13 20
3 10
RH LH
B54
LH RH
16
13
14 15
16
17 18
19 20
JOINT
CONNECTOR
3 4 5 6 7
1 2
8 9 10 11 12 13 14 15 16
22 23 24
17 18 19 20 21
B53
B53
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
5
10
B11
T4
RH : RHD MODEL
LH : LHD MODEL
TORQUE
CONVERTER
TURBINE SPEED
SENSOR
AT-01889
Step
Check
CHECK TORQUE CONVERTER TURBINE
SPEED SENSOR.
?
3) Measure the resistance between transmission connector receptacles terminals.
(T4) No. 5 No. 10:
4AT(diag)-48
Yes
Go to step 2.
No
Replace the
torque converter
turbine speed sensor. <Ref. to 4AT59, Torque Converter Turbine
Speed Sensor.>

Step
(B54) No. 7 (B11) No. 5:
(B54) No. 16 (B11) No. 10:
Check
?
Yes
Go to step 3.
No
Repair the open
circuit in harness
between TCM and

?
Go to step 4.


M?
Go to step 5.
Repair the open

circuit in harness
between TCM and
transmission connector, and poor
Repair the short
circuit in harness
between TCM and

M?
Go to step 6.

1) Connect the connectors to TCM and transmission.
link connector.
5) Shift the select lever to P or N range.
6) Read the data of turbine speed using Subaru Select Monitor.
Compare the tachometer with Subaru Select
Monitor indications.
CHECK POOR CONTACT.
Is the revolution value same as

the tachometer reading shown
on the combination meter?
Is there poor contact in torque

converter turbine speed sensor
circuit?
4AT(diag)-49
Repair the short

circuit in harness
between TCM and
indicator light is
temporary poor
be the cause.
Repair the poor
Replace the TCM.
contact.
<Ref. to 4AT-67,
(TCM).>

E: DTC P0719 TORQUE CONVERTER/BRAKE SWITCH B CIRCUIT LOW

Brake switch malfunction, open input signal circuit
TROUBLE SYMPTOM:
Gear is not shifted down when driving a down hill.
The neutral control does not operate.
WIRING DIAGRAM:
LHD model
SBF-1
SBF-3
B65
1
3
No.8
BATTERY
WC :
WC OC
1
2
OC :
1 2
OC :
B64
B159
WC :
B65
1 2
3 4
5 6 7 8 9
B: B280
JOINT
CONNECTOR
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
B159
C23
B64
STOP LIGHT
SWITCH
OC WC
2
3
2
4
BODY INTEGRATED
UNIT
C: B281
B20
B30
B: B280
C: B281
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
OC : WITHOUT CRUISE CONTROL
JOINT
CONNECTOR
B54
B352
WC : WITH CRUISE CONTROL
JOINT
CONNECTOR
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
B355
B54
12
B352
B355
1 2 3 4
5 6 7 8
TCM
AT-01890
4AT(diag)-50

RHD model
SBF-1
SBF-3
B64
No.8
BATTERY
1 2
B159
1 2
3 4
5 6 7 8 9
STOP LIGHT
SWITCH
B: B280
B64
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
JOINT
CONNECTOR
B159
C23
C: B281
BODY INTEGRATED
UNIT
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
B30
8
4
B20
2
B: B280
C: B281
JOINT
CONNECTOR
B352
1 2 3 4
5 6 7 8
B352
9
10
18
19
B53
JOINT
CONNECTOR
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
B53
B54
12
B54
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
TCM
AT-02357
4AT(diag)-51

Step
Check
Does the DTC of CAN communication appear in the on-board
diagnostics test mode?
Is ON displayed?
CHECK DTC.

link connector.
OFF)
4) Turn the Subaru Select Monitor switch to
ON.
5) Depress the brake pedal.
6) Read the data of brake pedal switch using
Subaru Select Monitor. <Ref. to LAN(diag)-14,
CHECK TCM.
Is ON displayed?
Read the data of brake pedal switch using
Subaru Select Monitor. <Ref. to 4AT(diag)-17,
CHECK BODY INTEGRATED UNIT INPUT

SIGNAL.
2) Disconnect the connector from body integrated unit.
body integrated unit and stop light switch.
BODY INTEGRATED UNIT AND STOP LIGHT
SWITCH.
2) Disconnect the connector from stop light
switch.
between body integrated unit and stop light
switch.
Model with cruise control
(B281) No. 23 (B65) No. 3:
Model without cruise control
(B281) No. 23 (B64) No. 2:
SWITCH.
CHECK POOR CONTACT.
Yes
No
Perform the diag- Go to step 2.
nosis according to
DTC.
Go to step 3.
Go to step 4.
A temporary poor
be the cause.
Check the poor
contact.
Replace the TCM.

<Ref. to 4AT-67,
(TCM).>
Go to step 5.

?
Go to step 6.
Repair the open

circuit of harness
between the body
integrated unit and
stop light switch.

M?
Go to step 7.
Repair the short

circuit of harness
between the body
integrated unit and
stop light switch.
Is there poor contact in input

signal of brake switch?
Repair the poor

contact.
Check the body

integrated unit.
4AT(diag)-52

F: DTC P0720 OUTPUT SPEED SENSOR CIRCUIT

The vehicle speed signal is abnormal.
The harness connector between TCM and vehicle speed sensor is shorted or open.
TROUBLE SYMPTOM:
The slip lock up control does not operate.
WIRING DIAGRAM:
B11
B54
TCM
1
11
11 12
LH RH
3 4
6 7
8
9 10
11 12
12
13
14 15
16
17 18
19 20
RH LH
15
JOINT
CONNECTOR
B53
B54
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
22 23 24
17 18 19 20 21
B53
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
14
18
B11
T4
LH : LHD MODEL
RH : RHD MODEL
FRONT
VEHICLE SPEED
SENSOR
AT-01891
4AT(diag)-53

Step
transmission.
(B54) No. 6 (B11) No. 14:
(B54) No. 15 (B11) No. 18:
Check
?
Yes
Go to step 2.
No
Repair the open
circuit in harness
between TCM and

?
Go to step 3.


M?
Go to step 4.
Repair the open

circuit in harness
between TCM and
Repair the short
circuit in harness
between TCM and

M?
Go to step 5.
CHECK FRONT VEHICLE SPEED SENSOR. Is the resistance 450 650

Measure the resistance between transmission ?
connector receptacles terminals.
(T4) No. 14 No. 18:
4AT(diag)-54
Go to step 6.
Repair the short

circuit in harness
between TCM and
Replace the front
vehicle speed sensor. <Ref. to 4AT55, Front Vehicle
Speed Sensor.>

Step
Check
Does the speedometer indicaSUBARU SELECT MONITOR.
tion increase as the Subaru
Select Monitor data increases?
link connector.
racks.
NOTE:
4) Turn the ignition switch to ON, and Subaru
Select Monitor switch to ON.
6) Read the data of vehicle speed using Subaru Select Monitor.
Compare the speedometer with Subaru
Select Monitor indications.
Vehicle speed is indicated either in km/h or
MPH.
7) Slowly increase the vehicle speed to 60 km/
h (37 MPH).
NOTE:
wheels may light the ABS warning light or VDC
warning light, but this indicates no malfunction.
When AT control diagnosis is finished, perform
the ABS memory clearance procedure or VDC
memory clearance procedure of on-board diagnostics system. <Ref. to ABS(diag)-27, Clear
Memory Mode.> <Ref. to VDC(diag)-24, Clear
Memory Mode.>
CHECK POOR CONTACT.
vehicle speed sensor circuit?
4AT(diag)-55
Yes
No
indicator light is
temporary poor
be the cause.
Repair the harness in the front
vehicle speed sensor circuit.
Repair the poor

contact.
Replace the TCM.

<Ref. to 4AT-67,
(TCM).>

G: DTC P0724 TORQUE CONVERTER/BRAKE SWITCH B CIRCUIT HIGH

TROUBLE SYMPTOM:
Gear is not shifted down when driving a down hill.
WIRING DIAGRAM:
LHD model
SBF-1
SBF-3
B65
1
3
No.8
BATTERY
WC :
WC OC
1
2
OC :
1 2
OC :
B64
B159
WC :
B65
1 2
3 4
5 6 7 8 9
B: B280
JOINT
CONNECTOR
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
B159
C23
B64
STOP LIGHT
SWITCH
OC WC
2
3
2
4
BODY INTEGRATED
UNIT
C: B281
B20
B30
B: B280
C: B281
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
OC : WITHOUT CRUISE CONTROL
JOINT
CONNECTOR
B54
B352
WC : WITH CRUISE CONTROL
JOINT
CONNECTOR
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
B355
B54
12
B352
B355
1 2 3 4
5 6 7 8
TCM
AT-01890
4AT(diag)-56

RHD model
SBF-1
SBF-3
B64
No.8
BATTERY
1 2
B159
1 2
3 4
5 6 7 8 9
STOP LIGHT
SWITCH
B: B280
B64
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
JOINT
CONNECTOR
B159
C23
C: B281
BODY INTEGRATED
UNIT
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
B30
8
4
B20
2
B: B280
C: B281
JOINT
CONNECTOR
B352
1 2 3 4
5 6 7 8
B352
9
10
18
19
B53
JOINT
CONNECTOR
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
B53
B54
12
B54
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
TCM
AT-02357
4AT(diag)-57

Step
Check
Does the DTC of CAN communication appear in the on-board
diagnostics test mode?
Is OFF displayed?
CHECK DTC.

link connector.
OFF)
ON.
CHECK TCM.
Is OFF displayed?

SIGNAL.
1) Disconnect harness connector of body integrated unit.
CHECK STOP LIGHT SWITCH.
switch.
between stop light switch connectors.
Terminals
MODEL WITH CRUISE CONTROL
No. 2 No. 3:
MODEL WITHOUT CRUISE CONTROL
No. 1 No. 2:
SWITCH.
body integrated unit and chassis ground.
CHECK POOR CONTACT.
Yes
No
nosis according to
DTC.
Go to step 3.
Go to step 4.
A temporary poor
be the cause.
Check the poor
contact.
Go to step 7.

M?
Go to step 6.
Replace the stop

light switch.
Go to step 7.
Repair the short

circuit in harness
between TCM and
stop light switch.

Repair the poor

contact.
Check the body

integrated unit.
4AT(diag)-58
Replace the TCM.

<Ref. to 4AT-67,
(TCM).>

H: DTC P0725 ENGINE SPEED INPUT CIRCUIT

Engine speed input signal circuit is open or shorted.
TROUBLE SYMPTOM:
No lock-up occurs. (After engine is warmed-up)
SPORT indicator light remains on when the vehicle speed is 0.
WIRING DIAGRAM:
B54
B54
TCM
13
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
22 23 24
17 18 19 20 21
ND
1
8 9
18 19
28 29
2
10
20
30
23
HU
27
B134
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
HU
ND
B135
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
ND : B134
ECM
HU : B135
ND : 2.5 L EK AND 2.5 L K4 MODEL

HU : EXCEPT 2.5 L EK AND 2.5 L K4 MODEL
AT-01892
4AT(diag)-59

Step
TCM AND ECM.
ECM.
between TCM and ECM.
2.5 L EK and 2.5 L K4 model
(B54) No. 13 (B134) No. 23:
Except for 2.5 L EK and 2.5 L K4 model
(B54) No. 13 (B135) No. 27:
TCM AND ECM.
1) Connect the connectors to TCM and ECM.
link connector.
3) Start the engine, and turn the Subaru
5) Read the data of engine speed using Subaru Select Monitor.
Display shows the engine speed signal value
sent from ECM.
CHECK POOR CONTACT.
CONFIRM DTC P0725.

Replace the ECM with a new one.
Check
?
Yes
Go to step 2.
No
Repair the open
circuit in harness
between TCM and
ECM connector.

M?
Go to step 3.
Repair the short

circuit in harness
between TCM and
ECM connector.
Is the revolution value same as Even if the SPORT Go to step 4.

the tachometer reading shown indicator light is
on the combination meter?
temporary poor
be the cause.
in the TCM and
ECM.
Is there poor contact in engine Repair the poor
Go to step 5.
speed signal circuit?
contact.
Does the DTC appear again, Replace the TCM. Replace the ECM.
after the memory has been
<Ref. to 4AT-67,
cleared?
(TCM).>
4AT(diag)-60

I:
DTC P0731 GEAR 1 INCORRECT RATIO
NOTE:
Refer to DTC P0736 for diagnostic procedure. <Ref. to 4AT(diag)-62, DTC P0736 REVERSE INCORRECT
RATIO, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
J: DTC P0732 GEAR 2 INCORRECT RATIO

NOTE:
K: DTC P0733 GEAR 3 INCORRECT RATIO

NOTE:
L: DTC P0734 GEAR 4 INCORRECT RATIO

NOTE:
4AT(diag)-61

M: DTC P0736 REVERSE INCORRECT RATIO

Vehicle sensor, torque converter turbine speed sensor or control valve malfunction
TROUBLE SYMPTOM:
Shift point is too high or too low.
Tight corner braking phenomenon is occurred.
Gear is not shifted to reverse.
Gear position is held by fail safe function.
1
2
Step
PREPARE SUBARU SELECT MONITOR.
Check
Yes
Do you have a Subaru Select Go to step 2.
Monitor?
CHECK ACCELERATOR PEDAL POSITION Does the value of accelerator Go to step 3.
SENSOR.
pedal position sensor change
1) Connect the Subaru Select Monitor to data from 0% to 100% smoothly
link connector.
when throttle was operated
from fully closing to fully open3) Read the value of accelerator pedal posi- ing?
tion sensor on Subaru Select Monitor display.
CHECK FRONT VEHICLE SPEED SENSOR.

racks.
3) Shift the select lever to D range and
slowly increase vehicle speed.
NOTE:
Memory Mode.>
SPEED SENSOR.
1) Shift the select lever to P or N range.
2) Idle the engine.
Does the vehicle speed disGo to step 4.

played by Subaru Select Monitor almost correspond with
vehicle speed indicated by
combination meter?
Does the turbine speed sensor revolution displayed by

Subaru Select Monitor almost
correspond with engine revolution indicated by tachometer?
CHECK ACCELERATOR PEDAL POSITION Is the voltage 0.8 1.2 V?

SENSOR.
2) Fully close the throttle.
chassis ground.
4AT(diag)-62
There are malfunctions in TCM,

TCM connector
poor contact, or
transmission
assembly mechanical malfunction.
Go to step 6.
No
Go to step 5.
Check the accelerator position sensor circuit. <Ref. to
4AT(diag)-92, DTC
P1708 THROTTLE POSITION
SENSOR CIRCUIT LOW INPUT,
(DTC).>
Check the front
vehicle speed sensor circuit.
Check the torque

converter turbine
speed sensor circuit.
Check the accelerator pedal position

sensor circuit.
<Ref. to 4AT(diag)92, DTC P1708
THROTTLE POSITION SENSOR
CIRCUIT LOW
INPUT, Diagnostic
Procedure with

Step
Check
CHECK ACCELERATOR PEDAL POSITION Is the voltage 3.3 4.6 V?
SENSOR.
1) Fully open the throttle.
chassis ground.
Yes
Go to step 7.
CHECK FRONT VEHICLE SPEED SENSOR. Is the front vehicle speed sen- Go to step 8.
Diagnose according to DTC P0720 procedure. sor OK?

Is the torque converter turbine There are malSPEED SENSOR.
speed sensor OK?
functions in TCM,
Diagnose according to DTC P0715 procedure.
TCM connector
poor contact, or
transmission
4AT(diag)-63
No
sensor circuit.
<Ref. to 4AT(diag)92, DTC P1708
THROTTLE POSITION SENSOR
CIRCUIT LOW
INPUT, Diagnostic
Procedure with
Repair or replace
the front vehicle
Repair or replace
the torque converter turbine

N: DTC P0741 TORQUE CONVERTER CLUTCH CIRCUIT PERFORMANCE OR

STUCK OFF
Lock up clutch malfunction
Locking of bulb
TROUBLE SYMPTOM:
No lock-up occurs.
5
6
10
11
Step
Check
CHECK LOCK-UP DUTY SOLENOID CIRIs there any trouble?
CUIT.
CHECK INHIBITOR SWITCH CIRCUIT.
Is there any trouble?
CHECK STOP LIGHT SWITCH CIRCUIT.
Diagnose according to DTC P0719 and P0724
procedure.
CHECK ATF TEMPERATURE SENSOR CIR- Is there any trouble?
CUIT.
procedure.
Do you have a Subaru Select
Monitor?
CHECK ACCELERATOR PEDAL POSITION Does the value of accelerator
SENSOR.
pedal position sensor change
1) Connect the Subaru Select Monitor to data from 0% to 100% smoothly
link connector.
when throttle was operated
from fully closing to fully open3) Read the value of accelerator pedal posi- ing?
tion sensor on Subaru Select Monitor display.
Does the turbine revolution disSPEED SENSOR.
played by Subaru Select Moni1) Shift the select lever to P or N range.
tor almost correspond with
2) Idle the engine.
engine revolution indicated by
tachometer?
CHECK ENGINE SPEED SIGNAL.
Does the turbine revolution disIdle the engine.
played by Subaru Select Monitor almost correspond with
engine revolution indicated by
tachometer?
CHECK ACCELERATOR PEDAL POSITION Is there any trouble?
SENSOR.
Diagnose according to DTC P1708, P1709,
P1714 procedure.
SPEED SENSOR.
CHECK ENGINE SPEED SIGNAL.

4AT(diag)-64
Yes
Repair or replace
the lock-up duty
solenoid circuit.
Repair or replace
the inhibitor switch
circuit.
Repair or replace
the stop light
switch circuit.
Repair or replace
the ATF temperature sensor circuit.
No
Go to step 2.
Go to step 3.
Go to step 4.
Go to step 5.
Go to step 6.
Go to step 9.
Go to step 7.

sensor circuit.
Go to step 8.
Check the torque

converter turbine
There is transmis- Check the engine

sion assembly
speed signal cirmechanical malcuit.
function.
Go to step 10.
Go to step 11.
Repair or replace
the engine speed
input circuit.
Repair or replace
the accelerator
pedal position sensor circuit.
Repair or replace
the torque converter turbine
There is transmission assembly
mechanical malfunction.

O: DTC P0743 TORQUE CONVERTER CLUTCH CIRCUIT ELECTRICAL

Output signal circuit of lock-up duty solenoid is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B11
3 4
8
6 7
9 10
11 12
14 15
13
16
17 18
19 20
1
B55
TCM
B55
1 2
3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26
27 28
29 30 31
12
AT3
1 2 3
4 5 6
B11
T4
AT3
LOCK-UP
DUTY
SOLENOID
TRANSMISSION
AT-01485
Step
1
CHECK DTC.
Check
Yes
Do multiple DTC appear in the Go to another
on-board diagnostics test
DTC.
mode?
4AT(diag)-65
No
Go to step 2.

Step
transmission.
(B55) No. 5 (B11) No. 12:
between TCM and chassis ground.
CHECK LOCK-UP DUTY SOLENOID.
(T4) No. 12 No. 19:
CHECK OUTPUT SIGNAL EMITTED FROM
TCM USING SUBARU SELECT MONITOR.
racks.
Check
?
Yes
Go to step 3.
No
Repair the open
circuit in harness
between TCM and

M?
Go to step 4.
Repair the short

circuit in harness
between TCM and
Is the resistance 2.0 6.0 ? Go to step 5.
Go to step 8.
Is the value 95%?
Go to step 7.
NOTE:
link connector.
5) Start the engine and warm-up the engine
until the ATF temperature is above 80C
(176F).
NOTE:
6) Read the data of lock-up duty solenoid
Lock-up duty solenoid is indicated in %.
7) Shift the select lever to D, and slowly
increase vehicle speed to 60 km/h (37 MPH).
NOTE:
Memory Mode.>
4AT(diag)-66
Go to step 6.

10
Step
Return the engine to idling speed, shift the
select lever to N range and read data.
Check
Is the value 5%?
Yes
No
indicator light is
temporary poor
be the cause.
NOTE:
Memory Mode.>
CHECK POOR CONTACT.
Is there poor contact in lock-up Repair the poor
duty solenoid circuit?
contact.
CHECK LOCK-UP DUTY SOLENOID (IN

TRANSMISSION).
1) Disconnect the transmission connector.
2) Drain the ATF.
CAUTION:
connector from control valve body.
4) Measure the resistance between lock-up
duty solenoid and transmission ground.
(AT3) No. 4 Transmission ground:
LOCK-UP DUTY SOLENOID AND TRANSMISSION.
lock-up duty solenoid and transmission connector.
(T4) No. 12 (AT3) No. 4:
LOCK-UP DUTY SOLENOID AND TRANSMISSION.
ground.
Replace the TCM.

<Ref. to 4AT-67,
(TCM).>
<Ref. to 4AT-62,
Control Valve
Body.>

?
Go to step 10.
Repair the open

circuit in harness
between TCM and

M?
Even if the SPORT

indicator light is
temporary poor
be the cause.
in lock-up duty
solenoid and
transmission.
Repair the short

circuit in harness
between lock-up
duty solenoid and
4AT(diag)-67

P: DTC P0748 PRESSURE CONTROL SOLENOID A ELECTRICAL

Output signal circuit of line pressure linear solenoid is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
TCM
20
19
B55
1
2
B11
2
4
T4
AT2
LINE
PRESSURE
LINEAR
SOLENOID
TRANSMISSION
B11
3 4
8
6 7
9 10
11 12
14 15
13
16
17 18
19 20
1
B55
AT2
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
1 2
3 4
AT-01486
Step
(B55) No. 19 (B11) No. 2:
(B55) No. 20 (B11) No. 1:
TCM AND CHASSIS GROUND.
CHECK LINE PRESSURE LINEAR SOLENOID.
(T4) No. 1 No. 2:
Check
?
Yes
Go to step 2.
No
Repair the open
circuit in harness
between TCM and

M?
Go to step 3.
Repair the short

circuit in harness
between TCM and
Go to step 4.
Go to step 7.
4AT(diag)-68

Step
Check
CHECK OUTPUT SIGNAL EMITTED FROM Is the value 45 50%?
link connector.
temperature exceeds approx. 80C (176F).
NOTE:
5) Stop the engine and turn the ignition switch
to ON (engine OFF).
7) Read the data of line pressure linear solenoid using Subaru Select Monitor.
Line pressure linear solenoid is indicated in
%.
Fully open the throttle.
CHECK POOR CONTACT.
Is there poor contact in line

pressure linear solenoid circuit?
CHECK LINE PRESSURE LINEAR SOLENOID (IN TRANSMISSION).

bracket.
2) Drain the ATF.
CAUTION:
4) Measure the resistance between line pressure linear solenoid connector terminals.
(AT2) No. 2 No. 4:
4AT(diag)-69
Yes
Go to step 5.
No
Go to step 6.

indicator light is
temporary poor
be the cause.
in transmission.
Repair the poor
Replace the TCM.
contact.
<Ref. to 4AT-67,
(TCM).>
Go to step 8.
<Ref. to 4AT-62,
Control Valve
Body.>

Step
TRANSMISSION AND LINE PRESSURE LINEAR SOLENOID.
line pressure linear solenoid and transmission
connector.
(T4) No. 2 (AT2) No. 4:
(T4) No. 1 (AT2) No. 2:
TRANSMISSION AND LINE PRESSURE LINEAR SOLENOID.
ground.
Check
?
Yes
Go to step 9.
No
Repair the open
circuit in harness
between line pressure linear solenoid and

M?
Even if the SPORT

indicator light is
temporary poor
be the cause.
in line pressure linear solenoid and
transmission.
Repair the short

circuit in harness
between line pressure linear solenoid and
4AT(diag)-70

Q: DTC P0753 SHIFT SOLENOID A ELECTRICAL

Output signal circuit of low clutch duty solenoid is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B11
3 4
8
6 7
9 10
11 12
14 15
13
16
17 18
19 20
1
B55
TCM
B55
1 2
3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26
27 28
29 30 31
AT3
1 2 3
4 5 6
B11
T4
AT3
LOW CLUTCH
DUTY
SOLENOID
TRANSMISSION
AT-01487
4AT(diag)-71

Step
transmission.
(B55) No. 9 (B11) No. 4:
TCM connector and transmission ground.
CHECK LOW CLUTCH DUTY SOLENOID.
(T4) No. 4 No. 20:
link connector.
temperature exceed approx. 80C (176F).
Check
?
Yes
Go to step 2.
No
Repair the open
circuit in harness
between TCM and

M?
Go to step 3.
Repair the short

circuit in harness
between TCM and
Go to step 7.
Is the value 100%?
Go to step 6.
NOTE:
drive the vehicle until ATF reaches its operating
temperature.
to ON (engine OFF).
6) Shift the select lever to P or N range,
and depress the accelerator pedal.
7) Read the data of low clutch duty solenoid
Low clutch duty solenoid is indicated in %.
CHECK OUTPUT SIGNAL EMITTED FROM Is the value 0%?
OFF).
3) Read the data of low clutch duty solenoid.
CHECK POOR CONTACT.
Is there poor contact in low

clutch duty solenoid circuit?
4AT(diag)-72
Go to step 5.

indicator light is
temporary poor
be the cause.
in transmission.
Repair the poor
Replace the TCM.
contact.
<Ref. to 4AT-67,
(TCM).>

Step
Check
Yes
CHECK LOW CLUTCH DUTY SOLENOID (IN Is the resistance 2.0 6.0 ? Go to step 8.
TRANSMISSION).
bracket.
2) Drain the ATF.
CAUTION:
4) Measure the resistance between low clutch
duty solenoid connector and transmission
ground.
TRANSMISSION AND LOW CLUTCH DUTY
SOLENOID.
low clutch duty solenoid and transmission connector.
(T4) No. 4 (AT3) No. 2:
TRANSMISSION AND LOW CLUTCH DUTY
SOLENOID.
ground.
No
<Ref. to 4AT-62,
Control Valve
Body.>

?
Go to step 9.
Repair the open

circuit in harness
between low clutch
duty solenoid and

M?
Even if the SPORT

indicator light is
temporary poor
be the cause.
in low clutch duty
solenoid and
transmission.
Repair the short

circuit of harness
between low clutch
duty solenoid and
4AT(diag)-73

R: DTC P0758 SHIFT SOLENOID B ELECTRICAL

Output signal circuit of 2-4 brake duty solenoid is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
TCM
B55
B11
T4
AT3
2-4 BRAKE
DUTY
SOLENOID
TRANSMISSION
B11
3 4
8
6 7
9 10
11 12
14 15
13
16
17 18
19 20
1
B55
AT3
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
1 2 3
4 5 6
AT-01488
Step
transmission.
(B55) No. 6 (B11) No. 3:
CHECK 2-4 BRAKE DUTY SOLENOID.
(T4) No. 3 No. 20:
Check
?
Yes
Go to step 2.
No
Repair the open
circuit in harness
between TCM and

M?
Go to step 3.
Repair the short

circuit in harness
between TCM and
4AT(diag)-74
Go to step 7.

Step
Check
link connector.
temperature exceed approx. 80C (176F).
NOTE:
to ON (engine OFF).
6) Shift the select lever to N range, and
depress the accelerator pedal.
7) Read the data of 2-4 brake duty solenoid
2-4 brake duty solenoid is indicated in %.
Shift the select lever to 2nd on manual mode.
CHECK POOR CONTACT.
CHECK 2-4 BRAKE DUTY SOLENOID (IN

TRANSMISSION).
bracket.
2) Drain the ATF.
Yes
Go to step 5.
No
Go to step 6.

indicator light is
temporary poor
be the cause.
Is there poor contact in 2-4
Repair the poor
Replace the TCM.
brake duty solenoid circuit?
contact.
<Ref. to 4AT-67,
(TCM).>
<Ref. to 4AT-62,
Control Valve
Body.>
CAUTION:
connector from 2-4 brake duty solenoid.
between 2-4 brake duty solenoid connector
and transmission ground.
4AT(diag)-75

Step
2-4 BRAKE DUTY SOLENOID AND TRANSMISSION.
Measure the resistance of harness between 24 brake duty solenoid and transmission connector.
(T4) No. 3 (AT12) No. 6:
2-4 BRAKE DUTY SOLENOID AND TRANSMISSION.
ground.
Check
?
Yes
Go to step 9.
No
Repair the open
circuit in harness
between 2-4 brake
duty solenoid and

M?
Even if the SPORT

indicator light is
temporary poor
be the cause.
in 2-4 brake duty
solenoid and
transmission.
Repair the short

circuit in harness
between 2-4 brake
duty solenoid and
4AT(diag)-76

S: DTC P0763 SHIFT SOLENOID C ELECTRICAL

Output signal circuit of high clutch duty solenoid is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B55
TCM
B11
3 4
8
6 7
9 10
11 12
14 15
13
16
17 18
19 20
1
B55
B11
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
T4
AT3
AT3
1 2 3
4 5 6
HIGH CLUTCH
DUTY
SOLENOID
TRANSMISSION
AT-01489
Step
transmission.
(B55) No. 8 (B11) No. 7:
CHECK HIGH CLUTCH DUTY SOLENOID.
(T4) No. 7 No. 20:
Check
?
Yes
Go to step 2.
No
Repair the open
circuit in harness
between TCM and

M?
Go to step 3.
Repair the short

circuit in harness
between TCM and
4AT(diag)-77
Go to step 7.

Step
Check
racks.
Yes
Go to step 5.
No
Go to step 6.
NOTE:
link connector.
5) Start the engine and warm-up the engine
until the ATF temperature is above 80C
(176F).
NOTE:
6) Read the data of high clutch duty solenoid
High clutch duty solenoid is indicated in %.
7) Shift the select lever to D, and slowly
increase vehicle speed at 3rd or 4th to measure.
NOTE:
Memory Mode.>
Return the engine to idling speed and shift the
select lever to N range.
NOTE:
Memory Mode.>
CHECK POOR CONTACT.
Is there poor contact in high
clutch duty solenoid circuit?
4AT(diag)-78

indicator light is
temporary poor
be the cause.
Repair the poor
contact.
Replace the TCM.

<Ref. to 4AT-67,
(TCM).>

Step
Check
Yes
CHECK HIGH CLUTCH DUTY SOLENOID (IN Is the resistance 2.0 6.0 ? Go to step 8.
TRANSMISSION).
bracket.
2) Drain the ATF.
CAUTION:
4) Measure the resistance between high
clutch duty solenoid connector and transmission ground.
HIGH CLUTCH DUTY SOLENOID AND
TRANSMISSION.
high clutch duty solenoid and transmission
connector.
(T4) No. 7 (AT3) No. 3:
HIGH CLUTCH DUTY SOLENOID AND
TRANSMISSION.
ground.
No
<Ref. to 4AT-62,
Control Valve
Body.>

?
Go to step 9.
Repair the open

circuit in harness
between TCM and

M?
Even if the SPORT

indicator light is
temporary poor
be the cause.
in high clutch duty
solenoid and
transmission.
Repair the short

circuit of harness
between high
clutch duty solenoid and transmission connector.
4AT(diag)-79

T: DTC P0768 SHIFT SOLENOID D ELECTRICAL

The output signal circuit of low & reverse duty solenoid is open or shorted.
TROUBLE SYMPTOM:
Gear is not changed.
WIRING DIAGRAM:
TCM
B55
B11
T4
AT3
LOW & REVERSE

DUTY
SOLENOID
TRANSMISSION
B11
3 4
8
6 7
9 10
11 12
14 15
13
16
17 18
19 20
1
B55
AT3
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
1 2 3
4 5 6
AT-01490
Step
(B55) No. 7 (B11) No. 6:
CHECK LOW & REVERSE DUTY SOLENOID.
(T4) No. 6 No. 20:
Check
?
Yes
Go to step 2.
No
Repair the open
circuit in harness
between TCM and

M?
Go to step 3.
Repair the short

circuit in harness
between TCM and
4AT(diag)-80
Go to step 7.

Step
Check
link connector.
temperature is above approx. 80C (176F).
NOTE:
to ON (engine OFF).
6) Shift the select lever to the N range.
7) Read the data of low & reverse duty solenoid using Subaru Select Monitor.
Low & reverse duty solenoid is indicated in
%.
racks.
NOTE:
2) Shift the select lever to manual mode, and
then hold it on 1st. Slowly increase the vehicle
speed up to 15 km/h (9 MPH), and then return
the accelerator pedal.
NOTE:
Memory Mode.>
3) Read the data of low & reverse duty solenoid.
CHECK POOR CONTACT.
Is there poor contact in low &
reverse duty solenoid circuit?
4AT(diag)-81
Yes
Go to step 5.
No
Go to step 6.

indicator light is
temporary poor
be the cause.
Repair the poor

contact.
Replace the TCM.

<Ref. to 4AT-67,
(TCM).>

Step
Check
Yes
CHECK LOW & REVERSE DUTY SOLENOID Is the resistance 2.0 6.0 ? Go to step 8.
(IN TRANSMISSION).
bracket.
2) Drain the ATF.
CAUTION:
4) Measure the resistance between low &
reverse duty solenoid connector and transmission ground.
TRANSMISSION AND LOW & REVERSE
DUTY SOLENOID.
low & reverse duty solenoid and transmission
connector.
(T4) No. 6 (AT3) No. 1:
TRANSMISSION AND LOW & REVERSE
DUTY SOLENOID.
ground.
No
<Ref. to 4AT-62,
Control Valve
Body.>

?
Go to step 9.
Repair the open

circuit in harness
between low &
reverse duty solenoid and transmission connector.

M?
Even if the SPORT

indicator light is
temporary poor
be the cause.
in low & reverse
duty solenoid and
transmission.
Repair the short

circuit in harness
between low &
reverse brake
solenoid and
4AT(diag)-82

U: DTC P0801 REVERSE INHIBIT CONTROL CIRCUIT

Shift lock solenoid malfunction, open or short reverse inhibitor control circuit
TROUBLE SYMPTOM:
Gear is shifted from N range to R range during driving at 20 km/h (12 MPH) or more.
Gear cannot be shifted from N range to R range.
WIRING DIAGRAM:
B55
3 4 5 6 7 8 9
1 2
10 11 12 13 14 15 16 17 18 19 20 21
29 30 31
22 23 24 25 26
27 28
B55
18
TCM
B116
3 4
1 2
5 6 7 8 9 10
SHIFT LOCK
SOLENOID
B116
3
4
AT-01893
4AT(diag)-83

Step
TCM AND SHIFT LOCK SOLENOID.
shift lock solenoid.
between TCM and shift lock solenoid connector.
(B55) No. 18 (B116) No. 3:
TCM and chassis ground.
CHECK HARNESS BETWEEN SHIFT LOCK
SOLENOID AND CHASSIS GROUND TERMINAL.
shift lock solenoid and chassis ground.
terminals.
(B116) No. 3 No. 4:
chassis ground.
racks.
Check
?
Yes
Go to step 2.
No
Repair the open
circuit in harness
between TCM and
shift lock solenoid
connector.

M?
Go to step 3.
Repair the short

circuit in harness
between TCM and
shift lock solenoid
connector.

?
Go to step 4.
Repair the open

circuit in harness
between chassis
ground and shift
lock solenoid connector.
Go to step 5.
Replace the shift

lock solenoid.

V?
Go to step 6.
Go to step 7.

indicator light is
temporary poor
be the cause.
in reverse inhibitor
control circuit.
NOTE:
slowly increase vehicle speed to 20 km/h (12
MPH).
NOTE:
Memory Mode.>
chassis ground.
4AT(diag)-84

Step
CHECK POOR CONTACT.
Check
Yes
Is there poor contact in the
Repair the poor
reverse inhibitor control circuit? contact.
4AT(diag)-85
No
Replace the TCM.
<Ref. to 4AT-67,
(TCM).>

V: DTC P1706 AT VEHICLE SPEED SENSOR CIRCUIT MALFUNCTION (REAR

WHEEL)
TROUBLE SYMPTOM:
No lock-up or occurring tight corner braking phenomenon
WIRING DIAGRAM:
SBF-7
SBF-1
BATTERY
B54
NO.12
23
24
IGNITION
SWITCH
TCM
9
17
13
B11
3
1
2
T4
AT1
REAR VEHICLE
SPEED SENSOR
AT1
B11
B54
1 2 3
3 4
8
6 7
9 10
11 12
14 15
13
16
17 18
19 20
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
22 23 24
17 18 19 20 21
AT-01492
4AT(diag)-86

Step
speed sensor.
between rear vehicle speed sensor connector
and transmission ground.
(AT1) No. 3 (+) Transmission ground ():
between TCM and rear vehicle speed sensor
connector.
(B54) No. 23 (AT1) No. 1:
TCM and rear vehicle speed sensor connector.
(B54) No. 24 (AT1) No. 2:
PREPARE OSCILLOSCOPE.
Check
Yes
No
Check the harness
between rear vehicle speed sensor
and battery for
open circuit, short
or poor contact.
Repair the harness if required.

?
Go to step 3.
Repair the open

circuit or poor contact of connector in
harness between
TCM and rear
vehicle speed sensor connector.

?
Go to step 4.

M?
Go to step 5.
Repair the open

circuit or poor contact of connector in
harness between
TCM and rear
Repair the short
circuit in harness
between TCM and
rear vehicle speed
sensor connector.

M?
Go to step 6.
Do you have an oscilloscope? Go to step 8.
4AT(diag)-87
Repair the short

circuit in harness
between TCM and
rear vehicle speed
sensor connector.
Go to step 7.

Step
Check
Is the voltage approx. 5 V?
racks.
Yes
Go to step 9.
No
Replace the rear
vehicle speed sensor.
Go to step 9.
Replace the rear

vehicle speed sensor.
Repair the poor

contact.
Replace the TCM.

<Ref. to 4AT-67,
(TCM).>
NOTE:
3) Start the engine and set vehicle in 20 km/h
(12 MPH) condition.
NOTE:
Memory Mode.>
4) Measure the AC voltage between TCM
(B54) No. 24 (+) No. 23 ():
Is the pulse voltage approx. 5
OSCILLOSCOPE.
V?
racks.
NOTE:
3) Set the oscilloscope to TCM connector terminals.
Positive probe; (B54) No. 24:
Ground lead; (B54) No. 23:
4) Start the engine and set vehicle in 20 km/h
(12 MPH) condition.
NOTE:
Memory Mode.>
5) Measure the signal voltage indicated on
oscilloscope.
CHECK POOR CONTACT.
Is there poor contact in rear
vehicle speed sensor circuit?
4AT(diag)-88

W: DTC P1707 AT AWD SOLENOID VALVE CIRCUIT MALFUNCTION

Output signal circuit of transfer duty solenoid is open or shorted.
TROUBLE SYMPTOM:
Front wheel slips on the slippery road.
WIRING DIAGRAM:
B55
B11
TCM
3 4
8
6 7
9 10
11 12
14 15
13
16
17 18
19 20
1
B55
B11
8
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
T4
AT3
1 2 3
4 5 6
AT3
TRANSFER
DUTY
SOLENOID
TRANSMISSION
AT-01493
Step
transmission.
(B55) No. 4 (B11) No. 8:
Measure the resistance harness connector
CHECK TRANSFER DUTY SOLENOID.
connector and transmission terminals.
(T4) No. 8 No. 20:
Check
?
Yes
Go to step 2.
No
Repair the open
circuit in harness
between TCM and

M?
Go to step 3.
Repair the short

circuit in harness
between TCM and
4AT(diag)-89
Go to step 7.

Step
Check
CHECK OUTPUT SIGNAL EMITTED FROM Is the value approx. 5%?
link connector.
3) Turn the ignition switch to ON (engine OFF)
and Subaru Select Monitor switch to ON.
4) Shift the select lever to N range, and fully
close the throttle pedal. (Vehicle speed is 0 km/
h (0 MPH))
5) Read the data of transfer duty solenoid
Transfer duty solenoid is indicated in %.
2) Read the data of transfer duty solenoid
Transfer duty solenoid is indicated in %.
CHECK POOR CONTACT.
CHECK TRANSFER DUTY SOLENOID (IN

TRANSMISSION).
racks.
NOTE:
2) Drain the ATF.
Yes
Go to step 5.
No
Go to step 6.

indicator light is
temporary poor
be the cause.
Is there poor contact in transfer Repair the poor
Replace the TCM.
duty solenoid circuit?
contact.
<Ref. to 4AT-67,
(TCM).>
<Ref. to 4AT-62,
Control Valve
Body.>
CAUTION:
3) Remove the extension case, and disconnect the connector from transfer duty solenoid.
4) Measure the resistance between transfer
duty solenoid connector and transmission
ground.
TRANSFER DUTY SOLENOID AND TRANS- ?
MISSION.
transfer duty solenoid and transmission connector.
(T4) No. 8 (AT3) No. 5:
4AT(diag)-90
Go to step 9.
Repair the open

circuit in harness
between transfer
duty solenoid and

Step
Check
TRANSFER DUTY SOLENOID AND TRANS- M?
MISSION.
ground.
4AT(diag)-91
Yes
Even if the SPORT
indicator light is
temporary poor
be the cause.
Repair the harness or poor contact in the transfer
duty solenoid and
transmission.
No
Repair the short
circuit in harness
between transfer
duty solenoid and

X: DTC P1708 THROTTLE POSITION SENSOR CIRCUIT LOW INPUT

The input signal circuit of accelerator pedal position sensor is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
2.0 L LHD and 2.5 L KS model
A: B134
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
ECM
B5
B: B135
C1
B6
C2
A7
D: B137
D1
C: B136
C6
B: B135
C5
D30
C17
C18
D18
10
A: B134
A2
TCM
19
B54
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
32 33
34 35
28 29 30 31
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
D: B137
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
28 29
30 31
26 27
B54
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21
22 23 24
B83
52
37
34
35
36
1 2 3 4
5 6 7 8
B21
B21
E2
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 45
46 47
48 49 50 51 52 53 54
1
2
6
B315
2
1
B315
1 2 3 4 5 6
B83
JOINT CONNECTOR
ACCELERATOR PEDAL POSITION SENSOR
AT-01894
4AT(diag)-92

2.5 L EC, K4 model

A: B134
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
ECM
A6
D1
B12
A7
B: B135
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
32 33
34 35
28 29 30 31
10
19
D2
D: B137
B1
C: B136
D3
B: B135
D7
A: B134
B4
TCM
C28
C16
C35
B54
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
D: B137
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
28 29
30 31
26 27
B54
B122
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21
22 23 24
1
B83
JOINT
CONNECTOR
B122
1 2 3 4
5 6 7 8
52
47
36
35
34
37
B21
B21
E2
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 45
46 47
48 49 50 51 52 53 54
1
2
6
B315
1
8
B315
1 2 3 4 5 6
B83
JOINT CONNECTOR
AT-02370
4AT(diag)-93

2.0 L RHD and 2.5 L KA model

A: B134
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
ECM
B6
C6
B: B135
B5
C5
D: B137
D1
A7
C1
D18
D19
C17
D30
C18
10
C: B136
A2
B: B135
A: B134
C2
TCM
19
B54
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
32 33
34 35
28 29 30 31
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
JOINT
CONNECTOR
D: B137
6
B53
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
28 29
30 31
26 27
B54
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21
22 23 24
*
*
*
B183
JOINT
CONNECTOR
B122
B122
1 2 3 4
5 6 7 8
52
36
35
T4
34
37
19
B11
B21
B21
E2
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 45
46 47
48 49 50 51 52 53 54
1
2
6
B315
RANDOM
ARRANGEMENT
B315
*
*
* :
TERMINAL NO.
1 2 3 4 5 6
B183
JOINT CONNECTOR
AT-01895
4AT(diag)-94

2.5 L EK model
A: B134
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
ECM
A6
D1
B: B135
B12
A7
D2
B1
D: B137
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
32 33
34 35
28 29 30 31
10
19
D3
C: B136
D7
B: B135
A: B134
B4
TCM
C28
C16
C35
B54
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
D: B137
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
28 29
30 31
26 27
B54
B122
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21
22 23 24
1
B83
JOINT
CONNECTOR
B122
1 2 3 4
5 6 7 8
52
47
36
35
34
37
B21
B21
E2
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
: TERMINAL NO.
RANDOM
ARRANGEMENT
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
1
2
6
B315
*
*
B315
1 2 3 4 5 6
B83
JOINT CONNECTOR
AT-01896
Step
CHECK ENGINE GROUND TERMINALS.
Check
Yes
Have engine ground terminals Go to step 2.
been tightened securely?
4AT(diag)-95
No
Tighten the engine
ground terminals.

Step
between ECM and engine ground.
2.0 L model and 2.5 L KS, KA model
CHECK ACCELERATOR PEDAL POSITION
SENSOR.
1) Disconnect the connectors from accelerator
pedal position sensor.
2) Measure the resistance between accelerator pedal position sensor connector receptacles terminals.
No. 1 No. 6:
SENSOR.
Measure the resistance between accelerator
pedal position sensor connector receptacles
terminals.
No. 6 No. 2:
TCM AND ACCELERATOR PEDAL POSITION SENSOR.
between TCM and accelerator pedal position
sensor connector.
(B54) No. 19 (B315) No. 2:
Check
?
Yes
Go to step 3.
No
Repair the open
circuit in harness
between ECM
connector and
engine grounding
terminal.

k?
Go to step 4.
Replace the accelerator pedal position sensor.

k?
Go to step 5.

?
Go to step 6.

M?
Go to step 7.
Repair the open

circuit in harness
between TCM and
accelerator pedal
position sensor
connector, and
poor contact in
coupling connector.
Repair the short
circuit in harness
between TCM and
accelerator pedal
position sensor
connector.
4AT(diag)-96

Step
ECM AND ACCELERATOR PEDAL POSITION SENSOR.
1) Remove the connector from ECM.
between the accelerator pedal position sensor
connector and chassis ground.
1) Connect the connectors to TCM, accelerator pedal position sensor, and ECM.
link connector.
OFF).
ON.
6) Read the data of accelerator pedal position
sensor using Subaru Select Monitor.
Accelerator pedal position sensor input signal is indicated.
CHECK POOR CONTACT.
Check
M?
Yes
Go to step 8.
Is the voltage more than 0.2 V? Even if the SPORT

indicator light is
temporary poor
be the cause.
in accelerator
Is there poor contact in accel- Repair the poor
contact.
erator pedal position sensor
circuit?
4AT(diag)-97
No
Repair the short
circuit in harness
between ECM and
accelerator pedal
position sensor.
Go to step 9.
Replace the TCM.

<Ref. to 4AT-67,
(TCM).>

Y: DTC P1709 THROTTLE POSITION SENSOR CIRCUIT HIGH INPUT

The input signal circuit of accelerator pedal position sensor is shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
A: B134
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
ECM
B5
B: B135
C1
B6
C2
A7
D: B137
D1
C: B136
C6
B: B135
C5
D30
C17
C18
D18
10
A: B134
A2
TCM
19
B54
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
32 33
34 35
28 29 30 31
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
D: B137
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
28 29
30 31
26 27
B54
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21
22 23 24
B83
52
37
34
35
36
1 2 3 4
5 6 7 8
B21
B21
E2
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 45
46 47
48 49 50 51 52 53 54
1
2
6
B315
2
1
B315
1 2 3 4 5 6
B83
JOINT CONNECTOR
AT-01894
4AT(diag)-98

2.5 L EC, K4 model

A: B134
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
ECM
A6
D1
B12
A7
B: B135
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
32 33
34 35
28 29 30 31
10
19
D2
D: B137
B1
C: B136
D3
B: B135
D7
A: B134
B4
TCM
C28
C16
C35
B54
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
D: B137
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
28 29
30 31
26 27
B54
B122
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21
22 23 24
1
B83
JOINT
CONNECTOR
B122
1 2 3 4
5 6 7 8
52
47
36
35
34
37
B21
B21
E2
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 45
46 47
48 49 50 51 52 53 54
1
2
6
B315
2
1
B315
1 2 3 4 5 6
B83
JOINT CONNECTOR
AT-01494
4AT(diag)-99


A: B134
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
ECM
B6
C6
B: B135
B5
C5
D: B137
D1
A7
C1
C: B136
A2
B: B135
D18
D19
C17
D30
C18
10
A: B134
C2
TCM
19
B54
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
32 33
34 35
28 29 30 31
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
JOINT
CONNECTOR
D: B137
6
B53
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
28 29
30 31
26 27
B54
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21
22 23 24
*
*
*
B183
JOINT
CONNECTOR
B122
B122
1 2 3 4
5 6 7 8
52
36
35
T4
34
37
19
B11
B21
B21
E2
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 45
46 47
48 49 50 51 52 53 54
1
2
6
B315
RANDOM
ARRANGEMENT
B315
*
*
* :
TERMINAL NO.
1 2 3 4 5 6
B183
JOINT CONNECTOR
AT-01895
4AT(diag)-100

2.5 L EK model
A: B134
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
ECM
A6
D1
B: B135
B12
A7
D2
B1
D: B137
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
32 33
34 35
28 29 30 31
10
19
D3
C: B136
D7
B: B135
A: B134
B4
TCM
C28
C16
C35
B54
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
D: B137
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
28 29
30 31
26 27
B54
B122
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21
22 23 24
1
B83
JOINT
CONNECTOR
B122
1 2 3 4
5 6 7 8
52
47
36
35
34
37
B21
B21
E2
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
: TERMINAL NO.
RANDOM
ARRANGEMENT
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
1
2
6
B315
*
*
B315
1 2 3 4 5 6
B83
JOINT CONNECTOR
AT-01896
Step
CHECK ENGINE GROUND TERMINALS.
Check
Yes
Have engine ground terminals Go to step 2.
been tightened securely?
4AT(diag)-101
No
Tighten the engine
ground terminals.

Step
between ECM and engine ground.
SENSOR.
1) Disconnect the connectors from accelerator
pedal position sensor.
2) Measure the resistance between accelerator pedal position sensor connector receptacles terminals.
No. 1 No. 6:
SENSOR.
Measure the resistance between accelerator
pedal position sensor connector receptacles
terminals.
No. 2 No. 6:
Check
?
Yes
Go to step 3.
No
Repair the open
circuit in harness
between ECM
connector and
engine grounding
terminal.

k?
Go to step 4.

k?
Go to step 5.

M?
Go to step 6.
Repair the short

circuit in harness
between TCM and
accelerator pedal
position sensor
connector.
4AT(diag)-102

Step
ECM AND ACCELERATOR PEDAL POSITION SENSOR.
1) Remove the connector from ECM.
between ECM connector and accelerator pedal
(B135) No. 6 (B136) No. 18:
(B135) No. 6 (B136) No. 35:
1) Connect the connectors to TCM, accelerator pedal position sensor and ECM.
link connector.
OFF).
ON.
5) Fully open the throttle.
6) Read the data of accelerator pedal position
sensor using Subaru Select Monitor.
Accelerator pedal position sensor input signal is indicated.
CHECK POOR CONTACT.
Check
?
Yes
Go to step 7.
No
Repair the open
circuit in harness
between ECM and
accelerator pedal
position sensor.
Even if the SPORT

indicator light is
temporary poor
be the cause.
in accelerator
Replace the TCM.
<Ref. to 4AT-67,
(TCM).>
Is there poor contact in accelerator pedal position sensor

circuit?
4AT(diag)-103
Repair the poor

contact.

Z: DTC P1714 THROTTLE POSITION SENSOR POWER SUPPLY CIRCUIT

The power supply circuit of accelerator pedal position sensor is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
T4
B5
B6
52
37
C1
ECM
C2
A7
34
D1
D: B137
35
A2
36
20
19
B11
C: B136
C6
B: B135
C5
D18
C17
D30
A: B134
A10
A19
B3
TCM
C18
B55
B:
B2
B54
A17
A8
A:
B21
2
1
B315
1
2
6
E2
JOINT
CONNECTOR
B83
AT CONTROL
B315
1 2 3 4 5 6
B83
1 2 3 4
5 6 7 8
A:
B:
B55
1 2
3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26
27 28
29 30 31
C: B136
A: B134
B54
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21
22 23 24
ACCELERATOR PEDAL
POSITION SENSOR
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
D: B137
B: B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
24 25
26 27
20 21 22 23
28 29 30 31
32 33
34 35
5 6
14 15 16
25 26 27
33 34 35
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
24 25
18 19 20 21 22 23
26 27
28 29
30 31
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
AT-04789
4AT(diag)-104

A6
A7
D1
D2
B12
ECM
D: B137
B1
B4
D3
D7
C16
C28
C: B136
52
47
36
35
34
B122
T4
37
20
19
B: B135
JOINT
CONNECTOR
B11
A: B134
TCM
C35
B55
A19
B:
A10
B54
B2
A17
A8
A:
B3
2.5 L EC, K4 model
B21
E2
E
2
1
B315
1
2
6
AT CONTROL
JOINT
CONNECTOR
: TERMINAL No. OPTIONAL

ARRANGEMENT
AMONG 1, 2, 5 AND 6
B315
1 2 3 4 5 6
B83
A:
B54
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21
22 23 24
B:
B55
1 2
3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26
27 28
29 30 31
C: B136
A: B134
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
5 6
14 15 16
25 26 27
33 34 35
D: B137
B: B135
B122
1 2 3 4
5 6 7 8
B83
ACCELERATOR PEDAL
POSITION SENSOR
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
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
AT-04775
4AT(diag)-105

B6
B5
C6
D1
A2
C5
ECM
D: B137
A7
C: B136
C2
C17
D30
D19
D18
B: B135
A19
A10
A: B134
C1
TCM
C18
B55
A8
B2
B3
B:
A17
B54
A:
52
36
35
34
B21
37
JOINT
CONNECTOR
T4
B315
1
2
6
*
*
B122
19
20
B11
E2
JOINT
CONNECTOR
B138

ARRANGEMENT
AMONG 1, 2, 5 AND 6
B315
1 2 3 4 5 6
B138
A:
B54
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21
22 23 24
B:
B55
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
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
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
D: B137
B: B135
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
C: B136
A: B134
B122
1 2 3 4
5 6 7 8
ACCELERATOR PEDAL
POSITION SENSOR
AT CONTROL
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
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
AT-04790
4AT(diag)-106

A6
A7
D1
D2
B12
ECM
D: B137
B1
B4
C: B136
D7
B: B135
D3
C28
A19
C16
A: B134
TCM
C35
B55
A10
B:
B54
B2
A17
A8
A:
B3
2.5 L EK model
JOINT
CONNECTOR
1
B21
52
47
36
35
37
B122
T4
34
20
19
B11
E2
E
B315
1
2
6
*
*
AT CONTROL
JOINT
CONNECTOR

ARRANGEMENT
AMONG 1, 2, 5 AND 6
B315
1 2 3 4 5 6
B138
A:
B54
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21
22 23 24
B:
B55
1 2
3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26
27 28
29 30 31
C: B136
A: B134
1
8 9
18 19
28 29
2
10
20
30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
5 6
14 15 16
25 26 27
33 34 35
D: B137
B: B135
B122
1 2 3 4
5 6 7 8
B138
ACCELERATOR PEDAL
POSITION SENSOR
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
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
AT-04791
Step
Check
CHECK TCM SIGNAL.
Is the value less than 4.75 V?
1) Connect the Subaru Select Monitor to the
data link connector.
3) Read the data of Throttle sensor power
supply using Subaru Select Monitor.
TCM AND ACCELERATOR PEDAL POSI?
TION SENSOR.
between TCM and accelerator pedal position
sensor connector.
(B54) No. 10 (B315) No. 1:
4AT(diag)-107
Yes
Go to step 2.
No
Go to step 5.
Go to step 3.
Repair the open

circuit of harness
between TCM and
accelerator pedal
position sensor
connector, and
poor contact of
connector.

Step
TCM AND ECM.
between TCM and ECM connector.
2.0L model and 2.5L KA, KS model
(B54) No. 10 (B137) No. 18:
2.5L EK, EC, K4 model
(B54) No. 10 (B136) No. 16:
CHECK HARNESS CONNECTOR AMONG
TCM, ACCELERATOR PEDAL POSITION
SENSOR AND ECM.
TCM CONNECTOR AND TRANSMISSION
GROUND.
(B54) No. 8 (B11) No. 19:
(B54) No. 17 (B11) No. 19:
(B55) No. 2 (B11) No. 20:
(B55) No. 3 (B11) No. 20:
CHECK CIRCUIT BETWEEN TRANSMISSION CONNECTOR AND TRANSMISSION
GROUND.
transmission connector and transmission case.
(B11) No. 19 Transmission ground:
(B11) No. 20 Transmission ground:
Check
Yes
Is the resistance less than 1 ? Go to step 4.
No
Repair the open
circuit of harness
between TCM and
ECM connector,
and poor contact
of connector.
Is the resistance 1 M or
more?
Repair the short

circuit of harness
among TCM,
accelerator pedal
position sensor
and ECM connector.
Repair the open
circuit of harness
between TCM and
contact of connector.
Go to step 5.
CHECK ECM POWER SUPPLY AND

Is there any abnormal condiGROUND LINE.
tion?
Check ECM power supply circuit and ground circuit.
<Ref. to EN(H4SO 2.0)(diag)-55, CHECK
POWER SUPPLY AND GROUND LINE OF
ENGINE CONTROL MODULE (ECM), Diagnostics for Engine Starting Failure.> <Ref. to
EN(H4SO 2.5)(diag)-58, CHECK POWER
SUPPLY AND GROUND LINE OF ENGINE
CONTROL MODULE (ECM), Diagnostics for
Engine Starting Failure.> <Ref. to
EN(H4DOTC)(diag)-46, CHECK POWER
SUPPLY AND GROUND LINE OF ENGINE
CONTROL MODULE (ECM), Diagnostics for
Engine Starting Failure.> <Ref. to
EN(H6DO)(diag)-56, CHECK POWER SUPPLY AND GROUND LINE OF ENGINE CONTROL MODULE (ECM), Diagnostics for Engine
Starting Failure.>
4AT(diag)-108
Repair the malfunction of ECM

power supply circuit and ground
circuit.
Repair the open

circuit of harness
between transmission connector
and transmission
ground, poor contact of connector
and insufficient
tightening of
ground bolt.
Replace the TCM.
<Ref. to 4AT-67,
(TCM).>

AA:DTC P1718 CAN COMMUNICATION CIRCUIT

NOTE:
Refer to Body Integrated Unit for diagnosis of P1718. <Ref. to LAN(diag)-2, Basic Diagnostic Procedure.>
4AT(diag)-109

AB:DTC P1760 LATERAL ACCELERATION SENSOR PERFORMANCE PROBLEM

Faulty lateral G sensor output voltage
WIRING DIAGRAM:
B54
11
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21
22 23 24
TCM
B54
B359
1 2 3
B359
G SENSOR
AT-01496
4AT(diag)-110

10
Step
CHECK OUTPUT OF LATERAL G SENSOR
USING SUBARU SELECT MONITOR.
1) Select {Current Data Display & Save} in
2) Read the Subaru Select Monitor display.
2) Remove the console box.
3) Remove the lateral G sensor from vehicle.
(Do not disconnect connector.)
Read the Subaru Select Monitor display.
Check
Yes
Is the reading on display 2.3 Go to step 2.
2.7 V when the vehicle is on a
level?
No
Go to step 7.
Is the value on the monitor dis- Go to step 3.

play 3.3 4.3 V when lateral
G sensor is inclined to the right
to 90?
Replace the lateral G sensor.

<Ref. to 4AT-68,
Lateral G Sensor.>
Is the value on the monitor display 0.7 1.7 V when lateral

G sensor is inclined to the left
to 90?
CHECK POOR CONTACT IN CONNECTOR. Is there poor contact in conTurn the ignition switch to OFF.
nector between TCM and the
lateral G sensor?
Is the same DTC still output?
CHECK ABSCM&H/U.
2) Erase the memory.
3) Perform the inspection mode.
4) Read the DTC.
CHECK OTHER DTC DETECTION.
Is any other DTC detected?
CHECK OPEN CIRCUIT IN LATERAL G SENSOR OUTPUT HARNESS AND GROUND

HARNESS.
(B54) No. 2 No. 9:
CHECK LATERAL G SENSOR.
3) Connect the connector to lateral G sensor.
4) Connect the connector to ABSCM&H/U.
6) Measure the voltage between lateral G
sensor connector terminals.
(B359) No. 3 (+) No. 2 ():
Measure the voltage between lateral G sensor
(B359) No. 3 (+) No. 2 ():
(B359) No. 3 (+) No. 2 ():

k?
Go to step 4.

Replace the TCM.
<Ref. to 4AT-67,
(TCM).>
Perform the diagnosis according to
DTC.
Go to step 8.

<Ref. to 4AT-68,
Lateral G Sensor.>
Go to step 5.
Go to step 6.
Temporary poor
contact occurs.
between lateral G
sensor and TCM.
Is the voltage 2.3 2.7 V

when the lateral G sensor is
horizontal?
Go to step 9.

<Ref. to 4AT-68,
Lateral G Sensor.>

when lateral G sensor is
inclined to the right to 90?
Go to step 10.

<Ref. to 4AT-68,
Lateral G Sensor.>

inclined to the left to 90?
Go to step 11.

<Ref. to 4AT-68,
Lateral G Sensor.>
4AT(diag)-111

11
12
Step
CHECK ABSCM&H/U.
5) Read the DTC.
Check
Yes
No
Replace the TCM. Go to step 12.
<Ref. to 4AT-67,
(TCM).>
Perform the diag- Temporary poor

nosis according to contact occurs.
DTC.
4AT(diag)-112

AC:DTC P1761 LATERAL ACCELERATION SENSOR CIRCUIT LOW

WIRING DIAGRAM:
B54
11
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21
22 23 24
TCM
B54
B359
1 2 3
B359
G SENSOR
AT-01496
4AT(diag)-113

Step
2) Read the lateral G sensor output on the
Subaru Select Monitor display.
CHECK POOR CONTACT IN CONNECTOR.
CHECK TCM.
4) Read the DTC.
Check
Yes
play 2.3 2.7 V when the lateral G sensor is in horizontal
position?
No
Go to step 5.

connector between TCM and
the lateral G sensor?
Go to step 3.
Replace the TCM.

<Ref. to 4AT-67,
(TCM).>
DTC.
Go to step 6.
Go to step 4.
Temporary poor
contact occurs.

HARNESS.
(B54) No. 2 No. 9:
CHECK GROUND SHORT OF HARNESS.
Measure the resistance between TCM connector and chassis ground.

k?

M?
Go to step 7.

4) Connect the connector to the TCM.
(B359) No. 3 (+) No. 2 ():
(B359) No. 3 (+) No. 2 ():
(B359) No. 3 (+) No. 2 ():

horizontal?
Go to step 8.

Go to step 9.

<Ref. to 4AT-68,
Lateral G Sensor.>

Go to step 10.

<Ref. to 4AT-68,
Lateral G Sensor.>
4AT(diag)-114

between lateral G
sensor and TCM.
Repair the harness between lateral G sensor and

TCM.
Replace the TCM.
<Ref. to 4AT-67,
(TCM).>
<Ref. to 4AT-68,
Lateral G Sensor.>

10
11
Step
CHECK TCM.
5) Read the DTC.
Check
Yes
No
<Ref. to 4AT-67,
(TCM).>

DTC.
4AT(diag)-115

AD:DTC P1762 LATERAL ACCELERATION SENSOR CIRCUIT HIGH

WIRING DIAGRAM:
B54
11
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21
22 23 24
TCM
B54
B359
1 2 3
B359
G SENSOR
AT-01496
4AT(diag)-116

10
11
Step
CHECK ABSCM&H/U.
4) Read the DTC.
No
Go to step 5.

connector between TCM and
lateral G sensor?
Go to step 3.
Replace the TCM.

<Ref. to 4AT-67,
(TCM).>
DTC.
Go to step 6.
Go to step 4.
CHECK CONDITIONAL INFORMATION

WHEN FAULTY.
Read the lateral G sensor output on Subaru
Select Monitor display.
HARNESS.
(B54) No. 2 No. 9:
CHECK BATTERY SHORT OF HARNESS.
3) Disconnect the connector from lateral G
sensor.
CHECK TCM.
4) Read the DTC.
Check
Yes
play between 2.3 and 2.7 V
when the lateral G sensor is in
horizontal position?
Is the reading on monitor display 4.65 V or more?
Temporary poor
contact occurs.
Go to step 12.

k?
Go to step 7.

between lateral G
sensor and
ABSCM&H/U.
Go to step 8.

TCM.
Go to step 9.

TCM.
Is there poor contact in connector between TCM and lateral G sensor?

Go to step 10.
4AT(diag)-117

<Ref. to 4AT-67,
(TCM).>
DTC.

12
13
14
15
16
17
18
19
Step
CHECK INPUT VOLTAGE OF LATERAL G
SENSOR.
(Do not disconnect the connector.)
(B359) No. 1 (+) No. 2 ():
HARNESS.
(B54) No. 2 No. 9:
(B359) No. 3 (+) No. 2 ():
(B359) No. 3 (+) No. 2 ():
(B359) No. 3 (+) No. 2 ():
CHECK ABSCM&H/U.
4) Read the DTC.
Check
Yes
Go to step 13.
No
between lateral G
sensor and TCM.

k?
Go to step 14.

between lateral G
sensor and TCM.

Go to step 15.
when lateral G sensor is in horizontal?

<Ref. to 4AT-68,
Lateral G Sensor.>

Go to step 16.

<Ref. to 4AT-68,
Lateral G Sensor.>

Go to step 17.

<Ref. to 4AT-68,
Lateral G Sensor.>
Is there poor contact in connector between TCM and lateral G sensor?

Go to step 18.
4AT(diag)-118

<Ref. to 4AT-67,
(TCM).>
DTC.

AE:DTC P1817 SPORTS MODE SWITCH CIRCUIT

Input signal circuit of SPORT shift switch is open or shorted.
TROUBLE SYMPTOM:
The manual mode is not engaged.
The SPORT indicator light does not illuminate.
No SPORT mode occurs.
WIRING DIAGRAM:
LHD model
A:
i84
1 2
3 4
5 6
7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35
B: B280
1 2 3
4 5
6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
A:
i84
B: B280
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
B30
C26
B54
B116
B20
C: B281
1 2
3 4
5 6 7 8 9 10
B352
JOINT
CONNECTOR
SELECT
LEVER
SPORT
MODE
SWITCH
B116
8
C: B281
JOINT
CONNECTOR
7
5
B54
12
B352
3
B355
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
B355
1 2 3 4
5 6 7 8
TCM
AT-01897
4AT(diag)-119

RHD model
A:
i84
1 2
3 4
5 6
7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35
B: B280
1 2 3
4 5
6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
A:
i84
B: B280
B30
C26
B54
JOINT
CONNECTOR
B116
SELECT
LEVER
JOINT
CONNECTOR
1 2
3 4
5 6 7 8 9 10
B116
8
SPORT
MODE
SWITCH
10
19
B352
18
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
B20
C: B281
C: B281
B53
12
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
E
B54
TCM
B352
1 2 3 4
5 6 7 8
B53
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
AT-02200
4AT(diag)-120

Step
link connector.
2) Turn the ignition switch to ON. (Engine
OFF)
3) Read the DTC of body integrated unit using
CHECK INPUT SIGNAL TO BODY INTEGRATED UNIT.
2) Read the Tiptronic Mode Switch data of
body integrated unit using Subaru Select Monitor. <Ref. to LAN(diag)-14, OPERATION, Subaru Select Monitor.>
1) Shift the select lever from P to D range.
1) Shift the select lever to SPORT mode.
2) Shift the select lever to any other than D
range.
Shift the select lever from P to D range.
Check
Is DTC displayed?
Yes
No
nosis according to
DTC.
Is the OFF displayed?
Go to step 3.
Go to step 7.
Is the indication per range

OFF?
Go to step 4.
Replace the select

lever assembly.
<Ref. to CS-7,
Select Lever.>
Is the OFF displayed?
Go to step 5.
Replace the select

lever assembly.
<Ref. to CS-7,
Select Lever.>
Is the indication of range posi- Go to step 6.

tion indicator light in combination meter synchronized with
position of select lever?
Is the indication per range

CHECK INPUT SIGNAL TO TCM.
1) Shift the select lever from P to D range. OFF?
TCM unit using Subaru Select Monitor. <Ref.
to 4AT(diag)-17, OPERATION, Subaru Select
Monitor.>
4AT(diag)-121
Adjust the inhibitor switch and

select cable. <Ref.
to 4AT-52,
ADJUSTMENT,
Inhibitor Switch.>
<Ref. to CS-15,
ADJUSTMENT,
Select Cable.>
Even if the SPORT Replace the TCM.
indicator light is
<Ref. to 4AT-67,
blinking, the cirTransmission Concuit has returned trol Module
to normal condi(TCM).>
tion at this time. A
temporary short
or harness may be
the cause. Repair
the harness or
connector.

Step
CHECK HARNESS BETWEEN BODY INTEGRATED UNIT AND SPORT SHIFT SWITCH.
body integrated unit and select lever.
3) Measure the resistance of body integrated
unit and chassis ground.
CHECK SPORT SHIFT SWITCH.
2) Measure the resistance of SPORT shift
Terminals
No. 7 No. 8
Check
M?
Yes
Go to step 8.
No
Repair the short
circuit in harness
between body integrated unit and
SPORT shift
switch.

M?
Check the body

integrated unit.
Replace the select

lever assembly.
<Ref. to CS-7,
Select Lever.>
4AT(diag)-122
Diagnostic Procedure without Diagnostic Trouble Code (DTC)

14.Diagnostic Procedure without Diagnostic Trouble Code (DTC)

A: CHECK FWD SWITCH
DIAGNOSIS:
The LED does not come on even if FWD switch is ON.
The FWD signal circuit is open or shorted.
WIRING DIAGRAM:
LHD model
No.5
i10
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
AWD
IGNITION
SWITCH
COMBINATION
METER
i77
A:
JOINT
CONNECTOR
A:
BATTERY
3
4
3 4 5 6 7 8 9
1 2
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31
JOINT
CONNECTOR
B: B281
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
B352
JOINT
CONNECTOR
F108
B355
1 2 3 4
5 6 7 8
9 10 11 12 13 14 15 16 17 18
A12
A3
B55
B: B281
1
2
5
i84
B:
B30
7
B20
A:
B54
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
i84
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
i77
22
1 2 3 4 5 6 7 8 9 10 11 12
A26
A27
SBF-1
SBF-7
21
i10
A:
B361
B54
1 2 3
4 5 6
7 8 9 10 11 12 13 14
TCM
B55
B17
B:
11
JOINT
THROUGH
CONNECTOR
1
2 4 5
3
10
8 9 11
12
18
F108
13
F27
B361
FWD
SWITCH
A/C RELAY HOLDER
18 19
20 21
22
23
24 25
26
27
28 29
6
7
30
31
19
F27
13
14 16 17
15
B352
B355
1 2 3 4
5 6 7 8
AT-01898
4AT(diag)-123

RHD model
No.5
i10
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
AWD
i77
IGNITION
SWITCH
COMBINATION
METER
1 2 3 4 5 6 7 8 9 10 11 12
i10
21
22
7
SBF-7
A:
JOINT
CONNECTOR
BATTERY
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
A:
B30
8
B20
B:
3 4 5 6 7 8 9
1 2
10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31
B: B281
JOINT
CONNECTOR
B: B281
4
9
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
JOINT
CONNECTOR
B53
10
2
19
B55
i84
B352
18
B54
i77
A26
A27
SBF-1
A:
i84
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
F108
B361
1 2 3 4
5 6 7 8
9 10 11 12 13 14 15 16 17 18
1 2 3
4 5 6
7 8 9 10 11 12 13 14
A3
A12
B352
A:
B54
B:
B55
1 2 3 4
5 6 7 8
B17
TCM
13
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
JOINT
THROUGH
CONNECTOR
F27
18
F108
11
B361
B53
FWD
SWITCH
1
2 4 5
3
A/C RELAY HOLDER

10
8 9 11
12
19
F27
18 19
20 21
22
23
24 25
26
27
28 29
13
14 16 17
15
6
7
30
31
E
AT-02201
4AT(diag)-124

2
3
Step
CONFIRM EQUIPMENT OF VEHICLE.
Check
Is the vehicle equipped with
VDC?
CHECK SPARE FUSE.

CHECK FWD SWITCH.
connector.
Is the spare fuse OK?

When the fuse is inserted to
FWD switch, does the LED
light up?
Does the AWD warning light
illuminate?

TCM AND FWD SWITCH.
between TCM and FWD switch connector.
(B55) No. 17 (F27) No. 18:
FWD SWITCH AND CHASSIS GROUND.
FWD switch and chassis ground.
TCM AND FWD SWITCH.
between TCM and body to make sure that circuit does not short.
4) Measure the signal voltage for TCM while
installing the fuse to FWD switch connector.

?
Yes
No
Go to INSPECGo to step 2.
TION FOR
SPORT SHIFT
SWITCH. <Ref. to
4AT(diag)-127,
CHECK SPORT
SHIFT SWITCH,
Diagnostic Procedure without Diagnostic Trouble
Code (DTC).>
Go to step 3.
Replace the fuse.
Go to step 4.
Go to step 5.
Go to INSPECGo to step 10.

TION FOR
SPORT SHIFT
SWITCH. <Ref. to
4AT(diag)-127,
CHECK SPORT
SHIFT SWITCH,
Diagnostic Procedure without Diagnostic Trouble
Code (DTC).>
Go to step 6.
Repair the open
circuit in harness
between TCM and
FWD switch connector.

?
Go to step 7.

M?
Go to step 8.
Go to step 9.
4AT(diag)-125
Repair the open

circuit in harness
between FWD
switch connector
and chassis
ground.
Repair the short
circuit in harness
between TCM and
FWD switch connector.
Go to step 11.

10
Step
Measure the signal voltage for TCM while
removing the fuse from FWD switch connector.
11

Check the AWD warning light. <Ref. to IDI-3,
INSPECTION, Combination Meter System.>
12
CHECK POOR CONTACT.
Check
V?
Yes
Go to step 10.
No
Replace the TCM.
<Ref. to 4AT-67,
(TCM).>
Go to step 11.
Is DTC of CAN communication Perform the diagdisplayed?

nosis according to
DTC.
Is the AWD warning light OK? Go to step 12.
Replace the combination meter
assembly. <Ref. to
Is there poor contact in FWD Repair the poor
Replace the TCM.
switch circuit?
contact.
<Ref. to 4AT-67,
(TCM).>
4AT(diag)-126

B: CHECK SPORT SHIFT SWITCH

DIAGNOSIS:
TROUBLE SYMPTOM:
Does not shift gears in manual mode.
WIRING DIAGRAM:
LHD model
B: B280
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
B: B280
C25
9
3
4
7
B116
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
B116
B54
12
1 2
3 4
5 6 7 8 9 10
3
B355
2
5
JOINT
CONNECTOR
B54
SELECT
LEVER
DOWN
SHIFT
SWITCH
UP SHIFT
SWITCH
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
10
B352
JOINT
CONNECTOR
C15
B30
7
C: B281
B20
5
C: B281
E
B352
TCM
B355
1 2 3 4
5 6 7 8
AT-01900
4AT(diag)-127

RHD model
B352
1 2 3 4
5 6 7 8
B53
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
B: B280
C25
C15
B352
B116
10
9
10
12
B54
19
18
3
B53
SELECT
LEVER
DOWN
SHIFT
SWITCH
UP SHIFT
SWITCH
JOINT
CONNECTOR
B54
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
8
4
B30
JOINT
CONNECTOR
B20
C: B281
B116
1 2
3 4
5 6 7 8 9 10
B: B280
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
TCM
C: B281
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
AT-02358
Step
1) Shift the select lever to manual mode.
2) Shift and hold the select lever to up side.
Shift and hold the select lever to down side.
Check
Does the LED light up?
Yes
Go to step 2.
Does the LED light up?
Go to the proceGo to step 12.

dure INSPECTION FOR
SPORT SHIFT
INDICATOR
LIGHT. <Ref. to
4AT(diag)-132,
CHECK SPORT
SHIFT INDICATOR, Diagnostic
Procedure without
4AT(diag)-128
No
Go to step 3.

10
Step
3) Read the data of up-shift switch using Subaru Select Monitor. <Ref. to LAN(diag)-14,
Check the DTC of body integrated unit. <Ref.
to LAN(diag)-14, OPERATION, Subaru Select
Monitor.>
CHECK SPORT SHIFT SWITCH GROUND
CIRCUIT.
2) Disconnect the connector from SPORT
shift switch.
between SPORT shift switch connector and
chassis ground.
Measure the resistance between SPORT shift
switch terminals.
(B116) No. 6 No. 5:
2) Measure the resistance between SPORT
shift switch terminals.
(B116) No. 6 No. 5:
BODY INTEGRATED UNIT AND SPORT
SHIFT SWITCH.
between body integrated unit and SPORT shift
switch connector.
(B116) No. 5 (B281) No. 15:
TCM AND SPORT SHIFT SWITCH.
SPORT shift switch connector and chassis
ground.
OFF).
3) Check the signal voltage for body integrated unit.
Check
Is ON displayed?
Yes
Go to step 4.
No
Go to step 5.
Is DTC of CAN communication Perform the diag- Check the TCM.

displayed?
nosis according to
DTC.
?
Go to step 6.
Repair the open

circuit in harness
between SPORT
shift switch and
chassis ground.

M?
Go to step 7.
Replace the guide

plate assembly.

?
Go to step 8.
Replace the guide

plate assembly.

?
Go to step 9.
Repair the open

circuit in harness
between SPORT
shift switch connector and TCM
connector, or poor

M?
Go to step 10.
Repair the short

circuit in harness
between SPORT
connector.
Is the voltage 1.5 8 V?
Go to step 11.
Replace the TCM.

<Ref. to 4AT-67,
(TCM).>
4AT(diag)-129

11
12
13
14
15
16
17
18
Step
2) Shift and hold the select lever to down side.
3) Read the data of up-shift switch using Subaru Select Monitor. <Ref. to LAN(diag)-14,
Check the DTC of body integrated unit.
CHECK SPORT SHIFT SWITCH CIRCUIT.
shift switch.
chassis ground.
Measure the resistance between SPORT shift
switch terminals.
(B116) No. 10 No. 9:
1) Shift and hold the select lever to down side.
2) Measure the resistance between SPORT
(B116) No. 10 No. 9:
SHIFT SWITCH.
between body integrated unit and SPORT shift
switch connector.
(B116) No. 9 (B281) No. 25:
SHIFT SWITCH.
SPORT shift switch connector and chassis
ground.
Check
Yes
Go to step 12.
No
Replace the TCM.
<Ref. to 4AT-67,
(TCM).>
Is ON displayed?
Go to step 13.
Go to step 14.
Is DTC of CAN communication Perform the diag- Check the TCM.

displayed?
nosis according to
DTC.
Go to step 15.
Repair the open
?
circuit in harness
between SPORT
shift switch and
chassis ground.

M?
Go to step 16.
Replace the guide

plate assembly.

?
Go to step 17.
Replace the guide

plate assembly.

?
Go to step 18.
Repair the open

circuit in harness
between SPORT
connector, or poor

M?
Go to step 19.
Repair the short

circuit in harness
between SPORT
connector.
4AT(diag)-130

19
20
21
Step
Check
CHECK THE INPUT SIGNAL TO BODY INTE- Is the voltage 1.5 8 V?
GRATED UNIT.
OFF).
CHECK THE INPUT SIGNAL TO BODY INTE- Is the voltage less than 1 V?
GRATED UNIT.
CHECK POOR CONTACT.
Is there poor contact in SPORT
shift switch circuit?
4AT(diag)-131
Yes
Go to step 20.
No
Go to step 21.
Go to step 21.
Replace the body

integrated unit.
<Ref. to 4AT-67,
(TCM).>
Repair the poor

contact.
A temporary poor
contact of SPORT
shift switch connector or harness.

C: CHECK SPORT SHIFT INDICATOR

DIAGNOSIS:
Output signal circuit of SPORT shift indicator is open or shorted.
TROUBLE SYMPTOM:
SPORT shift indicator does not display or remains displayed.
SPORT shift indicator display does not change.
WIRING DIAGRAM:
LHD model
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
No.5
i10
SPORT SHIFT
INDICATOR
IGNITION
SWITCH
COMBINATION
METER
1 2 3 4 5 6 7 8 9 10 11 12
22
SBF-7
21
i10
i77
7
8
SBF-1
A:
JOINT
CONNECTOR
i77
i84
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
A26
BATTERY
A27
B: B280
B: B280
B30
7
i84
B54
JOINT
CONNECTOR
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
B352
B352
JOINT
CONNECTOR
B54
B355
1 2 3 4
5 6 7 8
12
B355
B20
A:
1 2 3
4 5
6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
TCM
AT-01901
4AT(diag)-132

RHD model
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
No.5
i10
SPORT SHIFT
INDICATOR
IGNITION
SWITCH
COMBINATION
METER
i77
i10
22
SBF-7
21
1 2 3 4 5 6 7 8 9 10 11 12
7
8
SBF-1
A:
JOINT
CONNECTOR
i84
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
i77
A26
BATTERY
A27
B: B280
B30
8
4
B20
2
i84
B: B280
B352
JOINT
CONNECTOR
1 2 3 4
5 6 7 8
B352
9
10
18
19
B53
JOINT
CONNECTOR
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
B53
B54
B54
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
12
A:
1 2 3
4 5
6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
TCM
AT-02359
4AT(diag)-133

Step
Check
Yes
No
displayed?
nosis according to
DTC.
CHECK TCM.
Is the gear position 1?
Go to step 3.
Replace the TCM.
<Ref. to 4AT-67,
Transmission Conlink connector.
trol Module
(TCM).>
OFF)
4) Turn Subaru Select Monitor switch to ON.
5) Shift the select lever to manual mode side.
6) Read the data of gear position using Subaru Select Monitor.
CHECK TCM.
Is the gear position 2?
Go to step 4.
Replace the TCM.
1) Up-shift the select lever.
<Ref. to 4AT-67,
2) Read the data of gear position using SubTransmission Conaru Select Monitor.
trol Module
(TCM).>
Is the SPORT shift gear posi- Go to step 5.
Check the body
Read the data of SPORT shift gear position
tion 2?
integrated unit.
Is the SPORT shift indicator
Check the buzzer. Replace the comOK?
<Ref. to 4AT(diag)- bination meter
<Ref. to IDI-3, INSPECTION, Combination
Meter System.>
138, Diagnostics assembly. <Ref. to
IDI-16, Combinawith Phenomenon.>
tion Meter.>
4AT(diag)-134

D: CHECK BUZZER
DIAGNOSIS:
Output signal circuit of buzzer is open or shorted.
TROUBLE SYMPTOM:
Buzzer remains sounded.
WIRING DIAGRAM:
LHD model
IGNITION
SWITCH
SBF-7
No.5
SBF-1
i10
BATTERY
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
i77
SPORT
SHIFT
BUZZER
COMBINATION
METER
1 2 3 4 5 6 7 8 9 10 11 12
i10
B20
B30
7
22
7
B: B280
i84
JOINT
CONNECTOR
i77
B: B280
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
B54
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
JOINT
CONNECTOR
B352
B352
B355
1 2 3 4
5 6 7 8
JOINT
CONNECTOR
B54
7
12
B355
A:
i84
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
A27
21
A26
A:
TCM
AT-01902
4AT(diag)-135

RHD model
IGNITION
SWITCH
SBF-7
No.5
SBF-1
i10
BATTERY
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
i77
SPORT
SHIFT
BUZZER
COMBINATION
METER
1 2 3 4 5 6 7 8 9 10 11 12
i10
22
7
JOINT
CONNECTOR
i77
JOINT
CONNECTOR
B53
4
9
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
JOINT
CONNECTOR
B54
B53
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
12
10
2
19
18
B352
1 2 3 4
5 6 7 8
B352
B54
B: B280
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
B30
B: B280
B20
i84
A:
i84
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
A27
21
A26
A:
TCM
AT-02360
4AT(diag)-136

Step
Check
Is the SPORT shift buzzer dis1) Turn the ignition switch to OFF.
play ON?
link connector.
OFF)
4) Turn Subaru Select Monitor switch to ON.
5) Read the data of sport shift buzzer using
Is the buzzer OK?
<Ref. to IDI-3, INSPECTION, Combination
Meter System.>
4AT(diag)-137
Yes
No
<Ref. to 4AT-67,
(TCM).>
Perform Diagnostics with Phenomenon. <Ref. to

4AT(diag)-138,
Diagnostics with
Phenomenon.>

assembly. <Ref. to
Diagnostics with Phenomenon

15.Diagnostics with Phenomenon

A: INSPECTION
Symptom
Starter does not operate when select lever is in P or N
range. Starter operates when select lever is in R or D range.
Abnormal noise when select lever is in P or N.
Hissing noise occurs during standing start.
Noise occurs while driving in D1.
Vehicle moves when select lever is in N.
Shock occurs when select lever is shifted from N to D range.
Excessive time lag occurs when select lever is shifted from N
to D range.
Shock occurs when select lever is shifted from N to R range.
Excessive time lag occurs when select lever is shifted from N

to R range.
Problem parts
Inhibitor switch
Select cable
Select lever
Starter motor and harness
Strainer
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
Final gear
Low & reverse brake
Planetary gear
Reduction gear
Select cable
Inhibitor switch
TCM
Low clutch
Low clutch
TCM
Harness
Control valve
ATF deterioration
Control valve
Low clutch
Seal ring
Front gasket of transmission case
TCM
Harness
Control valve
ATF deterioration
Control valve
Low & reverse clutch
Reverse clutch
Seal ring
4AT(diag)-138

Symptom
Vehicle does not start in any shift range. (Engine stalls)
Vehicle does not start in any shift range. (Engine operates)
Vehicle does not start in R range only. (Engine operates)
Vehicle does not start in R range only. (Engine stalls)
Vehicle does not start in D range. (Engine operates)

Vehicle does not start in D range. (Engine stalls)
Vehicle does not start in R range only. (Engine operates)
Acceleration during standing start is poor. (High rpm stall)
Acceleration during standing start is poor. (Low rpm stall)
Acceleration is poor when select lever is in D range. (Normal

rpm stall)
Acceleration is poor when select lever is in R range. (Normal

rpm stall)
No shift occurs from 1st to 2nd gear.
No shift occurs from 2nd to 3rd gear.
Problem parts
Parking brake mechanism
Planetary gear
Strainer
Control valve
Drive pinion
Hypoid gear
Axle shaft
Differential gear
Oil pump
Input shaft
Output shaft
Planetary gear
Drive plate
ATF level too low.
Select cable
Select lever
Control valve
Reverse clutch
Low clutch
2-4 brake
Planetary gear
Parking brake mechanism
Low clutch
One-way clutch
Reverse clutch
Control valve
Control valve
Low clutch
Reverse clutch
ATF level too low.
ATF deterioration
Oil pump
Torque converter one-way clutch
Engine performance
TCM
Control valve
High clutch
2-4 brake
Planetary gear
Control valve
High clutch
2-4 brake
Planetary gear
TCM
Control valve
2-4 brake
TCM
Control valve
High clutch
4AT(diag)-139

Symptom
No shift occurs from 3rd to 4th gear.
Engine brake is not effected when select lever is shifted from

4th gear to 3rd gear.
3rd gear to 2nd gear.
2nd gear to 1st gear.
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.
Odor is produced from ATF supply pipe.
Shock occurs from 1st to 2nd gear.
Slippage occurs from 1st to 2nd gear.
Problem parts
TCM
Control valve
2-4 brake
Inhibitor switch
TCM
Control valve
Control valve
Control valve
Low & reverse brake
Inhibitor switch
TCM
Control valve
Ground
TCM
Control valve
Lock-up facing
Engine speed signal
Select cable
Select lever
Parking mechanism
ATF level too high.
Differential gear oil level too high.
Seal pipe
Double oil seal
High clutch
2-4 brake
Reverse clutch
Lock-up facing
ATF deterioration
TCM
Torque converter turbine speed sensor
Control valve
2-4 brake
ATF deterioration
Engine performance
TCM
Control valve
2-4 brake
4AT(diag)-140

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 shifted from 3rd gear to 2nd
gear.
Shock occurs when select lever is shifted from 2nd gear to 1st
gear.
Problem parts
TCM
Control valve
High clutch
2-4 brake
ATF deterioration
Engine performance
TCM
Control valve
High clutch
2-4 brake
TCM
Control valve
2-4 brake
ATF deterioration
Engine performance
TCM
Control valve
2-4 brake
TCM
Control valve
2-4 brake
ATF deterioration
TCM
Control valve
ATF deterioration
Low & reverse brake duty solenoid
4AT(diag)-141

Symptom
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 excessively hard to move. (Unreasonable resistance)
Select lever slips out of operation during acceleration or while
driving on rough terrain.
Manual mode is not engaged.
Gear does not change though the select lever is operated in

manual mode.
Problem parts
TCM
Control valve
Lock-up damper
Engine performance
TCM
Lock-up facing
Lock-up damper
TCM
Transfer clutch
Transfer valve
ATF deterioration
Harness
TCM
Control valve
Transfer clutch
Transfer valve
Transfer pipe
TCM
Transfer clutch
Transfer valve
Select cable
Select lever
Detent spring
Manual plate
Detent spring
Manual plate
Select cable
Select lever
Detent spring
Manual plate
SPORT shift switch
TCM
Up shift switch
Down shift switch
TCM
4AT(diag)-142
5AT
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.
Page
Road Test..................................................................................................31
Stall Test ...................................................................................................32
Time Lag Test ...........................................................................................34
Line Pressure Test ....................................................................................35
Automatic Transmission Assembly ...........................................................39
Extension Case Oil Seal ...........................................................................50
Inhibitor Switch..........................................................................................52
Front Vehicle Speed Sensor .....................................................................53
Rear Vehicle Speed Sensor......................................................................55
Turbine Speed Sensor 1 ...........................................................................58
Control Valve Body ...................................................................................59
ATF Filter ..................................................................................................61
Transmission Control Module (TCM) ........................................................62
Lateral G Sensor .......................................................................................63
ATF Cooler Pipe and Hose .......................................................................64
Air Breather Hose......................................................................................69
Oil Charge Pipe.........................................................................................70
Torque Converter Assembly .....................................................................71
Extension Case and Intermediate Case....................................................72
Transfer Clutch..........................................................................................74
Multi-plate Clutch ......................................................................................76
Rear Drive Shaft........................................................................................77
Center Differential Carrier .........................................................................80
Parking Pawl .............................................................................................82
Converter Case .........................................................................................84
Oil Pump Cover.........................................................................................86
Drive Pinion Shaft Assembly.....................................................................89
Front Differential Assembly .......................................................................94
AT Main Case ...........................................................................................99
Transmission Control Device ..................................................................109
General Description
Model
A: SPECIFICATION
1. TORQUE CONVERTER CLUTCH
Model
Type
Stall torque ratio
Nominal diameter
Stall speed (at sea
level)
One-way clutch
Turbo
Non-turbo
Symmetric, 3 element, single stage,
2 phase torque converter
2.1
250 mm (9.84 in)
3,100 3,500
2,400 2,800
rpm
rpm
Sprague type one-way clutch
Drive plate number of high & low

reverse clutch
Drive plate number of direct clutch
Drive plate number of reverse brake
Drive plate number of forward brake
Drive plate number of low coast brake
Type
Driving method
P (Park)
Number of teeth
N (Neutral)
Internal gear fixed displacement pump
Driven by engine
Inner rotor
9
Outer rotor
10
3. TRANSMISSION CONTROL ELEMENT

Type
Multi-plate clutch
Multi-plate brake
One-way clutch
(sprague type)
3 sets
3.540
2.264
1.471
1.000
0.834
2.370
5. PLANETARY GEAR AND PLATE

Model
Tooth number of front internal gear
Tooth number of front carrier
Tooth number of front sun gear
Tooth number of mid internal gear
Tooth number of mid carrier
Tooth number of mid sun gear
Tooth number of rear internal gear
Tooth number of rear carrier
Tooth number of rear sun gear
Drive plate number of front brake
Drive plate number of input clutch
Nonturbo
Turbo
106
28
50
78
18
42
110
24
62
2
6
4
5
5
5
6
4
3
D (Drive)
Manual mode (+)
Manual mode ()
Manual gear change

1st 2nd 3rd 4th 5th
Manual gear change
1st 2nd 3rd 4th 5th
Wire cable type
7. HYDRAULIC CONTROL & LUBRICATION
4. TRANSMISSION GEAR RATIO

1st
2nd
3rd
4th
5th
Rev
Transmission in neutral, output member immovable, and engine start possible

Transmission in reverse for backing
Transmission in neutral and engine
start possible
Automatic gear change
1st 2nd 3rd 4th 5th
Control method
5-forward, 1-reverse,
double-row planetary gears
3 sets
4 sets
Nonturbo
6. SELECTOR POSITION
R (Reverse)
2. OIL PUMP
Turbo
Electronic/hydraulic control
[5 forward speed changes by
Type
electrical signals of vehicle
speed and accelerator
(throttle) opening]
Specified fluid: SUBARU
ATF (Part No. K0140Y0700)
Recommended fluid: IDEMITSU ATF HP
Castrol Transmax J
Fluid
NOTE:
Using of recommended fluid
is permitted only on the area
where the specified is not
available.
Fluid capacity
9.6 10.0 (10.1 10.6,
2 (US qt, Imp qt) 8.4 8.8)
Forced feed lubrication with
Lubrication system
oil pump
8. COOLING & HARNESS

Cooling system
5AT-2
Liquid-cooled cooler incorporated in radiator or ATF liquidcooled cooler

20+ 8 poles
General Description
9. TRANSFER
Model
Transfer type
Drive & driven
plate number of
transfer clutch
Reduction gear
ratio
Turbo
Non-turbo
Variable torque distribution (VTD)
4
3
1.000 (41/41)
10.FINAL REDUCTION
Model
Front final reduction gear ratio
Turbo
NA (OUTBACK)
NA (except for OUTBACK)

3.083
3.272
11.RECOMMENDED GEAR OIL
( C)
( F)
(1)
(2)
(3)
GL-5
(4)
-30 -26 -15 -5 0
-22 -15 5 23 32
Lubrication oil
15
59
25 30
77 86
90
85W
80W
75W -90
MT-00001
(1) Item
(2) Front differential gear oil
Front differential gear oil capacity

2 (US qt, Imp qt)
(3) API classification

1.3 1.5 (1.4 1.6, 1.1 1.3)
5AT-3
General Description
B: COMPONENT
1. TORQUE CONVERTER CLUTCH & TRANSMISSION ASSEMBLY
(37)
(40)
(36)
(39)
(38)
(24)
(13)
(14)
(30)
(29)
(34)
T5
(5)
(15)
T1
(4)
(33)
(32)
(16)
(35)
(8)
(17)
(17)
(1)
(2)
(18)
(3)
(23)
(22) (19)
(20)
T2
T4
(25)
(6)
(26)
(7)
(31)
(27)
(28)
T3
(9)
T1
(21)
T1
T1
(11)
(10)
(12)
AT-02024
5AT-4
General Description
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
Torque converter ASSY

Circlip
Oil pump shaft
Differential oil level gauge
Differential oil drain plug
Gasket
Oil seal
Lock plate
Side retainer
O-ring
Oil seal
ATF level gauge
O-ring
Oil charge pipe
O-ring
Gasket
Union screw
(19)
(20)
(21)
(22)
(23)
Ball
Spring
Union screw
ATF outlet pipe
ATF inlet pipe (model without ATF
warmer)
(24)
ATF inlet pipe (model with ATF

warmer)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
Magnet
Oil pan
Gasket
ATF drain plug
Breather hose
Nipple
O-ring
Oil seal
Dust cover
Floating bracket
5AT-5
(35)
(36)
(37)
(38)
Turbine speed sensor 1

Hose clamp (model with ATF
warmer)
(39)
ATF cooler ASSY (model with ATF

warmer)
(40)
ATF cooler bracket (model with

ATF warmer)

T1: 25 (2.5, 18.1)
T2: 70 (7.1, 51.6)
T3: 20 (2.0, 14.8)
T4: 5 (0.5, 3.7)
T5: 40 (4.1, 29.5)
General Description
2. OIL PUMP & FRONT BRAKE
(9)
(6)
(7)
(4)
(3)
(2)
(1)
(8)
(5)
(18)
(2)
(15)
(20)
(14)
(13)
(19)
(12)
(11)
(17)
(10)
(16)
AT-02016
(1)
(2)
(3)
(4)
(5)
(6)
(7)
O-ring
Washer
Oil pump housing
Oil pump rotor
O-ring
Air breather hose
Oil pump cover
(8)
(9)
(10)
(11)
(12)
(13)
(14)
O-ring
Nipple
Needle bearing
D-ring (Inner)
D-ring (Outer)
Front brake piston
Return spring
5AT-6
(15)
(16)
(17)
(18)
(19)
(20)
Retainer
Snap ring
Driven plate
Drive plate
Retaining plate
Snap ring
General Description
3. FRONT PLANETARY CARRIER and MIDDLE & REAR PLANETARY CARRIER

(5)
(4)
(3)
(2)
(9)
(1)
(20)
(19)
(18)
(8)
(7)
(6)
(17)
(16)
(15)
(14)
(13)
(12)
(11)
(10)
AT-02017
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Thrust bearing
Front sun gear ASSY
Snap ring
Front carrier ASSY
Race bearing
O-ring
Seal ring
(8)
(9)
(10)
(11)
(12)
(13)
(14)
Thrust bearing
Input clutch ASSY
Rear internal gear ASSY
Thrust bearing
Middle carrier ASSY
Thrust bearing
Race bearing
5AT-7
(15)
(16)
(17)
(18)
(19)
(20)
Rear carrier ASSY

Thrust bearing
Middle & Rear sun gear ASSY
Washer
Thrust bearing
Seal ring
General Description
4. DIRECT CLUTCH and HIGH & LOW REVERSE CLUTCH
(3)
(2)
(1)
AT-02018
(1)
Thrust bearing
(2)
High & low reverse clutch ASSY
5AT-8
(3)
Direct clutch ASSY
General Description
5. REVERSE BRAKE
(4)
(13)
(3)
(2)
(1)
(5)
(12)
(11)
(10)
(9)
(8)
(7)
(6)
AT-02019
(1)
(2)
(3)
(4)
(5)
Snap ring
Retainer plate
Leaf spring
Drive plate
Driven plate
(6)
(7)
(8)
(9)
(10)
Dish plate
Snap ring
Retainer
Leaf spring
Reverse brake piston
5AT-9
(11)
(12)
(13)
D-ring (Outer)
D-ring (Inner)
AT main case
General Description
6. SHORT AT ASSY
(1)
(4)
(3)
(2)
AT-04324
(1)
(2)
Short AT ASSY (Non-disassembled)

Thrust bearing
(3)
Seal ring
5AT-10
(4)
Thrust bearing
General Description
7. CONTROL VALVE & TRANSMISSION HARNESS
(1)
(3)
(2)
(4)
(5)
(6)
AT-02020
(1)
(2)
Transmission harness ASSY

(3)
(4)
Sensor cover
Harness bracket
5AT-11
(5)
(6)
Clip
Control valve ASSY
General Description
8. DIFFERENTIAL GEAR
(1)
(7)
(13)
(12)
(14)
(12)
(13)
(8)
(4)
(2)
(3)
(14)
(5)
(6)
(9)
(10)
(1)
(11)
(5)
(3)
(15)
(4)
AT-02021
(1)
(2)
(3)
(4)
(5)
Retainer plate RH
Differential side retainer RH
O-ring
Oil seal
(6)
(7)
(8)
(9)
(10)
Hypoid driven gear

Drive pinion shaft
Pinion shaft
Straight pin
Differential case RH
5AT-12
(11)
(12)
(13)
(14)
(15)
Differential case LH
Washer
Differential side retainer LH
General Description
9. TRANSFER CASE, EXTENSION CASE & REDUCTION GEAR

(11)
(15)
(8)
(9)
(6)
(31)
(14)
(5)
(13)
(12)
(7)
(30)
(29)
(28)
(10)
(27)
(26)
(4)
(25)
(3)
(24)
(2)
(23)
(1)
(44)
(22)
(43)
(21)
(42)
(20)
(19)
(40)
(39)
(18)
(17)
(38)
(16)
(41)
(37)
(36)
(35)
(34)
(49)
(33)
(47)
(46)
(50)
(45)
(48)
(32)
AT-02022
5AT-13
General Description
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
Seal ring
Reduction gear shim
Ball bearing
Snap ring
Planetary pinion washer
Needle bearing
Spacer
Pinion gear
Washer
Planetary carrier ASSY
Planetary pinion shaft ASSY
Snap ring
Thrust bearing
Intermediate shaft
Thrust washer
Rear drive shaft
Ball bearing
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
Transfer clutch hub

Transfer clutch plate
Driven plate No. 3.
Ball bearing
Rear drive shaft shim
Revolution gear
Snap ring
Clutch spring retainer
Return spring
Spring retainer
Pressure plate
Ball bearing
O-ring
C-ring
Drive pinion shaft
Ball bearing
5AT-14
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
(43)
(44)
(45)
(46)
(47)
(48)
(49)
(50)
Snap ring
Ball bearing
Shim
Gasket
Intermediate case
Shim
Extension case
Transmission hanger
Oil seal
Dust cover
Drive pinion shim
Oil seal
Drive pinion collar
O-ring
Lock nut
General Description
10.TRANSMISSION CONTROL DEVICE & PARKING SUPPORT
T1
(1)
T1
(2)
(3)
T3
(12)
(11)
(10)
(9)
(5)
(4)
T2
(8)
(6)
(7)
T2
AT-02089
(1)
(2)
(3)
(4)
(5)
(6)
Bracket
Floating bracket
AT main case
Range select lever
Straight pin
Dimension spring
(7)
(8)
(9)
(10)
(11)
(12)
Manual plate
Parking rod
Parking support actuator
Parking pawl shaft
Return spring
Parking pawl
5AT-15

T1: 25 (2.5, 18.4)
T2: 6 (0.6, 4.4)
T3: <Ref. to 5AT-82, Parking Pawl.>
General Description
11.TRANSMISSION CONTROL MODULE
T2
(3)
T1
T1
T1
(1)
(2)
(2)
(4)
AT-02036
(1)

(TCM) (RHD model)
(2)
Relay
(3)
(4)
Lateral G sensor
(TCM) (LHD model)
5AT-16

T1: 7.5 (0.76, 5.5)
T2: 24.5 (2.5, 18.1)
General Description
12.TRANSMISSION MOUNTING
T2
(2)
T2
T4
(1)
(3)
T5
(4)
T3
T1
T5
AT-01738
(1)
(2)
Pitching stopper
Rear cushion rubber
(3)
(4)
Crossmember
Stopper
5AT-17

T1: 35 (3.6, 26)
T2: 40 (4.1, 29.5)
T3: 50 (5.1, 36.9)
T4: 58 (5.9, 42.8)
T5: 70 (7.1, 51.6)
General Description
C: CAUTION
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.
sure to clarify the failure. Avoid unnecessary removal, disassembly and replacement.
When disassembling the case and other light alloy parts, disassemble them by slightly tapping with
a plastic hammer. Do not pry it apart with a screwdriver or other tool.
the equivalent. Do not mix them with that of another
grade or from other manufacturers.
points.
Apply gear oil onto sliding or revolution surfaces
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.
Before securing a part on a vice, place cushioning material such as wood blocks, aluminum plate,
Before applying liquid gasket, completely remove the old seal.
5AT-18
General Description
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
498575400
DESCRIPTION
OIL PRESSURE
GAUGE ASSY
REMARKS
498897200
ADAPTER
Used with oil pump cover installed on when

measuring line pressure.
Used with extension case installed on when
measuring transfer clutch pressure.
498545400
FILTER WRENCH
Used for removing and installing ATF filter.
498277200
STOPPER SET
Used for removing and installing automatic

transmission assembly to engine.
ST-498575400
ST-498897200
ST-498545400
ST-498277200
5AT-19
General Description
ILLUSTRATION
TOOL NUMBER
41099AC000
DESCRIPTION
ENGINE SUPPORT
ASSEMBLY
REMARKS
(41099AC010)
(2) ENGINE SUPPORT ROD (41099AC020)
398527700
PULLER ASSY

Used for removing extension oil seal.
retainer bearing outer race.
retainer oil seal.
498057300
INSTALLER
498077000
REMOVER
Used for removing differential taper roller bearing.
ST41099AC000
ST-398527700
ST-498057300
ST-498077000
5AT-20
General Description
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
18630AA010
WRENCH COMPL
(Newly adopted tool) RETAINER
REMARKS
retainer.
ST18630AA010
398487700
DRIFT
Used for installing front differential taper roller

bearing.
498255400
PLATE
Used for measuring backlash of hypoid gear.
498247001
MAGNET BASE

ST-398487700
ST-498255400
ST-498247001
5AT-21
General Description
ILLUSTRATION
TOOL NUMBER
498247100
DESCRIPTION
DIAL GAUGE
REMARKS
498517000
REPLACER
Used for removing front roller bearing.
499787700
WRENCH

nut.
398643600
GAUGE

ST-498247100
ST-498517000
ST-499787700
ST-398643600
5AT-22
General Description
ILLUSTRATION
TOOL NUMBER
398744300
DESCRIPTION
GAUGE
REMARKS
Used for measuring contact surface between
multi-plate clutch end and transmission.
499737100
PULLER SET
Used for removing reduction drive gear assembly.
498077600
REMOVER
ST-398744300
ST-499737100
ST-498077600
18667AA010
HOLDER
(Newly adopted tool)
ST18667AA010
5AT-23
Used for removing and installing drive pinion

lock nut.
Used as a handle to rotate gear when checking tooth contact.
General Description
ILLUSTRATION
TOOL NUMBER
24082AA230
DESCRIPTION
CARTRIDGE
REMARKS
22771AA030
SUBARU SELECT
MONITOR KIT

18675AA000
DIFFERENTIAL
SIDE OIL SEAL
INSTALLER

seal.
28399SA010
OIL SEAL PROTEC- Used for protecting oil seal when installing front
TOR
drive shaft.
ST24082AA230
ST22771AA030
ST18675AA000
ST28399SA010
5AT-24
General Description
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
18680AA000
HOLDER GEAR
REMARKS
Used for removing reduction driven gear assembly. (2-piece)
18762AA000
COMPRESSOR
(Newly adopted tool) SPECIAL TOOL
Used for disassembling multiplate clutch for shift

transmission.
18673AA000
COMPRESSOR
(Newly adopted tool) SHAFT

transmission.
18765AA000
COMPRESSOR
(Newly adopted tool) SUPPORT

transmission.
ST18680AA000
ST18762AA000
ST18673AA000
ST18765AA000
5AT-25
General Description
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
18676AA020
TORX WRENCH
REMARKS
Used for disassembling torque converter case.
18854AA000
ANGLE GAUGE
Used for tightening parking support.
18679AA000
ADJUSTER
Used for adjusting position when tightening parking support.
ST18676AA020
ST18854AA000
ST18679AA000
498077300
REMOVER
ST-498077300
5AT-26
Used for removing ball bearing of reduction

driven gear.
General Description
ILLUSTRATION
TOOL NUMBER
499587100
DESCRIPTION
OIL SEAL
INSTALLER
REMARKS
Used for installing oil seal.
499787500
ADAPTER

nut.
499575400
GAUGE
Used for measuring height of total end play.
ST-499587100
ST-499787500
ST-499575400
2. GENERAL TOOL
TOOL NAME
Depth gauge
Thickness gauge
Micro meter
Spring balance
Circuit tester
TORX T70
Snap ring pliers
REMARKS
Used for measuring transmission end play.
Used for measuring clearance of clutch, brake and oil pump.
Used for measuring thickness of drive pinion.
Used for measuring starting torque of drive pinion.
Used for removing and installing differential gear oil drain plug.
Used for removing and installing each snap ring.
5AT-27

2. Automatic Transmission Fluid

A: INSPECTION
NOTE:
The level of ATF varies with fluid temperature. Pay
attention to the ATF temperature when checking
ATF level.
of 5 to 10 km (3 to 6 miles). Otherwise, idle the engine to raise ATF temperature to 70 to 80C (158 to
176F) on Subaru Select Monitor. <Ref. to 5AT(diag)-16, READ CURRENT DATA, OPERATION,
3) After selecting all positions (P, R, N, D), set the
B: REPLACEMENT
CAUTION:
3) Check the condition of ATF.
<Ref. to 5AT-29, CONDITION CHECK, Automatic
Transmission Fluid.>
NOTE:
Use a new gasket.
Tightening torque:
20 Nm (2.0 kgf-m, 14.8 ft-lb)
(A)
(B)
(B)
L
F
HOT
(A)
COLD
L
(C)
AT-01361
(B)
(C)
(A) Oil pan

(B) ATF drain plug
AT-00674

6) Pour ATF from the oil charge pipe.
(A) ATF level gauge

(B) Upper level
(C) Lower level
4) Make sure that ATF level is above the center between upper and lower marks at HOT side.
5) If the ATF level is below the center between upper and lower marks, add the recommended ATF
until the fluid level is found above the center between upper and lower marks.
CAUTION:
Use care not to exceed the upper level.
When the transmission is cold, be careful not
to add ATF to the upper level on HOT side.
Overfilling of ATF may cause oil splashing.
Visually check for leaks in the transmission. If there
are leaks, replace the gasket, oil seals, plugs or
other parts.
Specified fluid:
SUBARU ATF (Part No. K0140Y0700)
Recommended fluid:
IDEMITSU ATF HP
Castrol Transmax J
NOTE:
Using of recommended fluid is permitted only on
the area where the specified is not available.
Capacity:
Capacity when transmission is overhauled:
9.6 10.0 2 (10.1 10.6 US qt, 8.4 8.8 Imp
qt)
7) Check the level and leaks of ATF.
5AT-28

C: CONDITION CHECK
NOTE:
When replacing ATF, check the inside condition of transmission body by inspecting the drained ATF.
Fluid condition
Large amount of metallic pieces are
found.

Excessive wear of the internal of the transmission body
Thick and varnish-form fluid.
Burned clutch and etc.
Clouded fluid or bubbles are found in

fluid.
Water mixed in fluid
5AT-29
Corrective action
Replace ATF and check if AT operates
correctly.
Replace ATF and check if AT or vehicle
for faulty.
Replace ATF and check the water entering point.

Tightening torque:
70 Nm (7.1 kgf-m, 51.6 ft-lb)
A: INSPECTION
proper orientation.
5) Remove the oil level gauge again, and check the
level of differential gear oil. If the differential gear oil
level is below L line, add oil to bring the level up to
F line.
(A)
(B)
AT-01362
NOTE:
To prevent overfilling the differential gear oil, do not
add oil above F line.
(A) Oil pan



(A)
Gear oil capacity:

1.3 1.5 2 (1.3 1.6 US qt, 1.1 1.3 Imp qt)
6) Check the level of differential gear oil.
<Ref. to 5AT-30, INSPECTION, Differential Gear
Oil.>
(B)
AT-00017
(A) Upper level

(B) Lower level
B: REPLACEMENT
TORX BIT T70, and the drain the differential gear
oil.
CAUTION:
burn yourself.
3) Tighten the differential gear oil drain plug using
TORX BIT T70.
NOTE:
Use a new gasket.
5AT-30
Road Test
4. Road Test
9. OIL LEAKAGE
A: INSPECTION
After the driving test, inspect for oil leaks from the
transmission body.
1. GENERAL PRECAUTION
Road tests should be conducted to properly diagnose the condition of automatic transmission.
NOTE:
When performing the test, do not exceed posted
speed limit.
2. D RANGE SHIFT FUNCTION

Check shifting between 1st 2nd 3rd
4th 5th while driving on normal city streets.
3. D RANGE SHIFT SHOCK

Check the shock level when shifting up during normal driving.
4. KICK-DOWN FUNCTION
Check kick-down for each gear. Also check the
kick-down shock level.
5. ENGINE BRAKE OPERATION

Check the 4th gear engine brake when shifting
down from 5th to 4th range while driving in 5th gear
of manual mode [50 to 60 km/h (31 to 37 MPH)].
Check the 3rd gear engine brake when shifting
down from 4th to 3rd range while driving in 4th gear
of manual mode [50 to 60 km/h (31 to 37 MPH)].
Check the 2nd gear engine brake when shifting
down from 3rd to 2nd range while driving in 3rd
gear of manual mode [40 to 50 km/h (25 to 31
MPH)].
Check the 1st gear engine brake when shifting
down from 2nd to 1st range while driving in 2nd
gear of manual mode [20 to 30 km/h (12 to 19
MPH)].
6. LOCK-UP FUNCTION
Check that engine speed does not change sharply
when the accelerator pedal is lightly depressed
while driving on flat roads at normal speed in the
lock-up range.
7. P RANGE OPERATION
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. NOISE & VIBRATION

Check for unusual sounds and vibration while driving and during shifting.
5AT-31
Stall Test
5. Stall Test
9) While forcibly depressing the foot brake pedal,

gradually depress the accelerator pedal until the
engine operates at full throttle.
A: INSPECTION
NOTE:
The stall test is of extreme importance in diagnosing the condition of automatic transmission and engine. It should be conducted to measure the engine
stall speeds in R and 2nd of manual mode.
Purposes of the stall test:
To check the operation of automatic transmission clutch.
To check the operation of torque converter
clutch.
To check engine performance.
1) Check that the throttle valve opens fully.
2) Check that the engine oil level is correct.
3) Check that the coolant level is correct.
4) Check that the ATF level is correct.
5) Check that the differential gear oil level is correct.
7) Place the wheel chocks at the front and rear of
all wheels and engage the parking brake.
8) Move the manual linkage to ensure it operates
properly, and then set 2nd on manual mode.
AT-01325
(A)
(B)
AT-01326
(A) Brake pedal

(B) Accelerator pedal
10) When the engine speed is stabilized, quickly

record that speed and release the accelerator pedal.
11) Shift the select lever to N range, and cool
down the engine by idling it for more than one
minute.
12) Perform the procedure for R range in the
same way as 2nd on manual mode.
NOTE:
Do not continue the stall test for MORE THAN
FIVE SECONDS at a time (from fully closed throttle
to fully open throttle until stall speed reading). 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 with the select lever set in P or N range
and with the idle speed lower than 1,200 rpm after
performing stall test.
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):
TURBO MODEL
3,100 3,500 rpm
NON-TURBO MODEL
2,400 2,800 rpm
5AT-32
Stall Test
Stall speed (at sea level)
Less than standard
More than standard
Range
R
2nd gear of manual

mode
R
2nd gear of manual
mode
Within specifications
R
Possible faulty part

Engine
One-way clutch of the torque converter clutch
Forward brake
Forward brake one-way clutch
Direct clutch
3rd one-way clutch
Reverse clutch
Reverse clutch
One-way clutch of the torque converter
Forward brake
Forward brake one-way clutch
Direct clutch
3rd one-way clutch
One-way clutch of the torque converter
5AT-33
Time Lag Test

6. Time Lag Test

A: INSPECTION
NOTE:
When 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. Using this, check the
condition of forward brake, reverse brake, 1st oneway clutch, forward one-way clutch and 3rd oneway clutch.
Perform the test at normal operation fluid temperature 70 80C (158 176F).
Be sure to allow a one minute interval between
tests.
Make three measurements and take the average
value.
1) Fully apply the parking brake.
Check the idling speed (A/C OFF).
3) Shift the select lever from N to D range. Using
a stop watch, measure the time-lag which takes
from shifting the lever until the shock is felt.
Time-lag
Standard: 1.2 sec. or less
If N D time-lag is longer than specified:
Forward brake worn
One-way clutch not operating properly
4) In the same manner, measure the time lag for
N R.
Time-lag
Standard: 1.5 sec. or less
If N R time lag is longer than specified:
Reverse brake worn
5AT-34
Line Pressure Test

7. Line Pressure Test

A: MEASUREMENT
NOTE:
If the clutch or brake shows a sign of slippage, or
shifting interval is not correct, the line pressure
should be checked.
Excessive shocks during up-shift 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.
3) Remove the test plug and install the ST.
ST 498897200
AT-01752
4) Set the ST1 and ST2.

ST1 498897200 OIL PRESSURE ADAPTER
ASSY
5) Lower the vehicle, and pull the ST1 and ST2 into
vehicle.
ASSY
connector and read the current data. <Ref. to
(1) Start the engine.
(2) Turn the Subaru Select Monitor switch to
ON.
(3) On the Main Menu display screen, select
the {Each System Check} and press the [YES]
key.
(4) On the System Selection Menu display
[YES] key.
(5) Press the [YES] key after the information of
transmission type has been displayed.
5AT-35
(6) On the Transmission Diagnosis display

screen, select the {Current Data Display/Save},
and then press the [YES] key.
[YES] key.
(8) Using the scroll key, display the P/L solenoid target oil pressure.
Line Pressure Test

7) Perform the line pressure test.

NOTE:
Do not perform the line pressure test for more than 5 seconds at a time. It makes engine oil and ATF deteriorate and the clutch and brake to be adversely affected.
Be sure to cool down the engine for at least one minute with the select lever set in P or N range and with
the idle speed lower than 1,200 rpm after performing line pressure test.
Adjust the throttle valve angle in order to obtain the P/L solenoid target pressure displayed on the Subaru
Select Monitor.
Range of the
selector lever
Throttle valve
angle
ATF temperature
condition
P/L Solenoid Target Pressure

displayed on the Subaru Select
Monitor
kPa
Full closed
D
Full open
R
490
45 55C
(104 131 F)
1,370
Full closed
1,370
5AT-36

kPa (kg/cm2, psi)
385 555
(3.93 5.66, 55.8 80.5)
1,235 1,475
(12.59 15.04, 179.1 213.9)
1,530 1,925
(15.60 19.6, 221.9 279.2)

8. Transfer Clutch Pressure

Test
A: INSPECTION
2) Remove the heat shield cover securing bolts to
slide the heat shield cover.
AT-01754
3) Remove the test plug and install the ST.

ST 498897200
CAUTION:
Be careful not to cut your arm with the heat
shield cover when removing the test plug and
installing the ST.

connector and read the current data. <Ref. to
(1) Start the engine.
(2) Turn the Subaru Select Monitor switch to
ON.
key.
[YES] key.
[YES] key.
(8) Using the scroll key, display the T/F solenoid target oil pressure.
AT-01755
4) Set the ST1 and ST2.

ASSY
AT-01756
5) Lower the vehicle, and pull the ST1 and ST2 into
vehicle.
ASSY
5AT-37

7) Perform the transfer clutch pressure test.

NOTE:
Do not perform the transfer clutch pressure test for more than 5 seconds at a time. It makes engine oil and
ATF deteriorate and the clutch and brake to be adversely affected.
Be sure to cool down the engine for at least one minute with the select lever set in P or N range and with
the idle speed lower than 1,200 rpm after performing transfer clutch pressure test.
Adjust the throttle valve angle in order to obtain the T/F solenoid target pressure displayed on the Subaru
Select Monitor.
Range of the
selector lever
Throttle valve
angle
ATF temperature
condition
T/F Solenoid Target Pressure

displayed on the Subaru Select
Monitor
kPa
Full open
D
Partial throttle
N
900
45 55C
(104 131 F)
500
Full closed
5AT-38

kPa (kg/cm2, psi)
800 915
(8.16 9.33, 116.0 132.7)
400 535
(4.08 5.46, 58.0 77.6)
0 50
(0 0.51, 0 7.3)

9. Automatic Transmission Assembly
Non-turbo model
(2)
A: REMOVAL
2) Fully open the front hood and support with the
hood stay.
model) <Ref. to IN(H6DO)-7, REMOVAL, Air Intake
Chamber.>
7) Remove the air cleaner case. (Non-turbo model)
Case.>
8) Remove the air breather hose. <Ref. to 5AT-69,
REMOVAL, Air Breather Hose.>
9) Remove the starter. <Ref. to SC(H4SO 2.0)-6,
REMOVAL, Starter.>
Turbo model
(1)
AT-02025
(1) Front oxygen (A/F) sensor

(2) Transmission harness connector
11) Remove the intercooler stay and engine hanger rear. (Turbo model)
AT-01365
12) Disconnect the engine harness connectors,

and then remove the engine hanger rear. (Non-turbo model)
(B)
AT-01364
(A)

(A)
AT-02023
(A) Engine harness connectors

(B) Engine hanger rear
AT-01379
5AT-39

13) Remove the water by-pass pipe. (Turbo model)
19) Remove the ATF cooler inlet and outlet pipes.

(Non-turbo model) <Ref. to 5AT-64, REMOVAL,
ATF Cooler Pipe and Hose.>
AT-01366
14) Separate the torque converter from drive plate.

(2) Remove the bolts which hold torque converter to drive plate.
(3) Remove the four bolts by rotating the clamp
pulley a little at a time.
(4) Make sure the torque converter moves freely by rotating with finger through the starter installation hole.
AT-01368
CAUTION:
Be careful not to drop bolts into converter
housing.
AT-01369
22) Set the ST.

ST 41099AC000 ENGINE SUPPORT ASSEMBLY
AT-01367

ST 498277200
STOPPER SET
AT-01370
ST
AT-00103

17) Remove the under cover. (Non-turbo model)
18) Remove the front exhaust pipe, rear exhaust
pipe and muffler. (Non-turbo model) <Ref. to
EX(H6DO)-5, REMOVAL, Front Exhaust Pipe.>
23) Remove the air intake duct. (Turbo model)

<Ref. to IN(H4DOTC)-9, REMOVAL, Air Intake
Duct.>
24) Remove the air cleaner case. (Turbo model)
Case.>
25) Remove the linear motion mounting. (Turbo
model) <Ref. to ME(H4DOTC)-37, REMOVAL, Linear Motion Mounting.>
5AT-40

26) Remove the transmission mounting bolt (upper

side).
33) Remove the oil charge pipe.
AT-01371
AT-00106
27) Lift-up the vehicle. (Turbo model)

28) Remove the under cover. (Turbo model)
29) Remove the center exhaust pipe, rear exhaust
pipe and muffler. (Turbo model) <Ref. to
EX(H4DOTC)-6, REMOVAL, Center Exhaust
Pipe.> <Ref. to EX(H4DOTC)-11, REMOVAL,
Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-12,
REMOVAL, Muffler.>
34) Disconnect the connector from turbine speed

sensor 1.
AT-01642
35) Remove the turbine speed sensor 1 connector

mounting bolt and rotate the sensor by 180.
CAUTION:
Failure to follow this procedure may cause the
interference between vehicle body and sensor
while removing/installing transmission, resulting in damage.
AT-01331

(A)
(B)
AT-01640

37) Remove the shift select cable. <Ref. to CS-12,
REMOVAL, Select Cable.>
AT-01361
(A) Oil pan

(B) Drain plug
5AT-41

38) Disconnect the hose from the ATF inlet and

outlet pipes.
41) Remove the two clutch housing cover securing

bolts.
AT-01390
AT-01373
39) Remove the ATF cooler bracket from transmission body. (ATF cooler model with warmer function)
Non-turbo model
AT-01374
42) Remove the front stabilizer bracket. <Ref. to

FS-16, REMOVAL, Front Stabilizer.>
43) Remove the bolts which secure front ball joint
to the housing. <Ref. to FS-17, REMOVAL, Front
Ball Joint.>
44) Pull out the drive shaft from transmission.
45) Set the transmission jack under the transmission.
AT-02034
40) Remove the front crossmember support plate.

<Ref. to FS-15, REMOVAL, Front Crossmember
Support Plate.>
AT-01376
46) Remove the rear crossmember.
AT-01377
5AT-42

47) Remove the transmission mounting bolt (lower

side).

Tightening torque:
70 Nm (7.1 kgf-m, 51.6 ft-lb)
AT-00108
AT-01377
NOTE:
Turn the engine support assembly from the vehicle under body to the left (to shorten the engine
support length), and lower the rear of the engine for
easy disassembly.
Be careful not to allow breather pipe and etc. to
touch the vehicle body when detaching the automatic transmission assembly by pulling it backward.
B: INSTALLATION
1) Install the ST to torque converter case.
ST 498277200
STOPPER SET
5) Take off the transmission jack.

7) Install the engine mounting bolt (upper side).
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
8) Remove the ST from converter case.
ST 498277200
STOPPER SET
10) Install the torque converter to drive plate.
(1) Install the bolts which hold torque converter
to drive plate.
(2) Install all four bolts by rotating the crank pulley a little at a time.
(3) Install the service hole.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
11) Remove the ST and install the pitching stopper
bracket.
ST
Tightening torque:
40 Nm (4.1 kgf-m, 29.5 ft-lb)
AT-00103

(1) Lift up the transmission gradually using a
transmission jack.
3) Install the engine mounting bolt (lower side).
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
AT-01369
5AT-43

17) Install the front drive shaft into transmission.
Tightening torque:
T1: 50 Nm (5.1 kgf-m, 36.9 ft-lb)
T2: 58 Nm (5.9 kgf-m, 42.8 ft-lb)
NOTE:
Replace the circlip of drive shaft with a new one.
18) Install the front drive shaft into transmission, remove the ST and insert the drive shaft securely.
19) Install the ATF cooler inlet and outlet pipes.
(Non-turbo model) <Ref. to 5AT-66, INSTALLATION, ATF Cooler Pipe and Hose.>
20) Install the ATF cooler bracket to transmission
proper. (ATF cooler model with warmer function)
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
Non-turbo model
T2
T1
AT-01380

14) Replace the front differential side retainer oil
seal.
(1) Remove the oil seal by using flat tip screwdriver and etc.
(2) Fit a new oil seal using ST.
SEAL INSTALLER
NOTE:
Apply oil to the oil seal lips.
Always replace the differential side oil seal after
extracting front drive shaft from the transmission.
AT-02034
AT-01378
15) Apply grease to the oil seal lips.

16) Set the ST to the side retainer.
21) Install the inlet and outlet hoses to the ATF inlet
and outlet pipes.
AT-01390
ST
AT-00110
22) Insert the ball joint into housing.<Ref. to FS-17,

INSTALLATION, Front Ball Joint.>
23) Install the front stabilizer bracket. <Ref. to FS16, INSTALLATION, Front Stabilizer.>
5AT-44

24) Screw the securing bolts for clutch housing

cover.
29) Install the oil charge pipe.

Tightening torque:
41 Nm (4.2 kgf-m, 30.2 ft-lb)
AT-01373
AT-01371
AT-01374
25) Install the front crossmember support plate.

<Ref. to FS-15, INSTALLATION, Front Crossmember Support Plate.>
27) Install the shift select cable. <Ref. to CS-13, INSTALLATION, Select Cable.>
28) Install the turbine speed sensor 1 and harness,
and then connect the connector.
Tightening torque:
7 Nm (0.7 kgf-m, 5.2 ft-lb)
AT-01736
AT-01331
31) Install the center exhaust pipe, rear exhaust

EX(H4DOTC)-7, INSTALLATION, Center Exhaust
Pipe.> <Ref. to EX(H4DOTC)-11, INSTALLATION,
Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-12, INSTALLATION, Muffler.>
32) Install the front exhaust pipe, rear exhaust pipe
and muffler. (Non-turbo model) <Ref. to
EX(H6DO)-6, INSTALLATION, Front Exhaust
Pipe.> <Ref. to EX(H6DO)-8, INSTALLATION,
Rear Exhaust Pipe.> <Ref. to EX(H6DO)-10, INSTALLATION, Muffler.>
35) Install the linear motion mounting. (Turbo model) <Ref. to ME(H4DOTC)-37, INSTALLATION,
Linear Motion Mounting.>
36) Install the air cleaner hose.
<Ref. to IN(H4DOTC)-8, INSTALLATION, Air
Cleaner Case.>
<Ref. to IN(H4DOTC)-9, INSTALLATION, Air Intake Duct.>
5AT-45

40) Install the engine hanger rear, and then connect the engine harness connector. (Non-turbo
model)
38) Connect the following connectors.

Turbo model
(B)
(A)
(A)
AT-02023
AT-01364
(A) Engine harness connectors

(B) Engine hanger rear
41) Install the water by-pass pipe. (Turbo model)
AT-01379
Non-turbo model
AT-01366
(2)
(1)
AT-02025

39) Install the intercooler stay RH and engine

hanger rear. (Turbo model)
AT-01365
42) Pour ATF from the oil charge pipe. <Ref. to

5AT-28, REPLACEMENT, Automatic Transmission Fluid.>
44) Install the intercooler. (Turbo model) <Ref. to
IN(H4DOTC)-12, INSTALLATION, Intercooler.>
45) Install the air intake chamber. (Non-turbo model) <Ref. to IN(H6DO)-7, INSTALLATION, Air Intake Chamber.>
46) Install the air cleaner case. (Non-turbo model)
<Ref. to IN(H6DO)-6, INSTALLATION, Air Cleaner
Case.>
49) Perform the Clear Memory 2. <Ref. to 5AT(diag)-18, CLEAR MEMORY MODE, OPERATION,
(1) Connect the Subaru Select Monitor to data
link connector.
(2) Turn the ignition switch to ON (engine OFF)
and turn Subaru Select Monitor switch to ON.
(3) Ensure that the select lever is in P range.
key.
5AT-46


[YES] key.
screen, select the {Clear Memory 2} and press
the [YES] key.
50) Perform the inspection with driving the vehicle
at the end of repair work and make sure there is no
faulty as below;
Oil leakage from transmission proper and etc.
Occurrence of noise caused by interference etc.
NOTE:
If excessive shift shock is felt, execute the advance
operation of learning control. <Ref. to 5AT(diag)22, PROCEDURE, Learning Control.>
5AT-47

10.Transmission Mounting System
7) Remove the transmission rear crossmember.
A: REMOVAL
1. PITCHING STOPPER
Chamber.>
AT-01377
B: INSTALLATION
1. PITCHING STOPPER
Tightening torque:
T1: 50 Nm (5.1 kgf-m, 36.9 ft-lb)
T2: 58 Nm (5.9 kgf-m, 42.8 ft-lb)
AT-01368

2) Jack-up the vehicle and support it with rigid
racks.
pipe and muffler. (Turbo model)
<Ref. to EX(H4DOTC)-6, REMOVAL, Center Exhaust Pipe.> <Ref. to EX(H4DOTC)-11, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)12, REMOVAL, Muffler.>
6) Set the transmission jack under the transmission. Make sure that the support plate of transmission jack does not touch the oil pan.
T2
T1
AT-01380
2) Install the intercooler. (Turbo model)

3) Install the air intake chamber. (Non-turbo model)
Chamber.>
5AT-48


Tightening torque:
35 Nm (3.6 kgf-m, 26 ft-lb)
2) Install the crossmember.
Tightening torque:
70 Nm (7.1 kgf-m, 51.6 ft-lb)
AT-01377

5) Install the center exhaust pipe, rear exhaust pipe
and muffler. (Turbo model)
6) Install the front exhaust pipe, rear exhaust pipe
and muffler. (Non-turbo model) <Ref. to
EX(H6DO)-6, INSTALLATION, Front Exhaust
Pipe.> <Ref. to EX(H6DO)-8, INSTALLATION,
Rear Exhaust Pipe.> <Ref. to EX(H6DO)-10, INSTALLATION, Muffler.>
C: INSPECTION
Repair or replace parts if the results of the inspection below are not satisfied.
1. PITCHING STOPPER
Check pitching stopper for bends or damage. Ensure there are no cracks, hardening or damage on
rubbers.

Check the crossmember for bends or damage. Ensure there are no cracks, hardening, or damage on
cushion rubbers.
5AT-49
Extension Case Oil Seal

11.Extension Case Oil Seal

A: INSPECTION
Inspect there is no ATF leakage from the joint of
transmission and propeller shaft. If so, replace the
oil seal. <Ref. to 5AT-50, REPLACEMENT, Extension Case Oil Seal.>
B: REPLACEMENT

ST 398527700
PULLER ASSY
ST 498057300
INSTALLER
CAUTION:
NOTE:
Use a new gasket.
Tightening torque:
20 Nm (2.0 kgf-m, 14.8 ft-lb)
AT-01331
13) Install the rear exhaust pipe and muffler. (Turbo

model)
14) Install the rear exhaust pipe and muffler. (Nonturbo model) <Ref. to EX(H6DO)-8, INSTALLATION, Rear Exhaust Pipe.> <Ref. to EX(H6DO)-10,
15) Pour ATF into the oil charge pipe.
(A)
(B)
Specified fluid:
SUBARU ATF (Part No. K0140Y0700)
AT-01361
(A) Oil pan

(B) ATF drain plug
5) Remove the rear exhaust pipe and muffler. (Turbo model)

(Non-turbo model) <Ref. to EX(H6DO)-8, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H6DO)-10,
REMOVAL, Muffler.>
Recommended fluid:
IDEMITSU ATF HP
Castrol Transmax J
NOTE:
Use of recommended fluid is permitted only on the
area where the specified is not available.
Capacity:
16) Check the level and leaks of ATF. <Ref. to 5AT28, Automatic Transmission Fluid.>
AT-01331
5AT-50

12.Differential Side Retainer Oil

Seal
ST
A: INSPECTION
18675AA000 DIFFERENTIAL SIDE OIL

SEAL INSTALLER
ST
Check the leakage of gear oil from differential side

the oil seal.
B: REPLACEMENT
2) Remove the front exhaust pipe and center exhaust pipe. (Turbo model) <Ref. to EX(H4DOTC)5, REMOVAL, Front Exhaust Pipe.> <Ref. to
Pipe.>
3) Remove the front exhaust pipe. (Non-turbo model) <Ref. to EX(H6DO)-5, REMOVAL, Front Exhaust Pipe.>
TORX BIT T70 to drain differential gear oil.
CAUTION:
burn yourself.
AT-00029
9) Apply oil to the oil seal lips.

11) Install the front and center exhaust pipes. (Turbo model) <Ref. to EX(H4DOTC)-5, INSTALLATION,
Front
Exhaust
Pipe.>
<Ref.
to
EX(H4DOTC)-7, INSTALLATION, Center Exhaust
Pipe.>
12) Install the front exhaust pipe. (Non-turbo model) <Ref. to EX(H6DO)-6, INSTALLATION, Front
Exhaust Pipe.>
Gear oil capacity:
1.3 1.5 2 (1.4 1.6 US qt, 1.1 1.3 Imp qt)
5AT-30, INSPECTION, Differential Gear Oil.>
(A)
(B)
AT-01362
(A) Oil pan

5) Tighten the differential gear oil drain plug.

NOTE:
Use a new gasket.
Tightening torque:
44 Nm (4.5 kgf-m, 32.5 ft-lb)
7) Remove the differential side retainer oil seal using driver wrapped with vinyl tape or etc.
oil seal by slightly tapping with hammer.
5AT-51
Inhibitor Switch
13.Inhibitor Switch
A: INSPECTION
Inhibitor switch cannot be checked, because the inhibitor switch is installed on control valve assembly.
When the malfunction occurs, refer to 5AT (Diagnosis) section. <Ref. to 5AT(diag)-34, DTC P0705
TRANSMISSION RANGE SENSOR CIRCUIT
(PRNDL INPUT), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
5AT-52

14.Front Vehicle Speed Sensor
8) Disconnect the front vehicle speed sensor connector.
A: REMOVAL
NOTE:
Secure the harness of the rear vehicle speed sensor to the transmission proper using wire etc.
AT-01953
9) Remove the front vehicle speed sensor securing

bolt.
AT-01950
3) Remove the extension case.
AT-01954
10) Remove the front vehicle speed sensor through

the hole of the AT transmission main case.
B: INSTALLATION
1) Install the front vehicle speed sensor.
Tightening torque:
7 Nm (0.7 kgf-m, 5.2 ft-lb)
AT-01951
4) Remove the intermediate case.
AT-01954
AT-01952
5) Remove the center differential carrier. <Ref. to

6) Lay along the transmission case, and then remove the oil pan.
7) Remove the old gasket on the oil pan and transmission case completely.
2) Connect the front vehicle speed sensor connector.
5AT-53

Liquid gasket:

Tightening torque:
7 Nm (0.7 kgf-m, 5.2 ft-lb)
AT-01950
AT-01955

Tightening torque:
5 Nm (0.5 kgf-m, 3.7 ft-lb)
5) Install the center differential carrier. <Ref. to
5AT-80, INSTALLATION, Center Differential Carrier.>
6) Install the intermediate case.
10) Pour ATF from the oil charge pipe. <Ref. to
11) Check the level and leaks of the ATF. <Ref. to
5AT-28, INSPECTION, Automatic Transmission
Fluid.>
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
AT-01952
7) Install the extension case.

Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
AT-01951
5AT-54

15.Rear Vehicle Speed Sensor
Non-turbo model
A: REMOVAL
(2)

(1)
AT-02025

IN-00203

Chamber.>
Turbo model
AT-01364
6) Remove the transmission harness connector

and front oxygen (A/F) sensor connector from the
stay.
9) Drain ATF completely. <Ref. to 5AT-28, REPLACEMENT, Automatic Transmission Fluid.>
Pipe.> <Ref. to EX(H4DOTC)-11, REMOVAL,
Rear Exhaust Pipe.> <Ref. to EX(H4DOTC)-12,
REMOVAL, Muffler.>
(Non-turbo model) <Ref. to EX(H6DO)-8, REMOVAL, Rear Exhaust Pipe.> <Ref. to EX(H6DO)-10,
REMOVAL, Muffler.>
NOTE:
Make sure that the support plate of transmission
jack does not touch the crossmember.
bolt.
AT-01379
AT-01377
5AT-55

NOTE:
Do not separate the transmission jack and transmission.
18) Remove the ATF cooler inlet and outlet pipes.
NOTE:
When removing the outlet pipe, be careful not to
lose the ball and spring used with retaining screw.
19) Disconnect the connector from turbine speed
sensor 1.
AT-01957
24) Remove the bolt securing harness of transmission main case.
AT-01387
AT-02035

25) Remove the harness assembly.
B: INSTALLATION
1) Pass the harness assembly through the hole in
transmission case.
AT-01950

22) Disconnect the control valve connector and
front vehicle speed sensor connector.
AT-00048
2) Install the securing bolt of transmission main

case.
(B)
Tightening torque:
7 Nm (0.7 kgf-m, 5.2 ft-lb)
(A)
AT-01956
(A) Control valve connector

(B) Front vehicle speed sensor connector
AT-02035
5AT-56

7) Install the rear vehicle speed sensor and turbine

speed sensor 1, and then fasten the harness.
3) Install the control valve body.

Tightening torque:
8 Nm (0.8 kgf-m, 58 ft-lb)
Tightening torque:
7 Nm (0.7 kgf-m, 5.1 ft-lb)
8) Install a new aluminum washer and oil cooler
pipe.
NOTE:
Be careful not to catch harness in.
(2)
(1)
(1)
Tightening torque:
T: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
10) Install the transmission rear crossmember bolt.
(1)
(1)
(2)
(1)
(2)
(1)
(2)
(1)
(2)
(1)
AT-01958
(1) 58 mm (2.28 in)

(2) 65 mm (2.56 in)
4) Connect the control valve connector and front

(B)
(A)
AT-01956

Liquid gasket
Tightening torque:
70 Nm (7.1 kgf-m, 51 ft-lb)
13) Install the center exhaust pipe, rear exhaust
pipes and muffler. (Turbo model)
14) Install the rear exhaust pipe and muffler. (Nonturbo model) <Ref. to EX(H6DO)-8, INSTALLATION, Rear Exhaust Pipe.> <Ref. to EX(H6DO)-10,
16) Install the transmission connector to the stay,
and then connect the connector.
18) Install the air intake chamber. (Non-turbo model) <Ref. to IN(H6DO)-7, INSTALLATION, Air Intake Chamber.>
19) Pour ATF through the oil charge pipe. <Ref. to
20) Check the level and leaks of ATF. <Ref. to 5AT28, INSPECTION, Automatic Transmission Fluid.>
to 5AT(diag)-22, PROCEDURE, Learning Control.>
AT-01955

Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
5AT-57
Turbine Speed Sensor 1

16.Turbine Speed Sensor 1

A: REMOVAL
2) Remove the intercooler. (Turbo model) <Ref. to
IN(H4DOTC)-12, REMOVAL, Intercooler.>
Chamber.>
4) Disconnect the turbine speed sensor 1 connector.
AT-01387
5) Remove the turbine speed sensor 1.
B: INSTALLATION
1) Install the turbine speed sensor 1.
Tightening torque:
7 Nm (0.7 kgf-m, 5.2 ft-lb)
2) Connect the turbine speed sensor 1 connector.
AT-01387

Chamber.>
5AT-58
Control Valve Body

17.Control Valve Body
A: REMOVAL
NOTE:
Replace the control valve body as assembly, because it is non-disassemble part.

CAUTION:
NOTE:
Use a new gasket.
AT-01957
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
B: INSTALLATION
CAUTION:
Be sure to prevent the entering of dust and other foreign matters into oil pan.
1) Check the control valve body for dust and other

foreign matters.
2) Install the control valve body to transmission by
equally tightening the bolts.
Tightening torque:
8 Nm (0.8 kgf-m, 5.8 ft-lb)
(2)
(1)
(1)
(1)
(1)
(2)
(1)
(2)
(1)
(2)
(1)
(2)
(1)
AT-01959
AT-01958

on the transmission case and oil pan.
11) Disconnect the control valve connector and
front vehicle speed sensor connector.
(1) 58 mm (2.28 in)

(2) 65 mm (2.56 in)
3) Connect the control valve connector.
(B)
(B)
(A)
(A)
AT-01956
AT-01956


5AT-59
Control Valve Body

4) Attach the magnet at the specified position of oil

pan.
C: INSPECTION
Check each parts for holes, damages or other foreign matters.
AT-01959
5) Apply liquid gasket to the oil pan.

Liquid gasket:
AT-01955

Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
7) Pour ATF through the oil charge pipe.
Specified and recommended fluid:
<Ref. to 5AT-2, SPECIFICATION, General Description.>
Capacity:
Fill the same amount of the drained ATF.
<Ref. to 5AT-28, Automatic Transmission Fluid.>
at the end of repair work, and make sure there is no
faulty as below;
NOTE:
5AT-60
ATF Filter
18.ATF Filter
B: INSTALLATION
A: REMOVAL
1) Apply a thin coat of ATF to the oil seal part of

new ATF filter.
2) Install the ATF filter. Turn it by hand, being careful not to damage oil seal.
3) Tighten the ATF filter using ST.
Calculate the ATF filter tightening torque using following formula.
T2 = L2/(L1 + L2) T1
T1: 14 Nm (1.4 kgf-m, 10.1 ft-lb)
L1: ST length 78 mm (3.07 in)
Example:
NOTE:
ATF filter is maintenance free.
1) Disconnect the ground cable from battery and
remove the battery from vehicle.

mm (in)
100 (3.94)
150 (5.91)
200 (7.87)
IN-00203
2) Remove the harness securing bracket.
Tightening torque
Nm (kgf-m, ft-lb)
7.7 (0.79, 5.7)
9.0 (0.92, 6.7)
10 (1.0, 7.2)
NOTE:
Align the ST with torque wrench while tightening
the ATF filter.
ST 498545400
OIL FILTER WRENCH
4) Fill ATF.
5) Inspect the level of ATF. <Ref. to 5AT-28, Automatic Transmission Fluid.>
6) Install the harness securing bracket.
C: INSPECTION
Check for rust, hole, ATF leaks and other damage.
Replace the part if any defect is found from the inspection.
AT-01381
3) Using the ST, remove the ATF filter.

ST 498545400
OIL FILTER WRENCH
5AT-61
Transmission Control Module (TCM)

19.Transmission Control Module (TCM)
RHD model
(B)
A: REMOVAL
2) Remove the lower cover and then disconnect
the connector.
3) Remove the body integrated unit. (RHD model)
<Ref. to SL-45, REMOVAL, Body Integrated Module.>
RHD model
(A)
AT-01342
LHD model
(B)
(B)
(A)
(A)
AT-01342
AT-02026
LHD model

(B) Steering column
(B)
(A)
AT-02026

(B) Steering column
5) Remove the relay from TCM body.

6) Remove the TCM.
B: INSTALLATION
1) Install the relay to TCM body.
2) Install the TCM.

6) Perform the inspection with driving the vehicle at
the end of repair work, and make sure there is no
faulty as below;
NOTE:
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
5AT-62
Lateral G Sensor
20.Lateral G Sensor
A: REMOVAL
2) Disconnect the connector from lateral G sensor.
AT-01343
3) Remove the lateral G sensor.
B: INSTALLATION
Tightening torque:
T1: 7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
T2: 24.5 Nm (2.5 kgf-m, 18.1 ft-lb)
T2
T1
AT-01719
5AT-63

21.ATF Cooler Pipe and Hose
7) Disconnect the ATF cooler hoses from pipes.
A: REMOVAL
NOTE:
1. EXCEPT FOR ATF COOLER MODEL

WITH WARMER FUNCTION
5) Remove the radiator under cover.
AT-01388
8) Disconnect the ATF cooler pipe from frame.
AT-01344

NOTE:
AT-01345
AT-01347
5AT-64


NOTE:
When disconnecting the outlet pipe, be careful not
to lose the ball and spring used with retaining
screw.
5) Remove the pipe securing bolts on the side of

transmission.
AT-02028
(A)
(B)
AT-01383
(A) Outlet pipe

(B) Inlet pipe
2. ATF COOLER MODEL WITH WARMER

FUNCTION
Pipe.>
3) Disconnect the inlet and outlet hoses of the ATF
cooler pipe from oil cooler pipe.

8) Remove the resonator chamber.
<Ref. to IN(H6DO)-9, REMOVAL, Resonator
Chamber.>
10) Disconnect the ATF cooler hoses and pipes.
AT-02030
11) Remove the pitching stopper bracket securing

bolt and bolt on the side of transmission, and then
remove ATF cooler pipe.
AT-02027
4) Remove the union screw of oil cooler inlet and

outlet pipes.
AT-02033
AT-02029
5AT-65

12) Remove the ATF cooler from the installation

bracket as necessary.
2) Install the ATF cooler pipe to frame.
AT-02031
13) Remove the ATF cooler bracket from transmission body as necessary.
AT-01347
3) Connect the ATF cooler hose to pipe on the

transmission side.
AT-02032
B: INSTALLATION
1. EXCEPT FOR ATF COOLER MODEL
WITH WARMER FUNCTION
1) Install the oil cooler inlet and outlet pipes with
new washer.
NOTE:
Install so that the hose is not folded over, excessively bent or twisted.
Tightening torque:
T1: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
T2: 44 Nm (4.5 kgf-m, 32.5 ft-lb)
T1
AT-01388
T2
T1
AT-01384
5AT-66

4) Connect the ATF cooler hose to pipe on radiator

side.
2. ATF COOLER MODEL WITH WARMER

FUNCTION
NOTE:
1) Install the ATF cooler bracket if it is removed

from transmission body.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
AT-02032
AT-01345
2) Install the ATF cooler if it is removed from installation bracket.
5) Install the radiator under cover.

Tightening torque:
4.9 Nm (0.5 kgf-m, 3.6 ft-lb)
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
AT-01344

8) Fill ATF. <Ref. to 5AT-28, Automatic Transmission Fluid.>
AT-02031
3) Install the pitching stopper securing bracket and

bolt on the side of transmission.
NOTE:
Make sure there are no ATF leaks in joints between
the transmission, radiator, pipes, and hoses.
AT-02033
5AT-67

4) Install the ATF cooler hoses and pipes.
12) Install the inlet and outlet pipes of the ATF oil
cooler hose to oil cooler pipe.
AT-02030
5) Connect the engine harness connectors, and

then install the engine hanger rear.
7) Install the resonator chamber.
<Ref. to IN(H6DO)-9, INSTALLATION, Resonator
Chamber.>
Chamber.>
10) Install the pipe securing bolts on the side of
transmission.
AT-02027

<Ref. to EX(H6DO)-6, INSTALLATION, Front Exhaust Pipe.>
C: INSPECTION
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.
surface and other damages.
5) Check for peeling, cracks, and deformation at
the tip of the hose.
6) Check the ATF cooler for cracks or deformation.
(ATF cooler model with warmer function)
AT-02028
11) Install the union screw of oil cooler inlet and

outlet pipes.
Tightening torque:
T1: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
T2: 44 Nm (4.5 kgf-m, 32.5 ft-lb)
AT-02029
5AT-68
Air Breather Hose

22.Air Breather Hose

A: REMOVAL
1) Remove the intercooler. (Turbo model) <Ref. to
IN(H4DOTC)-12, REMOVAL, Intercooler.>
Chamber.>
(A)
(B)
AT-01385

(B) Air breather hose (Oil pump cover)
B: INSTALLATION
1) Connect the air breather hose.
(A)
(B)
AT-01385

(B) Air breather hose (Oil pump cover)

Chamber.>
C: INSPECTION
Make sure the hose is not cracked or clogged.
5AT-69
Oil Charge Pipe

23.Oil Charge Pipe

A: REMOVAL
Chamber.>
3) Remove the oil charge pipe, and then remove
the O-ring from flange side.
(A)
(B)
AT-01386
(A) Oil level gauge

(B) Oil charge pipe
B: INSTALLATION
1) Install the oil charge pipe with a new O-ring.
Tightening torque:
41 Nm (4.2 kgf-m, 30.2 ft-lb)
(A)
(B)
AT-01386
(A) Oil level gauge

(B) Oil charge pipe

Chamber.>
C: INSPECTION
Make sure the oil charge pipe is not deformed or
damaged.
5AT-70
Torque Converter Assembly

24.Torque Converter Assembly

A: REMOVAL
2) Pull out the torque converter and oil pump shaft
horizontally.
C: INSPECTION
Make sure the ring gear and protrusion of torque
converter end are not deformed or damaged.
NOTE:
Be sure not to scratch the inside of bush in oil
pump shaft.
Be careful that the oil pump shaft may drawn out
simultaneously.
AT-00113
3) Remove the oil pump shaft from torque converter as necessary.
B: INSTALLATION
1) When the oil pump shaft is removed, install the
shaft to torque converter.
NOTE:
Make sure the clip is firmly inserted.
2) Install the oil pump shaft to torque converter, and
then make sure that the clip is secured on groove.
3) Apply ATF to the revolution and sliding surface
oil pump shaft.
4) Holding the torque converter assembly by hand,
lightly rotate the torque converter assembly to engage the oil pump rotor.
5) Check the protruding dimension of the torque
converter assembly.
Dimension A:
Less than 8 mm (0.31 in)
(A)
AT-01641
(A) Dimension A
5AT-71
Extension Case and Intermediate Case

25.Extension Case and Intermediate Case
NOTE:
Use a new gasket.
A: REMOVAL
1) Remove the transmission assembly.
<Ref. to 5AT-39, REMOVAL, Automatic Transmission Assembly.>
AT-01952
2) Attach the selected reduction driven gear shim

to end surface of reduction driven gear with vaseline. <Ref. to 5AT-79, ADJUSTMENT, Reduction
Driven Gear.>
3) Install the extension case to intermediate case.
AT-01950
3) Separate the extension case and intermediate

case.
NOTE:
Use a new gasket.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
AT-01951
4) Separate the intermediate case and transmission main case.
AT-01951

Tightening torque:
7 Nm (0.7 kgf-m, 5.1 ft-lb)
AT-01952
B: INSTALLATION
1) Secure the intermediate case to transmission
main case.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
AT-01950

5AT-72

C: DISASSEMBLY
1) Take out the transfer clutch and multi-plate
clutch hub assembly by lightly tapping the end of
rear drive shaft.
4) Using the ST and compressor, install the snap

ring.
ST 18762AA000 COMPRESSOR SPECIAL
TOOL
NOTE:
Be careful not to damage the oil seal of extension.
2) Remove snap ring using ST and press.
ST 18762AA000 COMPRESSOR SPECIAL
TOOL
ST
ST
AT-01960
5) Install the transfer clutch. <Ref. to 5AT-74, INSTALLATION, Transfer Clutch.>
AT-01960
3) Supply compressed air to remove the clutch piston.
NOTE:
For 3-transfer clutch model, make sure the press
plate is included.
6) Install the multi-plate hub assembly.
E: INSPECTION
Use compressed air to make sure the extension
case routes are not clogged and not leaks.
within specifications.
<Ref. to 5AT-74, ADJUSTMENT, Transfer Clutch.>
AT-01961

D: ASSEMBLY
1) Press-fit new oil seal using ST and press.
ST 498057300
INSTALLER
3) Insert the multi-plate clutch, drive plate, driven
plate and spring retainer.
AT-01962
(A) Spring retainer

(B) Multi-plate clutch (LSD) piston assembly
5AT-73
Transfer Clutch
26.Transfer Clutch
ST
398643600
GAUGE
A: REMOVAL
2) Remove the extension case, and then remove
the transfer clutch. <Ref. to 5AT-72, REMOVAL,
Extension Case and Intermediate Case.> <Ref. to
5AT-73, DISASSEMBLY, Extension Case and Intermediate Case.>
AT-01964
B: INSTALLATION
1) Select the rear drive shaft shim. <Ref. to 5AT-74,
2) Select the driven plate No. 3. <Ref. to 5AT-74,
3) Install the extension case and intermediate
case. <Ref. to 5AT-72, INSTALLATION, Extension
Case and Intermediate Case.>
A Measured value
3) Using the ST, measure the height B from the

intermediate case mating surface to ball bearing
outer ring contact surface.
ST 398643600
GAUGE
C: INSPECTION
Inspect the snap ring for wear; return spring for
Check that the D-ring is not damaged.
D: ADJUSTMENT
1) Insert the rear drive shaft into the reduction drive
gear and center differential assembly.
AT-01963
2) Using the ST, measure the depth A, which is

from mating surface of extension case to ball bearing outer ring contact surface.
AT-01965
B Measured value
When clearances are 0.05 mm (0.0020 in):
T (mm) = A (B 0.28) 0.05
[T (in) = A (B 0.011) 0.0020]
T (mm) = A (B 0.28) 0.25
[T (in) = A (B 0.011) 0.0098]
A: Depth from end of extension case to ball bearing
outer ring contact surface
B: Height from end of intermediate case to ball
bearing outer ring contact surface
T: Shim thickness
0.05 0.25 mm (0.0020 0.0098 in)
NOTE:
Calculation formula for T is applied when measuring using ST (398643600 GAUGE). When not using ST, apply following.
T (mm) = (A ) ((B ) 0.28) 0.05
[T (in) = (A ) ((B ) 0.011) 0.0020]
T (mm) = (A ) ((B ) 0.28) 0.25
[T (in) = (A ) ((B ) 0.011) 0.0098]
5AT-74
Transfer Clutch
T: Shim thickness
A: Depth from end of extension case to ball bearing
outer ring contact surface
B: Height from end of intermediate case to ball
bearing outer ring contact surface
: Collar thickness used when measuring A
: Collar thickness used when measuring B
0.28 (0.011): Gasket thickness (Unit mm (in))
Part Number
33281AA040
33281AA050
33281AA060
Adjustment shim
Thickness mm (in)
0.2 (0.008)
0.5 (0.020)
0.3 (0.012)
5AT-75
Multi-plate Clutch
27.Multi-plate Clutch
NOTE:
Measure with driven plate No. 3 removed.
A: REMOVAL
Remove the multi-plate clutch following the same
instructions as for the extension case. <Ref. to
5AT-72, REMOVAL, Extension Case and Intermediate Case.>
B: INSTALLATION
Install the multi-plate clutch following the same instructions as for the extension case. <Ref. to 5AT72, INSTALLATION, Extension Case and Intermediate Case.>
AT-01967
C: INSPECTION
Inspect the snap ring for wear; return spring for
Inspect the damage for D-ring.
Measure the multi-plate clutch clearance and adjust it within specification. <Ref. to 5AT-76, ADJUSTMENT, Multi-plate Clutch.>
D: ADJUSTMENT
1) Remove drive plate and driven plate from center
differential carrier.
2) Measure the depth A from mating surface of
extension case to multi-plate clutch (LSD) piston.
AT-01966
A Measured value
3) Using the ST, measure the height B from intermediate case mating surface to end of center differential clutch drum, and then subtract the thickness
of ST gauge (50 mm (1.97 in)) from measured value.
ST 378744300
GAUGE
B Measured value
T (mm) = A (B 0.28) 0.2
[T (in) = A (B 0.011) 0.008]
T (mm) = A (B 0.28) 0.6
[T (in) = A (B 0.011) 0.024]
NOTE:
GAUGE). When not using ST, apply following.
T (mm) = A (B 0.28) 0.2
[T (in) = A (B 0.011) 0.008]
T (mm) = A (B 0.28) 0.6
[T (in) = A (B 0.011) 0.024]
T: Thickness of driven plate No. 3
A: Measure the depth from mating surface of extension case to multi-plate clutch (LSD) piston
B: Height from end of intermediate case to center
differential clutch drum
: Collar thickness used when measuring B
0.28 (0.011): Gasket thickness (Unit mm (in))
Measure multi-plate clutch (LSD) driven and
drive plate thickness to find the clearance between
measurement value and T.
Standard value:
0.2 0.6 mm (0.008 0.024 in)
If outside the standard value, replace the plate set
(drive and driven plate) and select the driven plate
No. 3 to bring clearance within the standard value.
Driven plate No. 3
Part Number
Thickness mm (in)
31589AA041
1.6 (0.063)
31589AA050
2.0 (0.079)
31589AA060
2.4 (0.094)
31589AA070
2.8 (0.110)
5AT-76
Rear Drive Shaft

28.Rear Drive Shaft
2) Using a press, remove the front and rear side

ball bearings, and clutch hub.
A: REMOVAL
remove the extension case. <Ref. to 5AT-72, REMOVAL, Extension Case and Intermediate Case.>
3) Pull out the rear drive shaft from center differential assembly.
(B)
(A)
(C)
AT-00151
(A) Rear ball bearing

(C) Clutch hub
D: ASSEMBLY
NOTE:
Use new ball bearings and revolution gear.
Make sure the clutch hub is oriented in the correct direction.
AT-01963
4) Remove the drive plate and driven plate.
B: INSTALLATION
1) Select the appropriate shim. <Ref. to 5AT-74,
2) Install drive plate and driven plate.
3) Insert the rear drive shaft into the center differential assembly.
4) Combine the extension case, and then install the
rear vehicle speed sensor. <Ref. to 5AT-72, INSTALLATION, Extension Case and Intermediate
Case.>
(B)
(A)
(D)
AT-00152
(A)
(B)
(C)
(D)
C: DISASSEMBLY
1) Using a press, remove the revolution gear.
(A)
(C)
Front side
Clutch hub
Rear side
Revolution gear
E: INSPECTION
Check each parts for holes, damages or other
foreign matters.
AT-00149
(A) Revolution gear
5AT-77

C: DISASSEMBLY
A: REMOVAL
1) Remove the ball bearing from reduction driven

gear using ST.
ST 498077300
REMOVER
separate the extension case and intermediate case
from transmission case. <Ref. to 5AT-72, REMOVAL, Extension Case and Intermediate Case.>
driven gear.
ST2 18680AA000 GEAR HOLDER
ST
(A)
AT-00157
(A) Ball bearing
2) Remove the ball bearing on reverse side with the

same procedure in step 1).
ST2
ST1
(A)
ST
(A)
AT-01968

AT-01969
B: INSTALLATION
2) Use a plastic hammer to install reduction driven
gear assembly.
3) Select the reduction gear shim. <Ref. to 5AT-79,
ADJUSTMENT, Reduction Driven Gear.>
4) Connect the transmission case, extension case
and intermediate case, and install the rear wheel
speed sensor. <Ref. to 5AT-72, INSTALLATION,
Extension Case and Intermediate Case.>

gear.
D: ASSEMBLY
2) Install the new ball bearing to reduction driven
gear using press.
AT-01970
(A) Ball bearing
5AT-78

3) Install the ball bearing on reverse side with the

same procedure in step 2).
T: Shim clearance
ball bearing outer ring end surface
B: Height from mating surface of extension case to
ball bearing inside low part
Reduction gear shim
Part Number
Thickness mm (in)
31288AA030
0.2 (0.008)
31288AA050
0.5 (0.020)
31288AA060
0.3 (0.012)
AT-01971
E: INSPECTION
Make sure the ball bearing and gear are not deformed or damaged.
F: ADJUSTMENT
1) Using depth gauge, measure depth A from
mating surface of extension case to ball bearing on
rear end of reduction driven gear.
AT-02090
2) Using a depth gauge, measure the height B

from mating surface of extension case to ball bearing inside low part of extension case.
AT-02091
Select the ball bearing from the table to adjust
clearances within 0.05 0.25 mm (0.0020
0.098 in).
T (mm) = A B + 0.23
[T (in) = A B + 0.0091]
T (mm) = A B + 0.03
[T (in) = A B +0.0011]
5AT-79


A: REMOVAL
2) Remove the rear wheel speed sensor, and separate the extension case and intermediate case
from transmission case. <Ref. to 5AT-72, REMOVAL, Extension Case and Intermediate Case.>
3) Pull out the rear drive shaft. <Ref. to 5AT-77,
REMOVAL, Rear Drive Shaft.>
4) Pull out the center differential carrier assembly.
C: DISASSEMBLY
(A)
AT-02015
(A) Seal ring
2) Using a press and ST, remove the ball bearing.

ST 498077600
REMOVER
AT-01972
5) Pull out the shim(s) from transmission case.
B: INSTALLATION
1) Install the center differential assembly with the
shim(s).
NOTE:
Press-fit it to the bottom of bearing shoulder completely.
AT-00167
3) Remove the snap ring, and pull out the shaft

from center differential assembly.
(B)
(A)
AT-01972
2) Insert the rear drive shaft. <Ref. to 5AT-77, INSTALLATION, Rear Drive Shaft.>
3) Connect the transmission case, extension case
and intermediate case, and install the rear wheel
speed sensor. <Ref. to 5AT-72, INSTALLATION,
Extension Case and Intermediate Case.>
5AT-80
AT-01973
(A) Snap ring

(B) Shaft

4) Remove the thrust washers, pinion gears and

washers from center differential assembly.
(A)
AT-00169
(A) Pinion gear
5) Pull out the intermediate shaft and thrust bearing.
D: ASSEMBLY
1) Install the thrust washer onto intermediate shaft.
2) Install the thrust bearing onto intermediate shaft.
3) Install the pinion gears and washers.
4) Insert the shaft into the center differential assembly.
6) Using a press, install a new ball bearing into the
center differential assembly.
ST 498077000
REMOVER
(A)
ST
(B)
AT-00170
(A) Plate
7) Apply vaseline onto the seal ring outer surface

and shaft grooves.
8) Install a new seal rings.
E: INSPECTION
Check each parts for holes, damages or other
foreign matters.
5AT-81
Parking Pawl
31.Parking Pawl
4) Set the ST between parking pawl and parking

support actuator.
ST 18679AA000 ADJUSTER
A: REMOVAL
2) Remove the extension case and intermediate
4) Remove the parking support actuator.
ST
AT-02069
5) Tighten the securing bolts while pressing parking support actuator with finger.
Tightening torque:
102 Nm (1.00.2 kgf-m, 7.41.5 ft-lb)
CAUTION:
Press the reduction driven gear and parking
pawl in top condition.
AT-02067
5) Remove the parking pawl, parking pawl shaft

and return spring.
AT-02068
B: INSTALLATION
1) Set the transmission to N range.
2) Install the parking pawl, parking pawl shaft and
return spring.
ST
AT-03362
6) Using the ST, tighten the bolts which tightened in

step 4) with specified angle.
Tightening angle:
182
ST 18554AA000 ANGLE GAUGE
AT-02068
3) Temporarily secure the parking support actuator.
5AT-82
Parking Pawl
NOTE:
Do not use extension as much as possible.
ST
AT-02071
ST
AT-02072

C: INSPECTION
Make sure that the tab of parking pawl on reduction
driven gear is not worn or otherwise damaged.
5AT-83
Converter Case
32.Converter Case
A: REMOVAL
2) Remove the torque converter assembly. <Ref. to
5AT-71, REMOVAL, Torque Converter Assembly.>
from stay.
4) Remove the turbine speed sensor 1. <Ref. to
5AT-58, REMOVAL, Turbine Speed Sensor 1.>
6) Remove the ATF filter inlet and outlet pipes.
<Ref. to 5AT-61, REMOVAL, ATF Filter.>
7) Remove the converter case aligning bolt.
8) Lay along the transmission body, and then remove the oil pan.
9) Remove the three converter case aligning bolts
(TORX).
ST 18676AA020 TORX WRENCH
3) Install the differential assembly to case. <Ref. to

5AT-94, INSTALLATION, Front Differential Assembly.>
4) Install the left and right side retainers. <Ref. to
5) Apply proper amount of liquid gasket to the entire matching surface of converter case.
Liquid gasket:
AT-01975
6) Install the converter case assembly without

damaging bushing and oil seal.
Tightening torque:
41 Nm (4.2 kgf-m, 30.4 ft-lb)
7) Install the three converter case aligning bolts
(TORX).
ST 18676AA020 TORX WRENCH
Tightening torque:
41 Nm (4.2 kgf-m, 30.4 ft-lb)
AT-01974
10) Separate the converter case by lightly tapping

with plastic hammer.
11) Remove the differential assembly. <Ref. to
5AT-94, REMOVAL, Front Differential Assembly.>
12) Remove the oil seal from converter case.
B: INSTALLATION
1) Check the appearance of each component and
clean them.
2) Press-fit the oil seal to converter case using ST.
ST 499587100
OIL SEAL INSTALLER
AT-01974
8) Apply proper amount of liquid gasket to the entire oil pan mating surface, and then install it.
Liquid gasket:
ST
AT-01979
5AT-84
Converter Case
Tightening torque:
5 Nm (0.5 kgf-m, 3.7 ft-lb)
AT-01955
9) Install the transmission harness connector to the

stay.
11) Install the ATF filter pipe. <Ref. to 5AT-61, INSTALLATION, ATF Filter.>
12) Install the oil charge pipe with O-ring.<Ref. to
13) Install the torque converter assembly. <Ref. to
5AT-71, INSTALLATION, Torque Converter Assembly.>
C: INSPECTION
specification. <Ref. to 5AT-91, ADJUSTMENT,
Drive Pinion Shaft Assembly.>
5AT-85
Oil Pump Cover

33.Oil Pump Cover

A: REMOVAL
2) Pull out the torque converter assembly. <Ref. to
from stay.
Case.>
7) Remove the oil pump cover aligning bolt, and
then separate it from the AT main case by lightly
tapping with plastic hammer.

C: DISASSEMBLY
1. FRONT BRAKE
AT-01980
2) Remove the retainer plate, drive plate and driven

plate.
3) Remove the snap ring using ST1, ST2 and ST3.
ST1 18762AA000 COMPRESSOR SPECIAL
TOOL
ST2 18765AA000 COMPRESSOR SUPPORT
ST3 18763AA000 COMPRESSOR SHAFT
AT-01976
ST1
B: INSTALLATION
ST2
1) Secure the oil pump cover.

Tightening torque:
41 Nm (4.2 kgf-m, 30.4 ft-lb)
ST3
AT-01981
4) Remove the retainer and return spring.

5) Remove the front brake piston by blowing compressed air.
AT-01976
2) Install the converter case assembly into transmission case assembly. <Ref. to 5AT-71, INSTALLATION, Torque Converter Assembly.>
stay.
AT-02349
6) Remove the D-ring from front brake piston.
5AT-86
Oil Pump Cover

2. OIL PUMP
ST3
18763AA000 COMPRESSOR SHAFT
1) Take out the oil pump housing.

ST1
ST2
ST3
AT-01981
5) Install the genuine driven plate instead of retainer plate, temporarily assemble the drive plate and
driven plate.
ST 31536AA290
DRIVEN PLATE
AT-01982
2) Take out the oil pump body.
D: ASSEMBLY
1. FRONT BRAKE
1) Apply ATF to D-ring, and then install it to the
front brake piston.
2) Install the front brake piston to oil pump cover.
NOTE:
Install by aligning the mark on front brake piston surface with the oil pump cover rib.
AT-01980
7) Measure the clearance between retainer plate

and snap ring, and then select a suitable retainer
plate from table.
Front brake clearance standard value:
0.7 1.1 mm (0.028 0.043 in)
AT-01983
Front brake retainer plate

Part Number
Thickness mm (in)
31567AB130
3.4 (0.134)
31567AB140
3.6 (0.142)
31567AB150
3.8 (0.150)
31567AB160
4.0 (0.157)
AT-02350
3) Install the retainer and return spring.

4) Install the front brake piston assembly using
ST1, ST2 and ST3.
TOOL
8) Remove the snap ring, replace the drive plate

which used in measurement of clearance with retainer plate, and then reassemble.
5AT-87
Oil Pump Cover

2. OIL PUMP
1) Apply ATF to oil pump assembly, and then install
it to oil pump housing.
2) Install the O-ring to oil pump cover.
3) Install the oil pump housing to oil pump housing
cover.
Tip clearance:
0.02 0.15 mm (0.0008 0.0059 in)
(A)
(B)
(C)
Tightening torque:
10 Nm (1.0 kgf-m, 7.4 ft-lb)
AT-01977
(A) Thickness gauge

(B) Inner rotor
(C) Outer rotor
(2) Side clearance

Set a depth gauge to oil pump housing, then
measure the oil pump housing-to-rotor clearance.
AT-01982
E: INSPECTION
1. FRONT BRAKE
Snap ring for wear, return spring for damage,
and retainer for damage
Piston for damage
D-ring for damage
Side clearance:
0.02 0.045 mm (0.0008 0.0018 in)
(A)
2. OIL PUMP
Oil pump cover and oil seal for breakage or damage
Oil pump body for scratch or damage
1) Check seal ring and oil seal for breaks or damages.
2) Check other parts for dents or abnormalities.
3) Selection of oil pump rotor assembly
(1) Tip clearance
Install the inner rotor and outer rotor to oil pump
housing. With rotor gears facing each other,
measure the crest-to-crest clearance.
(C)
(B)
AT-01978
(A) Depth gauge

(B) Inner rotor
(C) Outer rotor
(3) If the depth and/or side clearance are not

within the specifications, replace the rotor assembly.
Part Number
15008AA130
15008AA140
15008AA150
Oil pump rotor ASSY

Thickness mm (in)
11.37 11.38 (0.4476 0.4480)
11.38 11.39 (0.4480 0.4484)
11.39 11.40 (0.4484 0.4488)

specifications. <Ref. to 5AT-107, ADJUSTMENT, AT Main Case.>
5AT-88


A: REMOVAL
from stay.
Case.>
8) Remove the drive pinion shaft mounting bolt,
and then remove the drive shaft assembly from oil
pump cover.
2) Adjust the tooth contact between drive pinion

shaft assembly and front differential side gear.
<Ref. to 5AT-91, ADJUSTMENT, Drive Pinion
Shaft Assembly.>
3) Combine the converter case with transmission
case. <Ref. to 5AT-84, INSTALLATION, Converter
Case.>
stay.
6) Install the oil charge pipe with O-ring.
C: DISASSEMBLY
1) Remove the caulking part of lock nut, and then
remove the lock nut with holding rear spline part of
the shaft using ST1 and ST2. Pull out the drive pinion collar.
ST1 18667AA010 HOLDER
ST3
ST2
AT-01984
9) Remove the oil pump cover from AT main case.

<Ref. to 5AT-86, Oil Pump Cover.>
ST1
B: INSTALLATION
1) Assemble the drive pinion assembly to oil pump
cover.
NOTE:
Be careful not to bend the shim.
AT-00197

3) Separate the rear roller bearing and outer race
from the shaft using press.
Tightening torque:
70 Nm (7.1 kgf-m, 51.6 ft-lb)
(A)
AT-00198
(A) Outer race

AT-01984
4) Separate the front roller bearing from the shaft

using press and ST.
5AT-89

ST
498517000
T1: 116 Nm (11.8 kgf-m, 85.3 ft-lb)

L1: ST2 length 0.072 m (2.83 in)
Example:
REPLACER
(A)
ST

m (in)
0.4 (15.75)
0.45 (17.72)
0.5 (19.69)
0.55 (21.65)
AT-00199
Tightening torque
Nm (kgf-m, ft-lb)
98 (10.0, 72)
100 (10.2, 73.8)
101 (10.3, 74.5)
102 (10.4, 75)
(A) Front roller bearing
D: ASSEMBLY
1) Measure the dimension A of drive pinion shaft.
ST 398643600
GAUGE
ST1
ST2
ST3
18667AA010 HOLDER
499787700 WRENCH
499787500 ADAPTER
NOTE:
Install the ST2 to torque wrench as straight as possible.
ST3
ST2
L1 [m (in)]
A
AT-00200
L2 [m (in)]
2) Using a press, press-fit the new roller bearing

into specified position.
NOTE:
If excessive force is applied to roller bearing, the
roller bearing will not turn easily.
ST1
AT-00202
6) Measure the starting torque of bearing. Make

sure the starting torque is within the specified
range. If the torque is not within specified range, replace the roller bearing.
Starting torque:
7.6 38.1 N (0.776 3.88 kgf, 1.7 3.88 kg)
(A)
(B)
AT-00201

(B) Roller bearing
AT-00203
3) After fitting a new O-ring to the shaft, attach the

drive pinion collar to shaft.
4) Install the lock washer to drive pinion shaft in
proper direction.
5) Tighten new lock nuts using ST1, ST2 and ST3.
Calculate the lock washer and lock nut specifications using following formula.
T2 = L2/(L1 + L2) T1
7) Stake the caulking of lock nut at two points.

8) Measure the dimension B of drive pinion shaft.
5AT-90

ST
398643600
GAUGE
ST2
499787700 WRENCH
ST1
ST2
B
AT-00204
AT-01985
9) Calculate the thickness t (mm) of drive pinion

shim.
t = 6.5 0.0625 (B A)
10) Select three or less shims from following table.
Part Number
31451AA180
31451AA190
31451AA200
31451AA210
31451AA220
31451AA230
Drive pinion shim

Thickness mm (in)
0.150 (0.0059)
0.175 (0.0069)
0.200 (0.0079)
0.225 (0.0089)
0.250 (0.0098)
0.275 (0.0108)
E: INSPECTION
Make sure that all component parts are free of
scratch, hole and other faults.
Adjust the teeth alignment. <Ref. to 5AT-91, ADJUSTMENT, Drive Pinion Shaft Assembly.>
4) Adjust the backlash between drive pinion and

hypoid driven gear. <Ref. to 5AT-97, ADJUSTMENT, Front Differential Assembly.>
5) Apply red lead evenly to the surfaces of three or
four teeth on hypoid driven gear. Rotate the drive
pinion in the leftward and rightward for several
times. Remove the oil pump cover, and check the
tooth contact pattern.
If the tooth contact is improper, readjust the backlash or shim thickness. <Ref. to 5AT-97, ADJUSTMENT, Front Differential Assembly.>
toward heel.]
(A)
F: ADJUSTMENT
1) Remove the liquid gasket completely from mating surfaces.
2) Install the converter case to oil pump cover, and
secure them with tightening four bolts evenly.
(B)
NOTE:
Use an old gasket or aluminum washer so as not to
damage the mating surface of housing.
Tightening torque:
41 Nm (4.2 kgf-m, 30.4 ft-lb)
and ST2.
AT-00207
(A) Toe side

(B) Heel side
Face contact
Contact pattern
AT-00208
5AT-91

Corrective action: Increase thickness of drive pinion height adjusting shim in order to bring drive pinion close to hypoid driven gear.
Corrective action: Reduce thickness of drive pinion

height adjusting shim in order to bring drive pinion
away from hypoid driven gear.
AT-00212
AT-00213

Checking item: Contact areas are too small
Contact pattern
Flank contact
Contact pattern
AT-00209
AT-00211

height adjusting shim in order to bring drive pinion
away from hypoid driven gear.
Corrective action: Increase thickness of drive pinion height adjusting shim in order to bring drive pinion close to hypoid driven gear.
AT-00213

Checking item: Contact areas are too small
Contact pattern
AT-00212
6) If tooth contact is correct, mark the retainer position and loosen it. After fitting a new O-ring and oil
seal, screw in the retainer to the marked position.
Tighten the lock plate with specified torque.
AT-00210
5AT-92

Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
(A)
AT-01986
(A) Lock plate
5AT-93

Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
A: REMOVAL
from stay.
Case.>
7) Remove the differential side retainers using ST.
NOTE:
Hold the differential case assembly by hand to
avoid damaging the retainer mounting hole of converter case.
ST 18630AA010 WRENCH COMPL RETAINER
8) Remove the differential assembly without damaging the installation part of retainer.
B: INSTALLATION
1) When installing the differential assembly to
case, be careful not to damage the inside of case
(particularly, the differential side retainer mating
surface).
(A)
AT-01988
(A) Lock plate
6) Install the converter case to transmission case.

<Ref. to 5AT-84, INSTALLATION, Converter
Case.>
stay.
C: DISASSEMBLY
(A)
1) Remove the taper roller bearing using ST and

press.
ST 498077000
REMOVER
AT-01987
(A) Differential ASSY
2) Install the O-ring to left and right side retainer.

3) Install the side retainers using ST. <Ref. to 5AT94, REMOVAL, Front Differential Assembly.>
ST 18630AA010 WRENCH COMPL RETAINER
4) Adjust the front differential backlash. <Ref. to
5) Install the lock plate.
5AT-94
AT-00216

2) Secure the case in a vise and remove the hypoid

driven gear tightening bolts, then separate the hypoid driven gear case (RH) and case (LH).
(A)
(B)
(C)
AT-00220
3) Remove the split pin, and then remove the claw.

ST 398527700
PULLER ASSY
AT-00217

3) Pull out the straight pin and shaft, and then remove the differential bevel gear, washer and differential bevel pinion.
AT-00221
(A) Claw
(B) Split pin
(C) Pin
(A)
4) Attach two claws to the outer race, and set the

ST to side retainer.
ST 398527700
PULLER ASSY
AT-00218
2. SIDE RETAINER
NOTE:
After adjusting the drive pinion backlash and tooth
contact, remove and install the oil seal and O-ring.
AT-00222
(A) Shaft
(B) Claw
AT-00219
5) Restore the removed claws to original position,

and install the pin and split pin.
6) Hold the shaft of ST to avoid removing from side
retainer, and then remove the bearing outer race.
ST 398527700
PULLER ASSY
5AT-95

NOTE:
Replace the bearing inner and outer races as a single unit.
4) Install the hypoid driven gear and secure by

tightening the bolt.
Tightening torque:
62 Nm (6.3 kgf-m, 45.6 ft-lb)
(A)
(B)
(C)
AT-00223
AT-00217
(A) Shaft
(B) Side retainer

D: ASSEMBLY
1) Install the washer, differential bevel gear and differential bevel pinion in the differential case (RH).
Insert the pinion shaft.
2) Install the straight pin in reverse direction.
(A)
5) Measurement of backlash (Selection of washer)

(1) Install the SUBARU genuine axle shaft to
differential case.
(2) Measure the gear backlash using ST1 and
ST2, and then insert the ST2 from the access
window of case.
NOTE:
Measure the backlash by applying a pinion tooth
between two bevel gear teeth.
Fix the bevel pinion gear in place with a screwdriver or similar tool when measuring.
AT-00218
Standard value:
0.13 0.18 mm (0.0051 0.0071 in)
3) Install the washer and differential bevel gear to

differential case (LH). Put the differential case (RH)
on the case, and then combine the both cases.
ST1
ST2
AT-00224
(3) If the backlash is not within specifications,

select a washer from the table below.
Washer
Part Number
803038021
803038022
803038023
5AT-96
Thickness mm (in)
0.95 (0.037)
1.00 (0.039)
1.05 (0.041)

ST
6) Using the ST, install the taper roller bearing.

ST 398487700
DRIFT
18630AA010 WRENCH ASSY
2. SIDE RETAINER
NOTE:
Install the oil seal and O-ring of side retainer after
the adjustment of backlash and tooth contact.
1) Install the bearing outer race to side retainer.
2) Fit a new oil seal using ST.
SEAL INSTALLER
NOTE:
ST
AT-00227

3) Remove the liquid gasket from the mating surface completely.
4) Install the oil pump cover to converter case, and
secure them with tightening four bolts evenly.
ST
NOTE:
Use an old gasket or aluminum washer so as not to
damage the mating surface of housing.
Tightening torque:
41 Nm (4.2 kgf-m, 30.4 ft-lb)
5) Rotate the drive pinion ten times or more using
ST1 and ST2.
AT-00226
3) Install a new O-ring.
ST1
ST2
AT-00219
E: INSPECTION
AT-01985
Check each component for scratches, damage

and other faults.
specification.
<Ref. to 5AT-97, ADJUSTMENT, Front Differential
Assembly.>
6) Tighten the retainer LH until contact is felt while

rotating the shaft. Then loosen the retainer RH.
Keep tightening the retainer LH, and loosening the
retainer RH until the pinion shaft cannot be turned.
This is the zero state.
F: ADJUSTMENT
1) Using the ST, screw-in the retainer until light
contact is felt.
(A)
NOTE:
Screw-in the RH side slightly deeper than the LH
side.
AT-01986
(A) Retainer
5AT-97

7) After the zero state is established, back off the

retainer LH 3 notches and secure it with the lock
plate. Then back off the retainer RH and retighten
until it stops. Rotate the drive pinion few times.
Tighten the retainer RH 1-3/4 notches further. This
sets the preload. Finally, secure the retainer with its
lock plate.
(A)
AT-01988
(A) Lock plate
NOTE:
Turning the retainer by one tooth changes the
backlash about 0.05 mm (0.0020 in).
(A)
AT-01989
(A) 0.05 mm (0.0020 in)
8) Turn the drive pinion several times with ST1 and

check to see if the backlash is within the specified
value with ST2, ST3, ST4 and ST5.
ST5 498255400 PLATE
Backlash:
0.13 0.18 mm (0.0051 0.0071 in)
9) Adjust the tooth contact between front differential and drive shaft. <Ref. to 5AT-91, ADJUSTMENT, Drive Pinion Shaft Assembly.>
5AT-98
AT Main Case
36.AT Main Case
14) Remove the mid carrier assembly.
A: REMOVAL
from stay.
7) Remove the extension case and intermediate
9) Remove the reduction driven gear. <Ref. to 5AT78, REMOVAL, Reduction Driven Gear.>
Case.>
11) Remove the control valve body. <Ref. to 5AT59, REMOVAL, Control Valve Body.>
<Ref. to 5AT-86, REMOVAL, Oil Pump Cover.>
AT-01992
15) Remove the rear carrier assembly.
NOTE:
The input clutch pack assembly and front sun gear
assembly are also removed together.
AT-01990
13) Remove the needle bearing of the mid carrier

assembly.
AT-01993
AT-01991
5AT-99
AT Main Case
16) Remove the mid & rear sun gear assembly.
19) Remove the direct clutch assembly.
AT-01997
20) Remove the snap ring of reverse brake.
AT-01994
17) Remove the thrust needle bearing of high & low

reverse clutch.
AT-01998
21) Remove the retaining plate.

22) Remove the leaf spring.
(A)
AT-01995
18) Remove the high & low reverse clutch assembly.

B
(A)
AT-01999
AT-01996
(A) Leaf spring
23) Take out the drive plate, driven plate and dish
plate.
24) Remove the snap ring of the spring retainer of
reverse brake.
5AT-100
AT Main Case
ST1
ST2
ST3
18762AA000 COMPRESSOR SPECIAL

TOOL
18765AA000 COMPRESSOR SUPPORT
28) Apply compressed air.
ST1
AT-02004
29) Remove the reverse brake piston.
ST2
ST3
AT-02005
30) Remove the thrust bearing and seal ring.

AT-02000
25) Remove the spring retainer.
(A)
(B)
(A)
AT-02001
26) Remove the return spring.

(A)
(B)
(A)
AT-04306
(A) Thrust bearing

(B) Seal ring
AT-02002
27) Remove the snap ring of reverse brake piston.

TOOL
5AT-101
AT Main Case
B: INSTALLATION
ST3
1) Apply ATF to a new seal ring.

2) Install the thrust bearing and new seal ring to
drum support.
ST1
(A)
(B)
(A)
ST2
ST3
(A)
(B)
(A)
AT-02000
6) Install the dish plate.

NOTE:
When installing, make sure that the identification
mark is facing the front side of transmission.
7) Install the drive plate and driven plate.
8) Install the leaf spring.
AT-04306
(A) Thrust bearing

(B) Seal ring
3) Install the reverse brake piston.

NOTE:
Apply ATF onto the piston sliding surface.
TOOL
4) Install the return spring.
(A)
(A)
AT-02002
5) Install the spring retainer and snap ring.

TOOL
AT-01999
(A) Leaf spring
9) Install the retaining plate.
5AT-102
AT Main Case
10) Install the snap ring of reverse brake.
13) Install the high & low reverse clutch assembly.
AT-01998
AT-01996
11) Perform the clearance check of reverse brake.

(1) Measure the clearance between retainer
plate and snap ring using thickness gauge.
14) Install the thrust needle bearing of high & low

reverse clutch.
Standard value:
0.7 1.1 mm (0.028 0.043 in)
AT-01995
15) Install the middle & rear sun gear assembly.

AT-02372
(2) If the clearance is out of specification, select

a suitable retainer plate from following table and
assemble it.
Part Number
31567AB100
31567AB170
31567AB180
31567AB190
31567AB200
Retainer plate
Thickness mm (in)
4.2 (0.165)
4.4 (0.173)
4.6 (0.181)
4.8 (0.189)
5.0 (0.197)
12) Install the direct clutch assembly.
AT-01994
AT-01997
5AT-103
AT Main Case
16) Install the rear carrier assembly.
18) Install the thrust needle bearing of middle carrier assembly.
AT-01991
19) Measure the total end play, and select the

bearing. <Ref. to 5AT-107, ADJUSTMENT, AT
Main Case.>
20) Install the impact clutch pack assembly to oil
pump cover.
(B)
AT-01993
17) Install the middle carrier assembly.
(A)
AT-02006
(A) Impact clutch pack ASSY

(B) Front sun gear ASSY
21) Turn the transmission sideways.

(1) Apply ATF to the O-ring of input clutch shaft.
(2) Install the oil pump cover to AT main case
while supporting the input clutch shaft and oil
pump housing by hand.
AT-01992
AT-01990
5AT-104
AT Main Case
(3) Make sure the rear end of drive pinion shaft

is engaged to the spline of reduction driven
gear.
(A)
AT-02092
(4) Using a cloth, protect the input clutch shaft

and rotate to engage the spline of input clutch
and rear carrier using pliers.
NOTE:
Work with pressing oil pump cover.
(A)

26) Install the control valve body. <Ref. to 5AT-59,
INSTALLATION, Control Valve Body.>
27) Install the converter case assembly into transmission case assembly. <Ref. to 5AT-84, INSTALLATION, Converter Case.>
at the end of repair work, and make sure there is no
faulty as below;
NOTE:
AT-02046
(A) Cloth
C: DISASSEMBLY
(5) Combine the oil pump cover with transmission main case.
1. INPUT CLUTCH PACK ASSY

1) Remove the front sun gear.
Tightening torque:
41 Nm (4.2 kgf-m, 30.4 ft-lb)
AT-02007
AT-01976

5AT-105
AT Main Case
2) Remove the snap ring, and then remove the

front carrier.
3) Install the front sun gear.
AT-02007
AT-02008
3) Remove the input clutch assembly from rear internal gear.
E: INSPECTION
1. FRONT, MIDDLE & REAR PLANETARY
CARRIER ASSY
Inspect the followings:
Visually inspect the tooth surface of planetary
gear, and replace with new one if damaged, broken
or excessively worn.
Inspect the planetary carrier body for damage or
brakeage.
2. INPUT CLUTCH
Check for damage of drive plate, driven plate and
snap ring, and replace them as input clutch assembly if damaged.
AT-02009
D: ASSEMBLY
1. INPUT CLUTCH PACK ASSY
1) Assemble the input clutch assembly to rear internal gear.
3. HIGH & LOW REVERSE CLUTCH ASSEMBLY

Check the clearance of high & low reverse clutch.
Measure the clearance L between snap ring and
retaining plate using thickness gauge. If the measured value is out of specification, replace them as
high & low reverse clutch assembly.
Standard value:
1.8 2.2 mm (0.070 0.087 in)
L
AT-02009
2) Install the front carrier, and then install the snap

ring.
AT-02010
4. DIRECT CLUTCH ASSEMBLY
AT-02008
Check the clearance of direct clutch.

Measure the clearance L between snap ring and
retaining plate using thickness gauge. If the measured value is out of specification, replace them as
direct clutch assembly.
5AT-106
AT Main Case
4) Using the ST, measure the depth D from AT

main case mating surface to thrust bearing transferring surface of front sun gear.
ST 499575400
GAUGE
Standard value:
0.6 1.0 mm (0.024 0.039 in)
L
D
AT-02011
5. REVERSE BRAKE
ST

Snap ring for wear, return spring for breakage,
and spring retainer for deformation
Piston operation
F: ADJUSTMENT
1) Using the ST, measure the height A from AT
main case mating surface to convex surface of oil
pump cover.
ST 499575400
GAUGE
ST
5) Set the value as E which subtract the thickness

of ST GAUGE from measured value on step 4).
Calculation formula: E (mm) = D 15
[E (in) = D 0.59]
Select a thrust bearing from the table to adjust
clearance within 0.25 0.55 mm (0.0098 0.022
in).
T (mm) = E C + 0.03
[T (in) = E C + 0.0012]
T (mm) = E C 0.27
[T (in) = E C 0.012]
T: Thrust bearing clearance
C: Distance from oil pump cover mating surface to
rear end of oil pump cover
E: Depth from mating surface of AT main case to
bearing surface of front sun gear
AT-02012
2) Using the ST, measure the depth B from the

convex surface of oil pump cover to thrust bearing
transferring surface.
ST 499575400
GAUGE
AT-02014
ST
AT-02013
3) Calculate the measured value on step 1) and 2),

and then set the calculated value as C
Calculation formula: C = A B
Example:
When the A is 39.50 mm (1.56 in), B is going to be
16.20 mm (0.64 in), so the C would be 23.30 mm
(0.92 in) by calculation.
When the D is 41.90 mm (1.65 in), subtract the
thickness of ST GAUGE from D, and then the value
E would be 26.90 mm (1.06 in).
T (mm) = 26.90 23.30 + 0.03 = 3.63
[T (in) = 1.059 0.917 + 0.0012 = 0.143]
Calculation formula when clearances are 0.55 mm
(0.022 in)
T (mm) = 26.90 23.30 0.27 = 3.33
[T (in) = 1.059 0.917 0.012 = 0.131]
According to the calculation, the value T would be
3.33 3.63 mm (0.131 0.143 in), therefore select the thrust bearing with the thickness of 3.4 mm
(0.134 in) or 3.6 mm (0.142 in) thrust bearing from
the table.
5AT-107
AT Main Case
NOTE:
Calculation formula for T is applied when measuring using ST (499575400 GAUGE). In the calculation without using ST, insert the thickness of collar
to calculate value E on step 5).
5AT-108

37.Transmission Control Device
10) Remove the detention spring.
A: REMOVAL
3) Lift-up the lever on rear side of transmission harness connector, and then disconnect it from stay.
5) Wrap vinyl tape around the nipple attached to
the air breather hose.
7) Remove the control valve body assembly. <Ref.
to 5AT-59, REMOVAL, Control Valve Body.>
8) Pull out the straight pin of manual plate.
AT-00307
B: INSTALLATION
1) Install the detention spring to transmission case.
Tightening torque:
6 Nm (0.6 kgf-m, 4.3 ft-lb)
AT-00307
AT-00305
2) Insert the select lever, and then tighten the bolt.
9) Remove the bolts securing select lever, and then

remove the select lever, manual plate and parking
rod.
Tightening torque:
6 Nm (0.6 kgf-m, 4.3 ft-lb)
NOTE:
Be careful not to damage the lips of press-fitted oil
seal in the case.
AT-00308
AT-00306
(A)
(B)
(C)
(D)
Bolt
Range select lever
Manual plate
Parking rod
5AT-109

3) Insert the manual plate and parking rod.
AT-00306
(A)
(B)
(C)
(D)
Bolt
Range select lever
Manual plate
Parking rod
4) Insert the spring pin to manual plate.
AT-00305
5) Install the oil pan and control valve assembly.

<Ref. to 5AT-59, INSTALLATION, Control Valve
Body.>
6) Install the pitching stopper bracket.
Tightening torque:
41 Nm (4.2 kgf-m, 30.4 ft-lb)
7) Insert the transmission connector to the stay.
8) Install the air breather hose.<Ref. to 5AT-69, INSTALLATION, Air Breather Hose.>
C: INSPECTION
Make sure the manual lever and detention spring
are not worn or otherwise damaged.
5AT-110
(DIAGNOSTICS)
5AT(diag)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Page
Transmission Control Module (TCM) I/O Signal .......................................12
Inspection Mode........................................................................................20
Learning Control........................................................................................22
SPORT Indicator Light Display .................................................................23
Diagnostic Procedure for Subaru Select Monitor Communication ............26
Diagnostic Procedure without Diagnostic Trouble Code (DTC) ..............139


A: PROCEDURE
1
Step
<Ref. to 5AT(diag)-4, Check List for Interview.>
2) Before performing diagnosis, inspect the
following items which might influence the AT
problems.
General inspection <Ref. to 5AT(diag)-5,
INSPECTION, General Description.>
Oil Leakage
Stall speed test <Ref. to 5AT-32, Stall Test.>
Line Pressure Test <Ref. to 5AT-35, Line
Pressure Test.>
Transfer Clutch Pressure Test <Ref. to 5AT37, Transfer Clutch Pressure Test.>
Time Lag Test <Ref. to 5AT-34, Time Lag
Test.>
Road Test <Ref. to 5AT-31, Road Test.>
Inhibitor Switch <Ref. to 5AT-52, Inhibitor
Switch.>
After the ignition switch is turned to ON, wait
for at least 2 seconds.
2) Check the SPORT indicator light. <Ref. to
5AT(diag)-24, INSPECTION, SPORT Indicator
Light Display.>
3) After the ignition switch is turned to ON,
wait for at least 2 seconds.
CHECK DTC.
Read the DTC. <Ref. to 5AT(diag)-19, OPERATION, Read Diagnostic Trouble Code (DTC).>
Check
Yes
Is the unit that might influence Go to step 2.
the AT problem normal?
No
Repair or replace
each item.

light illuminate?
Go to step 4.
Go to step 3.

light blink?
Go to step 4.
Go to step 5.
Go to step 6.
Go to step 5.
Is DTC displayed?
NOTE:
If the communication function of the Subaru Select Monitor cannot be executed normally,
check the communication circuit. <Ref. to
5AT(diag)-26, COMMUNICATION FOR INITIALIZING IMPOSSIBLE, Diagnostic Procedure
for
Subaru
Select
Monitor
Communication.>
PERFORM THE GENERAL DIAGNOSTICS. Is DTC displayed?
1) Inspect using Diagnostic Procedure without Diagnostic Trouble Code (DTC). <Ref. to
5AT(diag)-139, Diagnostic Procedure without
2) Perform clear memory mode.
4) Display DTC.
5AT(diag)-2
NOTE:
Record all DTC.
Go to step 6.
Inspect using
5AT(diag)-148,

Step
Check
Is DTC displayed?
with Diagnostic Trouble Code (DTC). <Ref. to
5AT(diag)-34, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
NOTE:
For DTC table, refer to List of Diagnostic Trouble Code (DTC). <Ref. to 5AT(diag)-30, List of
5) Display DTC.
5AT(diag)-3
Yes
Inspect using the
(DTC). <Ref. to
5AT(diag)-34,
(DTC).>
No
Inspect using
5AT(diag)-148,


A: CHECK
NOTE:
Customers name
Date of sale
Date of repair
Trans. model
Odometer reading
Symptom
Frequency
Weather
Place

Vehicle speed
AT warning light (SPORT indicator
light)
Driving condition
Manual mode
TRANSMISSION
V.I.N.
km (miles)
No up-shift
No down-shift
No kick down
Vehicle does not move ( Any position Particular position)
Lock-up malfunction
Noise or vibration
Shift shock or slip
Select lever does not move
Others
(
)
Continuous Intermittent (
times a day)
Fine Cloudy Rainy Snowy
Others
(
)
Highland Suburbs Inner city Uphill Rough road
Others
(
)
Hot Warm Cool Cold
km/h (MPH)
Blinks continuously
P R N D
Not affected
At racing
When decelerating
ON
Not blink
Manual mode
At starting
When accelerating
While turning ( RH /
LH)
OFF
5AT(diag)-4
While idling
While cruising
General Description
3. ATF LEVEL
A: CAUTION
Make sure that ATF level is in the specification.

CAUTION:
All airbag system wiring harnesses and connectors are colored yellow. Do not use an electric test equipment on these circuits.
wiring harness when performing diagnostics
and servicing the TCM.
Measurement
When measuring the 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 a pin more than
0.65 mm (0.026 in) diameter.
(A)
(C)
(D)
(E)
Measure battery voltage and specific gravity of

electrolyte.
(B)
(C)
(D)
AT-01450
(A)
(B)
(C)
(D)
(E)
B: INSPECTION
1. BATTERY
COLD
L
Supplemental Restraint System

The airbag system wiring harness is routed near
the TCM.
L
F
HOT
Level gauge
Check position when HOT
Upper level
Lower level
Check position when COLD
4. FRONT DIFFERENTIAL OIL LEVEL

Make sure the front differential oil level is in the
specification. <Ref. to 5AT-30, INSPECTION, Differential Gear Oil.>
2. TRANSMISSION GROUND
Make sure that the ground terminal bolt is tightened

securely.
Chassis side
(A)
(B)
Tightening torque:
13 Nm (1.3 kgf-m, 9.4 ft-lb)
AT-00317
(A) Upper level

(B) Lower level
5. OPERATION OF SHIFT SELECT LEVER

Make sure there is no abnormal noise, dragging or
contact pattern in each select lever range.
AT-01464
WARNING:
Stop the engine while checking operation of the
select lever.
5AT(diag)-5
General Description
LHD model
RHD model
AT-01465
AT-02048
C: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
24082AA230
DESCRIPTION
CARTRIDGE
REMARKS
22771AA030
SUBARU SELECT
MONITOR KIT

ST24082AA230
ST22771AA030
2. GENERAL TOOL
TOOL NAME
Circuit tester
Oscilloscope
REMARKS
5AT(diag)-6


A: LOCATION
1. CONTROL MODULE
LHD model
(1)
(3)
(4) (2)
(5)
AT-02049
(1)
(2)

light)
(3)

(TCM)
(4)
(5)
Data link connector

RHD model
(3)
(2) (4)
(5)
(1)
AT-01467
(1)
(2)

light)
(3)

(TCM)
5AT(diag)-7
(4)
(5)
Data link connector


LHD model
(1)
(2)
AT-01470
AT-02051
(4)
(3)
AT-02053
AT-02052
(5)
AT-02054
RHD model
(1)
(2)
AT-01468
5AT(diag)-8
AT-01470

(4)
(3)
AT-01469
AT-01471
(5)
AT-01472
2. SENSOR
LHD model
(3)
(5),(8)
(1) (2)
(6),(9)
(7)
(4)
AT-02050
5AT(diag)-9

RHD model
(1)
(3)
(5),(8)
(6),(9)
(2)
(7)
(4)
AT-01443
(1)
(2)
(3)
Accelerator position sensor

Inhibitor switch
(4)
(5)
(6)

ATF temperature sensor 1
(7)
(8)
(9)
Lateral G sensor
ATF temperature sensor 2
(2)
(1)
AT-00375
AT-01447
(5)
(4)
(3)
AT-01445
5AT(diag)-10
AT-01448

(7)
(6)
AT-01446
AT-01475
(9)
(8)
AT-01759
AT-01760
3. SOLENOID
(3)
(2)
(4)
(7)
(8)
(6)
(5)
(1)
(9)
AT-01449
(1)
(2)
(3)
High & low reverse clutch solenoid

Direct clutch solenoid
Front brake solenoid
(4)
(5)
(6)
Input clutch solenoid

Line pressure solenoid
Lock up solenoid
5AT(diag)-11
(7)
(8)
(9)
Transfer solenoid
Low coast brake solenoid
Memory box

5. Transmission Control Module (TCM) I/O Signal

B55
B54
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
1 2 3 4
10 11 12 13
19 20 21
9
18
24
5 6
14 15
7
16
22
8
17
23
9
18
24
AT-01451
NOTE:
The measurement should perform after warming up.
Item
P/L solenoid output
PVIGN power supply
I/C oil pressure switch

input
Power GND
CAN communication line
(+)
()

1 input
Connector
No.
B54
Termin
al
No.
Engine ON, P range,

Accelerator OFF, Brake
ON
Manual mode 1st, Accelerator OFF, Brake ON
Ignition switch ON
Ignition switch ON
B54
Approx. 4.0
6.0 V
Approx. 2.0
4.0 V
Power supply
voltage
Power supply
voltage
B54
B54
Ignition switch ON
5AT(diag)-12
2.5 2.9 V
(ATF temperature 20C
(68F))
0.8 1.0 V
(176F))
Driving frequency 750

850 Hz
B54
Approx. 0 V
Remarks
Always
3 9 (ATF
temperature
20C (68F))
B54
B54
Voltage (V)
Measure the
resistance
between terminal and chassis
ground.
4.0 5.0 k
(68F))
0.7 0.9 k
(176F))
The condition
of I/C oil pressure switch
cannot read by
the tester.

Item
Battery power supply
I/C solenoid output
H&LR/C solenoid output
Connector
No.
Termin
al
No.
B54
B54
B54
Control valve power supply output
B54
LC/B solenoid output
B54
Power GND
Analog GND (Sensor
GND)
LC/B oil pressure switch
input
18
17
16
Always
While driving at 1st 3rd
of manual mode
While driving at 4th or 5th
of manual mode
While driving at 2nd of
manual mode
While driving at 3rd 5th
of manual mode
Ignition switch ON
B54
14
Ignition switch OFF

While driving at 1st 2nd
of manual mode
of manual mode
Always
B54
13
Always
B54
15
12
Voltage (V)
Power supply
voltage
Approx. 5.5
7.5 V
Approx. 0 V
Approx. 5.5
7.5 V
Approx. 0 V
Power supply
voltage
Approx. 0 V
Power supply
voltage
Approx. 0 V
11
Ignition switch ON
PVIGN power supply

relay output
B54
10
Ignition switch ON
0 1.5 V
24
While driving at other than

4th of manual mode
While driving at 4th of
manual mode
Approx. 4.5
6.5 V
D/C solenoid output
B54
B54
23
22
When lock-up
When not lock-up
While driving at 1st or 5th
of manual mode
While driving at 2nd 4th
of manual mode
3 9 (ATF
temperature
20C (68F))

850 Hz
5 17 (ATF
temperature
25C (77F))
B54
L/U solenoid output

850 Hz
Approx. 0 V

2 input
B54
3 9 (ATF
temperature
20C (68F))
Approx. 0 V
Approx. 3.5
5.5 V
Approx. 0 V
Approx. 5.5
7.5 V
Approx. 0 V
The condition
of LC/B oil
pressure switch
cannot read by
the tester.
3.0 3.6 k
(68F))
0.4 0.6 k
(176F))
3 9 (ATF
temperature
20C (68F))

850 Hz
3 9 (ATF
temperature
20C (68F))

850 Hz
3 9 (ATF
temperature
20C (68F))

850 Hz
D/C oil pressure switch

input
B54
21

communication line
B54
20
5AT(diag)-13
Remarks
Approx. 0 V
2.3 2.7 V
(68F))
0.6 0.8 V
(176F))
Fr/B solenoid output
Measure the
resistance
ground.
The condition
of D/C oil pressure switch
cannot read by
the tester.

Connector
No.
Termin
al
No.
Control GND
B54
19
H&LR/C oil pressure

switch input
B55
Item
Front vehicle speed sensor input
Lateral G sensor power

supply
Lateral G sensor signal
input
Inhibitor switch 1 input
Accessory power supply
B55
B55
B55
B55
B55
B55
Always
While driving at 2nd of
manual mode
of manual mode
While driving at 2nd and
20 km/h (12 MPH) of manual mode
While driving at 4th and 80
km/h (50 MPH) of manual
mode
Approx. 0 V
Power supply
voltage
Ignition switch ON
4.75 5.25 V
2.0 3.0 V
Ignition switch ON, Engine

ON, Flat value
Ignition switch ON, P
range
Ignition switch ON, N
range
range
Ignition switch ON, D
range
Accessory switch ON
Accessory switch OFF
B55
Rear vehicle speed sensor input
B55
Fr/B oil pressure switch

input
B55

input
B55
18
17
16
Voltage (V)
Measure the
resistance
ground.
Ignition switch ON
Ignition switch OFF
While driving at 2nd and
20 km/h (12 MPH) of manual mode
While driving at 4th and 80
km/h (50 MPH) of manual
mode
ON, While driving at other
than 4th
ON, While driving at 4th
2nd of manual mode, Turbine speed sensor is
2,000 rpm (Read from
Subaru Select Monitor)
4th of manual mode, Turbine speed sensor is
5AT(diag)-14
Remarks
Approx. 0 V
Approx. 140
170 Hz
Approx. 560
680 Hz
4.0 5.0 V
1.5 V or less
4.0 5.0 V
1.5 V or less
Power supply
voltage
Approx. 0 V
Power supply
voltage
Approx. 0 V
Approx. 190
230 Hz
Approx. 760
920 Hz
Approx. 0 V
Power supply
voltage
Use an oscilloscope.
Approx. 0 Hz
Approx. 1,900
2,100 Hz

Item
Range lock solenoid output

Control valve communication line
Connector
No.
Termin
al
No.
Ignition switch ON, While

stopping at D range
B55
B55
B55
B55
15
14
13
12
Back-up light relay output
B55
11
B55
10
AWD solenoid output

input
B55
B55
23
22
Control GND
B55
21
Inhibitor switch 3 open

circuit monitor input
B55
20
PN signal output
B55
19
Ignition switch ON, Vehicle

speed at least 20 km/h (12
MPH)
Ignition switch ON, R
range
range
range
range
Voltage (V)
About Power
Supply Voltage
1.2 V
Ignition switch ON
Ignition switch OFF
Engine ON, P range or
N range, Accelerator
OFF
Engine ON, D range,
Accelerator OFF, Brake
ON
2nd of manual mode, Turbine speed sensor is
4th of manual mode, Turbine speed sensor is
Always
range
range
Ignition switch ON, Other
than P range or N
range
range or N range
5AT(diag)-15
Remarks
7 21
Approx. 0 V
4.0 5.0 V
1.5 V or less
4.0 5.0 V
1.5 V or less

range
Ignition switch ON, Other
than R range
Measure the
resistance
ground.
1.5 V
Power supply
voltage
Power supply
voltage
Approx. 0 V
Approx. 0 V
Approx. 2.0
3.0 V
Approx. 90
110 (ATF temperature 25C
(77F))
3 9 (ATF
temperature
20C (68F))
Approx. 1,300
1,500 Hz

850 Hz
Approx. 1,900
2,100 Hz
Approx. 0 V
4.0 5.0 V
Less than 1.5 V

Power supply
voltage
0 1.0 V
ECM should
connected correctly


A: OPERATION
(DTC)
NOTE:
Do not connect scan tools except for Subaru Select
Monitor.
on the Subaru Select Monitor.

(A)
AT-00341
AT-00338

Monitor.
<Ref. to 5AT(diag)-6, PREPARATION TOOL, General Description.>
AT-00339

connector.
side).
(1)
AT-01712

connector.
(A) Power switch

[YES] key.
screen, select the {Diagnosis Code(s) Display} and
press [YES] key.
NOTE:
Diagnostic Trouble Code (DTC). <Ref. to 5AT(diag)-30, List of Diagnostic Trouble Code (DTC).>

[YES] key.
[YES] key.
5AT(diag)-16


Item
Engine speed signal
Battery voltage
Accel. Pedal Position Sensor
Front vehicle speed sensor signal
Gear position
Turbine speed sensor signal
Rear vehicle speed sensor signal
Lateral G sensor
ATF Temperature Sensor 1 Signal
ATF Temperature Sensor 2 Signal
Turbine speed sensor 1 signal
Turbine speed sensor 2 signal
High & Low Reverse Clutch Solenoid Indicator Current
Direct Clutch Solenoid Indicator Current
Front Brake Solenoid Indicator Current
Input Clutch Solenoid Indicator Current
Line Pressure Solenoid Indicator Current
Lock-up Solenoid Indicator Current
Transfer Solenoid Indicator Current
High & Low Reverse Clutch Solenoid Target Oil Pressure
Direct Clutch Solenoid Target Oil Pressure
Front Brake Solenoid Target Oil Pressure
Input Clutch Solenoid Target Oil Pressure
Line Pressure Solenoid Target Oil Pressure
Lock-up Solenoid Target Oil Pressure
Transfer Solenoid Target Oil Pressure
Ignition switch
Tip signal
Cruise control On signal
Tip Down Shift Signal
Tip Up Shift Signal
Drive range signal
Reverse range signal
Diagnosis Light Output Signal
Shift lock solenoid signal
Parking range signal
P/N Range Output Signal
Neutral range signal
Inhibitor Switch 1 Input Signal
Inhibitor Switch 3 Monitor Input Signal
Back Lamp relay output signal
High & Low Reverse Clutch Fluid Pressure Switch Input Signal
Direct Clutch Fluid Pressure Switch Input Signal
Front Brake Fluid Pressure Switch Input Signal
Input Clutch Fluid Pressure Switch Input Signal
Low Coast Brake Fluid Pressure Switch Input Signal
Display
Engine speed
Battery Voltage
Accel. opening angle
Front Wheel Speed
Gear Position
Turbine Revolution Speed
Rear Wheel Speed
Lateral G sensor
ATF Temp.
ATF Temperature 2
AT Turbine Speed 1
AT Turbine Speed 2
H&LR/C Solenoid Current
D/C Solenoid Current
F/B Solenoid Current
I/C Solenoid Current
P/L Solenoid Current
L/U Solenoid Current
AWD Sol. Current
H&LR/C Solenoid Pressure
D/C Solenoid Pressure
F/B Solenoid Pressure
I/C Solenoid Pressure
P/L Solenoid Pressure
L/U Solenoid Pressure
4WD Solenoid Pressure
Ignition Switch
Tip Mode Switch
Cruise Control Signal
Down Switch
Stop Light Switch
Up Switch
D Range Signal
R Range Signal
Diagnosis Lamp
Shift lock solenoid
P Range
P/N Signal
N Range
Inhibitor SW1
Inhibitor SW2
Inhibitor SW3
Inhibitor SW4
Inhibitor SW3 Monitor
Back Lamp relay
H&LR/C Fluid Pressure
D/C Fluid Pressure
Fr/B Fluid Pressure
I/C Fluid Pressure
LC/B Fluid Pressure
5AT(diag)-17
Unit of measure
rpm
V
%
km/h
rpm
km/h
V
C
C
rpm
rpm
A
A
A
A
A
A
A
kPa
kPa
kPa
kPa
kPa
kPa
kPa
ON Input or OFF Input
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
High or Low
High or Low
High or Low
High or Low
High or Low
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF

Item
Low Coast Brake Solenoid Input Signal
Display
LC/B Solenoid
NOTE:
For details concerning operation procedure, refer
to the SUBARU SELECT MONITOR OPERATION
MANUAL.

NOTE:
To clear the previous DTC, use {Clear Memory},
and to clear the learned value, use {Clear Memory
2}.
1) Check that the select lever is in P range.
[YES] key.
[YES] key.
NOTE:
If {Clear Memory 2} is selected and performed,
DTC may not be cleared.
6) When the Done are shown on the display
screen, turn off the Subaru Select Monitor and turn
the ignition switch to OFF. To turn the ignition
switch ON again, wait for more than 10 seconds.
NOTE:
MANUAL.
5AT(diag)-18
Unit of measure
ON or OFF


Code (DTC)
A: OPERATION
about how to obtain and understand the DTC.
<Ref. to 5AT(diag)-16, OPERATION, Subaru Select Monitor.>
NOTE:
DTC can not be read by SPORT indicator light.
5AT(diag)-19
Inspection Mode
8. Inspection Mode
A: PROCEDURE
WARNING:
Observe the traffic law during actual driving.
1) Shift the select lever to D range, and then drive
the vehicle with changing the gear from 1st to 5th.
2) When driving the vehicle at 5th speed of D
range, set the gear to manual mode and drive the
vehicle with shifting down using of steering
switch or of select lever from 5th 4th, 4th
3rd, 3rd 2nd, 2nd 1st.
NOTE:
At shifting down, drive the vehicle at least 10 seconds in each speed.
3) Shift the select lever to R range and drive the
vehicle for more than 2 seconds.
5AT(diag)-20
Clear Memory Mode


A: OPERATION
Use Subaru Select Monitor to clear DTC. <Ref. to
5AT(diag)-18, CLEAR MEMORY MODE, OPERATION, Subaru Select Monitor.>
NOTE:
DTC cannot be cleared without using Subaru Select Monitor.
5AT(diag)-21
Learning Control
10.Learning Control
Be sure to perform the {Clear Memory 2} only when
the following services are performed. And when the
shifting shock is occurred in total check with vehicle
driving, perform the learning with following procedures. <Ref. to 5AT(diag)-18, CLEAR MEMORY
MODE, OPERATION, Subaru Select Monitor.>
Replacement of TCM
Replacement of transmission assembly
Replacement of each clutch
Replacement of control valve body
CAUTION:
When {Clear Memory 2} is executed, DTC may
not be cleared.
B: PROCEDURE
2) Turn the air conditioner switch to OFF.
3) Turn the headlight switch to OFF.
4) Turn the rear defogger switch to OFF.
6) Connect the Subaru Select Monitor to the vehicle.
7) Drive the vehicle for 5 10 km (3 6 miles) to
warm up ATF temperature more than 70 C (158
F).
8) While the throttle opening angle on SUBARU
Select Monitor indicates within specified range,
shift the gear from 1st 2nd, 2nd 3rd, 3rd
4th, with the vehicle at D range. <Ref. to 5AT(diag)-16, READ CURRENT DATA, OPERATION,
Throttle opening angle:
Turbo model
10%2%
Non-turbo model
19%2%
9) While the throttle opening angle on SUBARU
Select Monitor indicates within specified range,
shift the gear from 4th 5th with the vehicle at D
range.
Throttle opening angle:
Turbo model
12.5%2%
Non-turbo model
22%2%
10) Repeat the steps 8) 9) until reducing of shifting shock was felt.
11) Reducing of shifting shock was not felt though
the procedure was repeated 5 cycle, recheck that
the learning conditions (throttle opening angle, ATF
temperature, etc.) are specified and recheck that
other parts are normal.
5AT(diag)-22

11.SPORT Indicator Light Display

A: OPERATION
When any on-board diagnostics item is malfunctioning, the display on the SPORT 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 unit can be determined by a DTC during the on-board diagnostics operation. Problems
which occurred previously can also be identified through the memory function. If the SPORT indicator light
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 Subaru Select Monitor. Indicator light signal is as
When the SPORT indicator light does not operates normally though the DTC is not stored, perform the
SPORT indicator light inspection. <Ref. to 5AT(diag)-24, INSPECTION, SPORT Indicator Light Display.>
(A)
(1)
(2)
(B)
(1)
(3)
(2)
(4)
(C)
(1)
(3)
(2)
(5)
AT-01750
(A)
Ignition switch (Engine OFF)
(B)
Normal (Engine ON)
(C)
Faulty (Engine ON)
(1)
(2)
ON
OFF
(3)
(4)
2 sec.
0.25 sec.
(5)
Blink
5AT(diag)-23

B: INSPECTION
DIAGNOSIS:
SPORT indicator light circuit is open or shorted.
TROUBLE SYMPTOM:
When the ignition switch is turned to ON (engine OFF), SPORT indicator light does not illuminate.
WIRING DIAGRAM:
i10
IGNITION
SWITCH
SBF-1
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
SBF-7
BATTERY
No.12
i77
1 2 3 4 5 6 7 8 9 10 11 12
i84
A:
1 2
3 4
5 6
7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35
SPORT
COMBINATION
METER
B54
i84
22
7
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
JOINT
CONNECTOR
B54
i77
A27
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
9
18
24
B30
A:
B: B280
B20
B: B280
21
A26
i10
TCM
AT-01452
5AT(diag)-24

Step
Check
light illuminate?
Yes
Go to step 2.

After the ignition switch is ON, wait for at least
2 seconds.
Start the engine.

light illuminate?
Go to step 3.
CHECK SUBARU SELECT MONITOR COMMUNICATION.

connector.
CHECK TCM.
Display the current data of TCM using Subaru
Select Monitor.

Monitor.>
CHECK TCM.
2) Display the current data of TCM using Subaru Select Monitor. <Ref. to 5AT(diag)-16,
Monitor.>

light go off?
No
Go to step 4.
Normal. Go back Go to step 7.

to Basic Diagnosis Procedure.
<Ref. to 5AT(diag)2, Basic Diagnostic Procedure.>
Is the communication between Go to step 5.
Check the TCM
power supply
TCM normal?
ground circuit and
Subaru Select
Monitor communication. <Ref. to
5AT(diag)-26,
Diagnostic Procedure for Subaru
Select Monitor
Communication.>
Is Diagnosis light output sig- Go to step 6.
Replace the TCM.
nal set to ON?
<Ref. to 5AT-62,
(TCM).>
Is SPORT light input signal
Replace the com- Check DTC of
set to ON?
bination meter
body integrated
assembly. <Ref. to unit. <Ref. to
IDI-16, Combina- LAN(diag)-14,
tion Meter.>
OPERATION,
Subaru Select
Monitor.>
Is Diagnosis light output sig- Replace the TCM. Go to step 8.
nal set to ON?
<Ref. to 5AT-62,
(TCM).>
Is SPORT light input signal
Check DTC of
Perform the selfset to ON?
body integrated
diagnosis for comunit. Perform the bination meter.
diagnosis accord- <Ref. to IDI-3,
ing to DTC. <Ref. INSPECTION,
to LAN(diag)-14, Combination
OPERATION,
Meter System.>
Subaru Select
Monitor.>
5AT(diag)-25

12.Diagnostic Procedure for Subaru Select Monitor Communication

DIAGNOSIS:
Faulty harness connector
TROUBLE SYMPTOM:
Subaru Select Monitor communication failure
WIRING DIAGRAM:
BATTERY
SBF-1
No.13
SBF-7
NO.32
10
ACCESSORY
SWITCH
IGNITION
SWITCH
12
B357
DATA LINK
CONNECTOR
B40
NO.31
NO.12
13
16
B21
B21
A5
B21
B40
1 2 3 4
5 6 7 8
9 10 11 12
13 14 15 16
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
A20
B2
TCM
B55
A14
B:
B54
A19
A:
B1
B10
A10
A7
A8
A1
E2
TRANSMISSION
A:
B54
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8 9
17 18
23 24
B:
B55
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
9
18
24
AT-01453
5AT(diag)-26

Step
Check
Yes
CHECK SUBARU SELECT MONITOR POW- Is the voltage more than 10 V? Go to step 2.
ER SUPPLY CIRCUIT.
Measure the voltage between data link connector and chassis ground.

GROUND CIRCUIT.
data link connector and chassis ground.

?

whether communication to transmission systems can be executed normally.
2) Disconnect the TCM connector.
4) Check whether communication to engine
3) Disconnect the ECM connector.
5) Check whether communication to transmission systems can be executed normally.
EACH CONTROL UNIT AND DATA LINK
CONNECTOR.
2) Disconnect the TCM and ECM connector.
3) Measure the resistance between TCM connector and chassis ground.
CHECK OUTPUT SIGNAL OF TCM.
chassis ground.
TCM AND DATA LINK CONNECTOR.
Measure the resistance between TCM connector and data link connector.
(B54) No. 20 (B40) No. 10:
Are the name and year of sys- Go to step 8.

tem displayed on Subaru
Select Monitor?
Go to step 3.
No
Repair harness
connector and
connector
between battery
and data link connector, and poor
Repair the open
circuit in harness
between data link
connector and
ground terminal,
and poor contact
in coupling connector.
Go to step 4.
Are the name and year of sys- Go to step 6.

Select Monitor?
Go to step 5.
Are the name and year of sys- Inspect the ECM.

Select Monitor?
Go to step 6.

M?
Go to step 7.
Check harness
and connector
link connector.
Check harness
Go to step 8.
and connector
link connector.

?
Go to step 9.
5AT(diag)-27
Repair the harness and connector between TCM


10
11
12
13
Step
CHECK INSTALLATION OF TCM CONNECTOR.
CHECK INSTALLATION OF TRANSMISSION
HARNESS CONNECTOR.
Check
Is TCM connector connected
to TCM?
Yes
Go to step 10.
No
Connect the TCM
connector to TCM.
Is the transmission harness

connector connected to bulkhead harness connector?
Go to step 11.
Connect the bulkhead harness connector to

transmission harness connector.
Go to step 12.
CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in control

unit power supply and data link
connector?
CHECK POWER SUPPLY OF TCM.
Is the fuse (No. 32) blown out?
14
CHECK HARNESS.
Measure the resistance between TCM connec- ?
tor and chassis ground.
15

OFF).
Remove the fuse (No. 12).
16
Repair the poor

contact.
Go to step 15.
Go to step 13.
Go to step 14.
Repair the open

circuit in harness
between fuse (No.
32) and TCM, or
fuse (No. 32) and
battery, and poor
Replace the fuse
(No. 32).
Replace the fuse

(No. 32). If the
replaced fuse (No.
32) has blown out
easily, repair the
short circuit in harness between fuse
(No. 32) and TCM.
Go to step 17.
Go to step 16.
Is the fuse (No. 12) blown out? Replace the fuse

(No. 12). If the
replaced fuse (No.
12) has blown out
easily, repair the
(No. 12) and TCM.
5AT(diag)-28
Repair the open

circuit in harness
between fuse (No.
12) and TCM, or
fuse (No. 12) and
battery, and poor

17
18
Step
Check
Yes
M?
2) Disconnect the connectors from TCM and
transmission.
CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in TCM
Repair the conpower supply, ground and data nector.
link connector?
5AT(diag)-29
No
Repair the short
circuit in harness
between TCM and
transmission harness connector,
and poor contact
in coupling connector.
Replace the TCM.

<Ref. to 5AT-62,
(TCM).>


A: LIST
DTC
Item
P0705
Transmission Range
Sensor Circuit (PRNDL
Input)
Inhibitor switch 1 malfunction,

open or short circuit
P0712

Low Input
ATF temperature sensor 1 malfunction, open input signal circuit
P0713

High Input
ATF temperature sensor 1 malfunction, short input signal circuit
P0715
Input/Turbine Speed
Sensor Circuit
Turbine speed sensor 1 malfunction, short input signal circuit
P0719
Switch B Circuit Low
P0720
Output Speed Sensor

Circuit
P0724
Switch B Circuit High
P0725
Engine Speed Input Circuit
P0731
P0732
P0733
Vehicle sensor, turbine speed

sensor, or shift clutch malfunction
P0734

P0735

P0736
Reverse Incorrect Ratio

P0741

Circuit Performance or
Stuck Off
Lock-up clutch is faulty or valve is

stuck.
Brake switch malfunction, open

input signal circuit, body integrated unit malfunction, CAN
communication malfunction
Front wheel speed sensor is
faulty or input signal circuit,
ground, power supply is open or
shorted.
Brake switch malfunction, short
circuit of input signal, body integrated unit malfunction, CAN
communication malfunction
Open or short engine speed output signal circuit, ECM malfunction, CAN communication
malfunction
sensor, control valve malfunction
or shift clutch malfunction
sensor, control valve malfunction
or shift clutch malfunction
5AT(diag)-30
Reference target
<Ref. to 5AT(diag)-34, DTC P0705 TRANSMISSION RANGE SENSOR CIRCUIT (PRNDL
INPUT), Diagnostic Procedure with Diagnostic
CIRCUIT LOW INPUT, Diagnostic Procedure
CIRCUIT HIGH INPUT, Diagnostic Procedure
<Ref. to 5AT(diag)-45, DTC P0715 INPUT/
TURBINE SPEED SENSOR CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
LOW, Diagnostic Procedure with Diagnostic
<Ref. to 5AT(diag)-51, DTC P0720 OUTPUT
SPEED SENSOR CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
HIGH, Diagnostic Procedure with Diagnostic
<Ref. to 5AT(diag)-58, DTC P0725 ENGINE
SPEED INPUT CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
CONVERTER CLUTCH CIRCUIT PERFORMANCE OR STUCK OFF, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>

DTC
Item
P0743

Circuit Electrical
P0748
Pressure Control Solenoid A Electrical
P0751
Shift Solenoid A Performance or Stuck Off
P0753
Shift Solenoid A Electrical
P0756
Shift Solenoid B Performance or Stuck Off
P0758
Shift Solenoid B Electrical
P0761
Shift Solenoid C Performance or Stuck Off
P0763
Shift Solenoid C Electrical
P0766
Shift Solenoid D Performance or Stuck Off
P0768
Shift Solenoid D Electrical
P0771
Shift Solenoid E Performance or Stuck Off
P0773
Shift Solenoid E Electrical
P0801
Reverse Inhibit Control

Circuit
P0817
Starter Disable Circuit
P0882
PVIGN Power Supply

Circuit (Low)
Reference target
L/U solenoid circuit malfunction
CONVERTER CLUTCH CIRCUIT ELECTRIor L/U solenoid body malfunction CAL, Diagnostic Procedure with Diagnostic
<Ref. to 5AT(diag)-63, DTC P0748 PRESLine pressure solenoid circuit
SURE CONTROL SOLENOID A ELECTRImalfunction or line pressure soleCAL, Diagnostic Procedure with Diagnostic
noid body malfunction
Shift Solenoid A performance
SOLENOID A PERFORMANCE OR STUCK
malfunction
OFF, Diagnostic Procedure with Diagnostic
Fr/B solenoid circuit malfunction
SOLENOID A ELECTRICAL, Diagnostic Proor Fr/B solenoid body malfunction
cedure with Diagnostic Trouble Code (DTC).>
Shift Solenoid B Performance
SOLENOID B PERFORMANCE OR STUCK
malfunction
I/C solenoid circuit malfunction or
SOLENOID B ELECTRICAL, Diagnostic ProI/C solenoid body malfunction
SOLENOID C PERFORMANCE OR STUCK
H&LR/C solenoid malfunction
H&LR/C solenoid circuit malfunc- <Ref. to 5AT(diag)-82, DTC P0763 SHIFT
tion or H&LR/C solenoid body
SOLENOID C ELECTRICAL, Diagnostic Promalfunction
SOLENOID D PERFORMANCE OR STUCK
D/C solenoid malfunction
D/C solenoid circuit malfunction
SOLENOID D ELECTRICAL, Diagnostic Proor D/C solenoid body malfunction
SOLENOID E PERFORMANCE OR STUCK
LC/B solenoid malfunction
LC/B solenoid circuit malfunction or LC/B solenoid body mal<Ref. to 5AT(diag)-94, DTC P0773 SHIFT
function
SOLENOID E ELECTRICAL, Diagnostic Pro OFF malfunction of PVIGN
relay circuit or relay body
Shift lock solenoid is faulty or
INHIBIT CONTROL CIRCUIT, Diagnostic Proshorted.
Brown out of TCM+B fuse
PN signal output circuit is open
or shorted.
<Ref. to 5AT(diag)-100, DTC P0817 STARTER
ECM Source Voltage Is Abnor- DISABLE CIRCUIT, Diagnostic Procedure with
mal
Brown out of TCM+B fuse
PVIGN relay output circuit is
<Ref. to 5AT(diag)-102, DTC P0882 TCM
open, shorted or relay malfuncPOWER INPUT SIGNAL LOW, Diagnostic Protion
5AT(diag)-31

DTC
Item
Back-up relay output circuit is
open, shorted or relay OFF malfunction
Back-up relay output circuit is
open, shorted or relay ON malfunction
P0957
Backup Light Relay Circuit Low
P0958
Backup Light Relay Circuit High
P1601
TCM Communication
Malfunction
Communication Failure between

TCM and Memory Box
P1706

(Rear Wheel)
Rear wheel speed sensor is faulty

or input circuit, ground, power
supply is open or shorted.
P1707
AT AWD Solenoid Valve

Circuit Malfunction
AWD solenoid circuit malfunction

or AWD solenoid body malfunction
P1710
Torque Converter Turbine 2 Speed Signal Circuit 2 Malfunction
Torque converter sensor 2 malfunction, input circuit, ground,

power open, short circuit
P1716
ATF Temp. Sensor 2 Circuit Low
ATF temperature sensor 2 malfunction, open input signal circuit
P1717
ATF Temp. Sensor 2 Circuit High
ATF temperature sensor 2 malfunction, short input signal circuit
P1718
AT CAN Communication
Circuit
CAN communication line bus off

is open, EUM short circuit, ABS/
VDCCM, integrated CU malfunction
P1760
Sensor Performance
Problem
Lateral G sensor malfunction
P1761
Sensor Circuit Low
Lateral G sensor is faulty, input

signal circuit is open or CAN
communication is malfunction.
P1762
Sensor Circuit High

signal circuit is shorted.
P1798
Gear 1 Engine Brake
P1799
Interlock
P1817
SPORTS Mode Switch

Circuit (Manual Switch)
Malfunction of clutch oil pressure

related to 1st engine brake, solenoid current malfunction
Malfunction of clutch oil pressure
which emit interlock, solenoid
current malfunction
Manual mode switch is open or
shorted, or switch malfunction
5AT(diag)-32
Reference target
<Ref. to 5AT(diag)-104, DTC P0957 BACKUP
LIGHT RELAY CIRCUIT LOW, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to 5AT(diag)-106, DTC P0958 BACKUP
LIGHT RELAY CIRCUIT HIGH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to 5AT(diag)-108, DTC P1601 TCM
DATA COMMUNICATION FAILURE, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to 5AT(diag)-110, DTC P1706 AT VEHICLE SPEED SENSOR CIRCUIT MALFUNCTION (REAR WHEEL), Diagnostic Procedure
<Ref. to 5AT(diag)-114, DTC P1707 AT AWD
SOLENOID VALVE CIRCUIT MALFUNCTION, Diagnostic Procedure with Diagnostic
CONVERTER TURBINE 2 SPEED SIGNAL
CIRCUIT 2 MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to 5AT(diag)-120, DTC P1716 ATF
TEMP. SENSOR 2 CIRCUIT LOW, Diagnostic
Procedure with Diagnostic Trouble Code
(DTC).>
<Ref. to 5AT(diag)-123, DTC P1717 ATF
TEMP. SENSOR 2 CIRCUIT HIGH, Diagnostic
(DTC).>
<Ref. to 5AT(diag)-125, DTC P1718 AT CAN
COMMUNICATION CIRCUIT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
ACCELERATION SENSOR PERFORMANCE
PROBLEM, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
ACCELERATION SENSOR CIRCUIT LOW,
Code (DTC).>
ACCELERATION SENSOR CIRCUIT HIGH,
Code (DTC).>
ENGINE BRAKE, Diagnostic Procedure with
<Ref. to 5AT(diag)-135, DTC P1799 INTERLOCK, Diagnostic Procedure with Diagnostic
<Ref. to 5AT(diag)-136, DTC P1817 SPORTS
MODE SWITCH CIRCUIT (MANUAL
SWITCH), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>

DTC
Item
P1840
Transmission Fluid Pressure Sensor/Switch A

Circuit
H&LR/C oil pressure switch is

open or shorted, or switch malfunction
P1841
Transmission Fluid Pressure Sensor/Switch B

Circuit
D/C oil pressure switch is open or

P1842
Transmission Fluid Pressure Sensor/Switch C

Circuit
Fr/B oil pressure switch is open or

P1843
Transmission Fluid Pressure Sensor/Switch D

Circuit
I/C oil pressure switch is open or

P1844
Transmission Fluid Pressure Sensor/Switch E

Circuit
LC/B oil pressure switch is open

or shorted, or switch malfunction
5AT(diag)-33
Reference target
<Ref. to 5AT(diag)-138, DTC P1840 TRANSMISSION FLUID PRESSURE SENSOR/
SWITCH A CIRCUIT, Diagnostic Procedure
SWITCH B CIRCUIT, Diagnostic Procedure
SWITCH C CIRCUIT, Diagnostic Procedure
SWITCH D CIRCUIT, Diagnostic Procedure
SWITCH E CIRCUIT, Diagnostic Procedure


A: DTC P0705 TRANSMISSION RANGE SENSOR CIRCUIT (PRNDL INPUT)
The inhibitor switch is open or short.
TROUBLE SYMPTOM:
Shift indicator light does not match with select lever.
Shift indicator light does not illuminate.
N-D, N-R shock occur.
5AT(diag)-34

WIRING DIAGRAM:
SBF-1
SBF-7
No.12
BATTERY
i10
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
COMBINATION
METER
i10
i77
21
22
1 2 3 4 5 6 7 8 9 10 11 12
A:
JOINT
CONNECTOR
A27
A26
i77
A:
B54
B30
i84
B: B280
A3
A4
B20
A:
B:
i84
1 2
3 4
5 6
7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35
B:
B280
1 2 3
4 5
6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
A:
B54
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
B:
B55
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
9
18
24
7
16
22
8
17
23
9
18
24
TCM
B55
B13
B20
8
B3
B14
2
B12
B4
B12
1 2 3 4
5 6 7 8
T3
TRANSMISSION
E
AT-02073
5AT(diag)-35

Step
CHECK DTC OF TCM.

2) Check input signal of inhibitor SW 1 4
and inhibitor SW 3 monitor using Subaru
Select Monitor.
transmission.
3) Measure the resistance between TCM connector and chassis ground about the item
which indicated Low on step 3.
2) Check input signal of inhibitor SW 1 4
and inhibitor SW 3 monitor using Subaru
Select Monitor.
transmission.
between TCM and transmission connector
about the item which indicated High on step 5.
(B55) No. 4 (B12) No. 4:
(B55) No. 3 (B12) No. 3:
(B55) No. 14 (B12) No. 2:
(B55) No. 13 (B12) No. 1:
(B55) No. 20 (B12) No. 8:
transmission.
(B55) No. 4 (B12) No. 4:
(B55) No. 3 (B12) No. 3:
(B55) No. 14 (B12) No. 2:
(B55) No. 13 (B12) No. 1:
(B55) No. 20 (B12) No. 8:
Check
Yes
No
Is DTC of AT CAN communica- Perform the diag- Go to step 2.
tion circuit displayed?
nosis according to
DTC.
Go to step 7.
Monitor?
Are all indications High?
Go to step 5.
Go to step 4.

M?
Go to step 9.
Repair the short

circuit in harness
between TCM connector and chassis
ground.
Are all indications High?
Go to step 9.
Go to step 6.

?
Go to step 9.
Repair the open

circuit in harness
between TCM connector and transmission connector.

?
Go to step 8.
Repair the open

circuit in harness
5AT(diag)-36

10
11
Step
CIRCUIT TESTER.
2) Disconnect the transmission connector
(B12).
5) Measure the voltage between TCM terminals.
(B55) No. 4 (B54) No. 19:
(B55) No. 3 (B54) No. 19:
(B55) No. 14 (B54) No. 19:
(B55) No. 13 (B54) No. 19:
(B55) No. 20 (B54) No. 19:
CHECK TCM I/O SIGNAL.
Check I/O signal of power supply, ground and
PVIGN power supply relay.
<Ref. to 5AT(diag)-12, ELECTRICAL SPECIFICATION, Transmission Control Module (TCM)
I/O Signal.>
Check
M?
Yes
Go to step 9.
No
Repair the short
circuit in harness
between TCM connector and chassis
ground.
Is the voltage 4 6 V for the

inhibitor SW 1 4?
Is the voltage 3.5 5.5 V for
the inhibitor SW 3 monitor?
Go to step 11.
Go to step 10.
Is TCM I/O signal OK?
Replace the TCM.

<Ref. to 5AT-62,
(TCM).>
Repair the open or

short circuit for
power supply and
ground. Perform
the diagnosis
according to DTC
for PVIGN power
supply relay.
Repair the open
circuit in harness
between control
valve body connector and transmission connector.

TRANSMISSION AND CONTROL VALVE
?
BODY.
bracket.
racks.
NOTE:
5) Drain the ATF.
CAUTION:
connector from control valve body connector.
7) Measure the resistance between transmission connector and control valve body connector.
(T3) No. 4 (T5) No. 6:
(T3) No. 3 (T5) No. 5:
(T3) No. 2 (T5) No. 4:
(T3) No. 1 (T5) No. 3:
(T3) No. 8 (T5) No. 2:
5AT(diag)-37
Go to step 12.

12
13
Step
Check
Yes
M?
BODY.
ground and control valve body connector.
CHECK POOR CONTACT.
Is there any poor contact in
Repair the poor
inhibitor SW 1 4 or inhibitor contact.
SW 3 monitor circuit?
5AT(diag)-38
No
Repair the short
circuit in harness
between control

<Ref. to 5AT-59,
Control Valve
Body.>

B: DTC P0712 TRANSMISSION FLUID TEMPERATURE SENSOR CIRCUIT LOW

INPUT
Input signal circuit of TCM to ATF temperature sensor 1 is opened.
TROUBLE SYMPTOM:
Excessive shift shock.
WIRING DIAGRAM:
B54
TCM
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
9
18
24
13
B54
B11
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
B11
5
12
T4
T5
16
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16
T5
TRANSMISSION
AT-02037
5AT(diag)-39

4
5
Step
transmission.
(B54) No. 13 (B11) No. 12:
(B54) No. 2 (B11) No. 5:
and TCM.
engine.
NOTE:
(T4) No. 5 (T4) No. 12:
(T4) No. 5 (T4) No. 12:
CHECK INPUT SIGNAL FROM TCM.
temperature is approx. 80C (176F).
Check
?
Yes
Go to step 2.
No
Repair the open
circuit in harness
between TCM and
Is the resistance 500 1,200 Go to step 3.

?
Go to step 7.

Go to step 4.
Go to step 7.

Monitor?
Go to step 5.
NOTE:
3) Measure the voltage between TCM connector terminals.
(B54) No. 2 (+) (B54) No. 13 ():
5AT(diag)-40
Go to step 6.

indicator lights
blinks, the system
is in normal condition. A temporary
poor contact of
connector or harness may be the
cause. Repair the
poor contact of
harness between
ATF temperature
sensor and transmission connector.

Step
1) Connect the connector.
OFF).
3) Read the ATF temperature using Subaru
Select Monitor.
Check
gradually decrease?

?
BODY.
bracket.
racks.
Yes
Even if the SPORT
indicator lights
blinks, the system
poor contact of
cause. Repair the
poor contact of
harness between
ATF temperature
<Ref. to 5AT-59,
Control Valve
Body.>
No
Go to step 8.
Repair the open

circuit in harness
between control
NOTE:
5) Drain the ATF.
CAUTION:
(T4) No. 12 (T5) No. 1:
(T4) No. 5 (T5) No. 16:
CHECK POOR CONTACT.
temperature sensor circuit 1?
5AT(diag)-41
Repair the poor

contact.
Replace the TCM.

<Ref. to 5AT-62,
(TCM).>

C: DTC P0713 TRANSMISSION FLUID TEMPERATURE SENSOR CIRCUIT HIGH

INPUT
Input signal circuit of TCM to ATF temperature sensor 1 is shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B54
TCM
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
9
18
24
13
B54
B11
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
B11
5
12
T4
T5
16
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16
T5
TRANSMISSION
AT-02037
5AT(diag)-42

4
5
Step
transmission.
and TCM.
engine.
NOTE:
(T4) No. 5 (T4) No. 12:
(T4) No. 5 (T4) No. 12:
CHECK INPUT SIGNAL FROM TCM.
Check
M?
Yes
Go to step 2.
No
Repair the short
circuit in harness
between TCM and
Is the resistance 500 1,200 Go to step 3.

?
Go to step 7.

Go to step 4.
Go to step 7.

Monitor?
Go to step 5.
NOTE:
(B54) No. 2 (+) (B54) No. 13 ():
5AT(diag)-43
Go to step 6.

indicator lights
blinks, the system
poor contact of
cause. Repair the
poor contact of
harness between
ATF temperature

Step
OFF).
Select Monitor.
Check
gradually decrease?

M?
BODY.
bracket.
racks.
Yes
Even if the SPORT
indicator lights
blinks, the system
poor contact of
cause. Repair the
poor contact of
harness between
ATF temperature
<Ref. to 5AT-59,
Control Valve
Body.>
No
Go to step 8.
Repair the short

circuit in harness
between control
NOTE:
5) Drain the ATF.
CAUTION:
7) Measure the resistance between chassis
CHECK POOR CONTACT.

temperature sensor circuit 1?
5AT(diag)-44
Repair the poor

contact.
Replace the TCM.

<Ref. to 5AT-62,
(TCM).>

D: DTC P0715 INPUT/TURBINE SPEED SENSOR CIRCUIT

TROUBLE SYMPTOM:
Does not shift to 5th
WIRING DIAGRAM:
A:
B54
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
B:
B55
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
TCM
B:
B55
7
16
22
8
17
23
9
18
24
7
16
22
8
17
23
9
18
24
B16
B54
A16
A:
T4
B12
7
B11
B11
T3
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
B12
AT1
3
2
1
1 2 3 4
5 6 7 8
E
TURBINE SPEED SENSOR 1
AT1
1 2 3
AT-02074
5AT(diag)-45

Step
transmission.
(B55) No. 16 (B12) No. 7:
(B54) No. 16 (B11) No. 7:
CHECK TCM POWER SUPPLY OUTPUT.
1) Connect the TCM connector. (Transmission
connector is disconnected)
OFF)
CHECK TURBINE SPEED SENSOR INPUT
CIRCUIT OF TCM.
Measure the voltage between TCM connector
terminals.
(B55) No. 16 (+) (B54) No. 19 ():
I/O Signal.>
CHECK HARNESS ASSEMBLY (TURBINE

SPEED SENSOR GROUND).
Check the installing condition of ground connecting harness of harness assembly (used for
both of turbine speed sensor 1, rear vehicle
speed sensor).
Check
?
Yes
Go to step 2.
No
Repair the open
circuit in harness
between TCM and

M?
Go to step 3.
Repair the short

circuit in harness
between TCM and
chassis ground.
Go to step 4.
Go to step 5.
Go to step 6.
Go to step 5.
Replace the TCM.

<Ref. to 5AT-62,
(TCM).>
Is the ground connecting harness connected to transmission body securely?

And there are no excessive
damages on harness and terminal?
Go to step 7.
Repair the open or

short circuit for
power supply and
ground. Perform
the diagnosis
according to DTC
for PVIGN power
supply relay.
If the poor installation of ground
occurs, install it
securely. Replace
the transmission
assembly when
the harness or terminal is damaged.
<Ref. to 5AT-39,
Automatic Transmission Assembly.>
5AT(diag)-46

9
10
11
Step
CHECK HARNESS ASSEMBLY.
3) Disconnect the connector from turbine
speed sensor 1.
4) Measure the resistance between transmission connector and turbine speed sensor 1
connector.
(T4) No. 7 (AT1) No. 3:
(T3) No. 7 (AT1) No. 2:
(AT1) No. 1 Chassis ground:
CHECK HARNESS ASSEMBLY.
racks.
Check
?
Yes
Go to step 8.
No
Repair the open
circuit in harness
between TCM and

M?
Go to step 9.
Repair the short

circuit in harness
between TCM and

Monitor?
Do you have an oscilloscope?
Does the value of the turbine
speed sensor 1 change
depending on the acceleration,
deceleration and shifting range
of the vehicle?
Go to step 11.
Go to step 10.
Go to step 12.
Even if the SPORT
indicator lights
blinks, the system
is in normal condition.
A temporary poor
be the cause.
Repair the poor
contact of harness between the
ATF temperature
Go to step 13.
Replace the turbine speed sensor
1. <Ref. to 5AT-58,
Turbine Speed
Sensor 1.>
NOTE:
3) Start the engine, and set the vehicle in 4th
speed driving condition of manual mode.
NOTE:
Turbine speed sensor 1 signal can be measured only on 4th speed.
4) Read the current data of turbine speed sensor 1 using the Subaru Select Monitor. <Ref. to
5AT(diag)-16, READ CURRENT DATA,
NOTE:
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(diag)-27, Clear Memory
Mode.>
5AT(diag)-47

12
Step
OSCILLOSCOPE.
racks.
Check
Is the frequency of measured
waveform (pulse wave)
changed depending on the
acceleration, deceleration and
shifting range of the vehicle?
Yes
Even if the SPORT
indicator lights
blinks, the system
A temporary poor
be the cause.
Repair the poor
ATF temperature
No
1. <Ref. to 5AT-58,
Turbine Speed
Sensor 1.>
Does the voltage change

within the range of 2 3 V
when driving the vehicle with
4th of manual mode? Is the
voltage less than 0.5 V or more
than 4.5 V constantly when the
NOTE:
vehicle is parked with P
3) Start the engine, and set the vehicle in 4th range?
Even if the SPORT

indicator lights
blinks, the system
A temporary poor
be the cause.
Repair the poor
ATF temperature

1. <Ref. to 5AT-58,
Turbine Speed
Sensor 1.>
NOTE:
4) Start the engine, and set the vehicle in 4th
NOTE:
5) Display the pulse signal of turbine speed
sensor 1 to oscilloscope, and measure the frequency.
13
NOTE:
Mode.>
CIRCUIT TESTER.
racks.
NOTE:
(B55) No. 16 (+) (B54) No. 19 ():
5) Stop the vehicle, and shift the select lever
to P range.
(B55) No. 16 (+) (B54) No. 19 ():
NOTE:
Mode.>
5AT(diag)-48

E: DTC P0719 TORQUE CONVERTER/BRAKE SWITCH B CIRCUIT LOW

TROUBLE SYMPTOM:
Brake down control is not operated at SPORT mode.
No lock-up occurs at braking.
WIRING DIAGRAM:
SBF-3
C: B281
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
No.8
BATTERY
SBF-1
B64
1 2
STOP LIGHT
SWITCH
B159
B64
1 2
3 4
5 6 7 8 9
JOINT
CONNECTOR
B: B280
C23
B159
BODY INTEGRATED
UNIT
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
B30
B20
B: B280
B54
C: B281
B54
5 6
14 15
7
16
22
8 9
17 18
23 24
1 2 3 4
10 11 12 13
19 20 21
TCM
AT-01629
5AT(diag)-49

Step
Check
Is any of following DTC displayed?
AT CAN Communication Circuit
Output Speed Sensor Circuit
AT Vehicle Speed Sensor
Circuit Malfunction (Rear
Wheel)
Is the ON displayed?
CHECK DTC.

link connector.
OFF)
ON.
CHECK TCM.

SIGNAL.
3) Measure the voltage between body integrated unit connector and chassis ground.
SWITCH.
switch.
between body integrated unit and stop light
switch.
(B281) No. 23 (B64) No. 2:
SWITCH.
body integrated unit connector and stop light
switch.
CHECK POOR CONTACT.
Yes
No
nosis according to
DTC.
Go to step 3.
A temporary poor
be the cause.
Check the poor
contact.
Go to step 4.
Replace the TCM

<Ref. to 5AT-62,
(TCM).>
Go to step 5.

?
Go to step 6.
Repair the open

circuit of harness
between the body
integrated unit and
stop light switch.

M?
Go to step 7.
Repair the short

circuit of harness
between the body
integrated unit and
stop light switch.

Repair the poor

contact.
Check the body

integrated unit.
5AT(diag)-50

F: DTC P0720 OUTPUT SPEED SENSOR CIRCUIT

AT vehicle speed signal is abnormal.
The harness connector between TCM and vehicle speed sensor is in short or open.
TROUBLE SYMPTOM:
Deterioration of shifting quality.
Poor driving performance.
WIRING DIAGRAM:
A:
B54
B:
B55
B54
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
B:
B55
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
9
18
24
B7
1
A16
TCM
A:
B11
7
16
22
8
17
23
9
18
24
B11
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
14
T5
3
2
1
T5
15
T7
CONTROL
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16
VALVE
FRONT VEHICLE
SPEED SENSOR
T7
TRANSMISSION
3 2 1
AT-02075
5AT(diag)-51

Step
transmission.
(B54) No. 16 (B11) No. 7:
(B55) No. 7 (B11) No. 1:
1) Connect the connector to TCM. (Transmission connector is disconnected)
OFF)
CIRCUIT OF TCM.
terminals.
(B55) No. 7 (+) (B54) No. 19 ():
I/O Signal.>
Check
?
Yes
Go to step 2.
No
Repair the open
circuit in harness
between TCM and

M?
Go to step 3.
Repair the short

circuit in harness
between TCM and
chassis ground.
Go to step 4.
Go to step 5.
Go to step 6.
Go to step 5.
Replace the TCM.

<Ref. to 5AT-62,
(TCM).>
Repair the open or

short circuit for
power supply and
ground. Perform
the diagnosis
according to DTC
for PVIGN power
supply relay.
Go to step 7.

Monitor?
5AT(diag)-52
Go to step 10.

Step
racks.
Check
Does the value of the front
wheel speed depending on the
acceleration and deceleration
of the vehicle?
Yes
No
indicator lights
blinks, the system
A temporary poor
be the cause.
Repair the poor
ATF temperature

of the vehicle?

indicator lights
blinks, the system
A temporary poor
be the cause.
Repair the poor
ATF temperature
NOTE:
3) Start the engine, and drive it.
4) Read the current data of front wheel speed
5AT(diag)-16, READ CURRENT DATA,
NOTE:
Mode.>
OSCILLOSCOPE.
racks.
NOTE:
NOTE:
Mode.>
5AT(diag)-53

10
Step
CIRCUIT TESTER.
racks.
NOTE:
(B55) No. 7 (+) (B54) No. 19 ():
to P range.
(B55) No. 7 (+) (B54) No. 19 ():
11
Check
when vehicle is driving? Is the
range?
NOTE:
Mode.>
?
BODY.
bracket.
racks.
Yes
No
indicator lights
blinks, the system
A temporary poor
be the cause.
Repair the poor
ATF temperature
Go to step 12.
Repair the open

circuit in harness
between control
Go to step 13.
Repair the short

circuit in harness
and transmission
ground.
NOTE:
5) Drain the ATF.
12
CAUTION:
(B11) No. 7 (T5) No. 15:
(B11) No. 1 (T5) No. 14:
M?
BODY.
5AT(diag)-54

13
14
Step
CONTROL VALVE BODY AND VEHICLE
SPEED SENSOR.
1) Disconnect the connector from vehicle
speed sensor.
between control valve body connector and
(T5) No. 15 (T7) No. 3:
(T5) No. 14 (T7) No. 2:
CONTROL VALVE BODY AND VEHICLE
SPEED SENSOR.
control valve body connector and transmission
ground.
Check
?
Yes
Go to step 14.
No
<Ref. to 5AT-59,
Control Valve
Body.>

M?
Replace the vehicle speed sensor.

<Ref. to 5AT-59,
Control Valve
Body.>
5AT(diag)-55

G: DTC P0724 TORQUE CONVERTER/BRAKE SWITCH B CIRCUIT HIGH

TROUBLE SYMPTOM:
Gear is not shifted down when climbing a hill.
WIRING DIAGRAM:
SBF-3
C: B281
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
No.8
BATTERY
SBF-1
B64
1 2
STOP LIGHT
SWITCH
B159
B64
1 2
3 4
5 6 7 8 9
JOINT
CONNECTOR
B: B280
C23
B159
BODY INTEGRATED
UNIT
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
B30
B20
B: B280
B54
C: B281
B54
5 6
14 15
7
16
22
8 9
17 18
23 24
1 2 3 4
10 11 12 13
19 20 21
TCM
AT-01629
5AT(diag)-56

Step
Check
Is any of following DTC
detected?
Wheel)
Is OFF displayed?
CHECK DTC.

link connector.
OFF)
ON.
CHECK TCM.
Is OFF displayed?

SIGNAL.
switch.
between stop light switch connectors.
Terminals
No. 1 No. 2:
SWITCH.
the body integrated unit connector and chassis
ground.
CHECK POOR CONTACT.
Yes
No
nosis according to
DTC.
Go to step 3.
Go to step 4.
A temporary poor
be the cause.
Check the poor
contact.
Go to step 7.

M?
Go to step 6.
Replace stop light

switch.
Go to step 7.
Repair the short

circuit in harness
between TCM and
stop light switch.

Repair the poor

contact.
Check the body

integrated unit.
5AT(diag)-57
Replace the TCM

<Ref. to 5AT-62,
(TCM).>

H: DTC P0725 ENGINE SPEED INPUT CIRCUIT

Information of engine speed is not correctly received from ECM.
TROUBLE SYMPTOM:
No lock-up (after engine warm-up).
Step
CHECK DTC OF ECM.
CHECK DTC OF TCM.
CHECK DTC OF TCM.
I:
Check
Yes
Is DTC of AT CAN communica- Perform the diagtion circuit detected?
nosis according to
DTC.
Is DTC of AT CAN communica- Perform the diagtion circuit detected?
nosis according to
DTC.
Perform the diagdetected?
nosis according to
Output Speed Sensor Circuit DTC.
Wheel)
No
Go to step 2.
Go to step 3.
Replace the TCM.

<Ref. to 5AT-62,
(TCM).>
DTC P0731 GEAR 1 INCORRECT RATIO
NOTE:
J: DTC P0732 GEAR 2 INCORRECT RATIO

NOTE:
K: DTC P0733 GEAR 3 INCORRECT RATIO

NOTE:
L: DTC P0734 GEAR 4 INCORRECT RATIO

NOTE:
M: DTC P0735 GEAR 5 INCORRECT RATIO

NOTE:
5AT(diag)-58

N: DTC P0736 REVERSE INCORRECT RATIO

Vehicle speed sensor, turbine speed sensor or control valve malfunction
TROUBLE SYMPTOM:
Gear is not shifted to reverse.
Gear position is held by fail safe function.
Vehicle does not run.
2
3
Step
CHECK DTC OF TCM.
Check
detected?
Range/Performance
Input/Turbine Speed Sensor
Circuit
Torque Converter Turbine 2
Speed Signal Circuit 2 Malfunction
Wheel)
Transmission Range Sensor
Circuit (PRNDL Input)
PVIGN Power Supply Circuit (Low)
Monitor?
CHECK ENGINE SPEED.
Is the indication of Subaru
Compare the meter with Subaru Select Moni- Select Monitor and meter
tor indications.
matches?
CHECK TURBINE SPEED SENSOR.
Is the indication changes
Check the indication of Subaru Select Monitor. according to acceleration,
braking and shifting?
Yes
No
nosis according to
DTC.
Go to step 3.
Go to step 7.
Go to step 4.

DTC P0725.
DTC P0715,
P1710.
DTC P0720,
P1706.
DTC P0705.
Temporary poor
contact occurs.
Go to step 5.
CHECK FRONT AND REAR VEHICLE

SPEED SENSOR.

Select Monitor and meter
matches?
Go to step 6.
Go to step 7.
CHECK AFTER REPAIR.

Select Monitor and meter
matches?
Is DTC displayed?
5AT(diag)-59

<Ref. to 5AT-59,
Control Valve
Body.>

O: DTC P0741 TORQUE CONVERTER CLUTCH CIRCUIT PERFORMANCE OR

STUCK OFF
Lock up clutch malfunction
Locking of bulb
TROUBLE SYMPTOM:
Step
CHECK DTC OF TCM.
Check
detected?
Input/Turbine Speed Sensor
Circuit
Torque Converter Turbine 2
Speed Signal Circuit 2 Malfunction
Is DTC displayed?
CHECK DTC OF TCM.

5AT(diag)-18, CLEAR MEMORY MODE,
2) Read DTC.
procedure.
CHECK ATF TEMPERATURE SENSOR CIR- Is there any trouble?
CUIT.
Diagnose according to DTC P0712, P0713,
P1716 and P1717 procedure.
5AT(diag)-60
Yes
No
nosis according to
each DTC.

nosis according to
DTC.
Repair or replace
the inhibitor switch
circuit.
Repair or replace
the stop light
switch circuit.
Repair or replace
the ATF temperature sensor circuit.
Go to step 4.
Go to step 5.
There are malfunctions in TCM,

TCM connector
poor contact or
transmission

P: DTC P0743 TORQUE CONVERTER CLUTCH CIRCUIT ELECTRICAL

The output signal circuit of lock up solenoid is open or shorted.
TROUBLE SYMPTOM:
No lock-up (after engine warm-up).
WIRING DIAGRAM:
B54
TCM
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
9
18
24
5
14
23
B54
B11
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
20
E
B11
T4
T6
1 2
3 4
5 6 7 8 9 10 11 12
T6
TRANSMISSION
AT-02076
5AT(diag)-61

Step
transmission.
(B54) No. 23 (B11) No. 20:
Measure resistance of harness between TCM
BODY.
bracket.
racks.
5) Drain the ATF.
control valve body connector.
(T4) No. 20 (T6) No. 6:
BODY.
Measure the resistance between chassis
CHECK LOCK-UP SOLENOID.
CHECK POOR CONTACT.
Check that there are no poor contact in TCM
connector, transmission connector and control
valve body connector.
CHECK AFTER REPAIR.
2) Drive for a while, read the DTC, and verify
that there is no faulty.
Check
?
Yes
Go to step 2.
No
Repair the open
circuit in harness

M?
Go to step 3.
Repair the short

circuit in harness

?
Go to step 4.
Repair the open

circuit in harness
between control

M?
Go to step 5.
Repair the short

circuit in harness
between control
valve body connector and transmission ground.
Go to step 6.
Is there any loosing terminal,

entering foreign matter, damaging connector body?
Repair the poor

contact.

<Ref. to 5AT-59,
Control Valve
Body.>
Go to step 7.
Is DTC displayed?
Replace the TCM.

<Ref. to 5AT-62,
(TCM).>
5AT(diag)-62
Temporary poor
contact or open
circuit occurs.
Recheck that the
harness connector has no faulty.

Q: DTC P0748 PRESSURE CONTROL SOLENOID A ELECTRICAL

Output signal circuit of line pressure solenoid is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B54
TCM
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
9
18
24
5
14
B54
B11
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
E
19
B11
T4
T6
1 2
3 4
5 6 7 8 9 10 11 12
T6
TRANSMISSION
AT-02077
5AT(diag)-63

Step
transmission.
(B54) No. 9 (B11) No. 19:
BODY.
bracket.
racks.
5) Drain the ATF.
(T4) No. 19 (T6) No. 7:
BODY.
CHECK LINE PRESSURE SOLENOID.
CHECK POOR CONTACT.
CHECK AFTER REPAIR.
Check
?
Yes
Go to step 2.
No
Repair the open
circuit in harness

M?
Go to step 3.
Repair the short

circuit in harness

?
Go to step 4.
Repair the open

circuit in harness
between control

M?
Go to step 5.
Repair the short

circuit in harness
between control
Go to step 6.

Repair the poor

contact.

<Ref. to 5AT-59,
Control Valve
Body.>
Go to step 7.
Is DTC displayed?
Replace the TCM.

<Ref. to 5AT-62,
(TCM).>
5AT(diag)-64
Temporary poor
contact or open
circuit occurs.
Recheck that the

R: DTC P0751 SHIFT SOLENOID A PERFORMANCE OR STUCK OFF

Output signal of front brake solenoid does not match with oil pressure.
TROUBLE SYMPTOM:
Locked to 4th or 5th gear.
WIRING DIAGRAM:
A:
TCM
B54
B:
B55
5
14
B17
A24
A:
B54
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
B:
B55
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
9
18
24
7
16
22
8
17
23
9
18
24
B11
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
B11
3
17
T4
T5
T5
11
10
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16
T6
T6
1 2
3 4
5 6 7 8 9 10 11 12
TRANSMISSION
AT-02078
5AT(diag)-65

3
4
Step
transmission.
(B54) No. 24 (B11) No. 17:
(B55) No. 17 (B11) No. 3:
Check
?
Yes
Go to step 2.
No
Repair the open
circuit in harness
between TCM and

M?
Go to step 3.
Repair the short

circuit in harness
between TCM and

Monitor?
Is OFF displayed?
Go to step 4.
Go to step 7.
Go to step 5.
Go to step 11.
Go to step 6.

<Ref. to 5AT-59,
Control Valve
Body.>

OFF)
3) Check input signal of Fr/B oil pressure SW.
Is OFF displayed?
2) Turn the ignition switch to ON. (engine ON)
3) Shift to 4th speed with checking current
gear position using Subaru Select Monitor.
3) Shift to 1st speed with checking current

CIRCUIT TESTER.
OFF)
5AT(diag)-66

indicator lights
blinks, the system
A temporary poor
be the cause.
Repair the poor
contact of harness in the solenoid output and oil
pressure SW
input.
Go to step 8.
Go to step 11.

10
Step
Check
CIRCUIT TESTER.
3) Shift to 4th speed of manual mode with
checking indication of gear position in combination meter.
NOTE:
Read the value of gear position indication after
the shifting is completed (approx. 2 seconds
later from shifting).
CIRCUIT TESTER.
3) Shift to 1st speed of manual mode with
NOTE:
?
BODY.
bracket.
racks.
5) Drain the ATF.
(B11) No. 17 (T6) No. 10:
(B11) No. 3 (T6) No. 11:
5AT(diag)-67
Yes
Go to step 9.
No
<Ref. to 5AT-59,
Control Valve
Body.>

indicator lights
blinks, the system
A temporary poor
be the cause.
Repair the poor
pressure SW
input.
Replace the transmission assembly.
<Ref. to 5AT-39,
Repair the open

circuit in harness
between control

11
Step
Check
M?
BODY.
bracket.
racks.
5) Drain the ATF.
7) Measure the resistance between transmission ground and control valve body connector.
5AT(diag)-68
Yes
<Ref. to 5AT-59,
Control Valve
Body.>
No
Repair the short
circuit in harness
between control

S: DTC P0753 SHIFT SOLENOID A ELECTRICAL

Output signal circuit of front brake solenoid is open or shorted.
TROUBLE SYMPTOM:
Locked to 4th or 5th gear.
WIRING DIAGRAM:
A:
TCM
B54
B:
B55
5
14
B17
A24
A:
B54
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
B:
B55
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
9
18
24
7
16
22
8
17
23
9
18
24
B11
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
B11
3
17
T4
T5
T5
11
10
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16
T6
T6
1 2
3 4
5 6 7 8 9 10 11 12
TRANSMISSION
AT-02078
5AT(diag)-69

Step
transmission.
(B54) No. 24 (B11) No. 17:
(B55) No. 17 (B11) No. 3:
BODY.
bracket.
racks.
5) Drain the ATF.
(T4) No. 17 (T6) No. 9:
(T4) No. 3 (T5) No. 11:
BODY.
CHECK FRONT BRAKE SOLENOID.
CHECK POOR CONTACT.
Check
?
Yes
Go to step 2.
No
Repair the open
circuit in harness

M?
Go to step 3.
Repair the short

circuit in harness

?
Go to step 4.
Repair the open

circuit in harness
between control

M?
Go to step 5.
Repair the short

circuit in harness
between control
valve body and
Go to step 6.

Repair the poor

contact.

<Ref. to 5AT-59,
Control Valve
Body.>
Go to step 7.
5AT(diag)-70

Step
CHECK AFTER REPAIR.
Check
Is DTC displayed?
5AT(diag)-71
Yes
Replace the TCM.
<Ref. to 5AT-62,
(TCM).>
No
Temporary poor
contact or open
circuit occurs.
Recheck that the

T: DTC P0756 SHIFT SOLENOID B PERFORMANCE OR STUCK OFF

Output signal value of input clutch solenoid and oil pressure does not match.
TROUBLE SYMPTOM:
Locked to 4th gear.
WIRING DIAGRAM:
B54
TCM
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
9
18
24
6
18
5
14
B54
B11
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
E
11
18
B11
T4
T5
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16
T6
T5
8
8
1 2
3 4
5 6 7 8 9 10 11 12
T6
TRANSMISSION
AT-02079
5AT(diag)-72

Step
transmission.
(B54) No. 18 (B11) No. 18:
(B54) No. 6 (B11) No. 11:
OFF)
3) Check input signal of I/C oil pressure SW.
3) Shift to D range and brake ON (1st) with
checking current gear position using Subaru
Select Monitor.
3) Drive the vehicle on 4th speed of D range
with checking current gear position using Subaru Select Monitor.
Check
?
Yes
Go to step 2.
No
Repair the open
circuit in harness
between TCM and

M?
Go to step 3.
Repair the short

circuit in harness
between TCM and
Is OFF displayed?
Go to step 4.
Go to step 7.
Is OFF displayed?
Go to step 5.

<Ref. to 5AT-59,
Control Valve
Body.>

indicator lights
blinks, the system
A temporary poor
be the cause.
Repair the poor
pressure SW
input.
5AT(diag)-73

Step
BODY.
bracket.
racks.
5) Drain the ATF.
(T4) No. 18 (T6) No. 8:
(T4) No. 11 (T5) No. 8:
BODY.
bracket.
racks.
5) Drain the ATF.
Check
?
Yes
<Ref. to 5AT-39,
No
Repair the open
circuit in harness
between control

M?

<Ref. to 5AT-59,
Control Valve
Body.>
Repair the short

circuit in harness
between control
5AT(diag)-74

U: DTC P0758 SHIFT SOLENOID B ELECTRICAL

Output signal circuit of input clutch solenoid is open or shorted.
TROUBLE SYMPTOM:
Locked to 4th gear.
WIRING DIAGRAM:
B54
TCM
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
9
18
24
6
18
5
14
B54
B11
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
E
11
18
B11
T4
T5
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16
T6
T5
8
8
1 2
3 4
5 6 7 8 9 10 11 12
T6
TRANSMISSION
AT-02079
5AT(diag)-75

Step
transmission.
(B54) No. 18 (B11) No. 18:
(B54) No. 6 (B11) No. 11:
TCM AND BODY HARNESS.
connector and body harness.
BODY.
bracket.
racks.
5) Drain the ATF.
(T4) No. 18 (T6) No. 8:
(T4) No. 11 (T5) No. 8:
BODY.
CHECK INPUT CLUTCH SOLENOID.
CHECK POOR CONTACT.
Check
?
Yes
Go to step 2.
No
Repair the open
circuit in harness
between TCM and

M?
Go to step 3.
Repair the short

circuit in harness
between TCM and

?
Go to step 4.
Repair the open

circuit in harness
between control

M?
Go to step 5.
Repair the short

circuit in harness
between control
Go to step 6.

Repair the poor

contact.

<Ref. to 5AT-59,
Control Valve
Body.>
Go to step 7.
5AT(diag)-76

Step
CHECK AFTER REPAIR.
Check
Is DTC displayed?
5AT(diag)-77
Yes
Replace the TCM.
<Ref. to 5AT-62,
(TCM).>
No
Temporary poor
contact or open
circuit occurs.
Recheck that the

V: DTC P0761 SHIFT SOLENOID C PERFORMANCE OR STUCK OFF

Output signal value of high & low reverse clutch solenoid and oil pressure does not match.
TROUBLE SYMPTOM:
Locked to 4th gear.
WIRING DIAGRAM:
A:
TCM
B54
B:
B55
A5
A14
B8
A17
A:
B54
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
B:
B55
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
9
18
24
7
16
22
8
17
23
9
18
24
B11
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
B11
4
15
T4
T5
T5
12
12
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16
T6
T6
1 2
3 4
5 6 7 8 9 10 11 12
TRANSMISSION
AT-02080
5AT(diag)-78

3
4
Step
transmission.
(B54) No. 17 (B11) No. 15:
(B55) No. 8 (B11) No. 4:
Check
?
Yes
Go to step 2.
No
Repair the open
circuit in harness
between TCM and

M?
Go to step 3.
Repair the short

circuit in harness
between TCM and

Monitor?
Is OFF displayed?
Go to step 4.
Go to step 7.
Go to step 5.
Go to step 11.
Go to step 6.

<Ref. to 5AT-59,
Control Valve
Body.>

OFF)
3) Check input signal of H&LR/C oil pressure
SW.
Is OFF displayed?
3) Drive the vehicle on 2nd speed of D range
with checking current gear position using Subaru Select Monitor.
SW.
Select Monitor.
SW.
5AT(diag)-79

indicator lights
blinks, the system
A temporary poor
be the cause.
Repair the poor
pressure SW
input.

10
Step
Check
CIRCUIT TESTER.
OFF)
CIRCUIT TESTER.
3) Shift to 2nd speed of manual mode with
NOTE:
CIRCUIT TESTER.
3) Shift to 1st speed of manual mode with
NOTE:
?
BODY.
bracket.
racks.
5) Drain the ATF.
(T4) No. 15 (T6) No. 12:
(T4) No. 4 (T5) No. 12:
5AT(diag)-80
Yes
Go to step 8.
No
Go to step 11.
Go to step 9.

<Ref. to 5AT-59,
Control Valve
Body.>

indicator lights
blinks, the system
A temporary poor
be the cause.
Repair the poor
pressure SW
input.
<Ref. to 5AT-39,
Repair the open

circuit in harness
between control

11
Step
Check
M?
BODY.
bracket.
racks.
5) Drain the ATF.
5AT(diag)-81
Yes
<Ref. to 5AT-59,
Control Valve
Body.>
No
Repair the short
circuit in harness
between control

W: DTC P0763 SHIFT SOLENOID C ELECTRICAL

Output signal circuit of high & low reverse clutch solenoid is open or shorted.
TROUBLE SYMPTOM:
Locked to 4th gear.
WIRING DIAGRAM:
A:
TCM
B54
B:
B55
A5
A14
B8
A17
A:
B54
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
B:
B55
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
9
18
24
7
16
22
8
17
23
9
18
24
B11
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
B11
4
15
T4
T5
T5
12
12
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16
T6
T6
1 2
3 4
5 6 7 8 9 10 11 12
TRANSMISSION
AT-02080
5AT(diag)-82

Step
transmission.
(B54) No. 17 (B11) No. 15:
(B55) No. 8 (B11) No. 4:
BODY.
bracket.
racks.
5) Drain the ATF.
(T4) No. 15 (T6) No. 12:
(T4) No. 4 (T5) No. 12:
BODY.
chassis ground.
CHECK HIGH & LOW REVERSE CLUTCH
SOLENOID.
CHECK POOR CONTACT.
Check
?
Yes
Go to step 2.
No
Repair the open
circuit in harness

M?
Go to step 3.
Repair the short

circuit in harness

?
Go to step 4.
Repair the open

circuit in harness
between control

M?
Go to step 5.
Repair the open

circuit in harness
between control
Go to step 6.

<Ref. to 5AT-59,
Control Valve
Body.>

Repair the poor

contact.
Go to step 7.
5AT(diag)-83

Step
CHECK AFTER REPAIR.
Check
Is DTC displayed?
5AT(diag)-84
Yes
Replace the TCM.
<Ref. to 5AT-62,
(TCM).>
No
Temporary poor
contact or open
circuit occurs.
Recheck that the

X: DTC P0766 SHIFT SOLENOID D PERFORMANCE OR STUCK OFF

Output signal value of direct clutch solenoid and oil pressure does not match.
TROUBLE SYMPTOM:
Locked to 4th gear.
WIRING DIAGRAM:
B54
TCM
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
9
18
24
21
22
5
14
B54
B11
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
E
10
16
B11
T4
T6
T5
9
11
1 2
3 4
5 6 7 8 9 10 11 12
T6
TRANSMISSION
AT-02081
5AT(diag)-85

Step
transmission.
(B54) No. 22 (B11) No. 16:
(B54) No. 21 (B11) No. 10:
OFF)
3) Check input signal of D/C oil pressure SW.
Select Monitor.
3) Shift to 2nd speed of manual mode and
brake ON with checking current gear position
Check
?
Yes
Go to step 2.
No
Repair the open
circuit in harness
between TCM and

M?
Go to step 3.
Repair the short

circuit in harness
between TCM and
Is OFF displayed?
Go to step 4.
Go to step 7.
Is OFF displayed?
Go to step 5.

<Ref. to 5AT-59,
Control Valve
Body.>

indicator lights
blinks, the system
A temporary poor
be the cause.
Repair the poor
pressure SW
input.
5AT(diag)-86

Step
BODY.
bracket.
racks.
5) Drain the ATF.
(T4) No. 16 (T6) No. 10:
(T4) No. 10 (T5) No. 9:
BODY.
bracket.
racks.
5) Drain the ATF.
Check
?
Yes
<Ref. to 5AT-39,
No
Repair the open
circuit in harness
between control

M?

<Ref. to 5AT-59,
Control Valve
Body.>
Repair the short

circuit in harness
between control
5AT(diag)-87

Y: DTC P0768 SHIFT SOLENOID D ELECTRICAL

The output signal circuit of direct clutch solenoid is open or shorted.
TROUBLE SYMPTOM:
Locked to 4th gear.
WIRING DIAGRAM:
B54
TCM
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
9
18
24
21
22
5
14
B54
B11
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
E
10
16
B11
T4
T6
T5
9
11
1 2
3 4
5 6 7 8 9 10 11 12
T6
TRANSMISSION
AT-02081
5AT(diag)-88

Step
transmission.
(B54) No. 22 (B11) No. 16:
(B54) No. 21 (B11) No. 10:
BODY.
bracket.
racks.
5) Drain the ATF.
(T4) No. 16 (T6) No. 10:
(T4) No. 10 (T5) No. 9:
BODY.
CHECK DIRECT CLUTCH SOLENOID.
transmission ground.
CHECK POOR CONTACT.
Check
?
Yes
Go to step 2.
No
Repair the open
circuit in harness

M?
Go to step 3.
Repair the short

circuit in harness

?
Go to step 4.
Repair the open

circuit in harness
between control

M?
Go to step 5.
Repair the short

circuit in harness
between control
Go to step 6.

<Ref. to 5AT-59,
Control Valve
Body.>

Repair the poor

contact.
Go to step 7.
5AT(diag)-89

Step
CHECK AFTER REPAIR.
Check
Is DTC displayed?
5AT(diag)-90
Yes
Replace the TCM.
<Ref. to 5AT-62,
(TCM).>
No
Temporary poor
contact or open
circuit occurs.
Recheck that the

Z: DTC P0771 SHIFT SOLENOID E PERFORMANCE OR STUCK OFF

Output signal value of low coast brake solenoid and oil pressure does not match.
TROUBLE SYMPTOM:
Locked to 2nd gear.
Engine brake does not function at 1st or 2nd of manual mode.
WIRING DIAGRAM:
B54
TCM
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
9
18
24
12
15
5
14
B54
B11
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
E
9
13
B11
T4
T6
T5
10
13
1 2
3 4
5 6 7 8 9 10 11 12
T6
TRANSMISSION
AT-02082
5AT(diag)-91

Step
transmission.
(B54) No. 15 (B11) No. 13:
(B54) No. 12 (B11) No. 9:
OFF)
3) Check input signal of LC/B oil pressure SW.
3) Shift to 3rd speed with checking current
3) Drive the vehicle on 2nd speed of manual
mode 15 km/h (9 MPH) with checking current
Check
?
Yes
Go to step 2.
No
Repair the open
circuit in harness
between TCM and

M?
Go to step 3.
Repair the short

circuit in harness
between TCM and
Is OFF displayed?
Go to step 4.
Go to step 7.
Is OFF displayed?
Go to step 5.

<Ref. to 5AT-59,
Control Valve
Body.>

indicator lights
blinks, the system
A temporary poor
be the cause.
Repair the poor
pressure SW
input.
5AT(diag)-92

Step
BODY.
bracket.
racks.
5) Drain the ATF.
(T4) No. 13 (T6) No. 13:
(T4) No. 9 (T5) No. 10:
BODY.
bracket.
racks.
5) Drain the ATF.
Check
?
Yes
<Ref. to 5AT-39,
No
Repair the open
circuit in harness
between control

M?

<Ref. to 5AT-59,
Control Valve
Body.>
Repair the short

circuit in harness
between control
5AT(diag)-93

AA:DTC P0773 SHIFT SOLENOID E ELECTRICAL

Output signal circuit of low coast brake solenoid is open or shorted.
TROUBLE SYMPTOM:
Locked to 2nd gear.
Engine brake does not function at 1st or 2nd of manual mode.
WIRING DIAGRAM:
B54
TCM
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
9
18
24
12
15
5
14
B54
B11
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
E
9
13
B11
T4
T6
T5
10
13
1 2
3 4
5 6 7 8 9 10 11 12
T6
TRANSMISSION
AT-02082
5AT(diag)-94

Step
transmission.
(B54) No. 15 (B11) No. 13:
(B54) No. 12 (B11) No. 9:
BODY.
bracket.
racks.
5) Drain the ATF.
(T4) No. 13 (T6) No. 13:
(T4) No. 9 (T5) No. 10:
BODY.
CHECK LOW COAST BRAKE SOLENOID.
transmission ground.
CHECK POOR CONTACT.
Check
?
Yes
Go to step 2.
No
Repair the open
circuit in harness

M?
Go to step 3.
Repair the short

circuit in harness

?
Go to step 4.
Repair the open

circuit in harness
between control

M?
Go to step 5.
Repair the short

circuit in harness
between control

17 ?

<Ref. to 5AT-59,
Control Valve
Body.>

Go to step 7.
5AT(diag)-95
Repair the poor

contact.

Step
CHECK AFTER REPAIR.
Check
Is DTC displayed?
5AT(diag)-96
Yes
Replace the TCM.
<Ref. to 5AT-62,
(TCM).>
No
Temporary poor
contact or open
circuit occurs.
Recheck that the

AB:DTC P0801 REVERSE INHIBIT CONTROL CIRCUIT

Shift lock solenoid malfunction, open or short reverse inhibitor control circuit
TROUBLE SYMPTOM:
Gear is shifted from N range to R range during driving at 20 km/h 12 MPH) or more.
Gear can not be shifted from N range to R range though the vehicle is parked.
WIRING DIAGRAM:
B55
1 2 3 4
10 11 12 13
19 20 21
TCM
7
16
22
8
17
23
9
18
24
15
B55
5 6
14 15
B116
1 2
3 4
5 6 7 8 9 10
SHIFT LOCK
SOLENOID
B116
3
4
AT-01536
5AT(diag)-97

Step

2) With the brake pedal depressed, shift the
select lever to D range.
chassis ground.
shift lock solenoid.
between TCM and shift lock solenoid connector.
(B55) No. 15 (B116) No. 3:
Measure the voltage of harness between TCM
and chassis ground.
CHECK HARNESS BETWEEN SHIFT LOCK
SOLENOID AND CHASSIS GROUND TERMINAL.
shift lock solenoid and chassis ground.
terminals.
(B116) No. 3 No. 4:
Check
Yes
No
Is the fuse (No. 32) blown out? Replace the fuse Go to step 2.
(No. 32). If the
replaced fuse has
blown out easily,
repair the short circuit in harness
between fuse (No.
32) and TCM.
Is the voltage more than 10.5 Go to step 3.
Replace the TCM.
V?
<Ref. to 5AT-62,
(TCM).>

?
Go to step 4.
Repair the open

circuit in harness
between TCM and
shift lock solenoid
connector.

M?
Go to step 5.
Repair the short

circuit in harness
between TCM and
shift lock solenoid
connector.

?
Go to step 6.
Repair the open

circuit in harness
between chassis
ground and shift
lock solenoid connector.
Go to step 7.
Replace the shift

lock solenoid.
5AT(diag)-98

Step
racks.
Check
NOTE:
slowly increase vehicle speed to 20 km/h (12
MPH).
Yes
No
indicator lights up,
the circuit has
returned to normal condition at
of connector or
harness may be
the cause. Repair
harness or connector in reverse
inhibitor control
circuit.
NOTE:
Mode.>
chassis ground.
CHECK POOR CONTACT.
Repair the poor
reverse inhibitor control circuit? contact.
5AT(diag)-99
Replace the TCM.

<Ref. to 5AT-62,
(TCM).>

AC:DTC P0817 STARTER DISABLE CIRCUIT

Open or short in P/N signal output circuit
TROUBLE SYMPTOM:
Engine can be started on other than P or N range
Engine can not be started on P or N range
WIRING DIAGRAM:
B55
ECM
1 2 3 4
10 11 12 13
19 20 21
5 6 7 8 9
14 15 16 17 18
22 23 24
B137
B137
19
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
28 29
30 31
26 27
B55
TCM
AT-01632
5AT(diag)-100

Step
CHECK DTC OF TCM.
Check
Is DTC of Transmission Range
Sensor Circuit (PRNDL Input)
circuit detected?
Is the communication between
ECM normal?
Yes
No
nosis according to
DTC.
CHECK ECM.
Go to step 3.
DTC concerning
ECM.
Is the fuse (No. 32) blown out? Replace the fuse Go to step 4.
(No. 32). If the
2) Remove the fuse.
replaced fuse (No.
32) has blown out
easily, repair the
(No. 32) and TCM.
Go to step 5.
Repair the open
TCM AND ECM.
?
circuit in harness
between TCM and
transmission contransmission.
nector, and poor
contact in coubetween TCM and transmission connector.
pling connector.
(B55) No. 19 (B137) No. 9:
Repair the short
TCM AND ECM.
M?
circuit in harness
between transmisTCM connector and chassis ground.
sion connector
and chassis
ground.
Is the voltage 1 V or less?
Go to step 7.
Replace the TCM.
CHECK TCM OUTPUT SIGNAL.
<Ref. to 5AT-62,
1) Connect the TCM and ECM connector.
Transmission Con2) Turn the ignition switch to ON. (engine
trol Module
OFF)
(TCM).>
Is the voltage 10 V or more?
Go to step 8.
Replace the TCM.
<Ref. to 5AT-62,
Transmission Con2) Measure the voltage between TCM control Module
(TCM).>
CHECK POOR CONTACT.
Is there any open or poor con- Repair the poor
Check neutral cirtact of connector (loosing ter- contact.
cuit inside the
minal, entering foreign matter,
ECM.
damaging connector body)?
5AT(diag)-101

AD:DTC P0882 TCM POWER INPUT SIGNAL LOW

Malfunction of PVIGN power supply relay or open, short circuit of PVIGN power supply circuit.
TROUBLE SYMPTOM:
Gear is not changed.
WIRING DIAGRAM:
IGNITION
SWITCH
SBF-1
SBF-9
No.12
B54
BATTERY
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
9
18
24
B357
1 2
3
4
B54
10
B357
TCM
AT-01630
5AT(diag)-102

Step
CHECK FUSE.
2) Remove the SBF 1, SBF 2 and fuse (No.
12), and then check those are not blown out.
Check
CHECK INPUT VOLTAGE FOR PVIGN RELAY.

Measure the voltage between PVIGN relay and
chassis ground.
CHECK HARNESS BETWEEN PVIGN RELAY OF TCM.
Measure the resistance between TCM connector and PVIGN relay connector.
(B54) No. 10 (B357) No. 1:
(B54) No. 7 (B357) No. 4:
(B54) No. 8 (B357) No. 4:
CHECK PVIGN POWER SUPPLY CIRCUIT.
OFF)

?
Yes
No
Replace the fuse. Go to step 2.
If the replaced
fuse has blown out
easily, repair the
short circuit in harness of each fuse.
Go to step 3.
Check open circuit in harness
between fuse (No.
12) and PVIGN
relay.
Go to step 4.
Repair the open

circuit of harness.
Temporary poor
Go to step 5.
contact. Recheck
the harness
between TCM and
relay. (Lightly
move the harness
and check that the
open or short circuit is not
occurred.)
Is the voltage less than 1.5 V? Replace the
Replace the TCM.
CHECK PVIGN RELAY OUTPUT OF TCM.
PVIGN relay.
<Ref. to 5AT-62,
Transmission Conand chassis ground.
trol Module
(TCM).>
5AT(diag)-103

AE:DTC P0957 BACKUP LIGHT RELAY CIRCUIT LOW

Short circuit of back-up light relay output circuit
TROUBLE SYMPTOM:
Back-up light does not illuminate in R range.
WIRING DIAGRAM:
IGNITION
RELAY
SBF-1
SBF-9
B55
BATTERY
No.18
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
9
18
24
B356
1 2
3
4
B356
11
BACKUP LIGHT CIRCUIT
B55
TCM
AT-01631
5AT(diag)-104

Step
CHECK DTC OF TCM.
Check
circuit detected?
TCM AND BACK-UP LIGHT RELAY.
?
backup light relay.
between TCM and backup light relay connector.
(B55) No. 11 (B356) No. 1:
M?
OFF)

Shift the select lever to R range.
CHECK INPUT VOLTAGE FOR BACKUP

LIGHT RELAY.
Measure the voltage between back-up light
relay and chassis ground.
5AT(diag)-105
Yes
No
nosis according to
DTC.
Go to step 3.
Repair the open
circuit in harness
between TCM and
Go to step 4.
Go to step 5.
Repair the short

circuit in harness
between TCM and
Replace the TCM.

<Ref. to 5AT-62,
(TCM).>
Go to step 6.
Replace the TCM.
<Ref. to 5AT-62,
(TCM).>
Replace the back- Check open or
up light relay.
(No. 18) and
backup light relay.

AF:DTC P0958 BACKUP LIGHT RELAY CIRCUIT HIGH

Back-up light relay malfunction, or open/short circuit in back-up light relay output circuit
TROUBLE SYMPTOM:
Back-up light does not illuminate in R range.
Back-up light always illuminate in other than R range.
WIRING DIAGRAM:
IGNITION
RELAY
SBF-1
SBF-9
B55
BATTERY
No.18
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
9
18
24
B356
1 2
3
4
B356
11
BACKUP LIGHT CIRCUIT
B55
TCM
AT-01631
5AT(diag)-106

Step
CHECK DTC OF TCM.
Check
circuit detected?
TCM AND BACK-UP LIGHT RELAY.
?
back-up light relay.
between TCM and back-up light relay connector.
(B55) No. 11 (B356) No. 1:
M?
OFF)

Shift the select lever to R range.
CHECK INPUT VOLTAGE FOR BACK-UP

LIGHT RELAY.
Measure the voltage between back-up light
relay and chassis ground.
5AT(diag)-107
Yes
No
nosis according to
DTC.
Go to step 3.
Repair the open
circuit in harness
between TCM and
Go to step 4.
Go to step 5.
Repair the short

circuit in harness
between TCM and
Replace the TCM.

<Ref. to 5AT-62,
(TCM).>
Go to step 6.
Replace the TCM.
<Ref. to 5AT-62,
(TCM).>
Replace the back- Check open or
up light relay.
(No. 18) and
backup light relay.

AG:DTC P1601 TCM DATA COMMUNICATION FAILURE

Communication does not complete between control valve memory box.
TROUBLE SYMPTOM:
Shifting quality malfunction
WIRING DIAGRAM:
B54
TCM
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
9
18
24
21
12
B54
B11
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
11
10
B11
T5
10
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16
T5
TRANSMISSION
AT-01800
Step
CHECK POOR CONTACT OF TRANSMISSION CONNECTOR.
Check loose connection on TCM connector
(B54).
CHECK DTC OF TCM.
Check
Is there poor contact on connector?
Yes
Connect it
securely.
Is DTC of oil pressure switch

detected?

nosis according to
DTC.
5AT(diag)-108
No
Go to step 2.

Step
OFF)
transmission.
(B54) No. 12 (B11) No. 9:
(B54) No. 21 (B11) No. 10:
(B54) No. 6 (B11) No. 11:
TRANSMISSION CONNECTOR AND CONTROL VALVE BODY CONNECTOR.
connector and control valve body connector.
(B54) No. 9 (T5) No. 10:
(B54) No. 10 (T5) No. 9:
(B54) No. 11 (T5) No. 8:
TRANSMISSION CONNECTOR AND CONTROL VALVE BODY CONNECTOR.
CHECK POOR CONTACT.
Check
Yes
Go to step 4.
No
Go to step 5.

?
Go to step 5.
Repair the open

circuit in harness
between TCM and

M?
Go to step 6.
Repair the short

circuit in harness
between TCM and

?
Go to step 7.
Repair the open

circuit in harness
between control

M?
Go to step 8.
Repair the short

circuit in harness
between control
Is there any open or poor con- Repair the poor

tact of connector (loosing ter- contact.
NOTE:
Data communication malfunction is detected minal, entering foreign matter,
when the malfunction occurred on inspection damaging connector body)?
area above while transmission assembly is replacing or Clear Memory 2 is performing.
When the repair is performed with following diagnosis above, perform the Clear Memory 2,
and then recheck that the DTC of TCM data
communication malfunction is not detected.
5AT(diag)-109

<Ref. to 5AT-39,

AH:DTC P1706 AT VEHICLE SPEED SENSOR CIRCUIT MALFUNCTION (REAR

WHEEL)
TROUBLE SYMPTOM:
Shifting quality malfunction
WIRING DIAGRAM:
A:
B54
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
B:
B55
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
A:
B11
TCM
B54
B:
B55
7
16
22
8
17
23
9
18
24
7
16
22
8
17
23
9
18
24
A7
B5
A16
B18
A:
A:
B11
B:
B12
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
B:
B12
1 2 3 4
5 6 7 8
E
REAR VEHICLE
SPEED SENSOR
AT-01537
5AT(diag)-110

Step
transmission.
(B54) No. 16 (B11) No. 7:
(B55) No. 18 (B12) No. 5:
OFF)
CIRCUIT OF TCM.
terminals.
(B55) No. 18 (+) (B54) No. 19 ():
Check TCM I/O signal of power supply, ground
and PVIGN power supply relay.
I/O Signal.>
Check
?
Yes
Go to step 2.
No
Repair the open
circuit in harness
between TCM and

M?
Go to step 3.
Repair the short

circuit in harness
between TCM and
chassis ground.
Go to step 4.
Go to step 5.
Go to step 6.
Go to step 5.
Replace the TCM.

<Ref. to 5AT-62,
(TCM).>
Go to step 7.
Repair the open or

short circuit for
power supply and
ground. Perform
the diagnosis
according to DTC
for PVIGN power
supply relay.
When the poor
installation of
ground connecting harness, install
it securely.
Replace the transmission assembly
when the harness
is damaged. <Ref.
to 5AT-39, Automatic Transmission Assembly.>
Go to step 8.
CHECK HARNESS ASSEMBLY (TURBINE

SPEED SENSOR GROUND).
Check the installing condition of ground connecting harness (used for both of turbine
speed sensor 1, rear vehicle speed sensor).
Is the ground connecting harness installed to transmission

body correctly, or the harness
and connector terminals not
damaged?

Monitor?
5AT(diag)-111
Go to step 11.

Step
racks.
Check
Does the value of the front
wheel speed depending on the
of the vehicle?
Yes
No
Even if the SPORT Replace the transindicator lights
mission harness.
blinks, the system
A temporary poor
be the cause.
Repair harness or
contact in the ATF
temperature sensor and transmission connector.

of the vehicle?

mission harness.
blinks, the system
A temporary poor
be the cause.
Repair harness or
contact in the ATF
NOTE:
3) Start the engine, and drive the vehicle.
4) Read the current data of front wheel speed
<Ref. to 5AT(diag)-16, OPERATION, Subaru
Select Monitor.>
10
NOTE:
Mode.>
OSCILLOSCOPE.
racks.
NOTE:
NOTE:
Mode.>
5AT(diag)-112

11
Step
CIRCUIT TESTER.
racks.
NOTE:
(B55) No. 7 (+) (B54) No. 19 ():
to P range.
(B55) No. 7 (+) (B54) No. 19 ():
Check
range?
NOTE:
Mode.>
5AT(diag)-113
Yes
No
mission harness.
blinks, the system
A temporary poor
be the cause.
Repair harness or
contact in the ATF

AI: DTC P1707 AT AWD SOLENOID VALVE CIRCUIT MALFUNCTION

Output signal circuit of transfer solenoid is open or shorted.
TROUBLE SYMPTOM:
Drivability getting worse.
WIRING DIAGRAM:
B:
B55
B23
B54
A:
B54
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
B:
B55
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
9
18
24
7
16
22
8
17
23
9
18
24
A5
A14
TCM
A:
E
8
B11
T4
B11
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
11
T6
T6
1 2
3 4
5 6 7 8 9 10 11 12
TRANSMISSION
AT-02083
5AT(diag)-114

Step
transmission.
(B55) No. 23 (B11) No. 8:
BODY.
bracket.
racks.
5) Drain the ATF.
(T4) No. 8 (T6) No. 11:
BODY.
AWD SOLENOID CURRENT.
CHECK POOR CONTACT.
CHECK AFTER REPAIR.
Check
?
Yes
Go to step 2.
No
Repair the open
circuit in harness

M?
Go to step 3.
Repair the short

circuit in harness

?
Go to step 4.
Repair the open

circuit in harness
between control

M?
Go to step 5.
Repair the short

circuit in harness
between control
Go to step 6.

Repair the poor

contact.

<Ref. to 5AT-59,
Control Valve
Body.>
Go to step 7.
Is DTC displayed?
Replace the TCM.

<Ref. to 5AT-62,
(TCM).>
5AT(diag)-115
Temporary poor
contact or open
circuit occurs.
Recheck that the

AJ:DTC P1710 TORQUE CONVERTER TURBINE 2 SPEED SIGNAL CIRCUIT 2

MALFUNCTION
TROUBLE SYMPTOM:
Does not shift to 5th
WIRING DIAGRAM:
TCM
B:
B54
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
B:
B55
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
9
18
24
7
16
22
8
17
23
9
18
24
B55
B22
B54
A16
A:
A:
B11
B12
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
B11
T4
T3
T5
15
B12
T6
1 2 3 4
5 6 7 8
T5
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16
TURBINE SPEED SENSOR 2
T6
TRANSMISSION
1 2
3 4
5 6 7 8 9 10 11 12
AT-02084
5AT(diag)-116

Step
transmission.
(B55) No. 22 (B12) No. 6:
(B54) No. 16 (B11) No. 7:
OFF)
(B54) No. 16 (+) (B54) No. 19 ():
CIRCUIT OF TCM.
terminals.
(B55) No. 22 (+) (B54) No. 19 ():
Check TCM I/O signal of power supply, ground
and PVIGN power supply relay.
I/O Signal.>
Check
?
Yes
Go to step 2.
No
Repair the open
circuit in harness
between TCM and

M?
Go to step 3.
Repair the short

circuit in harness
between TCM and
Go to step 4.
Go to step 5.
Go to step 6.
Go to step 5.
Is I/O signal OK?
Replace the TCM.

<Ref. to 5AT-62,
(TCM).>
Repair the open or

short circuit for
power supply and
ground. Perform
the diagnosis
according to DTC
for PVIGN power
supply relay.
Go to step 7.

Monitor?
5AT(diag)-117
Go to step 10.

Step
racks.
Check
Does the value of the turbine
speed sensor 2 change
depending on the acceleration,
deceleration and shifting gear
of the vehicle?
Yes
No
indicator lights
blinks, the system
A temporary poor
be the cause.
Repair the poor
contact in harness
of turbine speed
sensor 2 and

of the vehicle?

indicator lights
blinks, the system
A temporary poor
be the cause.
Repair the poor
contact in harness
of turbine speed
sensor 2 and
NOTE:
3) Start the engine, and set the vehicle in 1st
4) Read the current data of torque converter
turbine speed 2 using the Subaru Select Monitor.
<Ref. to 5AT(diag)-16, OPERATION, Subaru
Select Monitor.>
NOTE:
Mode.>
OSCILLOSCOPE.
racks.
NOTE:
NOTE:
Mode.>
5AT(diag)-118

10
Step
CIRCUIT TESTER.
racks.
NOTE:
(B55) No. 22 (+) (B54) No. 19 ():
to P range.
(B55) No. 22 (+) (B54) No. 19 ():
11
Check
range?
NOTE:
Mode.>
?
BODY.
bracket.
racks.
Yes
No
indicator lights
blinks, the system
A temporary poor
be the cause.
Repair the poor
contact in harness
of turbine speed
sensor 2 and
Go to step 12.
Repair the open

circuit in harness
between control

<Ref. to 5AT-59,
Control Valve
Body.>
Repair the short

circuit in harness
and transmission
ground.
NOTE:
5) Drain the ATF.
12
CAUTION:
(T3) No. 6 (T6) No. 3:
(T4) No. 7 (T5) No. 15:
M?
BODY.
5AT(diag)-119

AK:DTC P1716 ATF TEMP. SENSOR 2 CIRCUIT LOW

Input signal circuit of TCM to ATF temperature sensor 2 is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B54
TCM
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
9
18
24
11
13
B54
B11
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
B11
6
12
T4
T5
3 4
1 2
5 6 7 8 9 10 11 12
T5
T6
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16
T6
TRANSMISSION
AT-01628
5AT(diag)-120

4
5
Step
transmission.
(B54) No. 13 (B11) No. 12:
(B54) No. 11 (B11) No. 6:
and TCM.
engine.
NOTE:
(T4) No. 6 (T4) No. 12:
(T4) No. 6 (T4) No. 12:
Check
?
Yes
Go to step 2.
No
Repair the open
circuit in harness
between TCM and

?
Go to step 3.
Go to step 7.

Go to step 4.
Go to step 7.

Monitor?
Go to step 5.
NOTE:
(B54) No. 11 (+) (B54) No. 13 ():
5AT(diag)-121
Go to step 6.

indicator lights
blinks, the system
poor contact of
cause. Repair harness or contact in

Step
OFF)
Select Monitor.
Check
gradually decrease?

?
BODY.
bracket.
racks.
Yes
Even if the SPORT
indicator lights
blinks, the system
poor contact of
<Ref. to 5AT-59,
Control Valve
Body.>
No
Go to step 8.
Repair the open

circuit in harness
between control
NOTE:
5) Drain the ATF.
CAUTION:
(T4) No. 12 (T5) No. 1:
(T4) No. 6 (T6) No. 2:
CHECK POOR CONTACT.
Check poor contact of ATF temperature sensor
1 circuit.
5AT(diag)-122
Repair the poor

contact.
Replace the TCM.

<Ref. to 5AT-62,
(TCM).>

AL:DTC P1717 ATF TEMP. SENSOR 2 CIRCUIT HIGH

Input signal circuit of TCM to ATF temperature sensor 2 is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B54
TCM
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
9
18
24
11
13
B54
B11
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
B11
6
12
T4
T5
3 4
1 2
5 6 7 8 9 10 11 12
T5
T6
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16
T6
TRANSMISSION
AT-01628
5AT(diag)-123

4
5
Step
transmission.
(B54) No. 13 (B11) No. 12:
(B54) No. 11 (B11) No. 6:
and TCM.
engine.
NOTE:
(T4) No. 6 (T4) No. 12:
(T4) No. 6 (T4) No. 12:
Check
M?
Yes
Go to step 2.
No
Repair the short
circuit in harness
between TCM and

?
Go to step 3.
Go to step 7.

Go to step 4.
Go to step 7.

Monitor?
Go to step 5.
NOTE:
(B54) No. 11 (+) (B54) No. 13 ():
5AT(diag)-124
Go to step 6.

indicator lights
blinks, the system
poor contact of

Step
OFF)
Select Monitor.
Check
gradually decrease?

M?
BODY.
bracket.
racks.
Yes
Even if the SPORT
indicator lights
blinks, the system
poor contact of
<Ref. to 5AT-59,
Control Valve
Body.>
No
Go to step 8.
Repair the short

circuit in harness
between control
NOTE:
5) Drain the ATF.
CAUTION:
CHECK POOR CONTACT.
Check poor contact of ATF temperature sensor
1 circuit.
Repair the poor

contact.
Replace the TCM.

<Ref. to 5AT-62,
(TCM).>
AM:DTC P1718 AT CAN COMMUNICATION CIRCUIT

NOTE:
For DTC P1718 AT CAN Communication circuit, Refer to LAN System. <Ref. to LAN(diag)-14, READ DIAGNOSTIC TROUBLE CODE (DTC), OPERATION, Subaru Select Monitor.>
5AT(diag)-125

AN:DTC P1760 LATERAL ACCELERATION SENSOR PERFORMANCE PROBLEM

WIRING DIAGRAM:
A:
B54
B:
B55
B54
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
B:
B55
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
9
18
24
7
16
22
8
17
23
9
18
24
B6
B5
A13
TCM
A:
B359
1 2 3
B359
G SENSOR
AT-01634
Step
CHECK DTC OF TCM.
CHECK DTC OF ABS.
Check
Yes
Is VDC equipped with the vehi- Go to step 2.
cle? And is there VDC OFF
switch in the instrument panel?
Is DTC of AT CAN communica- Perform the diagtion detected?
nosis according to
DTC.
Is DTC of ABS detected?
DTC of ABS.
5AT(diag)-126
No
Go to step 4.
Go to step 3.
Temporary poor
contact occurs.
Recheck the harness and connector for faulty.

10
11
12
13
Step
Check
Yes
play 2.3 2.7 V when the
vehicle is on a level?
No
Go to step 10.

play 3.3 4.3 V when lateral
G sensor is inclined to the right
to 90?

<Ref. to 5AT-63,
Lateral G Sensor.>
Is the value on the monitor display 0.7 1.7 V when lateral

G sensor is inclined to the left
to 90?
nector between TCM and the
lateral G sensor?
CHECK ABSCM&H/U.
4) Read the DTC.

HARNESS.
(B54) No. 13 (B55) No. 6:
(B359) No. 3 (+) No. 2 ():
(B359) No. 3 (+) No. 2 ():
(B359) No. 3 (+) No. 2 ():

k?
Go to step 7.

Replace the TCM.
<Ref. to 5AT-62,
(TCM).>
DTC.
Go to step 11.

<Ref. to 5AT-63,
Lateral G Sensor.>
Go to step 8.
Go to step 9.
Temporary poor
contact occurs.
between lateral G
sensor and TCM.

horizontal?
Go to step 12.

<Ref. to 5AT-63,
Lateral G Sensor.>

Go to step 13.

<Ref. to 5AT-63,
Lateral G Sensor.>

Go to step 14.

<Ref. to 5AT-63,
Lateral G Sensor.>
5AT(diag)-127

14
15
Step
CHECK ABSCM&H/U.
5) Read the DTC.
Check
Yes
No
<Ref. to 5AT-62,
(TCM).>

DTC.
5AT(diag)-128

AO:DTC P1761 LATERAL ACCELERATION SENSOR CIRCUIT LOW

Lateral G sensor is open or output voltage is faulty. (Model without VDC)
CAN communication malfunction (Model with VDC)
WIRING DIAGRAM:
A:
B54
B:
B55
B54
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
B:
B55
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
9
18
24
7
16
22
8
17
23
9
18
24
B6
B5
A13
TCM
A:
B359
1 2 3
B359
G SENSOR
AT-01634
Step
CHECK DTC OF TCM.
CHECK DTC OF ABS.
Check
Yes
nosis according to
DTC.
DTC of ABS.
5AT(diag)-129
No
Go to step 4.
Go to step 3.
Temporary poor
contact occurs.

10
11
12
Step
CHECK ABSCM&H/U.
4) Read the DTC.
Check
Yes
position?
No
Go to step 9.
Is there poor contact in connector between TCM and the

lateral G sensor?
Go to step 6.
Replace the TCM.

<Ref. to 5AT-62,
(TCM).>
DTC.
Go to step 9.
Go to step 7.
Temporary poor
contact occurs.

HARNESS.
(B54) No. 13 (B55) No. 6:

k?

M?
Go to step 10.

(B359) No. 3 (+) No. 2 ():
(B359) No. 3 (+) No. 2 ():
(B359) No. 3 (+) No. 2 ():

horizontal?
Go to step 11.

Go to step 12.

<Ref. to 5AT-63,
Lateral G Sensor.>

Go to step 13.

<Ref. to 5AT-63,
Lateral G Sensor.>
5AT(diag)-130

between lateral G
sensor and TCM.

TCM.
Replace the TCM.
<Ref. to 5AT-62,
(TCM).>
<Ref. to 5AT-63,
Lateral G Sensor.>

13
14
Step
CHECK TCM.
5) Read the DTC.
Check
Yes
No
<Ref. to 5AT-62,
(TCM).>

DTC.
5AT(diag)-131

AP:DTC P1762 LATERAL ACCELERATION SENSOR CIRCUIT HIGH

WIRING DIAGRAM:
A:
B54
B:
B55
B54
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
B:
B55
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
9
18
24
7
16
22
8
17
23
9
18
24
B6
B5
A13
TCM
A:
B359
1 2 3
B359
G SENSOR
AT-01634
Step
CHECK DTC OF TCM.
CHECK DTC OF ABS.
Check
Yes
nosis according to
DTC.
DTC of ABS.
5AT(diag)-132
No
Go to step 4.
Go to step 3.
Temporary poor
contact occurs.

10
11
12
13
14
Step
CHECK ABSCM&H/U.
4) Read the DTC.
No
Go to step 8.

lateral G sensor?
Go to step 6.
Replace the TCM.

<Ref. to 5AT-62,
(TCM).>
DTC.
Go to step 9.
Go to step 7.
CHECK CONDITIONAL INFORMATION

WHEN FAULTY.
Read the lateral G sensor output on the Subaru Select Monitor display.
HARNESS.
(B55) No. 5 No. 1:
3) Disconnect the connector from lateral G
sensor.
CHECK TCM.
4) Read the DTC.
Check
Yes
position?
Is the reading indicated on

monitor display 4.65 V or
more?
Temporary poor
contact occurs.
Go to step 15.

k?
Go to step 10.

between lateral G
sensor and
ABSCM&H/U.
Go to step 11.

TCM.
Go to step 12.

TCM.

lateral G sensor?
Go to step 13.
5AT(diag)-133

<Ref. to 5AT-62,
(TCM).>
DTC.

15
16
17
18
19
20
21
22
Step
CHECK INPUT VOLTAGE OF LATERAL G
SENSOR.
(B359) No. 1 (+) No. 2 ():
HARNESS.
(B55) No. 5 No. 6:
(B359) No. 3 (+) No. 2 ():
(B359) No. 3 (+) No. 2 ():
(B359) No. 3 (+) No. 2 ():
CHECK ABSCM&H/U.
4) Read the DTC.
Check
Yes
Go to step 16.
No
between lateral G
sensor and TCM.

k?
Go to step 17.

between lateral G
sensor and TCM.

horizontal?
Go to step 18.

<Ref. to 5AT-63,
Lateral G Sensor.>

Go to step 19.

<Ref. to 5AT-63,
Lateral G Sensor.>

Go to step 20.

<Ref. to 5AT-63,
Lateral G Sensor.>

lateral G sensor?
Go to step 21.

<Ref. to 5AT-62,
(TCM).>
DTC.
AQ:DTC P1798 GEAR 1 ENGINE BRAKE

NOTE:
Refer to DTC P0773 for diagnostic procedure. <Ref. to 5AT(diag)-94, DTC P0773 SHIFT SOLENOID E
ELECTRICAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
5AT(diag)-134

AR:DTC P1799 INTERLOCK

Perform the interlock judgment when the oil pressure switch pattern detect the specified interlock patterns for
more than 2 seconds other than shifting.
TROUBLE SYMPTOM:
Locked to 2nd, 4th or 5th gear.
Step
CHECK DTC OF TCM.
CHECK DTC P0756, P0766.
DRIVING CHECK.
5AT(diag)-20, PROCEDURE, Inspection
Mode.>
Check
Is any of the DTC P0751,
P0756, P0761, P0766, P0771
displayed at the same time
with P1799?
Perform the diagnosis according to DTC P0756, P0766. Is
any malfunction detected?
Is DTC displayed?
5AT(diag)-135
Yes
No
nosis according to
DTC.
nosis according to
DTC.
Replace the trans- Temporary poor
mission assembly. contact occurs.
Check that the

AS:DTC P1817 SPORTS MODE SWITCH CIRCUIT (MANUAL SWITCH)

TROUBLE SYMPTOM:
Can not set to manual mode.
SPORT light illuminates when shifting to N D range.
WIRING DIAGRAM:
i10
IGNITION
SWITCH
SBF-1
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
SBF-7
BATTERY
No.12
i77
1 2 3 4 5 6 7 8 9 10 11 12
A:
1 2
3 4
5 6
7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35
SPORT
COMBINATION
METER
i84
22
7
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
JOINT
CONNECTOR
B54
i77
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
9
18
24
B116
B: B280
1 2
3 4
5 6 7 8 9 10
B30
C26
C: B281
B20
B: B280
A27
21
A26
i10
A:
i84
C: B281
SELECT
LEVER
SPORT
SHIFT MODE
SWITCH
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
B116
E
B54
TCM
AT-01539
5AT(diag)-136

Step
link connector.
OFF)
3) Read the DTC of body integrated unit using
SIGNAL.
2) Read the TIP mode SW data of body integrated unit using Subaru Select Monitor. <Ref.
Monitor.>
SIGNAL.
1) Shift the select lever from P to D range.
Monitor.>
SIGNAL.
2) Shift the select lever to other than D
range.
Monitor.>
CHECK DTC OF TCM.
Check
Is DTC displayed?
Yes
No
nosis according to
DTC.
Is OFF displayed?
Go to step 3.
Is the indication on each range Go to step 4.

OFF?
Replace the select

lever assembly.
<Ref. to CS-7,
Select Lever.>
Is OFF displayed?
Replace the select

lever assembly.
<Ref. to CS-7,
Select Lever.>

and AT CAN communication
circuit displayed?
CHECK TCM INPUT SIGNAL.
Is the indication on each range
1) Shift the select lever from P to D range. OFF?
2) Read the TIP mode SW data of TCM using
CHECK HARNESS BETWEEN BODY INTEGRATED UNIT AND SPORT SHIFT SWITCH.
2) Disconnect harness connector from body
integrated unit and select lever.
3) Measure the harness resistance between
the body integrated unit and chassis ground.
2) Measure the resistance between harness
connector terminals of SPORT shift switch.
Terminals
(B116) No. 7 No. 8:
Go to step 7.

M?

M?
5AT(diag)-137
Go to step 5.

nosis according to
each DTC.
Even if the SPORT
indicator lights
blinks, the circuit is
in normal condition. A temporary
poor contact of
cause.
Go to step 8.
Replace the TCM.

<Ref. to 5AT-62,
(TCM).>
Check the body

integrated unit.
Replace the select

lever assembly.
<Ref. to CS-7,
Select Lever.>
Repair the short

circuit of harness
between the body
integrated unit and
SPORT shift
switch.

AT:DTC P1840 TRANSMISSION FLUID PRESSURE SENSOR/SWITCH A CIRCUIT

Front brake oil pressure switch malfunction.
TROUBLE SYMPTOM:
NOTE:
Refer to DTC P0751 for diagnostic procedure. <Ref. to 5AT(diag)-65, DTC P0751 SHIFT SOLENOID A
PERFORMANCE OR STUCK OFF, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
AU:DTC P1841 TRANSMISSION FLUID PRESSURE SENSOR/SWITCH B CIRCUIT

Low coast brake oil pressure switch malfunction.
TROUBLE SYMPTOM:
NOTE:
Refer to DTC P0771 for diagnostic procedure. <Ref. to 5AT(diag)-91, DTC P0771 SHIFT SOLENOID E
AV:DTC P1842 TRANSMISSION FLUID PRESSURE SENSOR/SWITCH C CIRCUIT

Input clutch oil pressure switch malfunction.
TROUBLE SYMPTOM:
NOTE:
Refer to DTC P0756 for diagnostic procedure. <Ref. to 5AT(diag)-72, DTC P0756 SHIFT SOLENOID B
AW:DTC P1843 TRANSMISSION FLUID PRESSURE SENSOR/SWITCH D CIRCUIT

Direct clutch oil pressure switch malfunction.
TROUBLE SYMPTOM:
NOTE:
Refer to DTC P0766 for diagnostic procedure. <Ref. to 5AT(diag)-85, DTC P0766 SHIFT SOLENOID D
AX:DTC P1844 TRANSMISSION FLUID PRESSURE SENSOR/SWITCH E CIRCUIT

High & low reverse clutch oil pressure switch malfunction.
TROUBLE SYMPTOM:
NOTE:
Refer to DTC P0761 for diagnostic procedure. <Ref. to 5AT(diag)-78, DTC P0761 SHIFT SOLENOID C
5AT(diag)-138

15.Diagnostic Procedure without Diagnostic Trouble Code (DTC)

A: CHECK SPORT SHIFT SWITCH
DIAGNOSIS:
TROUBLE SYMPTOM:
Does not shift on manual mode.
WIRING DIAGRAM:
A: B280
B25
A20
A30
B15
B: B281
TB
B68
2
7
8
TB
AT SELECT
LEVER
B116
ST3
4
3
4
2
3
10
ROLL CONNECTOR
TCM
B54
LH
RH
STEERING SHIFT SWITCH
A: B280
B54
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
9
18
24
B: B281
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
ST3
B68
1 2 3 4 5
6 7 8 9 10
1
2 3
4 5 6 7 8
4 5 6 7
1 2 3
8 9 10 11 12 13 14 15 16 17 18 19
26
27 28
22 23
24 25
20 21
B116
1 2
3 4
5 6 7 8 9 10
AT-01545
5AT(diag)-139

Step
Check
Yes
Both ON/OFF can be detected Go to step 2.
1) Perform the ON/OFF operation on SPORT normally?
shift switch.
2) Read the data of SPORT shift switch signal
CHECK DTC OF BODY INTEGRATED UNIT. Is DTC of CAN detected?
DTC.
CHECK TCM.
Both ON/OFF can be detected Go to step 4.
1) Perform the ON/OFF operation on SPORT normally?
shift switch.
2) Read the data of SPORT shift switch signal
CHECK TIP INDICATOR ON COMBINATION Is the TIP indicator OK?
Go to step 6.
METER.
CHECK DTC OF TCM.
Is DTC of CAN detected?
CHECK DTC OF METER.
Is DTC of CAN detected?

CIRCUIT.
shift switch.
chassis ground.
Measure the resistance between the SPORT
(B116) No. 6 No. 5:
2) Measure the resistance between the
SPORT shift switch terminals.
(B116) No. 6 No. 5:
SHIFT SWITCH.
between the body integrated unit and SPORT
shift switch connector.
(B116) No. 5 (B281) No. 15:

?
10
No
Go to step 7.
Go to step 3.
Go to step 5.

assembly. <Ref. to
Perform the diag- Replace the TCM.
nosis according to <Ref. to 5AT-62,
Transmission ConDTC.
trol Module
(TCM).>
Perform the diag- Replace the meter.
nosis according to
DTC.
Go to step 8.
Repair the open
circuit in harness
between SPORT
shift switch and
chassis ground.

M?
Go to step 9.
Replace the guide

plate assembly.

?
Go to step 10.
Replace the guide

plate assembly.

?
Go to step 11.
Repair the open

circuit in harness
between SPORT
connector, or poor
5AT(diag)-140

11
12
13
14
15
16
17
Step
SHIFT SWITCH.
chassis ground.
OFF).
3) Measure the signal voltage for TCM.
2) Measure the signal voltage for TCM.
CIRCUIT.
shift switch.
chassis ground.
Measure the resistance between the SPORT
(B116) No. 10 No. 9:
2) Measure the resistance between the
SPORT shift switch terminals.
(B116) No. 10 No. 9:
SHIFT SWITCH.
between the body integrated unit and SPORT
shift switch connector.
(B116) No. 9 (B281) No. 25:
Check
M?
Yes
Go to step 12.
No
Repair the short
circuit in harness
between SPORT
connector.
Go to step 13.
Replace the body

integrated unit.
<Ref. to SL-45,
Body Integrated
Module.>
Go to step 26.

?
Go to step 15.
Replace the body

integrated unit.
<Ref. to SL-45,
Body Integrated
Module.>
Repair the open
circuit in harness
between SPORT
shift switch and
chassis ground.

M?
Go to step 16.
Replace the guide

plate assembly.

?
Go to step 17.
Replace the guide

plate assembly.

?
Go to step 18.
Repair the open

circuit in harness
between SPORT
shift switch connector and body
integrated unit
connector, or poor
5AT(diag)-141

18
19
20
21
22
23
24
Step
SHIFT SWITCH.
1) Disconnect the steering roll connector.
chassis ground.
CHECK THE INPUT SIGNAL TO BODY INTEGRATED UNIT.
OFF).
CHECK THE INPUT SIGNAL TO BODY INTEGRATED UNIT.
CHECK STEERING SHIFT SWITCH
GROUND CIRCUIT.
2) Disconnect the connector from steering roll
connector.
between steering roll connector and chassis
ground.
(ST3) No. 3 Chassis ground:
CHECK STEERING SHIFT SWITCH.
Measure the resistance between steering roll
(ST3) No. 1 No. 3:
CHECK STEERING SHIFT SWITCH.
1) Press and hold the steering shift switch to +
side.
2) Measure the resistance between the steering shift switch terminals.
(ST3) No. 1 No. 3:
BODY INTEGRATED UNIT AND STEERING
ROLL CONNECTOR.
between the body integrated unit connector
and steering roll connector.
(B281) No. 15 (B68) No. 2:
Check
M?
Yes
Go to step 19.
No
Repair the short
circuit of harness
between the
SPORT shift
switch connector
and body integrated unit connector.
Go to step 20.
Replace the body

integrated unit.
<Ref. to SL-45,
Body Integrated
Module.>
Go to step 26.
Replace the body

integrated unit.
<Ref. to SL-45,
Body Integrated
Module.>

?
Go to step 22.
Repair the open

circuit in harness
between steering
roll connector and
chassis ground.

M?
Go to step 23.

?
Go to step 24.
Replace the steering roll connector

or steering shift
switch. Or repair
the poor contact in
connector.
Replace the steering roll connector
or steering shift
switch. Or repair
the poor contact in
connector.

?
Go to step 25.
5AT(diag)-142
Repair the open

circuit in harness
between body integrated unit connector and
steering roll connector, or poor

25
26
Step
Check
Yes
Go to step 26.
BODY INTEGRATED UNIT AND STEERING ?
ROLL CONNECTOR.
between the body integrated unit connector
and steering roll connector.
(B281) No. 25 (B68) No. 6:
CHECK POOR CONTACT.
Is there poor contact in SPORT Repair the poor
shift switch circuit?
contact.
5AT(diag)-143
No
Repair the open
circuit in harness
between body integrated unit connector and
steering roll connector, or poor
A temporary poor
contact of SPORT
shift switch connector or harness

B: CHECK SPORT SHIFT INDICATOR LIGHT

DIAGNOSIS:
Output signal circuit of SPORT shift indicator light is open or shorted.
TROUBLE SYMPTOM:
SPORT shift indicator light does not illuminate or remains illuminated.
SPORT shift indicator light display does not change.
WIRING DIAGRAM:
No.12
i10
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
SPORT SHIFT
INDICATOR
IGNITION
SWITCH
COMBINATION
METER
i77
i10
21
22
7
SBF-7
1 2 3 4 5 6 7 8 9 10 11 12
A27
A26
BATTERY
SBF-1
A:
JOINT
CONNECTOR
i77
B30
1 2
3 4
5 6
7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25 26 27 28 29 30 31 32 33 34 35
B: B280
BODY INTEGRATED
UNIT
A:
B20
i84
i84
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
B: B280
B54
B54
5 6
14 15
7
16
22
8
17
23
9
18
24
1 2 3 4
10 11 12 13
19 20 21
TCM
AT-01626
5AT(diag)-144

Step
Check
Yes
Is DTC of AT CAN communica- Perform the diagtion circuit displayed?
nosis according to
DTC.
Is DTC of AT CAN communica- Perform the diagtion circuit displayed?
nosis according to
DTC.
Is gear position 1 and dis- Go to step 4.
played?
CHECK TCM.
Check DTC of TCM.
CHECK TCM.
link connector.
OFF)
ON.
5) Shift the select lever to manual mode side,
and then shift down the select lever.
6) Read the indicator.
CHECK TCM.
Is gear position 2 and dis- Go to step 5.
1) Shift up the select lever.
played?
2) Read the indicator.

Read the data of gear position using Subaru
Select Monitor.
Is SPORT shift gear position

2?
Is the SPORT shift indicator

OK?
5AT(diag)-145
Refer to General
Diagnostic Table.
<Ref. to 5AT(diag)148, General Diagnostic Table.>
Refer to General
Diagnostic Table.
No
Go to step 2.
Go to step 3.
Replace the TCM.

<Ref. to 5AT-62,
(TCM).>
Replace the TCM.

<Ref. to 5AT-62,
(TCM).>
Check the body
integrated unit.
<Ref. to SL-45,
Body Integrated
Module.>
assembly. <Ref. to

C: CHECK BUZZER
DIAGNOSIS:
Output signal circuit of buzzer is open or shorted.
TROUBLE SYMPTOM:
Buzzer remains beeping.
WIRING DIAGRAM:
IGNITION
SWITCH
SBF-7
No.12
SBF-1
i10
BATTERY
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
i77
SPORT
SHIFT
BUZZER
COMBINATION
METER
1 2 3 4 5 6 7 8 9 10 11 12
i10
A:
22
7
i84
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
JOINT
CONNECTOR
i77
B: B280
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
A27
21
A26
A:
i84
B54
B54
B30
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8 9
17 18
23 24
B20
B: B280
TCM
AT-01627
5AT(diag)-146

Step
Check
Yes
Is DTC of CAN communication Perform the diagdisplayed?
nosis according to
DTC.
CHECK TCM.
Is DTC of CAN communication Perform the diagCheck DTC of TCM.
displayed?
nosis according to
DTC.
CHECK BUZZER STOP.
Does the buzzer stop?
Replace the TCM.
Disconnect the connector (B54).
<Ref. to 5AT-62,
(TCM).>
Is the SPORT shift buzzer dis- Replace the body
play ON?
integrated unit.
<Ref. to SL-45,
link connector.
Body Integrated
Module.>
OFF)
ON.
5) Read the data of SPORT shift buzzer using
Is the buzzer OK?
Refer to General
Diagnostic Table.
5AT(diag)-147
No
Go to step 2.
Go to step 5.
Go to step 4.

assembly. <Ref. to

assembly. <Ref. to


A: INSPECTION
Symptom
Shifting vehicle speed is low on D range.
Shifting vehicle speed is high on D range.
Excessive shock. (N D range)
Excessive shift shock on 1st of D range 2nd of D range or

1st of manual mode 2nd of manual mode.
Excessive shift shock on 2nd of D range 3rd of D range or

2nd of manual mode 3rd of manual mode.
Excessive shift shock on 3rd of D range 4th of D range or

3rd of manual mode 4th of manual mode.
Problem parts
Vehicle speed sensor 1 and Vehicle speed sensor 2
Brake switch signal
Lateral G sensor
Engine idle speed
Engine speed signal
Control cable adjustment
Oil pressure switch 1 and Front brake solenoid valve
Fluid level and condition
TCM power supply
PVIGN relay
Oil pressure switch 4 and Direct clutch solenoid valve
Engine speed signal
Turbine speed sensor
Oil pressure switch 5 and High & low reverse clutch solenoid
valve
Engine speed signal
Oil pressure switch 3 and Input clutch solenoid valve
Engine speed signal
5AT(diag)-148

Symptom
Excessive shift shock on 4th of D range 5th of D range or

4th of manual mode 5th of manual mode.
Excessive shock at kick down.
Excessive shock at shift up.
Excessive shock at lock up.
Excessive shock at engine brake.
Judder is occurred at lock up.
Noise at R, N and D range.
Hold at D range or 1st on manual mode.
Problem parts
Engine speed signal
Engine speed signal
Engine speed signal
Engine speed signal
Lock up solenoid valve
Line pressure
Low coast brake solenoid valve
Engine speed signal
ATF temperature sensor 1 and 2
Engine speed signal
Direct clutch solenoid valve
Line pressure
Up switch signal
5AT(diag)-149

Symptom
Hold at D range or 2nd on manual mode.
Hold at D range or 3rd on manual mode.
Hold at D range or 4th on manual mode.
Hold at D range or 5th on manual mode.
Gear does not shift 1st of D range 2nd of D range or 1st

of manual mode 2nd of manual mode.
Gear does not shift 2nd of D range 3rd of D range or 2nd

of manual mode 3rd of manual mode.
Gear does not shift 3rd of D range 4th of D range or 3rd

of manual mode 4th of manual mode.
Problem parts
Line pressure
Up switch signal
Down switch signal
Line pressure
Up switch signal
Down switch signal
valve
Front brake solenoid valve
Line pressure
Up switch signal
Down switch signal
TCM power supply
PVIGN relay
Line pressure
Down switch signal
Line pressure
Up switch
valve
Line pressure
Up switch signal
Line pressure
Up switch signal
5AT(diag)-150

Symptom
Gear does not shift 4th of D range 5th of D range or 4th

of manual mode 5th of manual mode.
Gear does not shift down to 4th on D range or manual mode.
Gear does not shift down to 3rd on D range or manual mode.
Gear does not shift down to 2nd on D range or manual mode.
Gear does not shift down to 1st on D range or manual mode.
No lock-up occurs.
No shift shock occurred when shifting 1st of D range 2nd of

D range or 1st of manual mode 2nd of manual mode. Or
clutch slipping occurred.
Problem parts
Line pressure
Up switch signal
Line pressure
Down switch signal
Line pressure
Down switch signal
TCM power supply
PVIGN relay
Line pressure
Down switch signal
Line pressure
Down switch signal
Line pressure
Engine speed signal
Brake switch signal
Range signal
Line pressure
5AT(diag)-151

Symptom
No shift shock occurred when shifting 2nd of D range 3rd of
D range or 2nd of manual mode 3rd of manual mode. Or
No shift shock occurred when shifting 3rd of D range 4th of

D range or 3rd of manual mode 4th of manual mode. Or
No shift shock occurred when shifting 4th of D range 5th of

D range or 4th of manual mode 5th of manual mode. Or
Engine skids when shifting 5th of D range 4th of D range

or 5th of manual mode 4th of manual mode. Or slipping
occurred.
Engine skids when shifting 4th of D range 3rd of D range

or 4th of manual mode 3rd of manual mode. Or slipping
occurred.
Engine skids when shifting 3rd of D range 2nd of D range

or 3rd of manual mode 2nd of manual mode. Or slipping
occurred.
Engine skids when shifting 2nd of D range 1st of D range

or 2nd of manual mode 1st of manual mode. Or slipping
occurred.
Engine brake does not function at 5th 4th of manual mode.
Engine brake does not function at 4th 3rd of manual mode.
Problem parts
valve
Line pressure
Line pressure
Line pressure
Line pressure
Line pressure
valve
Line pressure
Line pressure
Inhibitor switch
Manual mode switch
Oil pressure switch 1
Down switch signal
Inhibitor switch
Manual mode switch
Oil pressure switch 1 and Oil pressure switch 3
Down switch signal
5AT(diag)-152

Symptom
Engine brake does not function at 3rd 2nd of manual mode.
Engine brake does not function at 2nd 1st of manual mode.
Excessive acceleration failure on D range.
Excessive acceleration failure on R range.
Engine skids when start driving (1st) the vehicle. Or slipping

occurred.
Engine skids when driving at 2nd. Or slipping occurred.
Engine skids when driving at 3rd. Or slipping occurred.
Engine skids when driving at 4th. Or slipping occurred.
Problem parts
Inhibitor switch
Manual mode switch
Inhibitor switch
Manual mode switch
Line pressure
Inhibitor switch
Vehicle speed sensor 1, 2
Line pressure
valve
Inhibitor switch
Vehicle speed sensor 1, 2
Line pressure
Line pressure
Line pressure
valve
Line pressure
5AT(diag)-153

Symptom
5Engine skids when driving 5th. Or slipping occurred.
Slip at lock up.
Maximum vehicle speed is low.
There is completely no creep.
Excessive large creep.

Vehicle cannot be parking condition on P range. Parking condition is not released though shifting to other ranges.
Vehicle can drive on P range.
Vehicle can drive on N range.
Vehicle cannot drive at any range.
Vehicle cannot drive on D range.
Vehicle cannot drive on R range.
Problem parts
Line pressure
Line pressure
Engine speed signal
Line pressure
Direct clutch solenoid valve
Vehicle speed sensor 1 and 2
Engine speed signal
Line pressure
Engine speed signal
Inhibitor switch
Inhibitor switch
Line pressure
Inhibitor switch
Line pressure
Line pressure
Inhibitor switch
Loosing or damaging of propeller shaft.
Loosing or damaging of drive shaft.
Line pressure
Inhibitor switch
Line pressure
Inhibitor switch
5AT(diag)-154

Symptom
Engine cannot start on P or N range
Engine start other than P or N range
Engine stalls.
Engine stalls when shifting to N D and R range.
Problem parts
Key switch and Starter
Inhibitor switch
TCM
Key switch and Starter
Inhibitor switch
TCM
Engine speed signal
Line pressure
Engine speed signal
Line pressure
5AT(diag)-155

5AT(diag)-156
MANUAL TRANSMISSION
AND DIFFERENTIAL
5MT
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
Page
Transmission Gear Oil ..............................................................................30
Manual Transmission Assembly ...............................................................31
Oil Seal......................................................................................................39
Switches and Harness ..............................................................................41
Transfer Case and Extension Case Assembly..........................................44
Transfer Drive Gear ..................................................................................48
Transfer Driven Gear ................................................................................50
Center Differential .....................................................................................52
Reverse Check Sleeve..............................................................................53
Transmission Case ...................................................................................56
Main Shaft Assembly for Single-Range ....................................................62
Main Shaft Assembly for Dual-Range .......................................................67
Input Shaft Assembly ................................................................................73
Drive Pinion Shaft Assembly.....................................................................77
Reverse Idler Gear....................................................................................92
Shifter Fork and Rod .................................................................................94
Counter Gear ............................................................................................97
General Description
MANUAL TRANSMISSION AND DIFFERENTIAL
A: SPECIFICATION
1. MANUAL TRANSMISSION AND DIFFERENTIAL
Option code1
EC, K4, EK
KS
EC, K4, EK
KA
2.0 L
Model
Type
1st
2nd
3rd
Transmission gear ratio
4th
5th
Reverse
High
Low
ratio2
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 differential
2.5 L
Except
Except
OUTOUTOUTBACK
for OUTfor OUTBACK
BACK
BACK
BACK
5-forward speeds and 1-reverse
(5 2-forward speeds and 1 2-reverse)2
3.454
3.454
1.947
2.062
2.062
1.366
1.448
1.448
0.972
1.088
1.088
0.738
0.78
0.825
0.825
0.78
0.825
3.333
1.000
1.447
1.196
Hypoid
4.111
3.700
3.900
4.111
Helical
1.000
Hypoid
4.111
3.700
3.900
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
Except
for OUTBACK
Type and number of gear

Transmission gear oil capacity
Single-range
model
Dual-range
model
3.5 2 (3.7 US qt, 3.1 Imp qt)

4.0 2 (4.2 US qt, 3.5 Imp qt)
1:
: Dual-range model only
5MT-2
General Description
2. TRANSMISSION GEAR OIL
4. DRIVE PINION ASSEMBLY
Recommended oil:
Preload adjustment of thrust bearing

Starting torque:
0.3 0.8 Nm(0.03 0.08 kgf-m, 0.2 0.6 ftlb)
(1)
(2)
(3)
GL-5
(4)
-30 -26 -15 -5 0
-22 -15 5 23 32
( C)
( F)
15
59
Adjusting washer No. 1

Part Number
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)
25 30
77 86
90
85W
80W
75W -90
MT-00001
(1)
(2)
(3)
(4)
Item
API classification

Part Number
Thickness mm (in)
803025059
3.850 (0.1516)
803025054
4.000 (0.1575)
803025058
4.150 (0.1634)
3. TRANSMISSION CASE ASSEMBLY

Drive pinion shim adjustment
Hypoid gear backlash:
0.13 0.18 mm (0.0051 0.0071 in)
Part Number
32295AA031
32295AA041
32295AA051
32295AA061
Drive pinion shim

Thickness
Part Number
mm (in)
0.150
32295AA071
(0.0059)
0.175
32295AA081
(0.0069)
0.200
32295AA091
(0.0079)
0.225
32295AA101
(0.0089)
5. INPUT SHAFT ASSEMBLY
Thickness
mm (in)
0.250
(0.0098)
0.275
(0.0108)
0.300
(0.0118)
0.500
(0.0197)
Snap ring (Outer-28) to ball bearing clearance:

0 0.12 mm (0 0.0047 in)
Snap ring (Outer-28)
Part Number
Thickness mm (in)
805028050
2.48 (0.0976)
805028060
2.56 (0.1008)
805028070
2.64 (0.1039)
Snap ring (Inner-68) to ball bearing clearance:

0 0.12 mm (0 0.0047 in)
Selection of main shaft rear plate

Main shaft rear plate
Dimension A mm (in)
Part Number
4.00 4.13
32294AA041
(0.1575 0.1626)
3.87 3.99
32294AA051
(0.1524 0.1571)
Marking
1
2
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)
Snap ring (Inner-68)

Part Number
Thickness mm (in)
805168020
1.84 (0.0724)
805168030
1.92 (0.0756)
805168040
2.00 (0.0787)
Shim Number
6. MAIN SHAFT
Snap ring (Outer-25) to synchronizer hub clearance:
0.060 0.100 mm (0.0024 0.0039 in)
Part Number
805025051
805025052
805025053
805025054
5MT-3

Thickness
Part Number
mm (in)
2.42 (0.0953) 805025055
2.47 (0.0972) 805025056
2.52 (0.0992) 805025057
2.57 (0.1012) 805025058
Thickness
mm (in)
2.62 (0.1031)
2.67 (0.1051)
2.72 (0.1071)
2.37 (0.0933)
General Description
7. REVERSE IDLER GEAR
5th shifter fork (Non-turbo model)

Mark
Remarks
Approach to 5th gear
32812AA201
7
by 0.2 mm (0.008 in)
32812AA211
No mark
Standard
Become distant from
32812AA221
9
5th gear by 0.2 mm
(0.008 in)
Adjustment of reverse idler gear position
Part No.
Reverse idler gear to transmission case (LH)

wall clearance:
6.0 7.5 mm (0.236 0.295 in)
Part Number
32820AA070
32820AA080
32820AA090
Reverse shifter lever

Marking
Remarks
7
Further from case wall
8
Standard
9
Closer to the case wall
5th shifter fork (Turbo model)

Mark
Remarks
32812AA231
7
by 0.2 mm (0.008 in)
32812AA241
No mark
Standard
Become distant from
32812AA251
9
5th gear by 0.2 mm
(0.008 in)
Part No.
After installing a suitable reverse shifter lever, adjust the clearance using washer.
Reverse idler gear to transmission case wall
clearance:
0 0.5 mm (0 0.020 in)
Part Number
803020151
803020152
803020153
Washer (20.5 26 t)
Thickness
Part Number
mm (in)
0.4 (0.016)
803020154
1.1 (0.043)
803020155
1.5 (0.059)
9. TRANSFER CASE OR REAR CASE

Thickness
mm (in)
1.9 (0.075)
2.3 (0.091)
Neutral position adjustment

Part Number
32190AA000
32190AA010
Adjusting shim
Thickness mm (in)
0.15 (0.0059)
0.30 (0.0118)
8. SHIFTER FORK AND ROD

Select suitable shifter forks so that both the coupling sleeve and reverse driven gear are positioned
in the center of their synchromesh mechanisms.
Rod end clearance:
A: 3rd-4th 5th
0.5 1.3 mm (0.020 0.051 in)
B: 1st-2nd 3rd-4th
0.4 1.4 mm (0.016 0.055 in)
Part Number
32804AA060
32804AA070
32804AA080
Part No.
32188AA130
32188AA140
32188AA150
Reverse check plate adjustment
1st-2nd shifter fork

Marking
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)
Part Number
32189AA000
32189AA010
33189AA020
Part Number
32810AA061
32810AA071
32810AA101
Reverse accent shaft

Mark
Remarks
Neutral position is
S
closer to 1st.
T
Standard
Neutral position is
U
closer to reverse gear.
3rd-4th shifter fork

Marking
Remarks
1
by 0.2 mm (0.008 in).
No mark
Standard
Approach to 3rd gear
3
by 0.2 mm (0.008 in)
32189AA030
32189AA040
5MT-4
Reverse check plate

MarkAngle
Remarks
ing
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.
General Description
10.EXTENSION ASSEMBLY
11.FRONT DIFFERENTIAL
Standard protrusion amount of taper roller

bearing outer race:
0.2 0.3 mm (0.008 0.012 in)
Bevel gear to pinion backlash:

0.13 0.18 mm (0.0051 0.0071 in)
NOTE:
Be sure that it is within the standard protrusion
amount.
Thrust washer (50 61 t)
Part Number
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)
Part Number
803038021
803038022
Thickness
mm (in)
1.025
1.050
(0.0404
0.0413)
12.TRANSFER DRIVE GEAR

Snap ring (Outer-30) to ball bearing clearance:
0.01 0.15 mm (0.0004 0.0059 in)
Part Number
Thickness mm (in)
805030041
1.53 (0.0602)
805030042
1.65 (0.0650)
805030043
1.77 (0.0697)
Thrust washer to center differential side clearance:

0.15 0.35 mm (0.0059 0.0138 in)
Part Number
803036050
803036054
803036051
803036055
803036052
803036056
803036053
803036057
803036058
Washer (38.1 50 t)
Thickness
Part Number
mm (in)
0.925
0.950
803038023
(0.0364
0.0374)
0.975
1.000
(0.0384
0.0394)
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)
5MT-5
General Description
B: COMPONENT
1. TRANSMISSION CASE
(13)
(10)
(12)
(6)
(14)
(7)
(9)
T2
(5)
(8)
(11)
(4)
(1)
(2)
(3)
T1
MT-01360
5MT-6
General Description
(1)
Transmission case ASSY (Singlerange)
(2)
(3)
(4)
(5)
(6)
(7)
Gasket
Drain plug
Harness bracket
Clamp
Oil level gauge
(8)
(9)
(10)
(11)
Gasket
Plug
Oil seal (Dual-range)
Transmission case ASSY (Dualrange)
(12)
High-low cable bracket A (Dualrange)
(13)
High-low cable bracket B (Dualrange)

T1: 70 (7.1, 51)
T2: 60 (6.1, 43.7)
Transmission case tightening torque
(9)
(5)
(7)
(16)
Bolt No.
Bolt size
mm
Tightening torque: Nm (kgf-m,

ft-lb)
(5) (15)
25 (2.5, 18.4)
(1) (4)
(16) (17)
10
39 (4.0, 28.9)
(17)
(11)
(13)
(1)
(3)
(2)
(15)
(4)
(14)
(10) (6)
(8) (12)
MT-00003
5MT-7
General Description
2. DRIVE PINION ASSEMBLY
(3)
(4) (5)
(2)
(1)
(11)
(18)
(8)
(17)
(7)
(16)
(15)
(14)
(13)
(10)
(12)
(9)
(29)
(6)
T3
(28)
(27)
T1
(26)
(25)
(24)
(23)
(35)
T2
(34)
(33)
(32)
(22)
(21)
(20)
(19)
(30)
(30)
(31)
MT-00351
(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 (KS and K4 model)
Washer (KS and K4 model)
Sub gear (KS and K4 model)
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 bushing
3rd-4th driven gear
Driven pinion shim
Roller bearing
5th driven gear
Lock washer
5MT-8
(29)
(30)
(31)
(32)
(33)
(34)
(35)
Lock nut
Washer
Thrust bearing
Differential bevel gear sleeve
Washer
Lock washer
Lock nut

T1: 30 (3.1, 22.4)
T2: 120 (12.2, 88.2)
T3: 260 (26.5, 191.7)
General Description
3. MAIN SHAFT ASSEMBLY FOR SINGLE-RANGE
(3)
(2)
(1)
(17)
(16)
(15)
(13)
(11)
(14)
(12)
(10)
(9)
(8)
(7)
(6)
(5)
(38)
(4)
(33)
(32)
(24)
(31)
(30)
(29)
(28)
(27)
(26)
(25)
(23)
(37)
(22)
(36)
(21)
(34)
(20)
(39)
(18)
(35)
(19)
MT-01359
5MT-9
General Description
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
Oil seal
Needle bearing
Transmission main shaft
Needle bearing
3rd drive gear
Inner baulk ring
3rd synchro cone
Outer baulk ring
3rd-4th coupling sleeve
3rd-4th synchronizer hub
3rd-4th shifting insert key
4th baulk ring
4th drive gear
4th needle bearing race
Needle bearing
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
4th gear thrust washer

Ball bearing
Needle bearing
5th drive gear
5th baulk ring
5th-Rev shifting insert key
5th-Rev synchronizer hub
5th-Rev coupling sleeve
Reverse baulk ring
Reverse synchro cone
Ball bearing
Synchro cone stopper
5MT-10
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
Snap ring
Lock washer
Lock nut
Reverse idler gear shaft
Straight pin
Reverse idler gear
Washer
Taper roller bearing (Turbo model)
5th needle bearing race (Turbo
model)

T: 120 (12.2, 88.5)
General Description
4. MAIN SHAFT ASSEMBLY FOR DUAL-RANGE

(6)
(7)
(6)
(8)
(5)
(4)
(4)
(20)
(2)
(1)
(14)
(16)
(19)
(3)
(10)
(18)
(17)
(9)
(15)
(13)
(11)
(33)
(12)
T2
(32)
(26)
(31)
(30)
(29)
(28)
(68)
(22)
T3
(71)
(27)
(24)
(25)
(72)
(69)
(24)
(23)
(73)
(70)
(74)
(21)
(77)
T1
(78)
(79)
(76)
(75)
(34)
(38)
(37)
(36)
(35)
(47)
(46)
(43)
(42)
(41)
(40)
(39)
(45)
(44)
(63)
T4
(62)
(54)
(59)
(58)
(61)
(60)
(57)
(56)
(55)
(53)
(67)
(52)
(48) (49)
(50)
(51)
(66)
(64)
(65)
MT-01019
5MT-11
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)
(29)
O-ring
High-low counter shaft
Knock pin
High-low counter washer
Counter gear
Needle bearing
Counter gear collar
Input shaft holder
Input shaft shim
Oil seal
O-ring
Oil squeeze
Straight pin
Ball bearing
Snap ring (Inner-68)
Input shaft
Needle bearing
High-low baulk ring
High-low coupling sleeve
High-low synchronizer spring
High-low synchronizer hub
Shifting insert key
High-low baulk ring
Friction damper
Input low gear
(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)
(57)
(58)
Needle bearing
Input low gear spacer
Ball
Main shaft
Needle bearing
3rd drive gear
Inner baulk ring
Synchro cone
Outer baulk ring
3rd-4th coupling sleeve
3rd-4th shifting insert key
4th baulk ring
4th drive gear
Needle bearing
Ball bearing
Needle bearing
5th drive gear
5th baulk ring
5th-Rev shifting insert key
5th-Rev coupling sleeve
Rev baulk ring
Rev synchro cone
5MT-12
(59)
(60)
(61)
(62)
(63)
(64)
(65)
(66)
(67)
(68)
(69)
(70)
(71)
(72)
(73)
(74)
(75)
(76)
(77)
(78)
(79)
Ball bearing
Synchro cone stopper
Snap ring
Lock washer
Lock nut
Straight pin
Reverse idler gear
Washer
Straight pin
High-low shifter lever
High-low shifter shaft
Low switch
Gasket
Straight pin
High-low shifter fork
High-low shifter piece
Ball
Spring
Gasket
Plug

T1: 10 (1.0, 7.4)
T2: 20 (2.0, 14.5)
T3: 25 (2.5, 18.1)
T4: 120 (12.2, 88.5)
General Description
5. SHIFTER FORK AND SHIFTER ROD

(1)
(2)
(8)
(7)
(4)
(6)
(5)
T
(3)
(12)
(18)
(9)
(10)
(10)
(7)
(6)
(5)
(17)
(16)
(8)
(10)
(11)
(3)
(6)
(15)
(5)
(14)
(8)
(7)
(3)
(13)
MT-00007
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Shifter arm
5th shifter fork
Straight pin
Reverse fork rod
Checking ball plug
Gasket
Checking ball spring
(8)
(9)
(10)
(11)
(12)
(13)
(14)
Ball
3rd-4th fork rod
Interlock plunger
1st-2nd fork rod
Ball
5MT-13
(15)
(16)
(17)
(18)
Spring
Snap ring (Outer)
Reverse fork rod arm

T: 19.5 (2.0, 14.4)
General Description
6. TRANSFER CASE AND EXTENSION

(5)
(4)
T3
(7)
T2
(3)
(6)
(2)
(8)
T3
(20)
(1)
T1
(21)
(23)
(22)
T5
T5
(12)
(14)
(9)
(17)
(10)
(19)
(11)
(15)
T1
(13)
(16)
(35)
(18)
(34)
(36)
T6
T3
(26) (27)
(25)
(24)
(31)
T6
(30)
(37)
(29)
(33)
(32)
(28)
T4
MT-01254
(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
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
Gasket
Back-up light switch
Roller bearing
Transfer driven gear
Roller bearing
Adjusting washer
Ball bearing
Center differential
Adjusting washer
5MT-14
(31)
(32)
(33)
(34)
(35)
(36)
(37)
Transfer drive gear

Ball bearing
Extension case
Oil seal
Dust cover
Shift bracket
Snap ring

T1: 6.4 (0.65, 4.7)
T2: 10 (1.0, 7.4)
T3: 25 (2.5, 18.4)
T4: 26 (2.7, 20)
T5: 32 (3.3, 23.6)
T6: 40 (4.1, 29.7)
General Description
7. FRONT DIFFERENTIAL
(7)
(5)
(1)
(6)
(5)
(2)
(8)
(7)
(3)
(4)
T2
(8)
(11)
(10)
(10)
(12)
(9)
(12)
(13)
(11)
T1
T1
(13)
MT-01365
(1)
(2)
(3)
(4)
(5)
(6)
Drive pinion shaft

Hypoid driven gear
Pinion shaft
Straight pin
Washer
(7)
(8)
(9)
(10)
(11)
(12)

Roller bearing
Differential case
Oil seal
Differential side retainer
O-ring
5MT-15
(13)
Retainer lock plate

T1: 25 (2.5, 18.1)
T2: 62 (6.3, 45.6)
General Description
8. TRANSMISSION MOUNTING
(6)
(4)
(5)
(3)
T4
(2)
T3
T1
T2
(10)
(1)
(8)
(3)
(9)
(2)
(3)
(7)
T2
T5
T5
T6
MT-00998
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Pitching stopper
Spacer
Cushion rubber
Front plate
Rear cushion rubber
Rear crossmember
Cushion D
(8)
(9)
(10)
Center crossmember
Front crossmember
Cushion (crossmember)
5MT-16

T1: 70 (7.1, 51)
T2: 35 (3.6, 26)
T3: 50 (5.1, 37)
T4: 58 (5.9, 43)
T5: 70 (7.1, 51)
T6: 140 (14.3, 103)
General Description
C: CAUTION
goggles and protective shoes, during operation.
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.
equivalent. Do not mix gear oil, grease etc. with

points.
Replace deformed or damaged snap rings with
new ones.
Before installing O-rings or oil seals, apply sufficient amount of gear oil to avoid damage and deformation.
Before applying sealant, completely remove the
old seal.
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
399411700
DESCRIPTION
ACCENT BALL
INSTALLER
REMARKS
Used for installing reverse shifter rail arm.
PULLER SET
Used for removing and installing roller bearing

(Differential).
(1) Puller
(2) Cap
ST-399411700
899524100
ST-899524100
5MT-17
General Description
ILLUSTRATION
TOOL NUMBER
399780104
DESCRIPTION
WEIGHT
REMARKS
Used for measuring preload on roller bearing.
498077000
REMOVER
Used for removing roller bearing of drive pinion

shaft.
498077300
CENTER DIFFERENTIAL BEARING

REMOVER
Used for removing the center differential cover

ball bearing.
498147001
DEPTH GAUGE
Used for adjusting main shaft axial end play.
ST-399780104
ST-498077000
ST-498077300
ST-498147001
5MT-18
General Description
ILLUSTRATION
TOOL NUMBER
498247001
DESCRIPTION
MAGNET BASE
REMARKS
Used for measuring backlash between side
gear and pinion, and hypoid gear.
498247100
DIAL GAUGE

498427100
STOPPER
Used for securing drive pinion shaft assembly

and driven gear assembly when removing lock
nut of drive pinion shaft assembly.
498787100
MAIN SHAFT
STOPPER
Used for removing and installing lock nut of

transmission main shaft.
ST-498247001
ST-498247100
ST-498427100
ST-498787100
5MT-19
General Description
ILLUSTRATION
TOOL NUMBER
498937000
DESCRIPTION
TRANSMISSION
HOLDER
REMARKS
Used for removing and installing transmission
main shaft lock nut.
499277100
BUSHING 1-2
INSTALLER
Used for installing 1st driven gear thrust plate

and 1st-2nd driven gear bushing.
Used for installing roller bearing outer races to
differential case.
499277200
INSTALLER
Used for press-fitting 2nd driven gear, roller

bearings, and 5th driven gear onto driven shaft.
499757002
INSTALLER
Used for installing snap ring (OUT 25), and

ball bearing (25 26 17).
Used for installing bearing cone of transfer
driven gear (extension core side).
ST-498937000
ST-499277100
ST-499277200
ST-499757002
5MT-20
General Description
ILLUSTRATION
TOOL NUMBER
499787000
DESCRIPTION
WRENCH ASSY
REMARKS
retainer.
499827000
PRESS
Used for installing speedometer oil seal when

installing speedometer cable to transmission.
499857000
5TH DRIVEN GEAR

REMOVER
Used for removing 5th driven gear.
499877000
RACE 4-5
INSTALLER
Used for installing 4th needle bearing race and

ball bearing onto transmission main shaft.
Used with REMOVER (899714110).
ST-499787000
ST-499827000
ST-499857000
ST-499877000
5MT-21
General Description
ILLUSTRATION
TOOL NUMBER
499917500
DESCRIPTION
DRIVE PINION
GAUGE ASSY
REMARKS
Used for adjusting drive pinion shim.
499927100
HANDLE
Used for fitting transmission main shaft.
499937100
TRANSMISSION
STAND SET
Stand used for transmission disassembly and

assembly.
499987003
SOCKET WRENCH
(35)
Used for removing and installing driven pinion

lock nut and main shaft lock nut.
ST-499917500
ST-499927100
ST-499937100
ST-499987003
5MT-22
General Description
ILLUSTRATION
TOOL NUMBER
499987300
DESCRIPTION
SOCKET WRENCH
(50)
REMARKS
Used for removing and installing driven gear
assembly lock nut.
899714110
REMOVER
Used for installing transmission main shaft drive

pinion and rear drive shaft.
899864100
REMOVER
Used for removing parts on transmission main

shaft and drive pinion.
899884100
HOLDER
Used for tightening lock nut on sleeve.
ST-499987300
ST-899714110
ST-899864100
ST-899884100
5MT-23
General Description
ILLUSTRATION
TOOL NUMBER
899904100
DESCRIPTION
REMOVER
REMARKS
Used for removing and installing straight pin.
899988608
SOCKET WRENCH
(27)

nut.
398497701
ADAPTER
Used for installing roller bearing onto differential case.

Used with INSTALLER (499277100).
499587000
INSTALLER
Used for installing driven gears to driven shaft.
ST-899904100
ST-899988608
ST-398497701
ST-499587000
5MT-24
General Description
ILLUSTRATION
TOOL NUMBER
499987100
DESCRIPTION
SOCKET WRENCH
(35)
REMARKS
nut.
899984103
SOCKET WRENCH
(35)

nut.
498057300
INSTALLER
498255400
PLATE
Used for measuring backlash.
ST-499987100
ST-899984103
ST-498057300
ST-498255400
5MT-25
General Description
ILLUSTRATION
TOOL NUMBER
498077400
DESCRIPTION
SYNCHRONIZER
CONE REMOVER
REMARKS
Used for removing synchronizer cone of main
shaft.
Used for removing 5th driven gear of drive pinion shaft.
ENGINE SUPPORT
BRACKET

(41099AA010)
(1) ENGINE SUPPORT (41099AA020)
398527700
PULLER ASSY
398643600
GAUGE

ST-498077400
41099AA000
(1)
(2)
ST41099AA000
ST-398527700
ST-398643600
5MT-26
General Description
ILLUSTRATION
TOOL NUMBER
398177700
DESCRIPTION
INSTALLER
REMARKS
Used for installing bearing cone of transfer
driven gear (transfer case side).
Used for installing ball bearing of transfer drive
gear.
28399SA010
FRONT DRIVE
SHAFT OIL SEAL
PROTECTOR
Used for protecting oil seal from damage when

inserting front drive shaft.
18675AA000
DIFFERENTIAL
SIDE OIL SEAL
INSTALLER

seal.
DUMMY COLLAR
Used for installing input shaft holder oil seal.

For dual-range model.
ST-398177700
ST28399SA010
ST18675AA000
398507703
ST-398507703
5MT-27
General Description
ILLUSTRATION
TOOL NUMBER
398663600
DESCRIPTION
PLIERS
REMARKS
Used for removing and installing input shaft
snap ring.
499757001
SNAP RING GUIDE
Used for installing snap ring (OUT 25).

899858600
RETAINER

899474100
EXPANDER
Used for removing and installing snap ring.

ST-398663600
ST-499757001
ST-899858600
ST-899474100
5MT-28
General Description
ILLUSTRATION
TOOL NUMBER
899580100
DESCRIPTION
INSTALLER
REMARKS
Used for pressing ball bearings into input
shaft.
INSTALLER
Used for pressing ball bearings into input

shaft.
ST-899580100
399513600
ST-399513600
2. GENERAL TOOL
TOOL NAME
Circuit tester
REMARKS
Used for measuring resistance, voltage and ampere.
5MT-29
Transmission Gear Oil

2. Transmission Gear Oil
Tightening torque:
70 Nm (7.1 kgf-m, 51 ft-lb)
A: INSPECTION
2) Turn the ignition switch to OFF, and wait until the
engine cools.
proper direction.
5) Pull out the oil level gauge again, and check the
oil level. If it is below the lower level, add oil through
the oil level gauge hole to bring the level up to the
upper level.
(B)
(A)
MT-00061
(A) Drain plug

(B) Gasket
(A)

5) Pour gear oil through the gauge hole.
GL-5 (75W-90) or equivalent
(B)
(C)
Gear oil capacity:

Single-range model
3.5 2 (3.7 US qt, 3.1 Imp qt)
Dual-range model
4.0 2 (4.2 US qt, 3.5 Imp qt)
6) Check the level of transmission gear oil.
PM-00030
(A) Oil level gauge

(B) Upper level
(C) Lower level
CAUTION:
The level should be within the specified range
marked on the gauge.
B: REPLACEMENT
1) Pull out the oil level gauge.
3) Drain transmission gear oil completely.
CAUTION:
Immediately after the engine running, the transmission gear oil is very hot. Be careful not to
burn yourself.
NOTE:
Tighten the transmission gear oil drain plug after
draining transmission gear oil.
Use a new gasket.
5MT-30
Manual Transmission Assembly

3. Manual Transmission Assembly
8) Remove the drive select cable on transmission

side. (Dual-range model)
A: REMOVAL
1) Open the front hood fully, and support with stay.
3) Drain transmission gear oil completely.
4) Remove the air intake chamber and air cleaner
case. <Ref. to IN(H4SO 2.0)-8, REMOVAL, Air Intake Chamber.> <Ref. to IN(H4SO 2.0)-6, REMOVAL, Air Cleaner Case.>
5) Remove the air intake chamber stay.
(A)
(C)
(B)
MT-00066
(A) Snap pin

(B) Clevis pin
(C) Drive select cable
9) Remove the starter. <Ref. to SC(H4SO 2.0)-6,

REMOVAL, Starter.>
10) Remove the operating cylinder from transmission.
MT-00062
6) Disconnect the following connectors:

(1) Neutral position switch connector
(2) Back-up light switch connector
(3) High-low switch connector (Dual-range
model)
CL-00253
MT-00063
7) Remove the snap pin and clevis pin from drive

select cable. (Dual-range model)
MT-00069
5MT-31

12) Set the ST.

ST 41099AA000 ENGINE SUPPORT ASSY
(1) Disconnect the stay from transmission.

(2) Remove the rod from transmission.
ST
(A)
(B)
(B)
MT-00070
MT-00075
13) Remove the bolts which hold upper side of

(A) Stay
(B) Rod
21) Remove the stabilizer link from front arm.
MT-00073

15) Remove the front and center exhaust pipes.
MT-00988
22) Remove the bolt securing ball joint of front arm

to housing.
CAUTION:
When removing the exhaust pipes, be careful
each exhaust pipe does not drop out.
17) Remove the heat shield cover. (if equipped)
18) Remove the hanger bracket from the right side
of transmission.
(B)
(C)
(A)
MT-00987
(A) Front arm

(B) Ball joint
(C) Stabilizer link
MT-00074

20) Remove the gear shift rod and the stay from
transmission.
5MT-32

23) Using the lever, remove the left and right front
drive shaft from transmission.

from vehicle.
(A)
MT-00079
MT-01017
(A) Lever

NOTE:
Move the transmission jack toward rear until main
shaft is withdrawn from clutch disc.
28) Separate the transmission assembly from rear
cushion rubber.
B: INSTALLATION
1) Install the rear cushion rubber to transmission
assembly.
MT-00077

CAUTION:
Always support transmission case with a transmission jack.
Tightening torque:
35 Nm (3.57 kgf-m, 25.8 ft-lb)
(1) Gradually raise the transmission with transmission jack.
NOTE:
Be careful not to strike the main shaft against clutch
housing cover.
Tightening torque:
T1: 70 Nm (7.1 kgf-m, 51 ft-lb)
T2: 140 Nm (14.3 kgf-m, 103 ft-lb)
T1
T1
T2
MT-00078
T2
MT-00081
4) Take out the transmission jack.
5MT-33

5) Tighten the nuts which hold lower side of transmission to engine.

Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)

Tightening torque:
T1: 50 Nm (5.1 kgf-m, 37 ft-lb)
T2: 58 Nm (5.9 kgf-m, 43 ft-lb)
T1
T2
MT-00077
MT-00085
6) Connect the transmission to engine.

(1) Install the starter.
<Ref. to SC(H4SO 2.0)-6, INSTALLATION,
Starter.>
(2) Tighten the bolts that hold upper side of
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)

11) Replace the differential side retainer oil seal.
<Ref. to 5MT-40, REPLACEMENT, Differential
Side Retainer Oil Seal.>
SEAL INSTALLER
NOTE:
Be sure to replace the differential side retainer oil
seal after the procedure of removing the front drive
shaft.
ST
MT-00073
7) Remove the ST.

MT-00103
ST

ST 28399SA010 FRONT DRIVE SHAFT OIL
SEAL PROTECTOR
MT-00070
ST
AT-00110
5MT-34

18) Install the hanger bracket on the right side of

transmission.
13) Install the ball joint of lower arm.

Tightening torque:
49 Nm (5.0 kgf-m, 36 ft-lb)
(B)
(C)
MT-00074
(A)
14) Install the stabilizer link into front arm.
19) Install the front, center and rear exhaust pipe,

20) Install the operating cylinder.
Tightening torque:
45 Nm (4.6 kgf-m, 33.2 ft-lb)
Tightening torque:
37 Nm (3.8 kgf-m, 27.5 ft-lb)
MT-00987
(A) Front arm

(B) Ball joint
(C) Stabilizer link
MT-00988
CL-00253
15) Install the gear shift rod and the stay.

(1) Install the gear shift rod into transmission.
21) Install the drive select cable on transmission

side. (Dual-range model)
(A)
(A)
(B)
(B)
(C)
(B)
MT-00066
MT-00089
(A) Snap pin

(B) Clevis pin
(C) Drive select cable
(A) Stay
(B) Rod
(2) Install the stay onto transmission.

17) Install the heat shield cover. (if equipped)

(1) Transmission ground cable
Tightening torque:
13 Nm (1.3 kgf-m, 9.4 ft-lb)
5MT-35

(2) Neutral position switch connector

(3) Back-up light switch connector
(4) High-low switch connector (Dual-range
model)
23) Fill transmission gear oil through the transmission level gauge hole.
24) Install the air intake chamber stay.
Tightening torque:
16 Nm (1.6 kgf-m, 11.6 ft-lb)
25) Install the air intake chamber and air cleaner
case. <Ref. to IN(H4SO 2.0)-7, INSTALLATION,
Air Cleaner Case.> <Ref. to IN(H4SO 2.0)-8, INSTALLATION, Air Intake Chamber.>
27) Take off the vehicle from lift arms.
5MT-36

4. Transmission Mounting System
B: INSTALLATION
A: REMOVAL
1. PITCHING STOPPER
Tightening torque:
T1: 50 Nm (5.1 kgf-m, 37 ft-lb)
T2: 58 Nm (5.9 kgf-m, 43 ft-lb)

1. PITCHING STOPPER
T1
T2
MT-00085
2) Install the air intake chamber and cleaner case.

MT-00069
2. CROSSMEMBER AND CUSHION RUBBER

racks.
3) Remove the front, center and rear exhaust pipe,
and muffler. <Ref. to EX(H4SO 2.0)-7, REMOVAL,
Front Exhaust Pipe.> <Ref. to EX(H4SO 2.0)-11,
REMOVAL, Rear Exhaust Pipe.> <Ref. to
EX(H4SO 2.0)-13, REMOVAL, Muffler.>
4) Remove the heat shield cover. (If equipped)
5) Set the transmission jack under transmission
body.

Tightening torque:
35 Nm (3.6 kgf-m, 26 ft-lb)
2) Install the rear crossmember.
Tightening torque:
T1: 70 Nm (7.1 kgf-m, 51 ft-lb)
T2: 140 Nm (14.3 kgf-m, 103 ft-lb)
T1
T1
CAUTION:
Always support the transmission case with a
transmission jack.
6) Remove the rear crossmember.
T2
T2
MT-00081
MT-00079

4) Install the heat shield cover. (If equipped)
5) Install the front, center and rear exhaust pipe,
5MT-37

C: INSPECTION
Perform the following inspection procedures and
repair or replace defective parts.
1. PITCHING STOPPER
Check pitching stopper for bends or damage.
Check that the rubber is not stiff, cracked, or otherwise damaged.

Check crossmember for bends or damage. Check
that the cushion rubber is not stiff, cracked, or otherwise damaged.
5MT-38
Oil Seal
5. Oil Seal

ST 498057300
INSTALLER
A: INSPECTION
Check leakage of gear oil from the oil seal part. If
there is oil leakage, replace with a new oil seal.
B: REPLACEMENT
2) Drain gear oil completely.
NOTE:
Tighten the drain plug after draining gear oil.
Tightening torque:
70 Nm (7.1 kgf-m, 51 ft-lb)
MT-00099

9) Install the heat shield cover. (If equipped)
11) Pour gear oil and check the oil level. <Ref. to
5MT-30, REPLACEMENT, Transmission Gear
Oil.>
MT-00097

4) Remove the heat shield cover. (If equipped)
ST 398527700
PULLER ASSY
(A)
ST
MT-00098
(A) Oil seal
5MT-39

6. Differential Side Retainer Oil

Seal
A: INSPECTION
Check leakage of gear oil from the differential side
with a new oil seal.

by slightly tapping with a plastic hammer.
SEAL INSTALLER
NOTE:
B: REPLACEMENT
ST

2) Drain gear oil from differential oil drain plug.
MT-00103
(A)
MT-00339
(A) Differential oil drain plug
3) Replace with a new gasket and tighten the differential oil drain plug.
Tightening torque:
70 Nm (7.1 kgf-m, 51 ft-lb)
(A)
ST 28399SA010 FRONT DRIVE SHAFT OIL
SEAL PROTECTOR
Exhaust Pipe.>
11) Pour gear oil through the gauge hole. <Ref. to
5MT-30, REPLACEMENT, Transmission Gear
Oil.>
MT-00339
(A) Differential oil drain plug

6) Remove the differential side retainer oil seal.
NOTE:
Be sure to replace the differential side retainer oil
seal after the procedure of removing the front drive
shaft from transmission.
When prying to remove the part using flat tip
screwdriver, be careful not to scratch the differential side retainer. ST 398527700 puller assembly
may be used for this operation procedure.
5MT-40
Switches and Harness

7. Switches and Harness
3) Disconnect the connector of high-low switch.
A: REMOVAL
1. BACK-UP LIGHT SWITCH AND NEUTRAL POSITION SWITCH
(A)

2) Remove the air intake chamber and cleaner
case. <Ref. to IN(H4SO 2.0)-6, REMOVAL, Air
3) Disconnect the connectors of back-up light
switch and neutral position switch.
(B)
(C)
MT-00107
(A) Neutral switch (Brown)

(B) Back-up light switch (Gray)
(C) High-low switch (Black)
(A)
4) Remove the high-low switch cable from clamp.

5) Remove the high-low switch.
(A)
(B)
(B)
MT-00104
(A) Neutral position switch connector (Brown)

(B) Back-up light switch connector (Gray)

5) Remove the back-up light switch and neutral position switch with harness.
(A)
MT-00108
(A) Clamp
(B) High-low switch
B: INSTALLATION
1. BACK-UP LIGHT SWITCH AND NEUTRAL POSITION SWITCH
1) Install the back-up light switch and neutral position switch with harness.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
(B)
MT-00106
(A) Neutral position switch (Brown)

(B) Back-up light switch (Gray)
(A)
2. HIGH-LOW SWITCH (DUAL-RANGE

MODEL)
2) Remove the air intake chamber and cleaner
case. <Ref. to IN(H4SO 2.0)-6, REMOVAL, Air
(B)
MT-00106
(A) Neutral position switch

(B) Back-up light switch
5MT-41
Switches and Harness

2) Connect the connectors of back-up light switch

and neutral position switch.
2. HIGH-LOW SWITCH (DUAL-RANGE

MODEL)
1) Install the high-low switch.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
2) Install the high-low switch cable to clamp.
3) Connect the connector of high-low switch.
C: INSPECTION
1. BACK-UP LIGHT SWITCH
Inspect the back-up light switch. <Ref. to LI-7, INSPECTION, Back-up Light System.>
2. NEUTRAL POSITION SWITCH

2) Disconnect the connector of neutral position
switch.
3) Measure the resistance between neutral position switch terminals.
2 1
MT-00110
Gear shift position

Neutral position
Other positions
Terminal No.
1 and 2
Specified resistance
More than 1 M
Less than 1
4) Replace the faulty parts.
5MT-42

8. Preparation for Overhaul

A: PROCEDURE
1) Clean oil, grease, dirt and dust from transmission.
2) Remove the drain plug to drain oil. Tighten the
engine oil drain plug after draining.
NOTE:
Use a new gasket.
Tightening torque:
70 Nm (7.1 kgf-m, 51 ft-lb)
MT-00097
3) Attach the transmission to ST.

ST 499937100
TRANSMISSION STAND
ST
MT-00115
4) Rotating parts should be coated with oil prior to

assembly.
5) All disassembled parts, if to be reused, should
be reinstalled in the original positions and directions.
6) Always use new ones for gaskets, lock washers
and lock nut.
7) Liquid gasket should be used where specified to
prevent leakage.
5MT-43
Transfer Case and Extension Case Assembly

9. Transfer Case and Extension

Case Assembly
2) Remove the bearing outer race from extension

case.
(B)
A: REMOVAL
from vehicle. <Ref. to 5MT-31, REMOVAL, Manual
2) Remove the back-up light switch and neutral position switch. <Ref. to 5MT-41, REMOVAL, Switches and Harness.>
3) Remove the transfer case with extension case
assembly.
(A)
MT-00119
(A) Bearing outer race

(B) Extension case
3) While pressing the bearing outer race horizontally, turn the driven shaft ten rotations.
4) Measure the height W between transfer case
and taper roller bearing on the transfer driven gear.
MT-00116
4) Remove the shifter arm.

5) Remove the extension case assembly.
MT-00120
5) Measure the depth X on bearing insertion part

of extension case.
NOTE:
Measure with bearing outer race and thrust washer
removed.
MT-00117
B: INSTALLATION
1) Install the center differential and transfer driven
gear into transfer case.
MT-00121
MT-00118
6) Calculate the tight t using following equation.

t = X W + 0.2 to 0.3 mm (0.008 to 0.012 in)
7) Select the washer of nearest value in the following table:
Standard protrusion amount of taper roller
bearing outer race:
0.2 0.3 mm (0.008 0.012 in)
5MT-44

NOTE:
Be sure that it is within the standard protrusion
amount.
Thrust washer (50 61 t)
Part Number
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)
11) Measure the height T between extension

case and transfer drive gear.
ST 398643600
GAUGE
ST
MT-00123
NOTE:
Thickness of ST: 15 mm (0.59 in)
12) Calculate the space U using following equation:
U = S + T 30 mm (1.18 in) [Thickness of ST]
13) Select a suitable washer in the following table:
Standard clearance:
0.15 0.35 mm (0.0059 0.0138 in)
Thrust washer
Part Number
Thickness mm (in)
803036050
0.9 (0.035)
803036054
1.0 (0.039)
803036051
1.1 (0.043)
803036055
1.2 (0.047)
803036052
1.3 (0.051)
803036056
1.4 (0.055)
803036053
1.5 (0.059)
803036057
1.6 (0.063)
803036058
1.7 (0.067)
8) Fit the thrust washers on transfer drive shaft.

9) Install the bearing outer race into extension
case.
10) Measure the depth S between transfer case
and center differential.
ST 398643600
GAUGE
ST
14) Fit the thrust washer on center differential.

15) Apply proper amount of liquid gasket to the
transfer case mating surface.
S
Liquid gasket
equivalent
MT-00122
MT-00124
5MT-45

16) Install the extension assembly into transfer

case.
19) Install the transfer case with extension case assembly to transmission case.
Tightening torque:
40 Nm (4.1 kgf-m, 29.7 ft-lb)
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
MT-00117
17) Install the shifter arm to transfer case.
MT-00116
C: DISASSEMBLY
1. TRANSFER CASE
1) Remove the reverse check assembly. <Ref. to
5MT-53, REMOVAL, Reverse Check Sleeve.>
2) Remove the oil guide.
MT-00126
18) Hang the shifter arm on 3rd-4th fork rod.

(A)
MT-00129
2. EXTENSION CASE
1) Remove the transfer drive gear assembly. <Ref.
to 5MT-48, REMOVAL, Transfer Drive Gear.>
2) Remove the shift bracket.
(B)
MT-00127
(A) Shifter arm

(B) 3rd-4th fork rod
MT-00130
3) Remove the oil seal from extension case. <Ref.

to 5MT-39, Oil Seal.>
5MT-46

D: ASSEMBLY
1. EXTENSION CASE
1) Using the ST, install the oil seal to extension
case. <Ref. to 5MT-39, Oil Seal.>
NOTE:
Use a new oil seal.
2) Install the shift bracket to extension case.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
MT-00130
3) Install the transfer drive gear to extension case.

<Ref. to 5MT-48, INSTALLATION, Transfer Drive
Gear.>
2. TRANSFER CASE
1) Install the oil guide to transfer case.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
MT-00129
2) Install the reverse check sleeve assembly to

transfer case. <Ref. to 5MT-53, INSTALLATION,
Reverse Check Sleeve.>
5MT-47
Transfer Drive Gear

10.Transfer Drive Gear
C: DISASSEMBLY
A: REMOVAL

assembly. <Ref. to 5MT-44, REMOVAL, Transfer
Case and Extension Case Assembly.>
5) Remove the transfer driven gear.
6) Remove the transfer drive gear.
MT-00135
2) Remove the ball bearing.
MT-00136
MT-00133
D: ASSEMBLY
B: INSTALLATION
1) Set the ST applying to the inner race of bearing

to install the drive shaft.
ST 398177700
INSTALLER
1) Install the transfer drive gear.

Tightening torque:
26 Nm (2.7 kgf-m, 20 ft-lb)
NOTE:
Do not apply pressure in excess of 10 kN (1 ton, 1.1
US ton, 1.0 Imp ton).
ST
MT-00133
2) Install the transfer driven gear.

3) Install the extension case assembly.
4) Install the transfer case and extension case assembly. <Ref. to 5MT-44, INSTALLATION, Transfer Case and Extension Case Assembly.>
5) Install the back-up light switch and neutral position switch. <Ref. to 5MT-41, INSTALLATION,
Switches and Harness.>
6) Install the manual transmission assembly into
vehicle. <Ref. to 5MT-33, INSTALLATION, Manual
MT-00137
2) Install the snap ring on transfer drive shaft.

3) Inspect the clearance between snap ring and
ball bearing. <Ref. to 5MT-48, INSPECTION,
Transfer Drive Gear.>
E: INSPECTION
1) Bearings
Replace the bearing in following cases:
In case of broken or rusty bearings
In case of worn or damaged bearings
When the bearings fail to turn smoothly or emit
noise in rotation after gear oil lubrication.
5MT-48
Transfer Drive Gear

2) Drive gear
Replace the drive gear when their tooth surface
and shaft are excessively broken or damaged.
3) Measure the clearance between snap ring and
inner race of ball bearing with a thickness gauge.
Clearance:
0.01 0.15 mm (0.0004 0.0059 in)
MT-00138
If the measurement is not within specification, select a suitable snap ring and replace it.
Part Number
Thickness mm (in)
805030041
1.53 (0.0602)
805030042
1.65 (0.0650)
805030043
1.77 (0.0697)
5MT-49
Transfer Driven Gear

11.Transfer Driven Gear
B: INSTALLATION
A: REMOVAL
1) Install the bearing outer races to the extension

case and transfer case.

5) Remove the transfer driven gear.
(C)
(A)
(B)
(D)
MT-00118
MT-00141
6) Remove the bearing outer races from the extension case and transfer case.
(A)
(B)
(C)
(D)
Bearing outer race

Bearing outer race
Transfer case
Extension case
(A)
2) Install the transfer driven gear.
(B)
MT-00118
MT-00140
(A) Bearing outer race (Transfer case side)

(B) Bearing outer race (Extension case side)
3) Install the transfer case and extension case assembly. <Ref. to 5MT-44, INSTALLATION, Transfer Case and Extension Case Assembly.>
5MT-50

C: DISASSEMBLY
1) Using the ST, remove the roller bearing (extension case side).
ST 498077000
REMOVER
2) Using the ST, install the roller bearing (transfer

case side).
ST 499757002
INSTALLER
NOTE:
ST
ST
(A)
(A)
MT-00143
(A) Roller bearing
MT-00146
2) Using the ST1 and ST2, remove the roller bearing (transfer case side).
ST1 498077000 REMOVER
ST2
(A)
ST1
(A) Roller bearing
E: INSPECTION
1) Bearings
2) Driven gear
Replace the drive gear when their tooth surface
and shaft are excessively broken or damaged.
MT-00144
(A) Roller bearing
D: ASSEMBLY
1) Using the ST, install the roller bearing (extension
case side).
NOTE:
ST2
(A)
ST1
MT-00145
(A) Roller bearing
5MT-51
Center Differential
12.Center Differential
D: ASSEMBLY
A: REMOVAL
Install the ball bearing into center differential assembly.

3) Remove the extension case assembly. <Ref. to
5MT-44, REMOVAL, Transfer Case and Extension
Case Assembly.>
4) Remove the transfer driven gear. <Ref. to 5MT50, REMOVAL, Transfer Driven Gear.>
5) Remove the center differential.
NOTE:
B: INSTALLATION
(A)
1) Install the center differential into transfer case.

2) Install the transfer driven gear. <Ref. to 5MT-50,
INSTALLATION, Transfer Driven Gear.>
3) Install the extension case assembly. <Ref. to
5MT-44, INSTALLATION, Transfer Case and Extension Case Assembly.>
4) Install the transfer case with extension case assembly. <Ref. to 5MT-44, INSTALLATION, Transfer Case and Extension Case Assembly.>
MT-00148
(A) Ball bearing
E: INSPECTION
1) Bearings
When bearings have other defects.
2) Center differential
Replace the center differential case assembly if
worn or damaged.
C: DISASSEMBLY
NOTE:
Center differential is a non-disassembled part
which should not be disassembled.
Remove the ball bearing using ST.
NOTE:
Do not reuse the ball bearing.
ST 498077300
CENTER DIFFERENTIAL
BEARING REMOVER
ST
MT-00147
5MT-52
Reverse Check Sleeve

13.Reverse Check Sleeve
2) Install the ball, spring, washer and plug to transfer case.
A: REMOVAL
3) Remove the shifter arm.
4) Remove the plug, spring, washer and reverse
check ball.
Tightening torque:
10 Nm (1.0 kgf-m, 7.4 ft-lb)
MT-00149
MT-00149
3) Install the shifter arm to transfer case assembly.

C: DISASSEMBLY
5) Remove the reverse check sleeve.
1) Cover the reverse check sleeve with a rag, and

remove the snap ring using a screwdriver.
NOTE:
Replace the snap ring with a new one if it is deformed or reactive force is weakened.
(A)
MT-00150
B: INSTALLATION
1) Install the reverse check sleeve.
Tightening torque:
6.4 Nm (0.65 kgf-m, 4.7 ft-lb)
MT-00153
(A) Snap ring
MT-00150
5MT-53

2) Remove the reverse check plate, reverse check

spring, reverse check cam, return spring (5th-Rev),
reverse accent shaft, return spring cap and return
spring (1st-2nd).
(A)
(E)
(D)
1) Install the return spring (1st-2nd), return spring

cap, reverse accent shaft, check cam, return spring
(5th-Rev.) and reverse check spring onto reverse
check sleeve.
NOTE:
Be sure to position the bent section of reverse
check spring in the groove in check cam.
(C)
(B)
D: ASSEMBLY
(G)
(A)
(F)
(C)
(B)
MT-00154
(A)
(B)
(C)
(D)
(E)
(F)
(G)
(E)
(D)
Reverse check plate

Return spring (5th-Rev)
Reverse check cam
Return spring cap
Return spring (1st-2nd)
(G)
(F)
MT-00154
(A)
(B)
(C)
(D)
(E)
(F)
(G)

NOTE:
Visually check the O-ring. Replace if defective.
Be careful not to break adjustment shim placed
between reverse check sleeve assembly and case.
Reverse check plate

Return spring (5th-Rev)
Reverse check cam
Return spring cap
Return spring (1st-2nd)
2) Hook the bent section of reverse check spring

over reverse check plate.
3) Rotate the cam so that the protrusion of reverse
check cam is at the opening in plate.
4) With cam held in that position, install the reverse
check plate onto reverse check sleeve and hold
with snap ring.
5) Position the O-ring in the groove in sleeve.
5MT-54

E: INSPECTION
Make sure the cutout of reverse accent shaft is
aligned with the opening in reverse check sleeve.
Check the cam for smooth rotation by turning
with hand.
Make sure the cam and shaft move all the way
toward plate and release.
If the cam does not return properly, replace the reverse check spring. If the shaft does not return,
check for scratches on the inner surface of sleeve.
If the sleeve is in good order, replace the spring.
If the shims alone cannot adjust the clearance,

replace the reverse accent shaft and re-adjust.
Adjusting shim
Part Number
Thickness mm (in)
32190AA000
0.15 (0.0059)
32190AA010
0.30 (0.0118)
Part No.
32188AA090
32188AA100
(D)
32188AA110
(C)

Mark
Remarks
Neutral position is
3
closer to 1st.
0
Standard
Neutral position is
1
closer to reverse gear.
2. REVERSE CHECK PLATE ADJUSTMENT

1) Shift the shifter arm to 5th and then to reverse
to see if reverse check mechanism operates properly.
2) Also check to see if the arm returns to neutral
when released from the reverse position. If the arm
does not return properly, replace the reverse check
plate.
(A)
(B)
(A)
(B)
(C)
(D)
MT-00156
Snap ring
Reverse check plate
Checking spring
Check cam
Part Number
Select a suitable reverse accent shaft and reverse check plate. <Ref. to 5MT-55, ADJUSTMENT, Reverse Check Sleeve.>
32189AA000
F: ADJUSTMENT
32189AA010
1. NEUTRAL POSITION ADJUSTMENT
32189AA020
1) Shift the 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 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 the bolts holding reverse
check sleeve assembly to the case, move the
sleeve assembly outward, and place the adjustment shim between sleeve assembly and case to
adjust the clearance.
CAUTION:
Be careful not to break O-ring when placing
shim(s).
32189AA030
32189AA040
Reverse check plate

(A):
Angle
Remarks
No.
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.
(A)
MT-00157
NOTE:
When the shim is removed, the neutral position
will move closer to reverse; when the shim is added, the neutral position will move closer to 1st gear.
5MT-55
Transmission Case
14.Transmission Case
7) Remove the drive pinion shaft assembly from

the left side of transmission case.
A: REMOVAL
NOTE:
Use a hammer handle, etc. to remove if too tight.
1. SINGLE-RANGE MODEL
2) Remove the clutch release lever. <Ref. to CL18, REMOVAL, Release Bearing and Lever.>
4) Remove the bearing mounting bolts.
(A)
(B)
MT-00161
(A) Main shaft ASSY for single-range

(B) Drive pinion shaft ASSY
8) Remove the main shaft assembly for singlerange.

9) Remove the differential assembly.
NOTE:
Be careful not to confuse right and left roller
bearing outer races.
Be careful not to damage the oil seal of retainer.
MT-00158
5) Remove the main shaft rear plate.

(A)
MT-00159
MT-00162
2. DUAL-RANGE MODEL
(A) Main shaft rear plate
6) Separate the transmission case into the right

and left cases by loosening coupling bolts and nuts.

2) Remove the clutch release lever. <Ref. to CL18, REMOVAL, Release Bearing and Lever.>
MT-00160
5MT-56
Transmission Case
4) Remove the input shaft holder.
8) Separate the transmission case into right and

left cases by loosening the seventeen coupling
bolts and nuts.
(A)
(B)
MT-00163
(A) Input shaft holder

(B) Input shaft
MT-00160
5) Remove the high-low switch. <Ref. to 5MT-41,

REMOVAL, Switches and Harness.>
6) Using the ST, drive out the straight pin, and remove the high-low shifter lever.
ST 398791700
STRAIGHT PIN REMOVER 2
9) Remove the drive pinion shaft assembly from

transmission case LH.
NOTE:
(A)
(B)
NOTE:
When driving out the straight pin, remove it in the
direction that it does not hit against transmission
case.
(A)
(B)
MT-00161
ST
(A) Main shaft ASSY for dual-range

MT-00164
(A) Straight pin

(B) High-low shifter lever
10) Removing high-low shifter fork:

Raise the main shaft assembly slightly, and remove
the high-low shifter fork together with high-low
shifter shaft and washer.
NOTE:
Be careful not to drop the two high-low shifter pieces.
7) Remove the main shaft rear plate.

(A)
MT-00165
(B)
(A) Main shaft rear plate
(A)
(A) High-low shifter fork

(B) Input shaft ASSY
5MT-57
MT-00169
Transmission Case
11) Remove the main shaft assembly and input

shaft assembly.
NOTE:
Be careful not to drop the input shaft and main shaft
as they are separable.
(A)
NOTE:
Insert the bolts from the bottom and tighten nuts
on the top.
Put the cases together being careful that the
drive pinion shim and input shaft holder shim are
not caught up in between.
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)
(16)
(9)
(5)
(17)
(7)
(B)
(11)
MT-00170
(13)
(1)
(A) Main shaft ASSY

(B) Input shaft ASSY
(3)
(2)
(15)
(4)
(14)
NOTE:
Be careful not to confuse the right and left roller
Be careful not to damage the retainer oil seal.
(10) (6)
(8)
(12)
MT-00172
7) Tighten the ball bearing mounting bolts.

Tightening torque:
29 Nm (3.0 kgf-m, 21.7 ft-lb)
MT-00162
B: INSTALLATION
MT-00158
1. SINGLE-RANGE MODEL
8) Backlash adjustment of hypoid gear and preload

adjustment of roller bearing:
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 for single-range.
Install the transmission case knock pin into needle
bearing knock pin hole.
4) Install the drive pinion shaft assembly.
Install the transmission case knock pin into roller
5) Apply liquid gasket, and then put the case RH
and LH together.
NOTE:
Set the ST on drive pinion assembly.
ST 498427100
STOPPER
Liquid gasket
equivalent
6) Tighten seventeen bolts with bracket, clip, etc.
ST
MT-00174
9) Place the transmission with the left side of case

facing downward, and put ST1 on bearing cup.
5MT-58
Transmission Case
10) Screw the retainer assembly into left case from

the bottom with ST2. Fit the ST3 on transmission
main shaft. Shift the 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
NOTE:
Record how many times the retainer is turned
while loosening.
Carry out this job on both upper and lower retainers.
ST1
ST3
ST2
15) Turn the transmission main shaft several times

while tapping around retainer lightly with plastic
hammer.
16) Inspect and adjust the backlash and tooth contact of hypoid gear. <Ref. to 5MT-88, INSPECTION, Front Differential Assembly.>
17) After checking the tooth contact of hypoid
gears, remove the lock plate. Then loosen the retainer until the O-ring groove appears. Fit O-ring
into the groove and tighten the retainer to the original position.
Install the lock plate.
Tightening torque:
T: 25 Nm (2.5 kgf-m, 18.4 ft-lb)
MT-00175
11) Remove the weight, and screw in the retainer

without O-ring on the upper side and stop at the
point where slight resistance is felt.
NOTE:
At this condition, the backlash between hypoid gear
and drive pinion shaft is zero.
ST 499787000
WRENCH ASSY
T
MT-00177
ST
MT-00176
12) Loosen the retainer on the lower side by 3

notches and turn in the retainer on the upper side
by the same amount in order to obtain the backlash.
13) Turn in the retainer on the upper side additionally by 1 notch in order to apply preload on taper
roller bearing.
14) Install temporarily both the upper and lower
lock plates and mark both holder and lock plate for
later readjustment.
NOTE:
Install the lock plate upside down if it is hard to install.
18) Selecting of main shaft rear plate: <Ref. to

5MT-66, ADJUSTMENT, Main Shaft Assembly for
Single-Range.>
19) Install the clutch release lever and bearing.
<Ref. to CL-18, INSTALLATION, Release Bearing
and Lever.>
2. DUAL-RANGE MODEL
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 for dual-range
and the input shaft assembly.
Connect the main shaft assembly for dual-range
with the input shaft assembly, and install the transmission case knock pin into needle bearing knock
pin hole.
5MT-59
Transmission Case
4) Install the drive pinion shaft assembly.

Install the transmission case knock pin into roller
5) Apply liquid gasket, and then put the case right
side and left side together.
8) Tighten the input shaft holder attaching bolts.

Tightening torque:
20 Nm (2.0 kgf-m, 14.5 ft-lb)
Liquid gasket:
THREE BOND (Part No. 004403007) 1215 or
equivalent
6) Tighten the seventeen bolts with bracket, clip,
etc. as shown in the figure.
(A)
(B)
NOTE:
Insert the bolts from the bottom and tighten the
nuts at the top.
Put the cases together being careful that the
drive pinion shim and input shaft holder shim are
not caught up in between.
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)
MT-00163

(B) Input shaft
9) Backlash adjustment of hypoid gear and preload

adjustment of roller bearing
NOTE:
Set the ST to drive pinion assembly.
ST 498427100
STOPPER
(16)
(9)
(5)
(7)
(17)
(11)
(13)
(1)
(3)
(15)
(2)
(14)
(4)
(10)
(6)
(8) (12)
MT-00178
7) Tighten the ball bearing mounting bolts.

Tightening torque:
29 Nm (3.0 kgf-m, 21.7 ft-lb)
ST
MT-00174
10) Place the transmission with the left side of case

facing downward, and put ST1 on bearing cup.
11) Screw the retainer assembly into left case from
the bottom using ST2. Fit the ST3 on transmission
main shaft. Shift the 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.
MT-00158
5MT-60
Transmission Case
ST1 399780104
ST2 499787000
ST3 499927100
WEIGHT
WRENCH ASSY
HANDLE
18) After checking the tooth contact of hypoid

gears, remove the lock plate. Then loosen the retainer until the O-ring groove appears. Fit O-ring
into the groove and tighten the retainer to the original position.
Install the lock plate.
ST1
ST3
ST2
NOTE:
Record how many times the retainer is turned
while loosening.
Carry out this job on both upper and lower retainers.
Tightening torque:
T: 25 Nm (2.5 kgf-m, 18.4 ft-lb)
MT-00175
12) Remove the weight, and screw in the retainer

without O-ring on upper side and stop at the point
where slight resistance is felt.
NOTE:
In this condition, the backlash between hypoid gear
and drive pinion shaft is zero.
ST 499787000
WRENCH ASSY
T
ST
MT-00177
MT-00176
13) Loosen the retainer on the lower side by 3

notches and turn in the retainer on the upper side
by the same amount in order to obtain the backlash.
14) Turn in the retainer on the upper side additionally by 1 notch in order to apply preload on taper
roller bearing.
15) Install temporarily both the upper and lower
lock plates and mark both holder and lock plate for
later readjustment.
19) Selection of main shaft rear plate: <Ref. to

Single-Range.>
21) Install the clutch release lever and bearing.
<Ref. to CL-18, INSTALLATION, Release Bearing
and Lever.>
C: INSPECTION
Check the transmission case for cracks, damage,
or oil leaks.
NOTE:
Install the lock plate upside down if it is hard to install.
16) Turn the transmission main shaft several times
while tapping around the retainer lightly with plastic
hammer.
17) Inspect and adjust the backlash and tooth contact of hypoid gear. <Ref. to 5MT-88, INSPECTION, Front Differential Assembly.>
5MT-61
Main Shaft Assembly for Single-Range

15.Main Shaft Assembly for Single-Range

A: REMOVAL
3) Remove the transmission case. <Ref. to 5MT56, REMOVAL, Transmission Case.>
4) Remove the drive pinion shaft assembly. <Ref.
to 5MT-77, REMOVAL, Drive Pinion Shaft Assembly.>
5) Remove the main shaft assembly for single
range.
C: DISASSEMBLY
1) Put the vinyl tape around main shaft splines to
protect oil seal from damage. Then pull out the oil
seal and needle bearing by hand.
2) Remove the lock nut from transmission main
shaft assembly for single range.
NOTE:
Unlock the caulking before removing lock nut.
ST1 498937000 TRANSMISSION HOLDER
ST2 499987003 SOCKET WRENCH (35)
B: INSTALLATION
1) Install the needle bearing and oil seal onto the
front of transmission main shaft assembly for single
range.
NOTE:
Wrap the 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 oil seal.
2) Install the transmission case knock pin into needle bearing outer race knock pin hole.
ST1
ST2
MT-00186
3) Remove the 5th-Rev sleeve & hub assembly,

baulk ring, 5th drive gear & needle bearing.
(C)
(B)
(A)
NOTE:
Align the end face of seal with surface (A) when installing oil seal.
MT-00187
(A) 5th-Rev sleeve & hub ASSY

(B) Baulk ring
(C) 5th drive gear
4) Remove the snap ring and synchro cone stopper

from 5th-Rev sleeve & hub assembly.
(B)
(A)
MT-00185
(A)
3) Install the drive pinion assembly. <Ref. to 5MT77, INSTALLATION, Drive Pinion Shaft Assembly.>
4) Install the transmission case. <Ref. to 5MT-58,
INSTALLATION, Transmission Case.>
5MT-62
MT-00188
(A) Synchro cone stopper

(B) Snap ring

5) Using the ST1, ST2 and a press, remove the ball

bearing, synchro cone and baulk ring (Rev).
ST1
ST2
899864100
899714110
REMOVER
REMOVER
NOTE:
When replacing the sleeve & hub with new ones,
replace them as a set.
Do not disassemble the sleeve & hub, because
the aligning position is specified.
If it is necessary to disassemble, mark the engaging points on the splines beforehand.
ST2 498077400 SYNCHRO CONE REMOVER
(A)
ST1
ST1
(B)
ST2
ST2
(A)
(C)
MT-00190
MT-00189
(A) Push
(A) Ball bearing

(B) Synchro cone
(C) Baulk ring
D: ASSEMBLY
6) Using the ST1 and ST2, remove the rest of

parts.
1) When the sleeve & hub assemblies have been

disassembled, reassemble with aligning each engaging point.
NOTE:
When replacing the sleeve & hub with new ones,
replace them as a set.
Do not disassemble the sleeve & hub, because
the aligning position is specified.
5MT-63

NOTE:
Position open ends of spring 120 apart.
NOTE:
Align the groove in baulk ring with shifting insert.
4) Install the 4th needle bearing race onto transmission main shaft using ST1, ST2 and a press.
(A)
NOTE:
ST2 499877000 RACE 4-5 INSTALLER
ST2
(B)
(A)
(C)
ST1
MT-00192
(A) 4th needle bearing race
(D)
5) Install the baulk ring, needle bearing, 4th drive

gear and 4th gear thrust washer to transmission
main shaft.
MT-00191
(A)
(B)
(C)
(D)
3rd-4th hub ASSY

3rd gear side
5th-Rev hub ASSY
5th gear side
NOTE:
Align the baulk ring and gear & hub assembly with
key groove.
2) Install the 3rd drive gear, baulk ring, sleeve &

hub assembly for 3rd needle bearing, on the transmission main shaft. (2.0 L model)
3) Install the 3rd drive gear, outer baulk ring, synchro cone, inner baulk ring, sleeve & hub assembly
for 3rd needle bearing, on the transmission main
shaft. (2.5 L model)
(A)
(D)
(A)
(E)
(B)
MT-00193
(A) Groove
(B) 4th gear side
(B)
(A)
(B)
(C)
(D)
(E)
(F)
(C)
3rd needle bearing

3rd drive gear
Inner baulk ring
Synchro cone
Outer baulk ring
Sleeve & hub ASSY
(F)
6) Press the ball bearing into the rear section of

transmission main shaft using ST1, ST2 and a
press.
MT-01318
NOTE:
5MT-64

ST1
ST2
899714110
499877000
REMOVER
RACE 4-5 INSTALLER
ST
499757002
INSTALLER
ST
ST2
(A)
(B)
(C)
ST1
MT-00196
MT-00194
(A) Baulk ring

(B) Synchro cone
(C) Ball bearing
7) Using the ST1 and ST2, install the 5th gear

thrust washer and 5th needle bearing race onto the
rear section of transmission main shaft.
NOTE:
Do not apply pressure in excess of 10 kN (1 ton,
1.1 US ton, 1.0 Imp ton).
Face the thrust washer in the correct direction.
10) Install the synchro cone stopper and snap ring

to 5th-Rev sleeve & hub assembly.
(B)
(A)
(A)
MT-00188

(B) Snap ring
MT-00195
11) Install the rest of parts to the rear section of

(A) Face this surface to 5th gear side.
8) Install the bearing onto synchro cone.

9) Install the baulk ring and synchro cone onto 5thRev sleeve & hub assembly using ST and a press.
NOTE:
(A)
(B)
(C)
(D)
NOTE:
Use new ball bearing.
Make sure the synchro cone rotates smoothly after press-fitting.
(E)
(F)
MT-00198
(A)
(B)
(C)
(D)
(E)
(F)
5MT-65
Needle bearing
5th drive gear
Baulk ring
5th-Rev sleeve & hub ASSY
Lock washer
Lock nuts

Tightening torque:
120 Nm (12.2 kgf-m, 88.5 ft-lb)
6) Oil seal
Replace the oil seal if the lip is deformed, hardened, 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
F: ADJUSTMENT
Disassembled parts should be washed with unleaded gasoline first and then inspected carefully.
1) Bearings
When the bearing balls, outer races and inner
races are broken or rusty.
When the bearing is worn.
When bearings have other defects.
2) Bushing (each gear)
Replace the bushings in 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 following cases:
When the inner surface and end face is damaged.
When the ring inner surface is abnormally or partially worn.
When contact surfaces of the synchronizer ring
insert have cracks or abnormally worn.
5) Shifting insert key
Replace the insert key if deformed, excessively
worn or defective in any way.
Selection of main shaft rear plate:

Using the ST, measure the amount (A) of ball bearing protrusion from transmission main case surface, and select a suitable plate in the following
table.
NOTE:
Caulk the lock nuts in two places after tightening.
ST1 499987003 SOCKET WRENCH
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
moving flange of bearing.
ST 498147001
DEPTH GAUGE
(A)
MT-00989
(A) Insert key
5MT-66
Dimension (A)
mm (in)
4.00 4.13
(0.1575
0.1626)
3.87 3.99
(0.1524
0.1571)
Part Number
Marking
32294AA041
32294AA051
(A)
MT-00209
Main Shaft Assembly for Dual-Range

16.Main Shaft Assembly for

Dual-Range
ST1
ST2
498937000
499987003
TRANSMISSION HOLDER
SOCKET WRENCH (35)
A: REMOVAL
5) Remove the main shaft assembly and input shaft
assembly.
ST1
ST2
MT-00186
3) Remove the 5th-Rev sleeve & hub assembly,

baulk ring, 5th drive gear and needle bearing.
(C)
(B)
(A)
B: INSTALLATION
1) Install the needle bearing onto the front of transmission main shaft assembly.
2) Connect the main shaft assembly and input shaft
assembly.
7) Install the manual transmission assembly to vehicle. <Ref. to 5MT-33, INSTALLATION, Manual
MT-00187
(A) 5th-Rev sleeve & hub ASSY

(B) Baulk ring
(C) 5th drive gear
4) Remove the snap ring and synchro cone stopper

from 5th-Rev sleeve & hub assembly.
(B)
(A)
C: DISASSEMBLY
1) Put a vinyl tape around the main shaft splines to
protect oil seal from damage. Then pull out the oil
seal and needle bearing by hand.
2) Remove the lock nut from transmission main
shaft assembly.
MT-00188
NOTE:
Straighten the caulking before taking off lock nut.

(B) Snap ring
5) Using the ST1, ST2 and a press, remove the ball

bearing, synchro cone and baulk ring (Rev).
NOTE:
When replacing the sleeve and hub with new
ones, replace them as a set.
Do not disassemble the sleeve and hub, because the aligning position is specified.
5MT-67


ST2 498077400 SYNCHRO CONE REMOVER
7) Remove the snap ring from main shaft.

ST 899474100
EXPANDER
ST1
(B)
ST2
(A)
ST
(C)
(A)
MT-00215
(A) Snap ring
MT-00189
8) Remove rest of the parts.
(A) Ball bearing

(B) Synchro cone
(C) Baulk ring
6) Using the ST1 and ST2, remove rest of the

parts.
(G)
NOTE:
When replacing the sleeve and hub with new
ones, replace them as a set.
Do not disassemble the sleeve and hub, because the aligning position is specified.
(B)
(C)
(B)
(E)
(D)
(A)
(A)
(B)
(C)
(D)
(E)
(F)
(G)
(A)
(F)
MT-00216
Sleeve & hub ASSY

High-low baulk ring
Friction damper
Low input gear
Needle bearing
Ball
D: ASSEMBLY
ST1
1) Assemble with aligning the matching mark if the

sleeve & hub assembly have been disassembled.
ST2
MT-00190
(A) Press
5MT-68

NOTE:
Position the open ends of spring 120 apart.
(C)
(B) (A)
(F) (E)
(G)
(D)
(I)
NOTE:
4) Install the 4th needle bearing race onto transmission main shaft using ST1, ST2 and a press.
(H)
(J)
ST2
(A)
(K)
(A)
(B)
(C)
(D)
(E)
(F)
(G)
(H)
(I)
(J)
(K)
(L)
(M)
(N)
(O)
(P)
(L)
(M) (N)
(O) (P)
ST1
MT-00217
High-low coupling sleeve

Shifting insert
High-low synchronizer spring
High-low synchronizer hub
Sleeve
Insert key
Sleeve
Insert key
High side
Low side
3rd side
4th side
5th side
Rev side
MT-00201
(A) 4th needle bearing race
5) Install the baulk ring, needle bearing, 4th drive

gear and 4th gear thrust washer to transmission
main shaft.
NOTE:
Face the thrust washer in correct direction.
2) Install the 3rd drive gear, baulk ring, sleeve &

hub assembly for 3rd-4th needle bearing on transmission main shaft. (2.0 L model)
3) Install the 3rd drive gear, outer baulk ring, synchro cone, inner baulk ring, sleeve & hub assembly
for 3rd needle bearing, on the transmission main
shaft. (2.5 L model)
(A)
(D)
(A)
(B)
MT-00193
(A) Groove
(B) 4th gear side
6) Press-fit the ball bearing into the rear section of

transmission main shaft using ST1, ST2 and a
press.
(E)
NOTE:
(B)
(A)
(B)
(C)
(D)
(E)
(F)
(C)
(F)
MT-01318
3rd needle bearing

3rd drive gear
Inner baulk ring
Synchro cone
Outer baulk ring
Sleeve & hub ASSY
5MT-69

ST1
ST2
899714110
499877000
REMOVER
RACE 4-5 INSTALLER
ST
499757002
INSTALLER
ST
ST2
(A)
(B)
(C)
ST1
MT-00196
MT-00194
(A) Baulk ring

(B) Synchro cone
(C) Ball bearing
7) Using the ST1 and ST2, install the 5th gear

thrust washer and 5th needle bearing race onto the
rear section of transmission main shaft.
NOTE:
Face the thrust washer in correct direction.
10) Install the synchro cone stopper and snap ring

to 5th-Rev sleeve & hub assembly.
(B)
(A)
(A)
MT-00188

(B) Snap ring
MT-00195
11) Install rest of the parts to the rear section of

(A) Face this surface to 5th gear side.
8) Install the bearing onto synchro cone.

9) Install the baulk ring and synchro cone onto 5thRev sleeve & hub assembly using ST and a press.
NOTE:
(A)
(B)
(C)
(D)
NOTE:
Use a new ball bearing.
After press-fitting, make sure the synchro cone
rotates freely.
(E)
(F)
MT-00198
(A)
(B)
(C)
(D)
(E)
(F)
5MT-70
Needle bearing
5th drive gear
Baulk ring
5th-Rev sleeve & hub ASSY
Lock washer
Lock nuts

Snap ring
Part No.
805025051
805025052
805025053
805025054
805025055
805025056
805025057
805025058
NOTE:
Stake the caulking of lock nuts in two places after
tightening.
ST1 499987003 SOCKET WRENCH
Tightening torque:
120 Nm (12.2 kgf-m, 88.5 ft-lb)
13) Install the needle bearing on main shaft.
14) Install rest of the parts to the front section of
NOTE:
Be careful not to damage the graded section of
transmission main shaft when installing the needle
bearing.
Face the grooved side toward input gear.
Align the high-low baulk rings groove with shifting insert.
(A)
(F)
(E)
(F)
(C)
(D)
(G)
(A)
(B)
(C)
(D)
(E)
(F)
(G)
(B)
MT-00225
Ball
Needle bearing
Input low gear
Friction damper
High-low baulk ring
Sleeve & hub ASSY
15) Install a new snap ring to the rod section of

transmission main shaft using ST1 and ST2.
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).
ST2 499757001 SNAP RING GUIDE
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)
E: INSPECTION
1) Bearings
Replace the bearings in following cases:
Bearings balls, outer races and inner races are
broken or rusty.
Worn bearings
Bearings fail to turn smoothly or emit noise in rotation after gear oil lubrication.
Bearings having other defects
Replace the bushing in following cases:
3) Gears
Replace the gears with new ones if their tooth
surfaces are broken, damaged or excessively
worn.
is damaged.
4) Baulk ring
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.
6) Oil seal
7) O-ring
5MT-71

F: ADJUSTMENT
Select a suitable main shaft rear plate. <Ref. to
Single-Range.>
5MT-72
Input Shaft Assembly

17.Input Shaft Assembly

A: REMOVAL
5) Remove the main shaft assembly and input shaft
assembly.
B: INSTALLATION
1) Install the needle bearing onto the front of transmission main shaft assembly.
2) Connect the main shaft assembly and input shaft
assembly.
7) Install the manual transmission assembly on the
2) Put a vinyl tape around the input shaft splines to

protect oil seal from damage.
3) Remove the inner snap ring.
ST 398663600
PLIERS
ST
MT-00227
4) Hold the input shaft holder stationary and remove the input shaft by tapping its end with a plastic hammer.
(B)
(A)
MT-00228

(B) Input shaft
5) Remove the outer snap ring. Then remove the

oil squeeze plate and straight pin.
C: DISASSEMBLY
1) Remove the O-ring from input shaft holder. Also,
remove the input shaft holder shim.
NOTE:
Use a new O-ring.
Number of shims used varies from zero to two.
(A)
(B)
(B)
(A)
MT-00229
(A) Snap ring

(B) Oil squeeze plate
(C)
MT-00226

(B) O-ring
(C) Input shaft holder shim
5MT-73

2) Install the snap ring on input shaft.
(A)
(A)
MT-00230
MT-00230
(A) Snap ring
(A) Snap ring
7) Using a press and ST, remove the ball bearing.

NOTE:
Remove the inner snap ring before pressing.
ST 498077000
REMOVER
3) Inspect the clearance between ball bearing and

snap ring. <Ref. to 5MT-75, INSPECTION, Input
Shaft Assembly.>
4) Install the straight pin and oil squeeze plate to input shaft.
ST
(A)
(B)
MT-00231
MT-00234
8) Remove the oil seal from input shaft holder.

(A) Straight pin
(B) Oil squeeze plate
D: ASSEMBLY
1) Install the ball bearing onto input shaft.
NOTE:
Place the snap ring between input shaft gear and
ball bearing beforehand. Use the table at 8) as a
guide in selecting a suitable snap ring.

6) Install the oil seal into input shaft holder.
NOTE:
Apply a coat of grease to sealing lips before installing oil seal.
ST 398507703
DUMMY COLLAR
ST1
ST
ST2
MT-00232
MT-00235
5MT-74

7) Wind a vinyl tape around the shaft splines and

insert the input shaft into holder by lightly tapping it
by hand.
(B)
(A)
MT-00236
(A) Vinyl tape

(B) Input shaft
8) Install the 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
ST
MT-00227
Snap ring
Part No.
805168020
805168030
805168040
Thickness mm (in)
1.84 (0.0724)
1.92 (0.0756)
2.00 (0.0787)
9) Install the O-ring to input shaft holder.

(A)
(B)
E: INSPECTION
Disassembled parts should be washed clean first
with unleaded gasoline and then inspected carefully.
1) Bearings
Replace the bearings in following cases:
Bearing balls, outer races and inner races are
broken or rusty.
Worn bearings
Bearings fail to turn smoothly or emit noise in rotation after gear oil lubrication.
Bearings having other defects
Replace the bushing in following cases:
3) Gears
Replace the gears with new ones if their tooth
surfaces are broken, damaged or excessively
worn.
is damaged.
4) Baulk ring
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.
6) Oil seal
7) O-ring
9) Measure the clearance between snap ring and
ball bearing using thickness gauge.
MT-00238
(A) O-ring
(B) Input shaft holder
5MT-75

F: ADJUSTMENT
Clearance:
0 0.12 mm (0 0.0047 in)
1) Place transmission main shaft assembly and input shaft on transmission main case without shim.
2) The proper number of shim can be determined
as follows:
D = A (B + C)
A: Main case length (353 mm (13.90 in)
B: Input shaft complete length
C: Main shaft assembly length
(A)
MT-00239
(A) Snap ring
If the measurement is not within specification, select a suitable snap ring.

Snap ring
Part No.
805028050
805028060
805028070
Thickness mm (in)
2.48 (0.0976)
2.56 (0.1008)
2.64 (0.1039)
MT-01015
NOTE:
The thickness of shim is 0.45 to 0.55 mm (0.0177 to
0.0217 in).
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)
5MT-76
Number of shims
1
2


A: REMOVAL
4) Remove the drive pinion shaft assembly.
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)
NOTE:
(A)
(B)
(B)
ST
MT-00242
(A) Plate
(B) Scale
MT-00161
(A) Main shaft ASSY

B: INSTALLATION
2) Alignment marks/numbers on hypoid gear set:
Use hypoid driven gear of its match number corresponding with upper one on the drive pinion (A).
The figure (B) shows a number for shim adjustment. If no number is shown, the value is zero.
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
ST
(A)
(A)
MT-00243
+0
.1
(A)
(A) Adjust clearance to zero without shim.
(B)
MT-00990
(A) Match number

(B) Number for shim adjustment
3) Place the drive pinion shaft assembly on the

transmission main case RH without shim and tighten the bearing mounting bolts.
4) Inspection and adjustment of ST:
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
5MT-77

8) Select one to three shims in the next table for the

value determined as described above, and take the
shim(s) which thickness is closest to the said value.
Part Number
32295AA031
32295AA041
32295AA051
32295AA061
32295AA071
32295AA081
32295AA091
32295AA101
Drive pinion shim

Thickness mm (in)
0.150 (0.0059)
0.175 (0.0069)
0.200 (0.0079)
0.225 (0.0089)
0.250 (0.0098)
0.275 (0.0108)
0.300 (0.0118)
0.500 (0.0197)
2) Draw out the drive pinion from driven shaft.

Remove the differential bevel gear sleeve, adjusting washer No. 1, adjusting washer No. 2, thrust
bearing, needle bearing and drive pinion collar.
(F)
(E)
(G)
(H)
(A)
(B)
(D)
9) Install the differential assembly. <Ref. to 5MT85, INSTALLATION, Front Differential Assembly.>
10) Set the transmission main shaft assembly and
drive pinion assembly in position. (So there is no
clearance between these two when moved all the
way to the front). Inspect the suitable 1st 2nd,
3rd 4th and 5th shifter fork so that the coupling
sleeve and reverse driven gear are positioned in
the center of their synchronizing mechanisms.
<Ref. to 5MT-82, INSPECTION, Drive Pinion Shaft
Assembly.>
13) Install the manual transmission assembly to vehicle. <Ref. to 5MT-31, Manual Transmission Assembly.>
(A)
(B)
(C)
(D)
(E)
(F)
(G)
(H)
(C)
MT-00245

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
Thrust bearing (33 50 3)
3) Remove the roller bearing and washer using ST

and press.
NOTE:
Do not reuse the roller bearing.
ST 498077000
REMOVER
C: DISASSEMBLY
NOTE:
Attach a cloth to the end of driven shaft (on the frictional side of thrust needle bearing) to prevent
damage during disassembly or reassembly.
1) Unlock the caulking of lock nut. Remove the lock
nut using ST1, ST2 and ST3.
ST2 498427100 STOPPER
ST
MT-00246
4) Unlock the caulking of lock nut. Remove the lock

nut using ST1 and ST2.
ST1
ST2
ST1
ST2
ST3
MT-00244
MT-00247
5MT-78

5) Remove the 5th driven gear using ST.

ST 499857000
5TH DRIVEN GEAR REMOVER
10) Remove the 1st driven gear, 2nd gear bushing,

gear and hub using ST1 and ST2.
(A)
(B)
(C)
ST
(D)
MT-00991
MT-00248
6) Remove the woodruff key.

7) Remove the roller bearing and 3rd-4th driven
gear using ST1 and ST2.
ST1
ST2
(A)
(B)
(C)
(D)
1st driven gear

Inner baulk ring
Hub
2nd gear bushing
NOTE:
Replace the gear and hub if necessary. Do not disassemble because they must engage at a specified
point. If they have to be disassembled, mark the
engaging point on the spline beforehand.
ST1
MT-00249
8) Remove the key.

9) Remove the 2nd driven gear, inner baulk ring,
synchro cone and outer baulk ring.
(D)
ST2
(A)
MT-00251
D: ASSEMBLY
1) Install the sleeve and hub assembly by matching
alignment marks.
(C)
(A)
(B)
(C)
(D)
(B)
MT-00997
2nd driven gear

Inner baulk ring
Synchro cone
Outer baulk ring
5MT-79

NOTE:
Use the new gear and hub assembly, when replacing the gear or hub.
When press-fitting, align the oil holes of shaft and

bushing.
(B)
(A)
(C)
ST1
(D)
ST2
MT-00252
MT-00253
(A)
(B)
(C)
(D)
1st gear side

2nd gear side
Flush surface
Stepped surface
6) Install the 2nd driven gear, inner baulk ring, synchro cone and outer baulk ring, and insert onto driven shaft.
(D)
2) Install the washer to 1st driven gear. (EC, EK

and KA model)
3) Install the washer, snap ring and sub gear onto
1st driven gear. (Except for EC, EK and KA model)
4) Install the 1st driven gear, 1st baulk ring, gear
and hub assembly onto driven shaft.
(A)
(B)
(C)
(C)
(A)
(B)
(C)
(D)
(B)
MT-00997
2nd driven gear

Inner baulk ring
Synchro cone
Outer baulk ring
7) After installing the key on driven shaft, install the

3rd-4th driven gear using ST and press.
(D)
MT-00991
(A)
(B)
(C)
(D)
(A)
NOTE:
Align the groove in baulk ring with insert.
ST 499277200
INSTALLER
1st driven gear

1st baulk ring
Gear and hub ASSY
2nd gear bushing
NOTE:
Take care to install the gear and hub assembly in
proper direction.
Align the baulk ring and gear and hub assembly
with key groove.
5) Install the 2nd driven gear bushing onto driven
shaft using ST1, ST2 and a press.
NOTE:
Attach a cloth to the end of driven shaft to prevent damage.
ST
MT-00255
8) Install a set of roller bearings onto the driven

shaft using ST and press.
5MT-80

NOTE:
ST 499277200
INSTALLER
Using a 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 0.33 ft).
ST
MT-00259
11) Install the roller bearing onto drive pinion.
MT-00256
9) Position the woodruff key in groove on the rear

of driven shaft. Install the 5th driven gear onto driven shaft using ST and press.
NOTE:
ST 499277200
INSTALLER
NOTE:
When installing roller bearing, note its directions
(front and rear) because the knock pin hole in outer
race is offset.
(A)
ST
(B)
(A) Roller bearing

(B) Knock pin hole
MT-00257
10) Install the lock washer. Install the lock nut and
tighten to the specified torque using ST.
ST 499987300
SOCKET WRENCH (50)
Tightening torque:
260 Nm (26.5 kgf-m, 191.7 ft-lb)
MT-00260
12) Install the washer using ST1, ST2 and a press.

NOTE:
ST1 499277100 BUSHING 1-2 INSTALLER
ST
ST2
ST1
(A)
MT-00258
MT-00261
NOTE:
Stake the caulking of lock nut at two points.
(A) Washer
5MT-81

13) Install the thrust bearing and needle bearing.

Install the driven shaft assembly.
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 other bearings.
(A)
MT-00262
14) Install the drive pinion collar, needle bearing,

adjusting washer No. 2, thrust bearing, adjusting
washer No. 1 and differential bevel gear sleeve in
this order.
(B)
MT-00264
NOTE:
Be careful because the spacer must be installed in
proper direction.
(A) (B)
(C) (D) (E) (F) (G) (H)

MT-00263
(A)
(B)
(C)
(D)
(E)
(F)
(G)
(H)
Driven shaft
Drive shaft
Drive pinion collar
Washer No. 2 (25 36 4)
Thrust bearing (25 37.5 3)
Washer No. 1 (25 36 t)
15) Adjust the thrust bearing preload. <Ref. to

5MT-83, THRUST BEARING PRELOAD, ADJUSTMENT, Drive Pinion Shaft Assembly.>

(B) Ball bearing
When bearings have other defects:

Replace the bushings in following cases:
3) Gears
Replace gears with new ones if their tooth surfaces are broken, damaged, or excessively worn.
is damaged.
4) Baulk ring
When the ring inner surface is abnormally or partially worn.
If the gap between the end faces of ring and the
gear splined part is excessively small, check the
clearance (A) while pressing the ring against the
cone.
E: INSPECTION
1) Bearings
When the bearing balls, outer races and inner
races are broken or rusty.
When the bearing is worn.
5MT-82

F: ADJUSTMENT
Clearance (A):
0.5 1.0 mm (0.020 0.040 in)
1. THRUST BEARING PRELOAD

1) Select a suitable adjusting washer No. 1 to adjust dimension (H) to zero through visual check.
Position the washer (18.3 30 4) and lock washer
(18 30 2) and install the lock nut (18 13.5).
(A)
MT-00265
When the contact surface of synchronizer ring insert is scratched or abnormally worn.
worn, or defective in any way.
(A)
(H)
MT-00989
MT-00267
(A) Insert key
6) Oil seal
Replace the oil seal if the lip is deformed, hardened, worn, or defective in any way.
7) O-ring
hardened, damaged, worn, or defective in any way.
2) Using the ST1, ST2 and ST3, tighten new lock

nut to the specified torque.
ST2 498427100 STOPPER
Tightening torque:
120 Nm (12.2 kgf-m, 88.5 ft-lb)
ST1
ST2
ST3
MT-00268
5MT-83

3) After removing the ST2, measure the starting

torque using torque driver.
5) When the specified starting torque cannot be obtained by the adjusting washer No. 1, select the adjusting washer No. 2 from following table. Repeat
steps 1) through 4) to adjust starting torque.
Starting torque:
0.3 0.8 Nm (0.03 0.08 kgf-m, 0.2 0.6 ftlb)
ST1
ST3
(A)
(B)
MT-00270
(A) Adjusting washer No. 1

(B) Adjusting washer No. 2
MT-00269
4) If the starting torque is not within specified limit,

select new adjusting washer No. 1 and recheck
starting torque.
Starting torque
Low
High
Dimension H
Small
Large
Washer No. 2
Select thicker one.
Select thinner one.

Part Number
Thickness mm (in)
803025059
3.850 (0.1516)
803025054
4.000 (0.1575)
803025058
4.150 (0.1634)
6) Recheck that the starting torque is within specified range, then clinch the lock nut at four positions.
(A)
(B)
MT-00270
(A) Adjusting washer No. 1

(B) Adjusting washer No. 2
Part Number
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)
5MT-84

3) Install the differential assembly.
A: REMOVAL
NOTE:
Be careful not to fold the sealing lip of oil seal.

4) Removes the drive pinion shaft assembly. <Ref.
5) Remove the main shaft assembly.
Single-range model
<Ref. to 5MT-62, REMOVAL, Main Shaft Assembly
for Single-Range.>
Dual-range model
for Dual-Range.>
NOTE:
Be careful not to confuse right and left roller
Be careful not to damage the oil seal of retainer.
MT-00162
4) Install the main shaft assembly.

Single-range model
<Ref. to 5MT-62, INSTALLATION, Main Shaft Assembly for Single-Range.>
Dual-range model
<Ref. to 5MT-67, INSTALLATION, Main Shaft Assembly for Dual-Range.>
MT-00162
7) Remove the differential side retainers using ST.

ST 499787000
WRENCH ASSY
ST
MT-00176
B: INSTALLATION
1) Install the differential side retainers using ST.
ST 499787000WRENCH ASSY
2) Install the bearing outer race on transmission
case.
5MT-85

C: DISASSEMBLY
3) Pull out the pinion shaft, and remove the differential bevel pinion, bevel gear and washer.
(B)
(D)
1) Loosen the twelve bolts and remove hypoid driven gear.
(C)
(A)
(C)
(D)
(B)
(A)
MT-00277
(A)
(B)
(C)
(D)
Pinion shaft
Bevel pinion
Bevel gear
Washer
4) Using the ST, remove the roller bearing.

ST 899524100
PULLER SET
MT-00275
ST
2) Drive out the straight pin from differential assembly toward hypoid driven gear side.
ST 899904100
REMOVER
MT-00278
2. SIDE RETAINER
ST
MT-00276
MT-00279
5MT-86


NOTE:
Do not reuse the oil seal. Replace with a new oil
seal.
Standard backlash
0.13 0.18 mm (0.0051 0.0071 in)
ST2
ST1
MT-00285
3) Align the pinion shaft and differential case at

their holes, and drive the straight pin into holes
from the hypoid driven gear side, using ST.
MT-00363
D: ASSEMBLY
1) Install the bevel gear and bevel pinion together
with washers, and insert the pinion shaft.
NOTE:
Lock the straight pin after installing.
ST 899904100
REMOVER
NOTE:
Face the chamfered side of washer toward gear.
(A)
(C)
(B)
(B)
MT-00286
(A)
(A) Pinion shaft

(B) Differential case
(C) Straight pin
(C)
MT-00284
(A) Bevel pinion

(B) Bevel gear
(C) Pinion shaft
4) Install the roller bearing to differential case.
2) Measure the backlash between bevel gear and

pinion. If it is not within specifications, install a suitable washer to adjust. <Ref. to 5MT-89, ADJUSTMENT, Front Differential Assembly.>
NOTE:
Be sure the pinion gear teeth contacts adjacent
gear teeth during measurement.
NOTE:
Be careful because the roller bearing outer races
are used as a set.
ST1 499277100 BUSHING 1-2 INSTALLER
ST1
ST2
MT-00287
5MT-87

5) Install the hypoid driven gear to differential case

using twelve bolts.
Tightening torque:
T: 62 Nm (6.3 kgf-m, 45.6 ft-lb)
(A)
E: INSPECTION
Repair or replace the differential gear in following
cases:
When the hypoid drive gear and drive pinion
shaft tooth surface are damaged, excessively worn
or seized.
When the roller bearing on the drive pinion shaft
is worn or damaged.
When there is damage, wear or seizure of the differential bevel pinion, differential bevel gear, washer, pinion shaft and straight pin.
When the differential case sliding surfaces is
worn or damaged.
T
(B)
MT-00993
(A)

(B) Differential case
(G)
2. SIDE RETAINER
(E)
1) Install a new oil seal.

SEAL INSTALLER
(F)
(F)
(E)
(H)
(B)
(C)
(G)
(D)
ST
MT-00289
(I)
(H)
MT-00291
NOTE:
For press-fitting of oil seal to retainer, make tapping with plastic hammer etc.
Do not use press.
2) Install a new O-ring.
(A)
(B)
(C)
(D)
(E)
(F)
(G)
(H)
(I)
NOTE:
Do not stretch or damage the O-ring.
Drive pinion shaft

Hypoid driven gear
Pinion shaft
Straight pin
Washer
Roller bearing
Differential case
1. BEVEL PINION GEAR BACKLASH

Measure the backlash between bevel gear and pinion. If it is not within specifications, install a suitable
washer to adjust.
MT-00279
NOTE:
Be sure the pinion gear teeth contacts adjacent
gear teeth during measurement.
5MT-88

3. TOOTH CONTACT OF HYPOID GEAR
Standard backlash
0.13 0.18 mm (0.0051 0.0071 in)
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 5MT-89, ADJUSTMENT, Front Differential Assembly.>
Tooth contact is correct.
ST2
ST1
MT-00285
(A)
2. HYPOID GEAR BACKLASH

1) Set the ST1, ST2 and ST3. Insert the needle
through transmission oil drain plug hole so that the
needle comes in contact with the tooth surface on
the right corner and check the backlash.
ST3 498255400 PLATE
2) Install the SUBARU genuine axle shafts to both
side, rotate in the inversion direction so that the
gauge contact with the tooth surface and read the
dial gauge.
Part No. 38415AA100 AXLE SHAFT
Backlash
0.13 0.18 mm (0.0051 0.0071 in)
(D)
(A)
(B)
(C)
(D)
(C)
(B)
MT-00294
Toe
Coast side
Heel
Drive side
F: ADJUSTMENT
1. BEVEL PINION GEAR BACKLASH
ST3
1) Disassemble the front differential. <Ref. to 5MT85, REMOVAL, Front Differential Assembly.>
2) Select a different washer from the table and install.
ST2
Washer
Part Number
803038021
ST1
MT-00293
803038022
NOTE:
If the backlash is outside the specified range, adjust it by turning the side retainer in right side case.
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)
3) Adjust until the standard value is obtained.

Backlash:
Standard
0.13 0.18 mm (0.0051 0.0071 in)
5MT-89

2. HYPOID GEAR BACKLASH

Adjust the backlash by turning holder in the right
side case.
ST 499787000
WRENCH ASSY
Face contact
Contact pattern
ST
AT-00208
MT-00176
NOTE:
Each time the side retainer rotates one notch,
backlash changes by 0.05 mm (0.020 in).

height adjusting washer in order to bring drive pinion closer to driven gear.
0.05mm(0.0020 in)
AT-00212
Flank contact
Contact pattern
MT-00296
3. TOOTH CONTACT OF HYPOID GEAR

1) Adjust until correct teeth contact is obtained.
2) Check tooth contact as follows.
Tooth contact
shifted to toe side under no-load rotation.
[When loaded, contact pattern moves toward
heel.]
(A)
AT-00209

(B)
AT-00207
(A) Toe side

(B) Heel side
AT-00213
5MT-90


Contact pattern
AT-00210

height adjusting washer in order to bring drive pinion closer to driven gear.
AT-00213

Contact pattern
AT-00211

AT-00212
5MT-91
Reverse Idler Gear

20.Reverse Idler Gear
B: INSTALLATION
A: REMOVAL
1) Install the reverse shifter lever, reverse idler

gear and reverse idler gear shaft, and secure them
with straight pin.

4) Remove the transmission case. <Ref. to 5MT77, REMOVAL, Drive Pinion Shaft Assembly.>
Single-range model
for Single-Range.>
Dual-range model
for Dual-Range.>
7) Remove the differential assembly. <Ref. to 5MT85, REMOVAL, Front Differential Assembly.>
8) Remove the shifter forks and rods. <Ref. to 5MT94, REMOVAL, Shifter Fork and Rod.>
9) Pull out the straight pin, and remove the idler
gear shaft, reverse idler gear and washer.
(B)
(A)
(C)
(D)
MT-00303
(A)
(B)
(C)
(D)
Straight pin
Reverse idler gear
Washer
10) Remove the reverse shifter lever.
NOTE:
Be sure to install the reverse idler shaft from rear
side.
(A)
(B)
(D)
(C)
MT-00304
(A)
(B)
(C)
(D)

Reverse idler gear
Straight pin
2) Inspect and adjust the clearance between reverse idler gear and transmission case wall. <Ref.
to 5MT-92, INSTALLATION, Reverse Idler Gear.>
<Ref. to 5MT-93, ADJUSTMENT, Reverse Idler
Gear.>
3) Install the shifter forks and rods. <Ref. to 5MT94, INSTALLATION, Shifter Fork and Rod.>
Single-range model
Dual-range model
6) Install the drive pinion shaft assembly. <Ref. to
5MT-77, INSTALLATION, Drive Pinion Shaft Assembly.>
5MT-92
Reverse Idler Gear

C: INSPECTION
1) Move the reverse shifter rod toward reverse
side. Inspect the clearance between reverse idler
gear and transmission case wall.
If out of specification, select an appropriate reverse
shifter lever and adjust.
Clearance A:
6.0 7.5 mm (0.236 0.295 in)
Clearance A:
6.0 7.5 mm (0.236 0.295 in)
A
MT-00305
Part Number
32820AA070
32820AA080
32820AA090

Marking
Remarks
7
Further from case wall
8
Standard
9
Closer to case wall
MT-00305
2) After installing a suitable reverse shifter lever,

shift into neutral. Inspect the clearance between reverse idler gear and transmission case wall.
If out of specification, select an appropriate washer
and adjust.
Clearance:
0 0.5 mm (0 0.020 in)
2) Select an 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)
MT-00306
MT-00306
Washer
3) Check the reverse idler gear and shaft for damage. Replace if it is damaged.
D: ADJUSTMENT
1) Select an appropriate reverse shifter lever from
the table below, and adjust until the gap between
reverse idler gear and transmission case wall is
within specification.
5MT-93
Part Number
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)
Shifter Fork and Rod

21.Shifter Fork and Rod
ST
398791700
A: REMOVAL
STRAIGHT PIN REMOVER

(C)

4) Remove transmission case. <Ref. to 5MT-56,
REMOVAL, Transmission Case.>
5) Removes the drive pinion shaft assembly. <Ref.
Single-range model
for Single-Range.>
Dual-range model
for Dual-Range.>
7) Remove the differential assembly. <Ref. to 5MT85, REMOVAL, Front Differential Assembly.>
8) Drive out the straight pin tapping by ST, and pull
out the 5th shifter fork.
ST 398791700
(A)
(B)
MT-00994
(A) Straight pin

(B) 3-4 fork rod
(C) Shifter fork
11) Drive out the straight pin tapping by ST, and

pull out the 1-2 fork rod and shifter fork.
ST 398791700
12) Remove the outer snap ring, and pull out reverse fork rod from reverse shifter rod arm. Then
take out the ball, spring and interlock plunger from
rod.
And then remove the rod.
NOTE:
When pulling out reverse shifter rod arm, be careful
not to let ball pop out of arm.
13) Remove the reverse shifter lever.
B: INSTALLATION
1) Install the reverse arm fork spring, ball and interlock plunger to reverse fork rod arm. Insert the reverse fork rod into the hole in reverse fork rod arm,
and hold it with outer snap ring using ST.
(B)
(A)
MT-00309
(A) Straight pin

(B) 5th shifter fork
9) Remove the plugs, springs and checking balls.

10) Drive out the straight pin tapping by ST, and
pull out the 3-4 fork rod and shifter fork.
NOTE:
When removing a rod, keep other rods in neutral.
Also, when pulling out the straight pin, remove it toward the inside of case so that it does not hit
against the case.
NOTE:
Apply a coat of grease to plunger to prevent it from
falling.
ST 399411700
ACCENT BALL INSTALLER
2) Position the ball, spring and new gasket in the
reverse shifter rod hole on the left side of transmission case, and tighten the checking ball plug.
3) Install the 1-2 fork rod into 1-2 shifter fork
through the hole on the rear of transmission case.
4) Align the holes in rod and fork, and drive new
straight pin into these holes using ST.
NOTE:
Set other rods to neutral.
Make sure the interlock plunger is on the 3-4 fork
rod side.
ST 398791700
5) Install the interlock plunger onto 3-4 fork rod.
NOTE:
Apply a coat of grease to plunger to prevent it from
falling.
5MT-94

6) Install the 3-4 fork rod into 3-4 shifter fork

through the hole on the rear of transmission case.
7) Align the holes in rod and fork, and drive new
straight pin into these holes.
NOTE:
Set the reverse fork rod to neutral.
Make sure the interlock plunger (before installation) is on the reverse fork rod side.
ST 398791700
8) Install the 5th shifter fork onto the rear of reverse
fork rod. Align the holes in the two parts and drive
new straight pin into the specified place.
ST 398791700
(B)
(A)
(C)

C: INSPECTION
1) Inspect the fork and rod for damage. Replace if it
is damaged.
Repair or replace the gearshift mechanism if excessively worn, bent, or defective in any way.
3) Inspect the clearance between 1st, 2nd driven
gear and reverse driven gear. If any clearance is
not within specifications, replace the shifter fork as
required.
Clearance (a) and (b):
9.5 mm (0.374 in)
MT-00311
(A) 5th shifter fork

(B) Reverse fork rod
(C) Straight pin
(A)
(a)
(B)
(b)
(C)
9) Position the balls, checking ball springs and new

gaskets into 3-4 and 1-2 rod holes, and install
plugs.
MT-00999
(A) 1st driven gear

(B) Reverse driven gear
(C) 2nd driven gear
Part Number
MT-00366
Single-range model
Dual-range model
12) Install the drive pinion shaft assembly. <Ref. to
5MT-77, INSTALLATION, Drive Pinion Shaft Assembly.>
32804AA060
32804AA070
32804AA080

Marking
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).
4) Inspect the clearance between 3rd, 4th drive

gear and coupling sleeve. If any clearance is not
within specifications, replace the shifter fork as required.
5MT-95

Clearance (a) and (b):

7.3 mm (0.287 in)
6) Inspect the rod end clearances (A) and (B). If

any clearance is not within specifications, replace
the rod or fork as required.
(a)
(B)
(A)
(b)
Clearance (A):
3rd-4th 5th:
0.5 1.3 mm (0.020 0.051 in)
(C)
Clearance (B):
1st-2nd 3rd-4th
0.4 1.4 mm (0.016 0.055 in)
(A)
MT-00940
(B)
(A) 3rd drive gear

(B) Coupling sleeve
(C) 4th drive gear
Marking
Remarks
1
by 0.2 mm (0.008 in).
Standard
Become distant from
3
3rd gear by 0.2 mm
(0.008 in).
Part Number
32810AA061
32810AA071
32810AA101
5) Inspect the clearance between 5th drive gear

and coupling sleeve. If any clearance is not within
specifications, replace the shifter fork as required.
Clearance (a):
9.3 mm (0.366 in)
(A)
(a)
(B)
MT-00315
(A) 5th drive gear

(B) Coupling sleeve
Part Number
5th shifter fork

Marking
32812AA201
32812AA211
32812AA221
Remarks
by 0.2 mm (0.008 in).
Standard
Become distant from
5th gear by 0.2 mm
(0.008 in).
5MT-96
MT-00316
Counter Gear
22.Counter Gear
Be careful not to drop the two needle bearings

and collar contained in counter gear.
A: REMOVAL
4) Move the counter gear shaft until it touches
transmission case, and remove the snap ring with a
suitable tool.
(A)
(C)
(B)
MT-00319
(A) Counter shaft

(B) Counter gear
(C) Washers
(A)
B: INSTALLATION
MT-00317
(A) Snap ring
5) Slide the washer to the rear of high-low counter

shaft, and remove the straight pin from counter
shaft.
(B)
(A)
1) Install the 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
5) Install the manual transmission assembly on vehicle. <Ref. to 5MT-33, INSTALLATION, Manual
NOTE:
Make sure that the 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.
MT-00318
(A) Straight pin

(B) Counter gear
6) Remove the counter shaft from transmission

case, taking care not to drop the counter gear and
two washers.
NOTE:
Be careful not to damage the O-ring.
Be careful not to drop the straight pin on front
side.
C: INSPECTION
1) After installing the snap ring, measure the 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 specified value, select a
snap ring and install to put clearance within specified value. <Ref. to 5MT-98, ADJUSTMENT,
Counter Gear.>
5MT-97
Counter Gear
D: ADJUSTMENT
Selection of snap ring:
If the measurement is not within specification, select a suitable snap ring.
Snap ring
Part No.
031319000
805019010
Thickness mm (in)
1.50 (0.0591)
1.72 (0.0677)
5MT-98


A: INSPECTION
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 defective gear shift system and the other is
defective 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 slip-out
Gear slips out when coasting on rough
road.
Gear slips out during acceleration.
3. Noise emit from transmission.

NOTE:
If a noise is heard when the vehicle is
parked with its engine idling and if a noise
ceases when the clutch is disengaged, it
may be considered that the noise comes
from the transmission.
Possible cause
(a) Worn, damaged or burred chamfer of
internal spline of sleeve and reverse
driven gear
(b) Worn, damaged or burred chamfer of
spline of gears
(c) Worn or scratched bushings
(d) Incorrect contact between synchronizer ring and gear cone, or wear
(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
(caused by slip-out of 3rd gear)
(g) Worn 1st driven gear and driven shaft
(h) Worn 2nd driven gear and bushing
(i) Worn 3rd drive gear and needle bearing
(j) Worn 3rd drive gear and needle bearing
(k) Worn reverse idler gear and bushing
(a) Insufficient or improper lubrication
(b) Worn or damaged gears and bearings
NOTE:
If the trouble is only wear of the tooth surfaces, merely a high roaring noise will occur at high speeds, but if any part is
broken, rhythmical knocking sound will be
heard even at low speeds.
5MT-99
Corrective action
Replace.
Replace.
Replace.
Rectify or replace.
Adjust.
Tighten or replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Lubricate with specified oil or replace.
Replace.

2. DIFFERENTIAL
Symptom
1. Broken differential (case, gear, bearing, etc.)
NOTE:
Noise will be developed and finally it will
become impossible to continue to run due
to broken pieces obstructing the gear revolution.
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
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 the 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 coasting:
Cracked, broken or rusty bearings
Noise mainly when turning:
Noise occurs form differential side gear,
differential pinion or differential pinion
shaft, etc.
Possible cause
(a) Insufficient or improper oil
(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 under severe operating conditions
of the vehicle.
(f) Loose hypoid driven gear tightening
bolts
(a) Insufficient oil
(b) Improper adjustment of hypoid driven
gear and drive pinion
(c) Worn teeth of hypoid driven gear and
drive pinion
(d) Loose roller bearing
(e) Distorted hypoid driven gear or differential case
(f) Worn washer and differential pinion
shaft
5MT-100
Corrective action
Disassemble differential and replace broken components. At the same time check
other components for any trouble, and
replace if necessary.
Readjust bearing preload and backlash
and face contact of gears.
Adjustment.
Adjustment.
Add recommended oil to the specified
level. Do not use vehicle under severe
operating conditions.
Tighten.
Lubricate.
Check tooth contact.
Replace as a set.
Readjust bearing preload.
Readjust hypoid driven gear to drive pinion backlash and check tooth contact.
Replace.
Replace.
CLUTCH SYSTEM
CL
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Page
Clutch Disc and Cover ..............................................................................12
Flywheel ....................................................................................................16
Release Bearing and Lever.......................................................................18
Operating Cylinder ....................................................................................20
Master Cylinder .........................................................................................21
Clutch Pipe and Hose ...............................................................................23
Clutch Fluid ...............................................................................................24
Clutch Fluid Air Bleeding...........................................................................25
Clutch Pedal..............................................................................................26
Clutch Switch ............................................................................................32
General Description
CLUTCH SYSTEM
A: SPECIFICATION
Option code1
Model
Clutch cover Diaphragm set load
kgf (lb)
Facing material
Outer diameter Inner
mm (in)
diameter Thickness
Spline outer diameter
mm (in)
Clutch disc
Standard
Depth of rivet head
mm (in) Limit of
sinking
Limit for deflection
mm (in)
Clutch release lever ratio
Release bearing
Full stroke
mm (in)
Clutch pedal
Free play
mm (in)
Flywheel
Type
1:
EC, EK, KA
2.0 L
KS, K4
2.5 L
2.0 L
450 (992)
550 (1,213)
2.5 L
580 (1,279)
Woven
228.6 155 2.95
(9.00 6.10 0.1161)
225 150 3.5

(8.86 5.91 0.138)
25.2 (0.992)
1.3 1.9 (0.051 0.075)
0.3 (0.012)
1.0 (0.039) at R = 110 (4.33)
1.6
Grease-packed self-aligning
130 135 (5.12 5.31)
4 13 (0.16 0.51)
Dual mass
Flexible
CL-2
General Description
CLUTCH SYSTEM
B: COMPONENT
1. CLUTCH ASSEMBLY
EC, EK and KA model
(1)
(2)
(4)
(5)
(6)
T1
(3)
(9)
(5)
T1
(7)
(8)
T2
CL-00286
(1)
(2)
(3)
(4)
(5)
Dust cover
Lever spring
Pivot
Release lever
Clip
(6)
(7)
(8)
(9)
Release bearing
Clutch cover
Clutch disc
Dual mass flywheel
CL-3

T1: 16 (1.6, 11.8)
T2: 72 (7.3, 52.8)
General Description
CLUTCH SYSTEM
KS and K4 model
(1)
(4)
(2)
(5)
(3)
(6)
T1
(5)
T2
T2
(7)
(8)
(9)
CL-00287
(1)
(2)
(3)
(4)
(5)
Dust cover
Lever spring
Pivot
Release lever
Clip
(6)
(7)
(8)
(9)
Release bearing
Clutch cover
Clutch disc
Flexible flywheel
CL-4

T1: 16 (1.6, 11.8)
T2: 72 (7.3, 52.8)
General Description
CLUTCH SYSTEM
2. CLUTCH PIPE AND HOSE

LHD model
T2
(1)
(4)
T5
(5)
(2)
(3)
T3
(6)
T3
T4
(8)
T1
(7)
CL-00288
(1)
(2)
(3)
(4)
(5)
(6)
Master cylinder ASSY

Clutch pipe
Clamp
Bracket
Clutch hose
Washer
(7)
(8)
Operating cylinder
Clip
CL-5

T1: 8 (0.8, 5.8)
T2: 15 (1.5, 10.8)
T3: 18 (1.8, 13.0)
T4: 37 (3.8, 27.5)
T5: 25 (2.5, 18.4)
General Description
CLUTCH SYSTEM
RHD model
(9)
(7)
(6)
(8)
T3
(5)
T2
T3
(3)
T2
(11)
T4
T5
(2)
(4)
(1)
T1
(10)
CL-00289
(1)
(2)
(3)
(4)
(5)
(6)
Operating cylinder
Washer
Clutch hose
Clamp
Clutch pipe
Master cylinder ASSY
(7)
(8)
(9)
(10)
(11)
Clevis pin
Snap pin
Pedal
Clip
Bracket
CL-6

T1: 8 (0.8, 5.8)
T2: 15 (1.5, 10.8)
T3: 18 (1.8, 13.0)
T4: 25 (2.5, 18.4)
T5: 37 (3.8, 27.5)
General Description
CLUTCH SYSTEM
3. MASTER CYLINDER
T
(1)
(10)
(9)
(2)
(8)
(3)
(7)
(4)
(6)
(5)
CL-00151
(1)
(2)
(3)
(4)
(5)
Reservoir cap
Reservoir tank
Oil seal
Straight pin
Master cylinder
(6)
(7)
(8)
(9)
(10)
Return spring
Piston
Push rod ASSY
Piston stop ring
Cylinder boot
CL-7

T: 10 (1.0, 7)
General Description
CLUTCH SYSTEM
4. CLUTCH PEDAL
LHD model
(24) (4)
(3)
T2
(23)
T1
(2)
(10)
T2
(7)
(22)
(21)
T2
T1
(10)
(25)
T1
(20)
(13)
(12)
(19)
(1)
(13)
(2)
T1
(1)
(18) (17)
(11)
(16)(15)
(14)
(11)
(4)
(2)
(10)
(2)
(1)
(7)
(5)
(6)
(8)
(9)
CL-00290
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
Stopper
Bushing
Spring pin
Snap pin
Brake pedal pad
Brake pedal
Clevis pin
Clutch pedal pad
Clutch pedal
Bushing C
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
Clutch clevis pin

Assist rod A
Clip
Assist spring
Assist bushing
Assist rod B
Spring A (EC and 2.5 L model)
Rod (EC and 2.5 L model)
Bushing B (EC and 2.5 L model)
Clip (EC and 2.5 L model)
CL-8
(21)
(22)
(23)
(24)
(25)
Stop light switch

Pedal bracket
Clutch master cylinder bracket
Lever
Clutch switch

T1: 8 (0.8, 5.8)
T2: 18 (1.8, 13.0)
General Description
CLUTCH SYSTEM
RHD model
(9)
(10)
(8)
(5)
(6)
(7)
(4)
(18)
T2
(15)
T3
(14)
(13)
(1)
(16)
(19)
T2
T1
(4)
(11)
(20)
T2
(17)
(1)
(17)
(12)
(2)
(4)
(3)
CL-00291
(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)
(17)
(18)
Assist rod B
Spring A
Rod S
Bushing B
Clip
Clutch switch
Spacer
Bushing
Clutch pedal bracket
CL-9
(19)
(20)
Clutch pedal catcher

Bracket (Clutch pedal catcher)

T1: 8 (0.8, 5.8)
T2: 18 (1.8, 13.0)
T3: 30 (3.1, 22.4)
General Description
CLUTCH SYSTEM
C: CAUTION
Use SUBARU genuine fluid, grease etc. or
equivalent. Do not mix fluid, grease, etc. with that of
another grade or from other manufacturers.

points.
Before installing O-rings or snap rings, apply sufficient amount of fluid to avoid damage and deformation.
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 TOOL
ILLUSTRATION
TOOL NUMBER
498497100
DESCRIPTION
CRANKSHAFT
STOPPER
REMARKS
Used for stopping rotation of flywheel when loosening/tightening bolt, etc.
CLUTCH DISC
GUIDE
Used for installing clutch disc to flywheel.
ST-498497100
499747100
ST-499747100
CL-10
General Description
CLUTCH SYSTEM
ILLUSTRATION
TOOL NUMBER
499057000
DESCRIPTION
TORX PLUS
REMARKS
Used for removing flywheel (dual mass flywheel
type).
ST-499057000
2. GENERAL TOOL
TOOL NAME
Circuit tester
Dial gauge
REMARKS
Used for measuring clutch disk run-out.
CL-11
Clutch Disc and Cover

CLUTCH SYSTEM
2. Clutch Disc and Cover
ST
499747100
A: REMOVAL
CRANKSHAFT STOPPER
(A)
1. EC, EK AND KA MODEL

1) Remove the transmission assembly from vehicle. <Ref. to 5MT-31, REMOVAL, Manual Transmission Assembly.>
2) Insert the ST on flywheel.
ST 499747100
CLUTCH DISC GUIDE
ST
(A)
CL-00011
(A) Clutch cover
3) Remove the clutch cover and clutch disc.

NOTE:
Take care not to allow oil on the clutch disc facing.
Do not disassemble the clutch cover or clutch
disc.
ST
CL-00112
B: INSTALLATION
(A) Dual mass flywheel
3) Remove the clutch cover and clutch disc.

NOTE:
Take care not to allow oil on the clutch disc surface.
Do not disassemble the clutch cover or clutch
disc.
Be sure to mark alignment marks on the flywheel
and clutch cover before removing the clutch cover.
1) Insert the ST into clutch disc and install on the

flywheel by inserting the ST end into pilot bearing.
NOTE:
When installing the clutch disc, be careful of its direction.
ST 499747100
CLUTCH DISC GUIDE
(A)
(A)
ST
CL-00282
CL-00113
(A) Flywheel side
2. KS AND K4 MODEL
1) Remove the transmission assembly from vehicle
body. <Ref. to 5MT-33, INSTALLATION, Manual
2) Install the ST on flywheel.
2) Place the clutch cover on flywheel and tighten

the bolts to 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 the paint marks
on the
flywheel and clutch cover. (the paint marks
indicate the directions of residual unbalance.)

Note the front and rear of the clutch disc when installing.
CL-12

CLUTCH SYSTEM
Tighten the clutch cover installing bolts gradually. Each bolt should be tightened to the specified
torque in a crisscross order.
Temporarily tighten the bolts by hand. Each bolt

should be tightened to the specified torque in a
crisscross order.
Tightening torque:
16 Nm (1.6 kgf-m, 11.8 ft-lb)
Tightening torque:
16 Nm (1.6 kgf-m, 11.8 ft-lb)
(1)
(3)
(6)
(5)
(4)
(2)
CL-00115
(A)
3) Remove the ST.

ST 499747100
CLUTCH DISC GUIDE
4) Install the transmission assembly. <Ref. to 5MT33, INSTALLATION, Manual Transmission Assembly.>
(3)
2. KS AND K4 MODEL
(1)
(5)
1) Insert the ST into clutch disc and install them on

the flywheel by inserting the ST end into pilot bearing.
NOTE:
When installing the clutch disc, be careful to its direction.
ST 499747100
CLUTCH DISC GUIDE
(6)
(2)
(4)
ST
CL-00013
(A) 0 marks
3) Remove the ST.

ST 499747100
CLUTCH DISC GUIDE
C: INSPECTION
(A)
ST
1. CLUTCH DISC
1) Facing wear:
Measure the depth from the surface of facing to rivet head. Replace if the facings are worn locally or
worn down to less than the specified value.
CL-00208
(A) Flywheel side
2) Install the clutch cover on flywheel and tighten

the bolts to 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 the paint marks
on the
flywheel and clutch cover. (the paint marks
indicate the directions of residual unbalance.)

Note the front and rear of the clutch disc when installing.
Depth of rivet head:

Limit of sinking
0.3 mm (0.012 in)
NOTE:
Do not wash the clutch disc with any cleaning fluid.
CL-13

CLUTCH SYSTEM
EC, EK and KA model
KS and K4 model
(A)
CL-00116
CL-00015
KS and K4 model
(A) Clutch facing
4) Deflection on facing:
If deflection exceeds the specified value at the outer circumference of facing, replace the clutch disc.
ST 499747100
CLUTCH DISC GUIDE
Limit for deflection:
1.0 mm (0.039 in) at R = 110 mm (4.33 in)
EC, EK and KA model
CL-00014
2) Hardened facing:
Replace the clutch disc.
3) Oil leakage on facing:
Replace the clutch disc and inspect the transmission front oil seal, transmission case mating surface, engine rear oil seal and other points for oil
leakage.
EC, EK and KA model
(A)
ST
CL-00118
KS and K4 model
ST
CL-00117
(A) Clutch facing
CL-00016
5) If the spline wears, rivets loosen and damper

spring is failure, replace the clutch disc.
CL-14

CLUTCH SYSTEM
EC, EK and KA model
KS and K4 model
(A)
(A)
(B)
(B)
CL-00018
CL-00119
(A) Spline
(B) Rivet
(A) Thrust rivet

(B) Diaphragm spring
KS and K4 model
3) Damaged or worn disc contact surface of pressure plate

4) Loose strap plate installation area
5) Worn diaphragm sliding area
EC, EK and KA model
(A)
(B)
CL-00017
(A) Spline
(B) Rivet
(C) Damper spring
CL-00176
2. CLUTCH COVER
NOTE:
Visually check the following items without disassembling, and replace or repair if defective.
1) Loose thrust rivet
2) Damaged or worn bearing contact area at the
center of diaphragm spring
EC, EK and KA model
(A) Pressure plate

(B) Strap plate
KS and K4 model
(A)
(A)
(B)
CL-00177
(A) Pressure plate

(B) Strap plate
(B)
CL-00120
(A) Thrust rivet

(B) Diaphragm spring
CL-15
Flywheel
CLUTCH SYSTEM
3. Flywheel
ST
498497100
CRANKSHAFT STOPPER
A: REMOVAL
5MT-31, REMOVAL, Manual Transmission Assembly.>
2) Remove the clutch cover and clutch disc. <Ref.
to CL-12, REMOVAL, Clutch Disc and Cover.>
3) Using ST1 and ST2, remove the flywheel.
(A)
ST
CL-00122
2) Tighten the flywheel mounting bolts to specified

torque.
ST 499057000
TORX PLUS
NOTE:
Tighten the flywheel installing bolts gradually. Each
bolt should be tightened to the specified torque in a
crisscross order.
Tightening torque:
72 Nm (7.3 kgf-m, 52.8 ft-lb)
ST2
ST1
CL-00121
(A) Flywheel
(5)
2. KS AND K4 MODEL
(1)
(7)
(3)

5MT-31, REMOVAL, Manual Transmission Assembly.>
2) Remove the clutch cover and clutch disc. <Ref.
to CL-12, REMOVAL, Clutch Disc and Cover.>
3) Using the ST, remove the flywheel.
ST 498497100
CRANKSHAFT STOPPER
(4)
(8)
(2) (6)
CL-00123
3) Install the clutch disc and cover. <Ref. to CL-12,

INSTALLATION, Clutch Disc and Cover.>
2. KS AND K4 MODEL
1) Install the flywheel and ST.
ST 498497100
CRANKSHAFT STOPPER
(A)
ST
CL-00019
(A) Flywheel
B: INSTALLATION
1) Set the flywheel and ST.
ST
CL-00020
2) Tighten the flywheel attaching bolts to specified

torque.
CL-16
Flywheel
CLUTCH SYSTEM
NOTE:
Tighten the flywheel installing bolts gradually. Each
bolt should be tightened to the specified torque in a
crisscross order.
KS and K4 model
(B)
Tightening torque:
72 Nm (7.3 kgf-m, 52.8 ft-lb)
(5)
(1)
(A)
CL-00022
(7)
(3)
(A) Flywheel
(B) Ring gear
(4)
(8)
(2)
(6)
CL-00021
3) Install the clutch disc and cover. <Ref. to CL-13,

KS AND K4 MODEL, INSTALLATION, Clutch Disc
and Cover.>
2) Smoothness of rotation
Rotate the ball bearing while applying pressure in
thrust direction.
3) If noise or excessive play is noted, replace the
flywheel.
C: INSPECTION
CAUTION:
Since this bearing is grease-sealed and non-lubrication type, do not wash it with gasoline or
any solvent.
1) Damage on sliding surface of facing and ring
gear:
If defective, replace the flywheel.
EC, EK and KA model
(B)
(A)
CL-00124
(A) Flywheel
(B) Ring gear
CL-17
Release Bearing and Lever

CLUTCH SYSTEM
4. Release Bearing and Lever

A: REMOVAL
1) Remove the transmission assembly from vehicle
body.
<Ref. to 5MT-31, REMOVAL, Manual Transmission Assembly.>
2) Remove the two clips from clutch release lever
and remove the release bearing.
NOTE:
Apply grease (KOPR-KOTE: Part No.
003603001) to the contact point of release lever
and operating cylinder.
Observing from main case hole, check that the
lever spring is installed securely.
(A)
CAUTION:
Be careful not to deform the clips.
3) Remove the dust cover.
CL-00026
(A)
(A) Release lever
2) Place the release bearing and fasten it with two

clips.
3) Install the dust cover.
(B)
CL-00023
(A) Clutch release lever

(B) Dust cover
4) Remove the lever spring from pivot with a screwdriver by accessing it through the clutch housing release lever hole. Then remove the release lever.
(A)
(B)
(B)
CL-00023
(A) Release lever

(B) Dust cover
4) Check smooth movement of bearing with operating release lever.

<Ref. to 5MT-33, INSTALLATION, Manual Transmission Assembly.>
(A)
CL-00024

(B) Screwdriver
C: INSPECTION
B: INSTALLATION
1. RELEASE BEARING
NOTE:
Before or during installation, 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 disulphide.)
1) While pushing the release lever to pivot and
twisting it to both sides, fit the lever spring onto the
constricted portion of pivot.
NOTE:
Since this bearing is grease-sealed and non-lubrication type, do not wash with gasoline or any solvent when servicing the clutch.
CL-18
Release Bearing and Lever

CLUTCH SYSTEM
1) Check the bearing for smooth movement by applying force to the bearing in radial direction.
Radial direction stroke:
1.6 mm (0.063 in)
(A)
CL-00032
(A) Bearing case
2) Check the bearing for smooth rotation by applying force to the bearing in thrust direction.
(A)
CL-00160
(A) Bearing case
3) Check wear and damage of bearing case surface contacting with lever.
2. RELEASE LEVER
Check the lever pivot portion and contact point with
release bearing case for wear.
(A)
(B)
(C)
CL-00034

(B) Pivot
(C) Clutch release bearing
CL-19
Operating Cylinder
CLUTCH SYSTEM
5. 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)
A: REMOVAL
2) Disconnect the clutch hose from operating cylinder.
T2
T1
CAUTION:
Cover the hose joint to prevent clutch fluid from
flowing out.
(A)
T2
CL-00254
2) After bleeding air from the operating cylinder,

ensure that clutch operates properly.
<Ref. to CL-25, Clutch Fluid Air Bleeding.>
C: INSPECTION
(B)
1) Check the operating cylinder for damage. If operating cylinder is damaged, replace it.
2) Check the operating cylinder for fluid leakage or
damage on boot. If any leakage or damage is
found, replace the operating cylinder.
CL-00252
(A) Clutch hose

(B) Operating cylinder
3) Remove the operating cylinder from transmission.
CL-00253
B: INSTALLATION
NOTE:
Before installing the operating cylinder, apply
grease (KOPR-KOTE: Part No. 003603001) to the
contact point of the release lever and operating cylinder.
CL-20
Master Cylinder
CLUTCH SYSTEM
6. Master Cylinder
Tightening torque:
T1: 15 Nm (1.5 kgf-m, 10.8 ft-lb)
T2: 18 Nm (1.8 kgf-m, 13.0 ft-lb)
A: REMOVAL
1) Thoroughly drain the brake fluid from reservoir
tank.
2) Remove the snap pin and clevis pin, and then
separate the push rod of master cylinder from
clutch pedal.
(A)
T2
T1
(B)
(D)
CL-00153
2) Connect the push rod of master cylinder to

clutch pedal, and install the clevis pin and snap pin.
(C)
NOTE:
Apply grease to the clevis pin.
CL-00042
(A)
(B)
(C)
(D)
Clevis pin
Snap pin
Push rod
Lock nut
(A)
(B)

4) Disconnect the clutch pipes from master cylinder.
5) Remove the master cylinder and reservoir tank
as a unit.
CAUTION:
Be careful not to spill the brake fluid. Brake fluid spilt on the vehicle body will harm the paint
surface; wipe it off quickly if spilt.
(A)
(B)
(C)
CL-00045
(A) Clevis pin

(B) Snap pin
(C) Push rod
3) After bleeding air from the clutch system, ensure

that clutch operates properly. <Ref. to CL-25,
Clutch Fluid Air Bleeding.>
C: DISASSEMBLY
1) Remove the straight pin and reservoir tank.
CL-00152
(A) Master cylinder ASSY

(B) Clutch pipe
(A)
B: INSTALLATION
1) Install the master cylinder to the vehicle, and
connect the clutch pipe to master cylinder.
NOTE:
Check that the pipe is routed properly.
(B)
CL-00178
(A) Reservoir tank

(B) Straight pin
CL-21
Master Cylinder
CLUTCH SYSTEM
Tightening torque:
10 Nm (1.0 kgf-m, 7 ft-lb)
E: INSPECTION
(A)
If any damage, deformation, wear, swelling, rust or

other faults are found on the cylinder, piston, push
rod, fluid reservoir, return spring, gasket, clutch
damper cylinder boot or hose, replace the faulty
part.
(C)
(B)
(A)
CL-00179
(B)
(A) Oil seal

(B) Master cylinder
(F)
(D)
3) Pull the cylinder boot backward.

(E)
(A)
(A)
(B)
(C)
(D)
(E)
(F)
(B)
CL-00048
(A) Cylinder boot

(B) Master cylinder

CAUTION:
Be careful to prevent the rod, washer, piston
and return spring from flying out when removing the snap ring.
D: ASSEMBLY
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)
CL-00156
CL-22
Master cylinder body

Return spring
Piston
Stop ring
Push rod ASSY
Cylinder boot
CL-00157
Clutch Pipe and Hose

CLUTCH SYSTEM
7. Clutch Pipe and Hose
B: INSTALLATION
A: REMOVAL

2) Drain the clutch fluid. <Ref. to CL-24, Clutch Fluid.>
3) Disconnect the clutch pipe from the clutch hose
and master cylinder.
4) Pull out the clamp, then remove the clutch hose
from bracket.
NOTE:
Bleed the air of clutch fluid. <Ref. to CL-25, 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)
T3: 25 Nm (2.5 kgf-m, 18.4 ft-lb)
T1
T1
(A)
(A)
T3
(B)
T1
(B)
(C)
CL-00057
(D)
(A) Clamp
(B) Clutch hose
(C)
T1
T2
5) Disconnect the hose from operating cylinder.

T3
(C)
(B)
CL-00283
(A)
(B)
(C)
(D)
Clutch pipe (LHD model)

Clip
Clutch hose
Clutch pipe (RHD model)
C: INSPECTION
Check pipes and hoses for cracks, breakage or
damage. Check joints for fluid leakage. If any
crack, breakage, damage or leakage is found, repair or replace the defective pipe or hose.
CL-23
Clutch Fluid
CLUTCH SYSTEM
8. Clutch Fluid
NOTE:
Refill the brake fluid before reservoir tank becomes
empty.
A: INSPECTION
2) Inspect the fluid level using the scale on the outside of reservoir tank. If the level is below MIN,
add fluid to bring it up to MAX, and also inspect for
leakage.
(A)
(B)
M AX
MIN
(C)
CL-00183
(A) Reservoir tank

(B) MAX. level
(C) MIN. level
B: REPLACEMENT
CAUTION:
The FMVSS No. 116, fresh DOT3 or 4 brake
fluid must be used.
When loosening bleeder screw, cover the
bleeder with cloth to prevent brake fluid from
being splashed over surrounding parts.
Avoid mixing different brands of brake fluid
to prevent the quality of fluid from degrading.
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 the entry
of air.
Clutch pedal operating must be very slow.
For convenience and safety, it is advisable to
have two people working.
The amount of brake fluid required is approx. 70
m2 (2.4 US fl oz, 2.5 Imp fl oz) for total clutch system.
2) Drain the brake fluid from reservoir tank.
brake fluid.
FMVSS No. 116, fresh DOT3 or 4 brake fluid
4) Drain all contaminated fluid in the same method
as air bleeding.
CL-24
Clutch Fluid Air Bleeding

CLUTCH SYSTEM
9. Clutch Fluid Air Bleeding
Tightening torque:
T: 8 Nm (0.8 kgf-m, 5.8 ft-lb)
A: PROCEDURE
NOTE:
Bleed air from the oil line with help of a co-worker.
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.
(A)
CL-00261
6) After depressing the clutch pedal, make sure

that there are no leaks evident in the entire clutch
system.
7) After bleeding air from the clutch system, ensure
that clutch operates properly.
(B)
CL-00259
(A) Clutch hose

(B) Air bleeder
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.
CAUTION:
When loosening bleeder screw, cover the
bleeder with cloth to prevent brake fluid from
being splashed over surrounding parts.
(B)
(A)
CL-00260
(A) Operating cylinder

(B) Vinyl tube
4) Repeat the procedure 3), until there are no more

air bubbles in the vinyl tube.
5) Tighten the air bleeder.
CL-25
Clutch Pedal
CLUTCH SYSTEM
10.Clutch Pedal
3) Remove the clutch pedal catcher from bracket

(clutch pedal catcher).
A: REMOVAL
1. LHD MODEL
2) Remove the steering column. <Ref. to PS-23,
REMOVAL, Tilt Steering Column.>
3) Disconnect the connectors from the stop light
and clutch switches.
4) Remove the snap pins which secure lever to
push rod and operating rod.
5) Remove the clevis pins which secure lever to
push rod and operating rod.
(A)
(D)
(B)
(C)
CL-00274
(A)
(B)
(C)
(D)
(D)
4) Remove the clutch switch connector from clutch

pedal.
5) Remove the snap pin and clevis pin which join
the push rod and clutch pedal.
6) Remove the master cylinder mounting nuts.
(A)
(D)
(C)

Clutch pedal
Steering support beam
(C)
(B)
CL-00292
(A)
(B)
(C)
(D)
Operating rod
Push rod
Snap pin
Clevis pin
(A)
6) Remove the nut which secures clutch master

cylinder.
CL-00216
(A) Master cylinder
7) Remove the clutch pedal and bracket as a unit.
CL-00093
(A)
7) Remove the bolts and nuts which secure brake

pedal and clutch pedal, and remove the pedal assembly.
(B)
2. RHD MODEL
CL-00126

2) Remove the instrument panel lower cover.
(A) Clutch pedal bracket

(B) Clutch pedal
CL-26
Clutch Pedal
CLUTCH SYSTEM
B: INSTALLATION
3) Remove the spring pin and lever.

(A)
Tightening torque:
T: 18 Nm (1.8 kgf-m, 13.0 ft-lb)
(B)
(A)
CL-00095
(D)
(A) Pin
(B) Lever
(B)
(C)
4) Remove the clutch pedal and bushings.
CL-00275
(A)
(B)
(C)
(D)
(B)

Clutch pedal
(B)
CAUTION:
Always use a new clevis pin.
2) Adjust the clutch pedal after installation. <Ref. to
CL-29, ADJUSTMENT, Clutch Pedal.>
(A)
CL-00096
C: DISASSEMBLY
(A) Clutch pedal

(B) Bushing
1. LHD MODEL
1) Remove the clutch switches.
2) Remove the clips, assist spring, rod and bushing.
5) Remove the stopper, clip and rod S, and then remove the spring and bushing S.
(D)
(B)
(A)
(A)
(E)
(E)
(C)
(D)
(B)
(D)
(E)
(D)
(C)
(C)
CL-00097
CL-00094
(A)
(B)
(C)
(D)
(E)
(A)
(B)
(C)
(D)
(E)
Clip
Assist spring
Assist rod
Bushing
Clevis pin
Clip
Bushing S
Spring S
Rod S
Stopper
6) Remove the stoppers from clutch pedal.

7) Remove the clutch pedal pad.
CL-27
Clutch Pedal
CLUTCH SYSTEM
2. RHD MODEL
1) Remove the clutch switch.
2) Remove the clip, and then pull out the clevis pin.
6) Remove the spacer, bushing and pedal pad from

clutch pedal.
(A)
(B)
(F)
(C)
(B)
(F)
(D)
(E)
CL-00130
(A)
CL-00127
(A)
(B)
(C)
(D)
(E)
(F)
(A) Clevis pin
3) Remove the assist rod, spring and bushing.

4) Remove the clutch pedal from clutch pedal
bracket.
Spacer
Bushing
Bushing
Pedal pad
Clutch pedal
Bushing C
D: ASSEMBLY
1. LHD MODEL
(A)
1) Attach the clutch switch, etc. to pedal bracket

temporarily.
2) Clean the inside of bores of clutch pedal and
brake pedal, and apply grease, and set bushings
into bores.
3) Align the bores of pedal bracket, clutch pedal
and brake pedal, and then attach the brake pedal
return spring, assist rods, spring and bushing.
(B)
CL-00128

(B) Clutch pedal
5) Remove the following parts (B to G) from clutch

pedal bracket (A) as shown in the figure.
(B)
(A)
(C)
(G)
(F)
(A)
(B)
(C)
(D)
(E)
(F)
(G)
NOTE:
Clean up the inside of bushings and apply grease
before installing spacer.
2. RHD MODEL
1) Clean and apply grease to the hole of sliding
portion between clutch pedal and bushing.
2) Install the pad, stopper, bushing C, spacer and
bushing to clutch pedal.
3) Install the rod S, spring S, bushing S, clip, bushing, clutch switch and bushing C to clutch pedal
bracket.
(D)
(E)
CL-00184
Clutch pedal bracket

Bushing C
Clip
Bushing S
Spring S
Rod S
Bushing
CL-28
Clutch Pedal
CLUTCH SYSTEM
4) Install the clutch pedal assembly, stopper, adjusting rod, bushing and spring to clutch pedal
bracket.
RHD model
Tightening torque:
T: 30 Nm (3.1 kgf-m, 22.4 ft-lb)
(A)
(B)
(A)
CL-00077
T
(A) Clutch pedal

(B) Brake pedal
(B)
F: ADJUSTMENT
CL-00276
1) Measure the full stroke amount of clutch pedal.

(B) Clutch pedal
5) Install the assist rod, bushing and assist spring

to clutch pedal and pedal bracket.
E: INSPECTION
NOTE:
Measure the length between the seat cushion
front end and center portion of clutch pedal.
Slide the seat at seventh notch from first notch.
Specified clutch pedal full stroke A:
130 135 mm (5.12 5.31 in)
1. CLUTCH PEDAL
Move the clutch pedal pads in the lateral direction
with a force of approximately 10 N (1 kgf, 2 lb) to
ensure the pedal deflection is in specified range.
If excessive deflection is noted, replace the bushings with new ones.
Deflection of clutch pedal:
Service limit
5.0 mm (0.197 in) or less
LHD model
(C)
(A)
(B)
CL-00078
(A) Clutch pedal (Full stroke condition)

(B) Scale
(C) Seat
(A)
(B)
2) If the clutch pedal stroke is out of specification,

loosen the clutch stopper nut and adjust it.
Tightening torque (Clutch stopper nut):
8 Nm (0.8 kgf-m, 5.8 ft-lb)
CL-00098
(A) Clutch pedal

(B) Brake pedal
CL-29
Clutch Pedal
CLUTCH SYSTEM
5) Turn the push rod counterclockwise to shorten

until clearance is made at clutch switch.
3) Loosen the push rod lock nut.

(A)
(B)
(D)
(C)
(C)
(A)
(B)
CL-00042
CL-00132
(A)
(B)
(C)
(D)
Clevis pin
Snap pin
Push rod
Push rod lock nut
(A) Clutch switch

(B) Stopper
(C) Clearance
4) Turn the push rod to adjust.

(1) Ensure that the clutch pedal contacts clutch
switch, when releasing the clutch pedal.
(2) Ensure that the clutch pedal contacts clutch
pedal bracket stopper, when fully depressing
the clutch pedal.
6) Turn the push rod clockwise to lengthen until

clutch pedal contacts to clutch switch.
7) Turn the push rod further 270 counterclockwise
to shorten (arrow direction as shown in the figure).
LHD model
(B)
(A)
(A)
(B)
(F)
(C)
(E)
CL-00101
(D)
(A)
(B)
(C)
(D)
(E)
(F)
Clevis hole
Push rod lock nut
Shortening direction
Lengthening direction
Push rod
U shaped bracket
CL-00080
(A) Accelerator pedal

(B) Clevis
RHD model
(A)
(B)
CL-00085
(A) Clutch pedal

(B) Brake pedal
8) Move the clevis pin in lateral direction to ensure

it moves smoothly.
CL-30
Clutch Pedal
CLUTCH SYSTEM
9) Tighten the push rod lock nut.

Tightening torque:
10 Nm (1.0 kgf-m, 7.2 ft-lb)
10) Depress and release the clutch pedal two or
three times to ensure that clutch pedal and release
fork operates smoothly. If the clutch pedal and release fork do not operate smoothly, bleed air from
the clutch hydraulic system. <Ref. to CL-25, Clutch
Fluid Air Bleeding.>
11) Measure the 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)
12) Move the 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.
13) Push the release lever until operating cylinder
push rod retracts. Ensure that clutch fluid level in
reservoir tank increases. If the clutch fluid level increases, hydraulic clutch is properly adjusted; if fluid level does not increase or push rod does not
retract, replace the master cylinder with a new one.
<Ref. to CL-21, Master Cylinder.>
(1)
(2)
14) Push the release lever until operating cylinder

push rod retracts. Check that the clutch fluid level in
reservoir tank increases.
(1)
(3)
(2)
CL-00227
(1) Push rod

(2) Release lever
(3) Operating cylinder
15) If the clutch fluid level increases, hydraulic

clutch play is correct.
16) If the clutch fluid level does not increase or
push rod does not retract, clutch pedal must be readjusted.
17) Check the fluid level on the outside of the reservoir tank. If the level is below MIN, add clutch
fluid to bring it up to MAX.
Recommended clutch fluid:
FMVSS No. 116, fresh DOT 3 or DOT 4 brake
fluid
(C)
(A)
(3)
CL-00227
(B)
(1) Push rod

(2) Release lever
(3) Operating cylinder
CL-00214
(A) Max. level

(B) Min. level
(C) Reservoir tank
CL-31
Clutch Switch
CLUTCH SYSTEM
11.Clutch Switch
C: INSPECTION
A: REMOVAL
Check the clutch switch continuity. If the continuity

is not as specified, replace the switch.
(1) Disconnect the clutch switch connector.
(2) Measure the resistance between switch terminal 1 and 2.

3) Disconnect the connector from clutch switch.
4) Remove the clutch switch.
B: INSTALLATION
Condition
1) Install the clutch switch so that the clearance

from the clutch pedal stopper is 0 mm (0 in).
Tightening torque:
8 Nm (0.8 kgf-m, 5.8 ft-lb)
When clutch pedal

depressed
When clutch pedal
released
Terminal No.
No. 1 No. 2
No. 1 No. 2
Specified resistance
More than 1
M
Less than 1
2 1
(C)
(A)
(B)
CL-00133
CL-00084
D: ADJUSTMENT
(A) Clutch switch

(B) Stopper
(C) 0 mm (0 in)
Refer to ADJUSTMENT for clutch pedal. <Ref. to

CL-29, ADJUSTMENT, Clutch Pedal.>
2) Measure the stroke of clutch pedal.

Specified clutch pedal full stroke A:
Non-turbo model
130 135 mm (5.12 5.31 in)
Turbo model
135 140 mm (5.31 5.51 in)
(C)
(A)
(B)
CL-00078
(A) Clutch pedal (at full stroke condition)

(B) Scale
(C) Seat
3) If the clutch pedal stroke is out of specification,

adjust the stroke. <Ref. to CL-29, ADJUSTMENT,
Clutch Pedal.>
4) Connect the clutch switch connector.
CL-32

CLUTCH SYSTEM

A: INSPECTION
1. CLUTCH
Symptom
1. Clutch slippage
It is hard to perceive clutch slippage in
the early stage, but pay attention to the
following symptoms.
Engine speeds up when shifting.
High-speed driving is impossible; especially rapid acceleration is impossible and
vehicle speed does not increase in proportion to the 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 a
stationary condition with parking brake
fully applied. Disengage the clutch and
shift the transmission gear into the 1st.
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 1st gear.
However, because much trouble of this
sort is due to defective synchronization
mechanism, carry out the following tests.
Method of testing: <Ref. to CL-34,
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.
4. Noisy clutch
Examine whether the noise is generated
when the clutch is disengaged, engaged,
or partially engaged.
Possible cause
(a) Clutch facing smeared by oil
(b) Worn clutch facing
(c) Deteriorated diaphragm spring
(d) Distorted pressure plate or flywheel
(e) Defective release bearing holder
Corrective action
Replace.
Replace.
Replace.
Rectify or replace.
Rectify or replace.
(a) Worn or rusty clutch disc hub spline

(b) Excessive deflection of clutch disc
facing
(c) Stick of crankshaft pilot needle bearing
(d) Cracked clutch disc facing
(e) Stuck clutch disc (smeared by oil or
water)
Replace clutch disc.

Rectify or replace.
(a) Adhesion of oil on the facing

(b) Weak or broken damper 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
(a) Broken, worn or unlubricated release
bearing
(b) Insufficient lubrication of pilot bearing
(c) Loose clutch disc hub
(d) Loose damper spring retainer
(e) Deteriorated or broken damper spring

Replace the defective clutch disc.
CL-33
Replace.
Replace.
Replace.
Rectify or replace.
Retighten or replace mounting.
Adjustment.
Replace the release bearing.
Replace the pilot bearing.

CLUTCH SYSTEM
Symptom
5. Clutch grabs.
When starting the vehicle with the clutch
partially engaged, the clutch grabs suddenly and the vehicle jumps instead of
making a smooth start.
Possible cause
(a) Grease or oil on facing
(b) Deteriorated cushioning spring
(c) Worn or rusted spline of clutch disc or
main shaft
(d) Deteriorated or broken damper spring
(e) Loose engine mounting
(f) Deteriorated diaphragm spring
Corrective action
Take off rust, apply grease or replace
clutch disc or main shaft.
Retighten or replace mounting.
Replace.
2. CLUTCH PEDAL
Trouble
Corrective action
Adjust pedal free play.
Adjust pedal free play.
Replace the bushing and/or shaft with a new one.
Insufficient pedal play

Insufficient clutch pedal free play
Excessively worn and damaged pedal shaft and/or bushing
3. DIAGNOSTIC DIAGRAM OF CLUTCH DRAG
Step
CHECK GEAR NOISE.
2) Disengage the clutch and shift quickly from
neutral to reverse in idling condition.
CHECK GEAR NOISE.
Disengage the clutch at idle and shift from neutral to reverse within 0.5 1.0 seconds.
Check
Is there any abnormal noise
from the transmission gear?
Yes
Go to step 2.

from the transmission gear?
Go to step 3.
CHECK GEAR NOISE.

1) Disengage the clutch at idle and shift from from the transmission gear?
neutral to reverse within 0.5 1.0 seconds.
2) With the clutch disengaged, shift from neutral to reverse, reverse to neutral several times.
CL-34
No
Clutch is normal.
For defective
transmission or
excessive clutch
drag torque;
inspect the pilot
bearing, clutch
disc, transmission
and clutch disc
hub spline.
Defect in clutch
Clutch and flydisengaging.
wheel seizure.
Inspect clutch disc, Inspect clutch disc,
clutch cover, clutch spline of clutch
release, and clutch disc hub.
pedal free play.
CHASSIS SECTION

of SUBARU vehicles.
FRONT SUSPENSION
FS
REAR SUSPENSION
RS
WHEEL AND TIRE SYSTEM
WT
DIFFERENTIALS
DI
TRANSFER CASE
TC
DRIVE SHAFT SYSTEM
DS
ABS
ABS
ABS (DIAGNOSTICS)
ABS(diag)
VEHICLE DYNAMICS CONTROL (VDC)
VDC

(DIAGNOSTICS)
VDC(diag)
BRAKE
BR
PARKING BRAKE
PB
POWER ASSISTED SYSTEM

(POWER STEERING)
PS

approval.
G2320GE6
FRONT SUSPENSION
FS
1.
2.
3.
4.
5.
6.
7.
8.
9.
Page
Wheel Alignment .........................................................................................8
Front Crossmember Support Plate ...........................................................15
Front Stabilizer ..........................................................................................16
Front Ball Joint ..........................................................................................17
Front Arm ..................................................................................................19
Front Strut .................................................................................................22
Front Crossmember ..................................................................................26
General Description
FRONT SUSPENSION
A: SPECIFICATION
Sedan
Model
2.0 i
2.5 i
2.0 GT
Wagon
3.0 R
2.0 i
2.5 i
2.0 GT
3.0 R
OUTBACK
2.5 i,
OUTBACK
3.0 R
Wheel arch height

[Tolerance: +12 24 mm
mm (in)
376 (14.8)
381 (15.0)
376 (14.8)
429 (16.9)
020
015
020
030
(+0.47 in 0.94 in)]
Front
Camber (Tolerance: 045

Differences between RH and
LH: 45 or less)
Caster
Inner
Steering angle (Toler- wheel
ance: 1.5)
Outer
wheel
Toe-in
mm (in)
Kingpin angle
Diameter of stabilizer mm (in)
Wheel arch height
[Tolerance: +12 24 mm
(+0.47 in
Rear
mm (in)
600
545
505
37.3
37.8
33.0
33.5
03 (00.12) Toe angle (sum of both wheels): 0015

1350
1345
1350
1225
20 (0.79)
21 (0.83)
20 (0.79)
21 (0.83)
360 (14.2)
375 (14.8)
430 (16.9)
045
030
000
0.94 in)]

Differences between RH and
LH: 45 or less)
Toe-in
mm (in)
Thrust angle (Tolerance: 030)
Diameter of stabilizer
mm (in)

0
20
17.3 (0.68)
19.1 (0.75)
19.1 (0.75)
(0.78)
FS-2
17.3 (0.68)
General Description
FRONT SUSPENSION
NOTE:
Front and rear toe-ins and front camber can be
adjusted. If the toe-in or camber tolerance exceeds
specifications, adjust them.
Other items indicated in the specification table
cannot be adjusted. If those items exceed specifications, check suspension parts and connections
for deformities; replace with new ones as required.
(1)
FS-00001
(1) Front
A B = Positive: Toe-in, Negative: Toe-out
= Each toe angle
FS-3
General Description
FRONT SUSPENSION
B: COMPONENT
T1
(16)
(1)
(2)
T5
T6
(25)
(17)
T9
(15)
T8
(18)
(8)
(25)
(6)
T7
T8
(5)
(19)
(3)
T9
(25)
(20)
(4)
(7)
(24)
T7
T10
T3
(21)
T7
(13)
(26)
(12)
T4
(25)
T4
(25)
(22)
(23)
(11)
(9)
(10)
(14)
T2
T7
T7
(25)
(25)
T2
T11
FS-00131
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
Front crossmember
Housing
Ball joint
Front arm
Support plate
Rear bushing
Front bushing
Stud bolt
Stabilizer link
Bracket
Bushing
Stabilizer
Crossmember support plate
(Large type)
(14)
Crossmember support plate

(Small type)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
Jack-up plate
Dust seal
Strut mount
Upper spring seat
Dust cover
Helper
Coil spring
Damper strut
Adjusting bolt
Castle nut
Self-locking nut
Cotter pin
FS-4

T1: 20 (2.0, 14.5)
T2: 25 (2.5, 18.1)
T3: 39 (4.0, 28.8)
T4: 45 (4.6, 33.2)
T5: 50 (5.1, 36.9)
T6: 55 (5.6, 41)
T7: 60 (6.1, 44.3)
T8: 95 (9.7, 70.1)
T9: 110 (11.2, 81.1)
T10: 150 (15.3, 110.6)
T11: 175 (17.8, 129)
General Description
FRONT SUSPENSION
C: CAUTION
Use SUBARU genuine grease or the equivalent.
Do not mix grease, etc. with that of another grade
or from other manufacturers.
points.
FS-5
General Description
FRONT SUSPENSION
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
927380002
DESCRIPTION
ADAPTER
REMARKS
Used as an adapter for camber & caster gauge
when measuring camber and caster.
(1) 28199AC000 PLATE
(2) 28199AC010 BOLT
INSTALLER &
REMOVER SET
Used for replacing the front arm front bushing.
(1)
(2)
ST-927380002
927680000
ST-927680000
20299AG000
REMOVER
Used for replacing the front arm rear bushing.

Used with BASE (20999AG010).
20299AG010
BASE
Used for replacing the front arm rear bushing.

Used with REMOVER (20999AG000).
ST20299AG000
ST20299AG010
FS-6
General Description
FRONT SUSPENSION
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
20299AG020
STUD BOLT
(Newly adopted tool) SOCKET
REMARKS
Used for removing and installing the stud bolt for
front arm installing portion.
20399AG000
STRUT MOUNT
(Newly adopted tool) SOCKET
Used for disassembling and assembling the strut

mount.
ST20299AG020
ST20399AG000
2. GENERAL TOOL
TOOL NAME
Alignment gauge
Turning radius gauge
Toe-in gauge
Dial gauge
Coil spring compressor
REMARKS
Used for wheel alignment measurement.
Used for toe-in measurement.
Used for damper strut measurement.
Used for strut assembly/disassembly.
FS-7
Wheel Alignment
FRONT SUSPENSION
2. Wheel Alignment
A: INSPECTION
Check the following items before taking wheel alignment measurement.
Check items before taking wheel alignment measurement:
Tire inflation pressure
Unbalanced right and left tire wear, size difference
Tire runout
Excessive play and wear in ball joint
Excessive play and wear in tie rod end
Excessive play in wheel bearing
Right and left wheel base imbalance
Deformation and excessive play in steering link
Deformation and excessive play in suspension parts
Check, adjust and measure the wheel alignment in accordance with the procedures indicated in the figure.
Wheel arch height (front and rear wheels)
<Ref. to FS-9, WHEEL ARCH HEIGHT, INSPECTION, Wheel Alignment.>
Camber (front and rear wheels)

<Ref. to FS-10, CAMBER, INSPECTION, Wheel Alignment.>
Caster (front wheel)

<Ref. to FS-11, CASTER, INSPECTION, Wheel Alignment.>
Steering angle
<Ref. to FS-11, STEERING ANGLE, INSPECTION, Wheel Alignment.>
Front wheel toe-in

<Ref. to FS-12, FRONT WHEEL TOE-IN, INSPECTION, Wheel Alignment.>
Rear wheel toe-in

<Ref. to FS-12, REAR WHEEL TOE-IN, INSPECTION, Wheel Alignment.>
Thrust angle
<Ref. to FS-14, THRUST ANGLE, INSPECTION, Wheel Alignment.>
FS-8
Wheel Alignment
FRONT SUSPENSION
1. WHEEL ARCH HEIGHT

2) Set the vehicle under curb weight condition.
(Make the luggage compartment empty, install the
spare tire, jack and service tools, and top up the
fuel tank.)
3) Set the steering wheel in a straight-ahead position, and stabilize the suspensions by moving the
vehicle straight more than 5 m (16 ft).
4) Suspend a thread from wheel arch (point A in
the figure below) to determine the point directly
above the center of wheel.
5) Measure the distance between the point A and
the center of wheel.
(2)
(3)
A
(1)
(1)
(6)
(7)
(4)
(1)
(5)
(8)
FS-00125
(1)
(2)
(3)
Wheel arch height

Front fender
Rear quarter
(4)
(5)
(6)
Front wheel arch height

Rear wheel arch height
Flange bend line
(7)
(8)
Point of measurement
Tip end of spindle
Wheel arch height standard value mm (in) (Tolerance 12 mm)

Sedan
Model
Front
Rear
2.0 i
2.5 i
2.0 GT
3.0 R
376 (14.8)
360 (14.2)
2.0 i, 2.5 i
Wagon
2.0 GT, 3.0 R
381 (15.0)
376 (14.8)
375 (14.8)
FS-9
OUTBACK
2.5 i,
OUTBACK
3.0 R
429 (16.9)
430 (16.9)
Wheel Alignment
FRONT SUSPENSION
2. CAMBER
3) Turn the camber adjusting bolt so that the camber is set at specification.
INSPECTION
1) Place the front wheel on turning radius gauge.
Make sure the ground contacting surfaces of front
and rear wheels are set at the same height.
2) Set the ST into the center of wheel, and then set
the wheel alignment gauge.
ST 927380002
ADAPTER
NOTE:
Moving the adjusting bolt by one scale changes the
camber by approx. 015.
(1)
(4)
ST
(6)
(5)
(7)
(1)
(2)
FS-00007
(1) Alignment gauge

(2) Turning radius gauge
3) Measure the camber angle in accordance with

the operation manual for wheel alignment gauge.
Model
Wagon
Sedan
2.0 i, 2.5 i
2.0 GT, 3.0 R
OUTBACK 2.5 i,
OUTBACK 3.0 R
Camber (Differences between

RH and LH: 45 or less)
020045
015045
020045
030045
FRONT CAMBER ADJUSTMENT

1) When adjusting the camber, adjust it to the following value.
Model
Wagon
Sedan
2.0 i, 2.5 i
2.0 GT, 3.0 R
OUTBACK 2.5 i,
OUTBACK 3.0 R
Camber (Differences between

RH and LH: 45 or less)
020030
015030
020030
030030
2) Loosen the two self-locking nuts located at the

lower front portion of strut.
NOTE:
When the adjusting bolt needs to be loosened or
tightened, hold its head with a wrench and turn the
self-locking nut.
FS-10
(2)
(3)
FS-00008
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Strut
Adjusting bolt
Housing
Outer
Inner
Camber is increased.
Camber is decreased.
Wheel Alignment
FRONT SUSPENSION
To increase camber.
Rotate the left side counterclockwise.
Rotate the right side clockwise.
FS-00010
FS-00009
To decrease camber.
Rotate the left side clockwise.
Rotate the right side counterclockwise.
FS-00010
FS-00009
4) Tighten two new self-locking nuts.
3) Measure the caster angle in accordance with the

operation manual for wheel alignment gauge.
Tightening torque:
175 Nm (17.8 kgf-m, 129 ft-lb)
Model
Caster
600
545
505
Sedan
Wagon
OUTBACK
3. CASTER
INSPECTION
1) Place the front wheel on turning radius gauge.
Make sure the ground contacting surfaces of front
and rear wheels are set at the same height.
2) Set the ST into the center of wheel, and then set
the wheel alignment gauge.
ST 927380002
ADAPTER
ST
INSPECTION
1) Place the vehicle on turning radius gauge.
2) While depressing the brake pedal, turn the steering wheel fully to the left and right. With the steering
wheel held at each fully turned position, measure
both the inner and outer wheel steering angle.
Model
OUTBACK
Except for OUTBACK
(1)
(2)
4. STEERING ANGLE
FS-00007
(1) Alignment gauge

(2) Turning radius gauge
FS-11
Inner wheel
37.81.5
Outer wheel
33.51.5
37.31.5
33.01.5
Wheel Alignment
FRONT SUSPENSION
ADJUSTMENT
ADJUSTMENT
1) Turn the tie-rod to adjust the steering angle of

both inner and outer wheels.
2) Check the toe-in.
When adjusting the toe-in, adjust it to the following

value.
NOTE:
Correct the boot if it is twisted.
(1)
Toe-in:
02 mm (00.08 in)
1) Check that the left and right wheel steering angle
is within specifications.
2) Loosen the left and right side steering tie-rod
lock nuts.
3) 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 by equal amount (viewing from the inside
of vehicle).
FS-00014
(1) Lock nuts
5. FRONT WHEEL TOE-IN

INSPECTION
(1)
Toe-in:
03 mm (00.12 in)
1) Set the toe-in gauge in the position at wheel axis
center height behind the right and left front tires.
2) Measure the distance A between the marks
which are put on the centers of left and right tires.
3) Move the vehicle forward and rotate the tires
180.
NOTE:
Be sure to rotate the tires in the forward direction.
4) Measure the distance B between the left and
right marks. Detect toe-in by the following equation:
A B = Toe-in
FS-00014
(1) Lock nuts
4) Tighten the tie-rod lock nut.

Tightening torque:
85 Nm (8.7 kgf-m, 62.7 ft-lb)
NOTE:
Check and correct the tie rod boot if twisted.
6. REAR WHEEL TOE-IN

INSPECTION
Toe-in:
03 mm (00.12 in)
Refer to FRONT WHEEL TOE-IN for rear toe-in
inspection procedure.
ADJUSTMENT
When adjusting, adjust it to the following value.
FS-00015
Toe-in:
02 mm (00.08 in)
FS-12
Wheel Alignment
FRONT SUSPENSION
1) Loosen the self-locking nut on the inner side of

rear link.
2) Turn the adjusting bolt until toe-in is at the specification.
NOTE:
When loosening or tightening the adjusting bolt,
hold the bolt head and turn self-locking nut.
NOTE:
When the left and right wheels are adjusted for toein at the same time, the movement of one scale
graduation changes toe-in by approx. 0.6 mm (0.02
in).
(1)
(2)
FS-00103
(1) Adjusting bolt

(2) Rear link
To increase toe-in.
Rotate the left side clockwise.
Rotate the right side counterclockwise.
FS-00018
FS-00019
To decrease toe-in.
Rotate the left side counterclockwise.
Rotate the right side clockwise.
FS-00018
FS-00019
3) Tighten a new self-locking nut.

Tightening torque:
120 Nm (12.2 kgf-m, 88.5 ft-lb)
FS-13
Wheel Alignment
FRONT SUSPENSION
7. THRUST ANGLE
3) When the left and right adjusting bolts are turned

by one graduation, the thrust angle will change approx. 17 [L is approx. 13 mm (0.51 in)].
INSPECTION
2) Move the vehicle 3 to 4 meters (10 to 13 feet) directly forward.
3) Draw the center of loci of both the front and rear
axles.
4) Measure the distance L between center lines of
the loci of axles.
NOTE:
Thrust angle refers to a mean value of left and right
rear wheel toe angles in relation to the vehicle body
center line. Vehicle is driven straight in the thrust
angle direction while slanting in the oblique direction depending on the degree of the mean thrust
angle.
Thrust angle:
030
Less than 30 when L is less than 23 mm
(0.9 in).
(1)
(3)
(2)
(1)
FS-00024
(1) Front
(2) Thrust angle
(3) Body center line
(2)
Thrust angle: r = ( )/2

: Rear RH wheel toe-in angle
: Rear LH wheel toe-in angle
Use only positive toe-in values from each wheel to
substitute for and in the equation.
(1)
(2)
L
FS-00022
(1) Center line of loci (front axle)

(2) Center line of loci (rear axle)
ADJUSTMENT
FS-00976
When adjusting, adjust it to the following value.

Thrust angle:
020
Less than 20 when L is less than 15 mm
(0.6 in).
1) Make the thrust angle adjustments by turning the
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 toeout direction, in order to make the thrust angle adjustment.
FS-14
(1) Front
(2) Body center line
Front Crossmember Support Plate

FRONT SUSPENSION
3. Front Crossmember Support

Plate
A: REMOVAL
2) Remove the front under cover. <Ref. to EI-26,
REMOVAL, Front Under Cover.>
3) Remove the bolt and remove front crossmember
support plate.
Large type
FS-00104
Small type
(2)
(1)
(1)
FS-00105
(1) Crossmember support plate

(2) Jack-up plate
B: INSTALLATION
NOTE:
Tighten the small type crossmember support plate
together with stabilizer bracket.
After installing the stabilizer bracket to crossmember, tighten the crossmember support plate together.
Tightening torque:
Crossmember support plate:
60 Nm (6.1 kgf-m, 44.3 ft-lb)
Crossmember support plate (Joint tightening
portion of stabilizer bracket):
25 Nm (2.5 kgf-m, 18.1 ft-lb)
Jack-up plate:
60 Nm (6.1 kgf-m, 44.3 ft-lb)
FS-15
Front Stabilizer
FRONT SUSPENSION
4. Front Stabilizer
Stabilizer bracket has an orientation, so install it

with the arrow mark faced to the front side of vehicle.
A: REMOVAL
1) Lift-up the vehicle, and then remove the front
wheels.
2) Remove the front under cover. <Ref. to EI-26,
REMOVAL, Front Under Cover.>
Support Plate.>
4) Remove the stabilizer link.
(1)
FS-00116
(1) Front side of vehicle
Tightening torque:
Stabilizer link
45 Nm (4.6 kgf-m, 33.2 ft-lb)
Stabilizer bracket
25 Nm (2.5 kgf-m, 18.1 ft-lb)
FS-00117
C: INSPECTION
5) Remove the stabilizer bracket.
1) Check the bushing for crack, fatigue or damage.

2) Check the stabilizer link for damage.
FS-00114
B: INSTALLATION
NOTE:
Use a new self-locking nut.
Ensure that the stabilizer bushing and stabilizer
have the same identification colors.
Install the stabilizer bushing (front crossmember
side) while aligning it with the paint mark on stabilizer.
FS-16
Front Ball Joint

FRONT SUSPENSION
5. Front Ball Joint

A: REMOVAL
1) Lift-up the vehicle and remove the front wheels.
2) Remove the both sides of stabilizer bracket.
NOTE:
with the arrow mark faced to the front side of vehicle.
(1)
FS-00116
FS-00114
3) Pull out the pin from ball stud, remove the castle
nut, and extract the ball stud from front arm.
4) Remove the bolt installing ball joint to housing.
(1) Front side of vehicle
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
C: INSPECTION
1) Measure the play of ball joint by the following
procedures. Replace with a new one when the play
exceeds specified value.
(1) With 686 N (70 kgf, 154 lb) loaded in direction shown in the figure, measure the dimension
21.
FS-00115
5) Extract the ball joint from housing.
B: INSTALLATION
1) Insert the ball joint into housing.
Tightening torque (Bolt):
50 Nm (5.1 kgf-m, 36.9 ft-lb)
CAUTION:
Do not apply grease to the tapered portion of
ball stud.
2) Install the ball joint into front arm.
FS-00035
Tightening torque (Castle nut)

Front arm:
39 Nm (4.0 kgf-m, 28.8 ft-lb)
3) Retighten the castle nut further within 60 until
the hole in ball stud is aligned with a slot in castle
nut. Then, insert a new cotter pin and bend it
around castle nut.
4) Install the stabilizer bracket.
(2) With 686 N (70 kgf, 154 lb) loaded in direction shown in the figure, measure the dimension
22.
FS-00036
(3) Determine the plays from the following formula. S = 22 21
FS-17
Front Ball Joint

FRONT SUSPENSION
(4) Replace with a new one when the play exceeds specified value.
FRONT BALL JOINT
Specified play for replacement S:
2) When the play is within specified value, visually
check the dust cover.
3) Remove the ball joint and cover, check them for
wear, damage or cracks, and then replace them if
any defective part is found.
4) If the dust cover is damaged, replace with a new
ball joint.
FS-18
Front Arm
FRONT SUSPENSION
6. Front Arm
A: REMOVAL
wheels.
Support Plate.>
3) Remove the front stabilizer. <Ref. to FS-16, REMOVAL, Front Stabilizer.>
4) Remove the ball joint of front arm.
CAUTION:
Do not remove the stud bolt without necessity.
Always replace the parts with new ones when
removed.
(1)
(2)
ST
FS-00109
(1) Vehicle body

(2) Stud bolt
B: INSTALLATION
1) Using the ST, install the stud bolt.
ST 20299AG020 STUD BOLT SOCKET
FS-00106
5) Remove the nut securing the front arm to crossmember. (Do not remove the bolt.)
Tightening torque:
110 Nm (11.2 kgf-m, 81.1 ft-lb)
2) Using new bolts and self-locking nuts, temporarily tighten the front arm to crossmember.
3) Secure the front arm to body, and then install the
support plate with new bolts and self-locking nuts.
Tightening torque:
Support plate-to-Front arm:
110 Nm (11.2 kgf-m, 81.1 ft-lb)
Support plate-to-Body:
150 Nm (15.3 kgf-m, 110.6 ft-lb)
4) Install the ball joint into housing.
FS-00107
6) Remove the front arm support plate.
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
5) Install the stabilizer. <Ref. to FS-16, INSTALLATION, Front Stabilizer.>
6) Lower the vehicle from the lift, and tighten the
bolt which secures the front arm to crossmember at
the state that wheels are in full contact with the
ground and the vehicle is curb weight.
Tightening torque:
95 Nm (9.7 kgf-m, 70.1 ft-lb)
FS-00108
7) Remove the bolt securing the front arm to crossmember and extract the front arm from crossmember.
8) To remove the stud bolt, use ST.
ST 20299AG020 STUD BOLT SOCKET
NOTE:
Inspect the wheel alignment and adjust if necessary.
FS-19
Front Arm
FRONT SUSPENSION
C: DISASSEMBLY
1. FRONT BUSHING
Using the ST and a press, remove the front bushing.
ST 927680000
INSTALLER & REMOVER
SET
2) Using the ST and a press, remove the rear bushing.

ST1 20299AG000 REMOVER
ST2 20299AG010 BASE
(1)
ST1
(2)
ST2
ST
(3)
FS-00126
(1) Press
(2) Front arm
(3) Rear bushing
FS-00110
2. REAR BUSHING
1) Scribe an aligning mark on the front arm based
on the center of rear bushing recess portion.
CAUTION:
Always put an alignment mark for aligning the
position on bushing installation.
D: ASSEMBLY
1. FRONT BUSHING
CAUTION:
Install the front bushing in proper direction as
(3)
(1)
(1)
(2)
(2)
(1)
FS-00136
FS-00102
(1) Put an alignment mark.

(2) Recess portion
(1) Face the bushing toward the center of ball joint.

(2) Ball joint
(3) 3
FS-20
Front Arm
FRONT SUSPENSION
2. REAR BUSHING
1) Install the rear bushing with its longer inner cylinder faced upward and its shorter one faced downward and protruding part rearward as shown in the
figure.
3) Using the ST and a press, install the rear bushing.

ST1 20299AG000 REMOVER
ST2 20299AG010 BASE
(1)
ST1
(1)
(5)
(2)
(3)
(4)
ST2
(2)
FS-00127
FS-00113
(1)
(2)
(3)
(4)
(5)
(3)
(1) Press
(2) Front arm
(3) Rear bushing
Front arm
Bushing inner cylinder
Longer
Shorter
Protrusion portion
E: INSPECTION
2) Align the center of rear bushing recess portion

with the aligning mark on the front arm.
1) Check the front arm for wear, damage or cracks,

and correct or replace if defective.
2) Check the bushing for crack, fatigue or damage.
(1)
(2)
(1)
FS-00136
(1) Alignment mark

(2) Recess portion
FS-21
Front Strut
FRONT SUSPENSION
7. Front Strut
6) Remove the three nuts securing strut mount to

body.
A: REMOVAL
wheels.
2) Scribe an alignment mark on the camber adjusting bolt and strut.
3) Remove the bolt securing brake hose from strut.
FS-00037
4) Remove the bolt securing ABS wheel speed

sensor harness.
FS-00039
B: INSTALLATION
1) Install the strut mount at the upper side of strut to
body, and tighten it with new self-locking nuts.
FS-00038
5) Remove the two bolts securing housing to strut.

NOTE:
While holding the head of adjusting bolt, loosen the
self-locking nut.
Tightening torque:
20 Nm (2.0 kgf-m, 14.5 ft-lb)
2) Align alignment marks on the camber adjusting
bolt and strut.
Using new self-locking nuts, install the strut to
housing.
NOTE:
While holding the head of adjusting bolt, tighten the
self-locking nut.
Tightening torque:
175 Nm (17.8 kgf-m, 129 ft-lb)
3) Secure the ABS wheel speed sensor harness to
strut.
Tightening torque:
33 Nm (3.4 kgf-m, 24.3 ft-lb)
4) Install the bolts which secure the brake hose to
strut.
Tightening torque:
33 Nm (3.4 kgf-m, 24.3 ft-lb)
NOTE:
Inspect the wheel alignment and adjust if necessary.
FS-22
Front Strut
FRONT SUSPENSION
C: DISASSEMBLY
(5) Repeat 3 to 4 times from the step (1).
1) Using a coil spring compressor, compress the

coil spring.
NOTE:
After completely purging air from the strut, be sure
to place the strut with the piston rod facing up. If the
strut is laid down and set, check for the entry of air
in accordance with Check for 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 the figure.
(1)
FS-00040
2) Using the ST, remove the self-locking nut.

ST 20399AG000 STRUT MOUNT SOCKET
(2)
ST
(3)
FS-00042
(1) Diameter is small (Upper part)

(2) Identification paint
(3) Diameter is large (Bottom part)
FS-00041
3) Remove the strut mount and upper spring seat

from strut.
4) Gradually decrease the compression force of
compressor, and remove the coil spring.
5) Remove the dust cover and helper spring.
5) Set the coil spring correctly so that its end face

fits well into the spring seat as shown in the figure.
D: ASSEMBLY
1) Before installing the coil spring, strut mount, etc.
on strut, check for the presence of air in the dampening force generating mechanism of the strut
since air prevents proper dampening force production.
2) Check for 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.
(1)
FS-00043
(1) Coil spring end face
6) Install the helper and dust cover to piston rod.
FS-23
Front Strut
FRONT SUSPENSION
7) Pull the piston rod fully upward, and install the

spring seat.
NOTE:
Ensure the upper spring seat is positioned as
E: INSPECTION
Check the removed part for wear, damage or
cracks, and then repair or replace it if defective.
1. DAMPER STRUT
1) Check for oil leaks.
2) Move the piston rod up and down to check that it
operates smoothly without any hitch.
3) Piston rod play
Measure the play as follows:
Fix the outer shell and fully extend the rod. Set a
dial gauge at the end of rod L [10 mm (0.39 in)], and
then read the dial gauge indication P1 while applying a force of W [20 N (2 kgf, 4 lb)] to threaded portion. Apply a force of 20 N (2 kgf, 4 lb) in the
opposite direction of W, and then read the dial
gauge indication P2.
(1)
FS-00128
(1) Outside of body
8) Install the strut mount to piston rod, and tighten a

new self-locking nut temporarily.
9) Using a hexagon wrench to prevent strut rod
from turning, tighten the new self-locking nut with
ST.
ST 20399AG000 STRUT MOUNT SOCKET
Tightening torque:
55 Nm (5.6 kgf-m, 41 ft-lb)
FS-00046
Play limit (P1 + P2):

0.8 mm (0.031 in)
If the play exceeds limit, replace the strut.
ST
2. STRUT MOUNT
Check the rubber part for deformation, cracks or
deterioration, and then replace it with a new one if
defective.
FS-00041
10) Loosen the coil spring carefully.
3. DUST COVER
If any cracks or damage are found, replace it with a
new one.
4. COIL SPRING
If a permanent strain is found, replaced it with a
new one.
5. HELPER
Replace it with a new one if cracked or damaged.
FS-24
Front Strut
FRONT SUSPENSION
F: DISPOSAL
CAUTION:
Before handling struts, be sure to wear goggles to protect eyes from gas, oil and cutting
powder.
Do not disassemble the strut damper or place
into a fire.
Drill a hole into struts in case of discarding
struts filled with gas.
1) Place the strut on a level surface with the piston
rod fully expanded.
2) Using a 2 to 3 mm (0.08 to 0.12 in) dia. drill,
make holes in areas shown in the figure.
(1)
FS-00047
(1) 40 mm (1.57 in)
FS-25
Front Crossmember
FRONT SUSPENSION
8. Front Crossmember
B: INSTALLATION
A: REMOVAL

wheels.
Support Plate.>
4) Remove the front stabilizer. <Ref. to FS-16, REMOVAL, Front Stabilizer.>
5) Disconnect the tie-rod end from housing.
6) Remove the front arm. <Ref. to FS-19, REMOVAL, Front Arm.>
7) Remove the nuts attaching the engine mount
cushion rubber to crossmember.
FS-00118
8) Remove the steering universal joint.

9) Disconnect the power steering hose from steering gearbox.
10) Lift the engine approx. 10 mm (0.39 in) using a
chain block.
11) Support the crossmember with a jack, remove
the bolts securing crossmember to body, and then
gradually lower the crossmember with steering
gearbox as a unit.
CAUTION:
When removing the crossmember downward,
be careful that the tie-rod end does not interfere
with drive shaft boot.
NOTE:
Use a new bolt and self-locking nut. For the parts
which are not reusable, refer to COMPONENT.
<Ref. to FS-4, COMPONENT, General Description.>
Always tighten the bushing in the state that
wheels are in full contact with the ground and the
vehicle is curb weight.
Tightening torque:
Crossmember to body:
95 Nm (9.7 kgf-m, 70.1 ft-lb)
Engine mounting to crossmember:
85 Nm (8.7 kgf-m, 62.7 ft-lb)
Front arm-to-Crossmember:
95 Nm (9.7 kgf-m, 70.1 ft-lb)
Front arm-to-Support plate:
110 Nm (11.2 kgf-m, 81.1 ft-lb)
Support plate body:
150 Nm (15.3 kgf-m, 110.6 ft-lb)
Tie-rod end to housing:
27.0 Nm (2.75 kgf-m, 19.9 ft-lb)
Retighten the castle nut further within 60 until the
hole in ball stud is aligned with a slot in castle nut
after tightening in specified torque.
Universal joint:
24 Nm (2.4 kgf-m, 17.4 ft-lb)
Stabilizer bracket:
25 Nm (4.6 kgf-m, 33.2 ft-lb)
Stabilizer link:
45 Nm (2.5 kgf-m, 18.4 ft-lb)
Power steering hose-to-Steering gearbox:
15 Nm (1.5 kgf-m, 11 ft-lb)
2) Purge air from the power steering system.
3) Inspect the wheel alignment and adjust if necessary.
C: INSPECTION
Check the crossmember for wear, damage or
cracks, and then repair or replace if defective.
FS-00119
FS-26

FRONT SUSPENSION

A: INSPECTION
1. IMPROPER VEHICLE POSTURE OR IMPROPER WHEEL ARCH HEIGHT
Possible cause
(1) Permanent distortion or breakage of coil spring
(2) Rough operation of damper strut or shock absorber
(3) Installation of wrong strut or shock absorber
(4) Installation of wrong coil spring
Corrective action
Replace.
Replace.
Replace with proper parts.
2. POOR RIDE COMFORT

1) Large rebound shock
2) Rocking of the vehicle continues too long after running over bump and hump.
3) Large shock in bumping
Possible cause
(1) Breakage of coil spring
(2) Overinflating pressure of tire
(3) Improper wheel arch height
(4) Fault in operation of damper strut or shock absorber
(5) Damage or deformation of strut mount or shock absorber mount
(6) Unsuitability of maximum or minimum length of damper strut or shock
absorber
(7) Deformation or loss of bushing
(8) Deformation or damage of helper in strut assembly or shock absorber
(9) Oil leakage of damper strut or shock absorber
Corrective action
Replace.
Adjust.
Adjust or replace the coil springs with new ones.
Replace.
Replace.
Replace.
Replace.
Replace.
3. NOISE
Possible cause
(1) Wear or damage of damper strut or shock absorber component parts
(2) Loosening of suspension link installing bolt
absorber
(6) Wear or damage of ball joint
(7) Deformation of stabilizer clamp
FS-27
Corrective action
Replace.
Tighten to specified torque.
Replace.
Replace.
Replace.
Replace.

FRONT SUSPENSION
FS-28
REAR SUSPENSION
RS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Page
Wheel Alignment .........................................................................................8
Rear Stabilizer.............................................................................................9
Rear Arm...................................................................................................10
Upper Link.................................................................................................14
Rear Shock Absorber................................................................................16
Front Link ..................................................................................................18
Rear Link...................................................................................................19
Sub Frame Support Arm ...........................................................................21
Sub Frame Support Plate..........................................................................22
Rear Sub Frame........................................................................................23
Helper........................................................................................................24
General Description
REAR SUSPENSION
A: SPECIFICATION
Sedan
Model
Wheel arch height
[Tolerance: +12 mm 24
2.0 i, 2.5 i
mm (in)
Wagon
2.0 GT, 3.0 R
2.0 i
2.5 i
OUTBACK 2.5 i,
OUTBACK 3.0 R
360 (14.2)
375 (14.8)
430 (16.9)
045
030
000
+0.47 in
mm (
0.94 in)]

Differences between RH and LH:
45 or less)
Toe-in
mm (in)
Thrust angle (tolerance: 030)
Diameter of stabilizer
mm (in)
17.3 (0.68)

0
19.1 (0.75)
19.1 (0.75)
20 (0.78)
NOTE:
Front and rear toe-ins and front camber can be
adjusted. If the toe-in or camber tolerance exceeds
specifications, adjust them.
Other items indicated in the specification table
cannot be adjusted. If other items exceeds specifications, check suspension parts and connections
for deformation, and replace with new ones as required.
(1)
FS-00001
(1) Front
A B = Positive: Toe-in, Negative: Toe-out
= Each toe angle
RS-2
17.3 (0.68)
General Description
REAR SUSPENSION
B: COMPONENT
1. REAR SUSPENSION
(2)
T1
(1)
(21)
(23)
(3)
T6
(2)
T12
(5)
(4)
(6)
T7
T12
T3
(8)
T4
(9)
(10)
(2)
(2)
(2)
(7)
T5
T5
(2)
(2)
T9
T5
(20)
(18)
(17)
(11)
(2)
T2
(16)
T7
T7
(2)
(14)
(19)
(2)
(13)
T10
T8
(12)
(15)
(22)
T11
T12
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
Shock absorber
Self-locking nut
Stabilizer
Stabilizer bushing
Bracket
Stabilizer link
Rear link
Adjusting bolt
Rear link bushing
Adjusting washer
Rear arm
Rear arm rear bushing
Rear arm front bushing
RS-00137
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
Rear arm bracket

Hub bearing unit
Helper
Upper link
Upper link bushing (inner side)
Upper link bushing (outer side)
Front link
Rear sub frame
Sub frame support arm
Sub frame support plate
RS-3

T1: 30 (3.1, 22.4)
T2: 32 (3.3, 24)
T3: 40 (4.1, 30)
T4: 44 (4.5, 32.5)
T5: 57 (5.8, 42)
T6: 62 (6.3, 48)
T7: 65 (6.6, 48)
T8: 80 (8.2, 59)
T9: 120 (12.2, 89)
T10: 125 (12.7, 92)
T11: 150 (15.3, 111)
T12: 175 (17.8, 129)
General Description
REAR SUSPENSION
2. SHOCK ABSORBER
T1
(6)
(4)
(6)
T2
(1)
(2)
(3)
(5)
T3
(6)
RS-00037
(1)
(2)
(3)
Mount
Upper rubber sheet
Dust cover
(4)
(5)
(6)
Coil spring
Shock absorber
Self-locking nut
C: CAUTION
Before discarding shock absorbers, be sure to
bleed gas completely. Also, do not throw away in
fire.
Use SUBARU genuine grease etc. or the equivalent. Do not mix grease, etc. with that of another
nuts to specified torque.
points.
RS-4

T1: 30 (3.1, 22.4)
T2: 35 (3.6, 26)
T3: 62 (6.3, 48)
General Description
REAR SUSPENSION
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
927380002
DESCRIPTION
ADAPTER
REMARKS
Used for an adapter of camber & caster gauge
when measuring the camber and caster.
(1) 28199AC000 PLATE
(2) 28199AC010 BOLT
20099AE000
INSTALLER &
REMOVER
Used for replacing the rear link bushing.
20099AE010
INSTALLER &
REMOVER
Used for replacing the upper link bushing.
20099AE020
INSTALLER &
REMOVER SET
Used for replacing the rear arm front bushing.
(1)
(2)
ST-927380002
ST20099AE000
ST20099AE010
ST20099AE020
RS-5
General Description
REAR SUSPENSION
ILLUSTRATION
TOOL NUMBER
20099AE040
DESCRIPTION
INSTALLER &
REMOVER SET
REMARKS
Used for replacing the rear arm rear bushing.
20099AE030
HELPER SOCKET
WRENCH
Used for replacing the helper.
STRUT MOUNT
SOCKET
Used for removing and installing the shock

mount.
ST20099AE040
ST20099AE030
20399AG000
(New adopted tool)
ST20399AG000
28099PA090
OIL SEAL PROTEC- Used for installing the rear drive shaft to rear
TOR
differential.
For oil seal protection
ST28099PA090
RS-6
General Description
REAR SUSPENSION
ILLUSTRATION
TOOL NUMBER
28099PA100
DESCRIPTION
REMOVER
REMARKS
Used for removal of DOJ.
ST28099PA100
2. GENERAL TOOL
TOOL NAME
Alignment gauge
Turning radius gauge
Toe-in gauge
Transmission jack
Bearing puller
Coil spring compressor
REMARKS
Used for toe-in measurement.
Used for removing and installing suspension.
Used for removing bushings.
Used for disassembling and assembling shock absorber.
RS-7
Wheel Alignment
REAR SUSPENSION
2. Wheel Alignment
A: INSPECTION
NOTE:
Measure and adjust the front and rear wheel alignment at a time. Refer to FS section for measurement and adjustment of wheel alignment. <Ref. to
FS-8, INSPECTION, Wheel Alignment.>
RS-8
Rear Stabilizer
REAR SUSPENSION
3. Rear Stabilizer
2) Always tighten the stabilizer bushing in the state

that wheels are in full contact with the ground and
the vehicle is curb weight.
A: REMOVAL
1) Lift-up the vehicle, and then remove the rear
wheels.
Tightening torque:
Stabilizer link
44 Nm (4.5 kgf-m, 32.5 ft-lb)
Stabilizer bracket
40 Nm (4.1 kgf-m, 30 ft-lb)
C: INSPECTION
1) Check the bushing for crack, fatigue and damage.
2) Check the stabilizer link for damage.
RS-00038
3) Remove the stabilizer bracket.
RS-00116
B: INSTALLATION
NOTE:
Ensure the stabilizer bushing and stabilizer have
the same identification colors.
To install the stabilizer bushing, align the paint
mark end of stabilizer to the end of stabilizer bushing.
with the arrow mark faced to the upper side of vehicle.
(1)
RS-00117
(1) Paint mark
RS-9
Rear Arm
REAR SUSPENSION
4. Rear Arm
7) Remove the bolts which secure the brake hose

bracket to rear arm. Remove the bolts which secure the ABS wheel speed sensor to rear arm.
A: REMOVAL
wheels.
2) Remove the sub frame support arm.
<Ref. to RS-21, REMOVAL, Sub Frame Support
Arm.>
3) Remove the bearing unit.
<Ref. to DS-19, REMOVAL, Rear Hub Unit Bearing.>
4) Hang the back plate from sub frame.
RS-00124
8) Remove the stabilizer link from rear arm.
RS-00043
5) Remove the bolts which secure the parking

brake cable clamp to rear arm bracket.
RS-00044
9) Remove the shock absorber from rear arm.
RS-00040
6) Remove the bolt which hold the brake hose

bracket and ABS wheel speed sensor bracket to
rear arm.
RS-00045
10) Support the rear arm horizontally using a transmission jack.
RS-00041
RS-00046
RS-10
Rear Arm
REAR SUSPENSION
11) Remove the nuts which hold the rear arm to

bracket. Remove the rear arm bracket.
14) Loosen the nut which hold the upper link to rear
arm.
RS-00050
15) Remove the bolt which secure the rear arm to

the link, and then remove the rear arm.
B: INSTALLATION
RS-00118
12) Loosen the nut which hold the front link to rear
arm.
RS-00048
13) Loosen the nut which hold the rear link to rear
arm.
NOTE:
Use a new bolt and self-locking nut. For the parts
which are not reusable, refer to COMPONENT.
<Ref. to RS-3, REAR SUSPENSION, COMPONENT, General Description.>
1) Support the rear arm using a transmission jack.
2) Install the rear arm and temporarily tighten the
bolts which hold the rear arm to the link.
3) Install the bearing unit.
<Ref. to DS-20, INSTALLATION, Rear Hub Unit
Bearing.>
4) Install the bolts which secure the ABS wheel
speed sensor to rear arm.
5) Install the bolts which secure the brake hose to
rear arm.
6) Install the bolts which secure the parking brake
cable clamp to rear arm bracket.
7) Set the jack which is originally equipped to the
vehicle under the upside down situation, and place
the jack between rear link and sub frame. Align the
installing position of rear shock absorber and rear
arm by adjusting the jack position, temporarily tighten the bolt and nut.
CAUTION:
Protect the rear link and sub frame from scratch
in the way of putting a cloth between the jack
and mating portion.
RS-00049
RS-00051
RS-11
Rear Arm
REAR SUSPENSION
8) Using the transmission jack, support the rear

arm horizontally.
9) Tighten the nuts and bolts which hold the rear
arm, front link, rear link, upper link and shock absorber.
NOTE:
Always tighten the bushing in the state that wheels
are in full contact with the ground and the vehicle is
curb weight.
3) Place the ST B on bushing, and push the bushing out.

ST A 20099AE020 INSTALLER & REMOVER
SET
ST B 20099AE020 INSTALLER & REMOVER
SET
ST-B
(1)
ST-A
RS-00119
(1)
(2)
(1) Bushing
RS-00052
2. REAR BUSHING
Using the ST C and bearing puller, press the rear
bushing out of place.
ST C 20099AE040 INSTALLER & REMOVER
SET
(1) Rear arm

(2) Transmission jack
10) Install the sub frame support arm.

NOTE:
Inspect the wheel alignment and adjust it if necessary.
ST-C
Tightening torque:
Refer to COMPONENT of General Description for tightening torque. <Ref. to RS-3,
REAR SUSPENSION, COMPONENT, General
Description.>
(1)
C: DISASSEMBLY
RS-00054
1. FRONT BUSHING
1) Set the ST A with the larger side of its inner diameter turned upward.
2) Set the rear arm with the protruding side of bushing turned upward.
(1) Bearing puller
D: ASSEMBLY
1. FRONT BUSHING
1) Set the ST A with the larger side of its inner diameter turned upward.
2) Set the rear arm with the vehicle inner side of
arm turned downward.
3) Place the bushing on rear arm as shown in the
figure.
RS-12
Rear Arm
REAR SUSPENSION
4) Place the ST B on bushing, and press-fit until

each edge surface of bushing and rear arm comes
to be aligned.
SET
SET
E: INSPECTION
Check the rear arm for bend, corrosion or damage.
(2)
(1)
ST-B
ST-A
RS-00221
(1) 05
(2) Rubber protrusion: Assemble with the
rubber protrusion side faced to the arm
inner side.
2. REAR BUSHING
1) Press the bushing into the bore inside of ST D.
2) Set the ST C, ST D and bearing puller in the
specified position as shown in the figure, and then
press-fit the bush until the outer end of bush and
rear end of rear arm in flat.
ST C 20099AE040 INSTALLER & REMOVER
SET
ST D 20099AE040 INSTALLER & REMOVER
SET
ST-C
ST-D
RS-00056
RS-13
Upper Link
REAR SUSPENSION
5. Upper Link
2) Using new self-locking nuts, install the upper

link.
A: REMOVAL
wheels.
arm horizontally.
(1)
(2)
RS-00052
(1)
(1) Rear arm

(2)
NOTE:
RS-00052
(1) Rear arm

3) Remove the bolt which secure the upper link to

sub frame.
Tightening torque:
Upper link to Sub frame
57 Nm (5.8 kgf-m, 42 ft-lb)
Upper link to Rear arm
65 Nm (6.6 kgf-m, 48 ft-lb)
C: DISASSEMBLY
Using the ST, press the bushing out of place.
ST 20099AE010 INSTALLER & REMOVER
RS-00058
ST
4) Remove the bolts which secure the upper link to

rear arm, and then remove the upper link.
RS-00061
D: ASSEMBLY
Using the ST, press the bushing into place.
ST 20099AE010 INSTALLER & REMOVER
RS-00059
B: INSTALLATION
ST

arm horizontally.
RS-00090
RS-14
Upper Link
REAR SUSPENSION
CAUTION:
Outer side bushing has an orientation. Assemble it with the longer protrusion faced to the
rear side of vehicle.
(2)
(3)
(1)
RS-00121
(1) Rear arm

(2) Rear sub frame
(3) Rear side of vehicle
E: INSPECTION
1) Visually check the upper link for damage and deformation.
2) Visually check the bush for crack, damage and
fatigue.
RS-15
Rear Shock Absorber

REAR SUSPENSION
6. Rear Shock Absorber

A: REMOVAL
1) Remove the luggage floor mat. (Wagon model)
2) Roll up the trunk side trim. (Sedan model)
wheels.
4) Remove the bolts which secure the shock absorber to rear arm.
CAUTION:
Protect the rear link and sub frame from scratch
in the way of putting a shop cloth between the
jack and the mating portion.
RS-00051

arm horizontally.
5) Using new self-locking nuts, tighten the bolt and
nut which secure the shock absorber.
RS-00065
5) Support the shock absorber using a jack.

6) Remove the nuts which secure the shock absorber mount to vehicle.
(1)
(2)
RS-00052
(1) Rear arm

RS-00066
7) Remove the shock absorber.
B: INSTALLATION
1) Support the shock absorber using a jack.
2) Using new self-locking nuts, secure the shock
absorber to vehicle.
Tightening torque:
30 Nm (3.1 kgf-m, 22.4 ft-lb)
3) Set the jack which is originally equipped to the
vehicle under the upside down situation, and place
the jack between rear link and sub frame. Align the
installing position of rear shock absorber and rear
arm by adjusting the jack position. Using new selflocking nuts, temporary tighten the bolt.
Tightening torque:
62 Nm (6.3 kgf-m, 48 ft-lb)
6) Install the floor mat. (Wagon model)
7) Set the trunk side trim. (Sedan model)
NOTE:
Check the wheel alignment and adjust it if necessary.
C: DISASSEMBLY
Refer to Front Strut for disassembly procedures.
<Ref. to FS-23, DISASSEMBLY, Front Strut.>
D: ASSEMBLY
Refer to Front Strut for installation procedures.
<Ref. to FS-23, ASSEMBLY, Front Strut.>
E: INSPECTION
Refer to Front Strut for inspection procedures.
<Ref. to FS-24, INSPECTION, Front Strut.>
RS-16
Rear Shock Absorber

REAR SUSPENSION
F: DISPOSAL
CAUTION:
Before handling shock absorbers, be sure to
wear goggles to protect eyes from gas, oil and
cutting powder.
Do not disassemble the shock absorber or
place it into a fire.
Drill a hole into shock absorbers in case of
discarding shock absorbers filled with gas.
1) Place the shock absorber on a level surface with
the piston rod fully expanded.
2) Make a hole into the specified position 30 mm
(1.18 in) deep using a drill with 2 to 3 mm (0.08 to
0.12 in) diameter.
(1)
RS-00135
(1) 40 mm (1.57 in)
RS-17
Front Link
REAR SUSPENSION
7. Front Link
2) Using new self-locking nuts, install the front link.
A: REMOVAL
wheels.
arm horizontally.
(1)
(2)
RS-00052
(1) Rear arm

(1)
(2)
CAUTION:
Install the front link with the protrusion side
faced to the front side of vehicle.
RS-00052
(1) Rear arm

3) Remove the bolt which secure the front link to

sub frame.
(1)
RS-00075
(1) Front
RS-00072
4) Remove the bolt which secure the front link to

rear arm, and then remove the front link.
NOTE:
Tightening torque:
57 Nm (5.8 kgf-m, 42 ft-lb)
C: INSPECTION
Visually check the front link for damage and deformation.
RS-00073
B: INSTALLATION
arm horizontally.
RS-18
Rear Link
REAR SUSPENSION
8. Rear Link
B: INSTALLATION
A: REMOVAL

arm horizontally.
2) Using new self-locking nuts, install the rear link.

wheels.
2) Remove the rear stabilizer. <Ref. to RS-9, REMOVAL, Rear Stabilizer.>
arm horizontally.
(1)
(2)
RS-00052
(1)
(1) Rear arm

(2)
RS-00052
(1) Rear arm

4) Remove the bolts which secure the rear link to

rear arm.
NOTE:
Tighten the self-locking nut with the bolt head secured when installing the adjusting bolt.
Tightening torque:
Rear link to Sub frame
120 Nm (12.2 kgf-m, 89 ft-lb)
Rear link to Rear arm
57 Nm (5.8 kgf-m, 42 ft-lb)
C: DISASSEMBLY
Using the ST A and ST B, press the bushing out of
place.
RS-00080
5) Put alignment marks on the rear link adjusting

bolt and sub frame.
6) Remove the bolt which secure the rear link to
sub frame, and then remove the rear link.
ST-A
CAUTION:
Loosen the nut with the bolt head secured
when loosening the adjusting bolt.
ST-B
RS-00083
RS-00081
RS-19
Rear Link
REAR SUSPENSION
D: ASSEMBLY
Using the ST A and ST B, press-fit the bushing.
ST-A
ST-B
RS-00083
E: INSPECTION
Visually check the rear link for damage and deformation.
RS-20
Sub Frame Support Arm

REAR SUSPENSION
9. Sub Frame Support Arm

A: REMOVAL
1) Lift-up the vehicle, and support the rear sub
frame with support stand.
RS-00088
B: INSTALLATION
Tightening torque:
Sub frame support arm to Rear arm bracket
80 Nm (8.2 kgf-m, 59 ft-lb)
Sub frame support arm to Rear sub frame
175 Nm (17.8 kgf-m, 129 ft-lb)
C: INSPECTION
Visually check the sub frame support arm for damage and deformation.
RS-21
Sub Frame Support Plate

REAR SUSPENSION
10.Sub Frame Support Plate

A: REMOVAL
1) Lift-up the vehicle, and support the rear sub
frame with support stand.
2) Remove the sub frame support plate.
FU-01134
B: INSTALLATION
Tightening torque:
Support plate to Sub frame
175 Nm (17.8 kgf-m, 129 ft-lb)
Support plate to Body
65 Nm (6.6 kgf-m, 48 ft-lb)
C: INSPECTION
Visually check the support plate for damage.
RS-22
Rear Sub Frame

REAR SUSPENSION
11.Rear Sub Frame

A: REMOVAL
1) Separate the front exhaust pipe from rear exhaust pipe.
3) Remove the rear differential.
T-type
<Ref. to DI-28, REMOVAL, Rear Differential (Ttype).>
VA-type
<Ref. to DI-45, REMOVAL, Rear Differential (VAtype).>
4) Remove the rear stabilizer. <Ref. to RS-9, REMOVAL, Rear Stabilizer.>
5) Remove the bolts which secure the rear shock
absorber to rear arm.
6) Support the sub frame using a transmission jack.

arm horizontally. Then tighten the nuts and bolts
which hold the rear arm, front link, rear link, upper
link and shock absorber.
(1)
(2)
RS-00052
(1) Rear arm

NOTE:
Check the wheel alignment and adjust it if necessary.
C: INSPECTION
Check the removed parts for wear, damage and
crack, and repair or replace them if faulty.
RS-00085
7) Remove the front link from sub frame.

<Ref. to RS-18, REMOVAL, Front Link.>
8) Remove the rear link from sub frame.
<Ref. to RS-19, REMOVAL, Rear Link.>
9) Remove the upper link from sub frame.
<Ref. to RS-14, REMOVAL, Upper Link.>
11) After removing the bolt, remove the sub frame
and sub frame support plate from vehicle.
B: INSTALLATION
2) Follow the procedure below for the rear differential installation and tightening torque.
T-type
<Ref. to DI-29, INSTALLATION, Rear Differential
(T-type).>
VA-type
(VA-type).>
RS-23
Helper
REAR SUSPENSION
12.Helper
A: REMOVAL
wheels.
2) Remove the helper using ST.
ST 20099AE030 HELPER SOCKET WRENCH
ST
RS-00087
B: INSTALLATION
Tightening torque:
32 Nm (3.3 kgf-m, 24 ft-lb)
C: INSPECTION
Check the helper for crack, fatigue and damage.
RS-24

REAR SUSPENSION

A: INSPECTION
1. IMPROPER VEHICLE POSTURE OR IMPROPER WHEEL ARCH HEIGHT
Possible cause
(1) Permanent distortion or breakage of coil spring
(2) Rough operation of damper strut or shock absorber
(3) Installation of wrong strut or shock absorber
(4) Installation of wrong coil spring
Corrective action
Replace.
Replace.
2. POOR RIDE COMFORT

1) Large rebound shock
2) Rocking of the vehicle continues too long after running over bump and hump.
3) Large shock in bumping
Possible cause
(2) Overinflating pressure of tire
(3) Improper wheel arch height
(4) Fault in operation of damper strut or shock absorber
(5) Damage or deformation of strut mount or shock absorber mount
absorber
(8) Deformation or damage of helper in strut assembly or shock absorber
(9) Oil leakage of damper strut or shock absorber
Corrective action
Replace.
Adjust.
Adjust or replace the coil springs with new ones.
Replace.
Replace.
Replace.
Replace.
Replace.
3. NOISE
Possible cause
(1) Wear or damage of damper strut or shock absorber component parts
(2) Loosening of suspension link installing bolt
absorber
(6) Wear or damage of ball joint
(7) Deformation of stabilizer clamp
RS-25
Corrective action
Replace.
Tighten to the specified torque.
Replace.
Replace.
Replace.
Replace.

REAR SUSPENSION
RS-26
WT
1.
2.
3.
4.
5.
6.
7.
Page
Tire ..............................................................................................................4
Steel Wheel.................................................................................................5
Aluminum Wheel .........................................................................................6
Wheel Balancing .........................................................................................7
T-type Tire ................................................................................................9
General Description
A: SPECIFICATION
1. WHEEL AND TIRE SIZE
WT-00001
(1) Offset
(2) P.C.D.
Specification
Sedan
Wagon
T-type
Tire
Offset
mm (in)
P.C.D.
mm (in)
Tire inflation pressure

kPa (kgf/cm2, psi)
Front wheel
Rear wheel
Tire size
Wheel size
2.0 i, 2.5 i
205/55R16 89V
16 61/2JJ
220 (2.2, 32)
220 (2.2, 32)
2.5 i (OP)
2.5 i (KA model)
3.0 R
2.0 GT
215/45R17 87W
215/45R17 87W
215/45R17 87W
215/45R17 87W
17 7JJ
17 7JJ
17 7JJ
17 7JJ
230 (2.3, 33)

230 (2.3, 33)
230 (2.3, 33)
230 (2.3, 33)
220 (2.2, 32)

220 (2.2, 32)
220 (2.2, 32)
220 (2.2, 32)
2.0 i, 2.5 i
205/55R16 89V
16 61/2JJ
2.5 i (OP)
2.5 i (KA model)
3.0 R
2.0 GT
215/45R17 87W
215/45R17 87W
215/45R17 87W
215/45R17 87W
17 7JJ
17 7JJ
17 7JJ
17 7JJ
OUTBACK 2.5 i
215/60R16 95V
16 61/2JJ
OUTBACK 3.0 R
2.0 GT, 3.0 R
2.0 i, 2.5 i
215/55R17 94V
T135/70D17 102M
T135/80D16 101M
17 7JJ
17 4T
16 4T
55 (2.17)
100 (3.94)
48 (1.89)
220 (2.2, 32)
220 (2.2, 32)
230 (2.3, 33)

230 (2.3, 33)
230 (2.3, 33)
230 (2.3, 33)
210 (2.1, 31)

210 (2.1, 31)
210 (2.1, 31)
210 (2.1, 31)
210 (2.1, 31)
200 (2.0, 29)
210 (2.1, 31)
200 (2.0, 29)
40 (1.57)
50 (1.97)
NOTE:
Except for KA, KS model, T-type tire for temporary use is supplied as a spare tire.
For KA, KS model, a spare tire of standard tire size is supplied.
WT-2
420 (4.2, 60)
General Description
2. SERVICE DATA
Part
Steel wheel
Aluminum wheel
Balance weight part number

(Adhesive type weight for aluminum wheel)
28101AG000
28101AG010
28101AG020
28101AG030
28101AG040
28101AG050
28101AG060
28101AG070
28101AG080
28101AG090
28101AG100
28101AG110
28101AG120
28101AG130
28101AG140
28101AG150
28101AG160
28101AG170
28101AG180
28101AG190
28101AG200
28101AG210
28101AG220
28101AG230
28101AG240
28101AG250
28101AG260
28101AG270
28101AG280
28101AG290
28101AG300
28101AG310
28101AG320
28101AG330
28101AG340
28101AG350
28101AG360
28101AG370
28101AG380
Axial runout
Radial runout
1.5 mm (0.059 in)
1.0 mm (0.039 in)
3. ADJUSTING PARTS
Wheel balancing
Dynamic unbalance
Standard
Service limit
10 g (0.35 oz) or less

(Knock-on type weight for steel
wheel)
28101TC000
28101SA060
28101SA070
28101SA080
28101SA090
723141340
723141350
723141360
723141370
723241380
723241580
723241590
(Knock-on type weight for aluminum wheel)
28101SA000
28101SA010
28101SA020
28101SA030
28101SA040
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)
Weight
5 g (0.18 oz)
7.5 g (0.26 oz)
10 g (0.35 oz)
12.5 g (0.44 oz)
15 g (0.53 oz)
17.5 g (0.62 oz)
20 g (0.71 oz)
22.5 g (0.79 oz)
25 g (0.88 oz)
27.5 g (0.97 oz)
30 g (1.06 oz)
32.5 g (1.15 oz)
35 g (1.23 oz)
37.5 g (1.32 oz)
40 g (1.41 oz)
42.5 g (1.50 oz)
45 g (1.59 oz)
47.5 g (1.68 oz)
50 g (1.76 oz)
52.5 g (1.85 oz)
55 g (1.94 oz)
57.5 g (2.03 oz)
60 g (2.12 oz)
62.5 g (2.20 oz)
65 g (2.29 oz)
67.5 g (2.38 oz)
70 g (2.47 oz)
72.5 g (2.56 oz)
75 g (2.65 oz)
77.5 g (2.73 oz)
80 g (2.82 oz)
82.5 g (2.91 oz)
85 g (3.00 oz)
87.5 g (3.09 oz)
90 g (3.17 oz)
92.5 g (3.26 oz)
95 g (3.35 oz)
97.5 g (3.44 oz)
100 g (3.53 oz)
B: PREPARATION TOOL
1. GENERAL TOOL
TOOL NAME
Air pressure gauge
Dial gauge with
magnet stand
Wheel balancer
WT-3
REMARKS
Used for measuring tire inflation pressure.
Used for measuring wheel runout.
Used for adjusting wheel balance.
Tire
2. Tire
With instruction for the direction of tire rotation.
A: INSPECTION
1) Take stones, glass, nails etc. out of the tread
groove.
2) Replace the tire if as follows.
CAUTION:
When replacing a tire, make sure to use only
the same size, construction and load range as
originally installed.
(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.
WT-00002
(1) Tread wear indicator

(2) Tire tread
3) When a crack on tire valve is found, replace the

tire valve.
1. TIRE ROTATION
Rotate tires periodically (5,000 km/3,100 miles) as
shown in the figure, in order to prevent them from
uneven wear and to prolong their life.
Without instruction for the direction of tire rotation.
WT-00113
(1) Front
WT-4
WT-00115
(1) Front
Steel Wheel
3. Steel Wheel
C: INSPECTION
A: REMOVAL
1) Deformation or damage on the rim may cause

air leakage. Check the rim flange for deformation,
crack or damage, and repair or replace as necessary.
2) Jack-up the vehicle until wheels clear the floor.
3) Slowly rotate the wheel to check rim runout using a dial gauge.
1) Apply the parking brake, and position the select

lever to P or LOW.
2) Set the shop jacks or a lift to specified point, and
support the vehicle with its wheels slightly contacting the floor.
3) Loosen the wheel nuts.
4) Raise the vehicle until its wheels take off the
ground using a jack or a lift.
5) Remove the wheel nuts and wheels.
NOTE:
When removing the wheels, prevent hub bolts
from damage.
Place the wheels with their outer sides facing upward to prevent wheels from damage.
B: INSTALLATION
WT-00004
1) Remove dirt from the mating surface of wheel

and brake rotor.
2) Attach the wheel to the hub by aligning the wheel
bolt hole with the hub bolt.
3) Temporarily attach the wheel nuts to the hub
bolts. (In the case of aluminum wheel, use SUBARU genuine wheel nut for aluminum wheel.)
4) Manually tighten the nuts making sure the wheel
hub hole is aligned correctly to the guide portion of
hub.
5) Tighten the wheel nuts in a diagonal selection to
the specified torque. Use a wheel nut wrench.
Rim runout:
Axial runout specification
Radial runout specification
1.5 mm (0.059 in)
4) If the rim runout exceeds specifications, remove

the tire from wheel and check runout while attaching the dial gauge to positions shown in the figure.
Wheel nut tightening torque:

90 Nm (9.1 kgf-m, 65.7 ft-lb)
(1)
CAUTION:
Tighten the wheel nuts in two or three steps
by gradually increasing the torque and working
diagonally, until they reach the specified
torque.
Do not depress the wrench with foot. Always
use both hands when tightening.
Make sure the bolt, nut and the nut seating
surface of the wheel are free from oil.
6) 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).
(1)
(1)
WT-00005
(1) Approx. 7 mm (0.28 in)
5) If the measured runout still exceeds specifications, replace the wheel.
WT-5
Aluminum Wheel
4. Aluminum Wheel
A: REMOVAL
Refer to Steel Wheel for removal procedure of
aluminum wheels. <Ref. to WT-5, REMOVAL,
Steel Wheel.>
B: INSTALLATION
Refer to Steel Wheel for installation procedure of
aluminum wheels. <Ref. to WT-5, INSTALLATION,
Steel Wheel.>
C: INSPECTION
Refer to Steel Wheel for inspection procedure of
aluminum wheels. <Ref. to WT-5, INSPECTION,
Steel Wheel.>
Rim runout:
Axial runout specification
Radial runout specification
1.0 mm (0.039 in)
D: CAUTION
Aluminum wheels are easily scratched. To maintain their appearance and safety, do the followings:
1) Do not damage the aluminum wheels during removal, installation, wheel balancing, etc. After removing the aluminum wheels, place them on a
rubber mat, etc.
2) When washing the 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
5. Wheel Balancing

(Adhesive type weight for aluminum wheel)
28101AG000
28101AG010
28101AG020
28101AG030
28101AG040
28101AG050
28101AG060
28101AG070
28101AG080
28101AG090
28101AG100
28101AG110
28101AG120
28101AG130
28101AG140
28101AG150
28101AG160
28101AG170
28101AG180
28101AG190
28101AG200
28101AG210
28101AG220
28101AG230
28101AG240
28101AG250
28101AG260
28101AG270
28101AG280
28101AG290
28101AG300
28101AG310
28101AG320
28101AG330
28101AG340
28101AG350
28101AG360
28101AG370
28101AG380
A: ADJUSTMENT
NOTE:
Change the setting of wheel balancer to adhesive
type weight as adhesive type weight is adopted for
outside balance weight of 17-inch wheel.
1) Remove the balance weights.
CAUTION:
Be careful not to damage the wheel.
Completely remove the two-sided tape of the
adhesive type weight from the wheel.
2) Using the wheel balancer, measure the wheel
balance.
3) Select a weight close to the value measured by
wheel balancer.
CAUTION:
Use SUBARU genuine balance weight.
(Knock-on type weight for steel
wheel)
28101TC000
28101SA060
28101SA070
28101SA080
28101SA090
723141340
723141350
723141360
723141370
723241380
723241580
723241590
(Knock-on type weight for aluminum wheel)
28101SA000
28101SA010
28101SA020
28101SA030
28101SA040
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)
Weight
5 g (0.18 oz)
7.5 g (0.26 oz)
10 g (0.35 oz)
12.5 g (0.44 oz)
15 g (0.53 oz)
17.5 g (0.62 oz)
20 g (0.71 oz)
22.5 g (0.79 oz)
25 g (0.88 oz)
27.5 g (0.97 oz)
30 g (1.06 oz)
32.5 g (1.15 oz)
35 g (1.23 oz)
37.5 g (1.32 oz)
40 g (1.41 oz)
42.5 g (1.50 oz)
45 g (1.59 oz)
47.5 g (1.68 oz)
50 g (1.76 oz)
52.5 g (1.85 oz)
55 g (1.94 oz)
57.5 g (2.03 oz)
60 g (2.12 oz)
62.5 g (2.20 oz)
65 g (2.29 oz)
67.5 g (2.38 oz)
70 g (2.47 oz)
72.5 g (2.56 oz)
75 g (2.65 oz)
77.5 g (2.73 oz)
80 g (2.82 oz)
82.5 g (2.91 oz)
85 g (3.00 oz)
87.5 g (3.09 oz)
90 g (3.17 oz)
92.5 g (3.26 oz)
95 g (3.35 oz)
97.5 g (3.44 oz)
100 g (3.53 oz)
4) Install the selected weight to the point designated by wheel balancer.

CAUTION:
Remove grease from adhesive type weight
applying surface of wheel.
Press the adhesive type weight by 25 N (2.5
kgf, 5.6 lb) or more per 5 g (0.18 oz) for 2 seconds at least to attain close contact.
Make all amounts of the applied adhesive
type weight to be 100 g (3.53 oz) or less.
WT-7
Wheel Balancing
5) Using the wheel balancer, measure the wheel

balance again. Check that wheel balance is correctly adjusted.
NOTE:
55 g (1.94 oz) knock-on type weight used with
aluminum wheel is not available.
Balance weights of knock-on type weight for aluminum wheel are available for use with any of 15to 17-inch aluminum wheels.
WT-00006
(1) Knock-on type weight for aluminum wheel

(2) Knock-on type weight for steel wheel
Service limit: A
Knock-on type weight for steel wheel:
5 25 g (0.18 0.88 oz) 2.0 mm (0.08 in)
30 g (1.06 oz) or more 1.8 mm (0.07 in)
Knock-on type weight for aluminum wheel:
5 25 g (0.18 0.88 oz) 5.0 mm (0.20 in)
30 g (1.06 oz) or more 4.5 mm (0.177 in)
WT-8
T-type Tire
6. T-type Tire
A: NOTE
T-type tire for temporary use is prepared as a
spare tire. (Except for KA, KS model)
CAUTION:
Do not use a tire chain with the T-type tire.
Because of the smaller tire size, a tire chain will
not fit properly and will result in damage to the
vehicle and the tire.
Do not drive at a speed greater than 100 km/h
(62 MPH).
Drive as slowly as possible and avoid passing over bumps.
B: REPLACEMENT
Refer to Steel Wheel for installation procedure of
T-type tire. <Ref. to WT-5, REMOVAL, Steel
Wheel.>
CAUTION:
Replace with a conventional tire as soon as
possible since the T-type tire is only for temporary use.
C: INSPECTION
1) Check the tire air pressure.
Specifications:
420 kPa (4.2 kg/cm2, 60 psi)
2) Take the stones, glass, nails, etc. out of the
tread groove.
3) Check the tires for deformation, cracks, partial
wear or wear.
CAUTION:
Replace the tire with a new one if defective.
WT-9


A: INSPECTION
Symptom
Wheel wobble.
Possible cause
Improperly inflated tire.
Uneven wear
Front wheel alignment
Rear wheel alignment
Front strut
Rear shock absorber
Front axle
Front hub unit bearing
Rear hub unit bearing
Vehicle is abnormally out of

balance.

Uneven wear
Front stabilizer
Abnormal wheel vibration

Uneven wear
Improper wheel balancing
Front axle
WT-10
Corrective action
Adjust the tire pressure.
Check the tire referring to Abnormal
tire wear in this table, carry out the
procedure and replace the tire.
Check the front wheel alignments.
<Ref. to FS-8, INSPECTION, Wheel
Alignment.>
Check the rear wheel alignments.
<Ref. to RS-8, INSPECTION, Wheel
Alignment.>
Check the front strut. <Ref. to FS24, INSPECTION, Front Strut.>
Check the rear shock absorber.
<Ref. to RS-16, INSPECTION, Rear
Shock Absorber.>
Check the front axle. <Ref. to DS15, INSPECTION, Front Axle.>
Check the front hub unit bearing.
<Ref. to DS-18, INSPECTION, Front
Hub Unit Bearing.>
Check the rear hub unit bearing.
<Ref. to DS-21, INSPECTION, Rear
Hub Unit Bearing.>
Check the front stabilizer. <Ref. to
FS-16, INSPECTION, Front Stabilizer.>
Alignment.>
Alignment.>
Check the wheel balance. <Ref. to
WT-7, ADJUSTMENT, Wheel Balancing.>
Check the front axle. <Ref. to DS15, INSPECTION, Front Axle.>
Check the front hub unit bearing.
<Ref. to DS-18, INSPECTION, Front
Hub Unit Bearing.>
Check the rear hub unit bearing.
<Ref. to DS-21, INSPECTION, Rear
Hub Unit Bearing.>

Symptom
Abnormal tire wear
Possible cause
Improper wheel balancing
WT-11
Corrective action
Check the wheel balance. <Ref. to
WT-7, ADJUSTMENT, Wheel Balancing.>
Alignment.>
Alignment.>

WT-12
DIFFERENTIALS
DI
1.
2.
3.
4.
5.
6.
7.
8.
9.
Page
Rear Differential (T-type)...........................................................................28
Rear Differential (VA-type) ........................................................................45
Rear Differential Front Oil Seal .................................................................71
Rear Differential Side Oil Seal ..................................................................73
Rear Differential Front Member.................................................................74
General Description
DIFFERENTIALS
A: SPECIFICATION
1. REAR DIFFERENTIAL
When replacing a rear differential assembly, select the correct one according to the following table.
NOTE:
Using the different rear differential assembly causes the drive line and tires to drag or emit noise.
For option code, refer to ID section. <Ref. to ID-2, IDENTIFICATION, Identification.>
Sedan, Wagon
2.5 L
MT
2.0 L Non-turbo
Model
AT
Rear differential type
Classification
LSD type
Type of gear
Gear ratio (Number of gear
teeth)
Oil capacity
VA1-type
XJ
KA, KS1
EC, EK,
K41
T-type
T2
4.111 (37/9)
AT
1:
AT
VB
2.0 L Turbo
AT
VA2-type
XT
XU
Viscous coupling
Hypoid gear
Model
Rear differential type

Classification
LSD type
Type of gear
Gear ratio (Number of gear
teeth)
Oil capacity
MT
3.0 L
CF
4.444
(40/9)
3.700
(37/10)
0.82 (0.8 US qt, 0.7 Imp qt)
GL-5
OUTBACK
2.5 L
MT
EC, EK,
KS, KA1
K41
T-type
EZ
JE
Viscous coupling
Hypoid gear
3.900
4.111
(39/10)
(37/9)
0.82 (0.8 US qt, 0.7 Imp qt)
GL-5
Option code
DI-2
3.0 L
AT
VA2-type
XU
3.272
(36/11)
3.083
(37/12)
3.272
(36/11)
General Description
DIFFERENTIALS
2. CLASSIFICATION
VA2-type
Identification label positions are shown in the following figures. For details concerning identification,
refer to ID section.
T-type
(1)
(1)
DI-00397
(1) Identification
3. REAR DIFFERENTIAL GEAR OIL

ID-00056

GL-5 (75W-90)
(1) Identification
NOTE:
VA1-type
(1)
( C)
( F)
(1)
(2)
(3)
GL-5
(4)
-30 -26 -15 -5 0
-22 -15 5 23 32
15
59
25 30
77 86
90
85W
80W
75W -90
DI-00396
(1) Identification
MT-00001
(1)
(2)
(3)
(4)
Item
API classification
4. SERVICE DATA
Drive pinion bearing preload
(at companion flange bolt hole)
Side gear backlash
Side bearing standard width
Hypoid driven gear to drive pinion
backlash
Hypoid driven gear runout on its
back surface
T-type
VA-type
T-type
mm (in)
VA1-type only
mm (in)
T-type
mm (in)
VA-type
N (kgf, lb)
mm (in) T-type only
18.1 38.8 (1.8 4.0, 4.1 8.7)

12.7 32.4 (1.3 3.3, 2.9 7.3)
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)
0.05 (0.0020)
DI-3
General Description
DIFFERENTIALS
5. ADJUSTING PART
T-type
Drive pinion bearing preload (at companion
flange bolt hole)
N (kgf, lb)
Part No.
383695201
383695202
383695203
383695204
383695205
383695206
Part No.
383705200
383715200
383725200
383735200
383745200
383755200
383765200
383775200
383785200
383795200
383805200
383815200
383825200
383835200
383845200
Part No.
383495200
383505200
383515200
383525200
383535200
383545200
383555200
383565200
383575200
383585200
383595200
383605200
383615200
383625200
383635200
383645200
383655200
383665200
383675200
383685200
Preload adjusting collar
Preload adjusting washer
Pinion height adjusting washer
Side gear backlash
18.1 38.8 (1.8 4.0, 4.1 8.7)
mm (in)
DI-4
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)
Length 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)
Thickness mm (in)
3.09 (0.1217)
3.12 (0.1228)
3.15 (0.1240)
3.18 (0.1252)
3.21 (0.1264)
3.24 (0.1276)
3.27 (0.1287)
3.30 (0.1299)
3.33 (0.1311)
3.36 (0.1323)
3.39 (0.1335)
3.42 (0.1346)
3.45 (0.1358)
3.48 (0.1370)
3.51 (0.1382)
3.54 (0.1394)
3.57 (0.1406)
3.60 (0.1417)
3.63 (0.1429)
3.66 (0.1441)
0.1 0.2 (0.0039 0.0079)
General Description
DIFFERENTIALS
Side gear thrust washer

(Model without LSD)
Side bearing standard width
mm (in)
Side bearing retainer shim
Hypoid driven gear to drive pinion backlash

Hypoid driven gear runout on its back surface
Part No.
383445201
383445202
383445203
Part No.
383475201
383475202
383475203
383475204
383475205
Limit mm (in)
DI-5
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)
20.00 (0.7874)
Thickness mm (in)
0.20 (0.0079)
0.25 (0.0098)
0.30 (0.0118)
0.40 (0.0157)
0.50 (0.0197)
0.10 0.20 (0.0039 0.0079)
0.05 (0.0020)
General Description
DIFFERENTIALS
VA1-type
flange bolt hole)
N (kgf, lb)
Side gear backlash
mm (in)
12.7 32.4 (1.3 3.3, 2.9 7.3)

Part No.
Length mm (in)
32288AA040
52.3 (2.059)
32288AA050
52.5 (2.067)
31454AA100
52.6 (2.071)
32288AA060
52.7 (2.075)
31454AA110
52.8 (2.079)
32288AA070
52.9 (2.083)
31454AA120
53.0 (2.087)
32288AA080
53.1 (2.091)
32288AA090
53.3 (2.098)
Part No.
Thickness mm (in)
38336AA000
1.500 (0.0591)
38336AA120
1.513 (0.0596)
38336AA010
1.525 (0.0600)
38336AA130
1.538 (0.0606)
38336AA020
1.550 (0.0610)
38336AA140
1.563 (0.0615)
38336AA030
1.575 (0.0620)
38336AA150
1.588 (0.0625)
38336AA040
1.600 (0.0630)
38336AA160
1.613 (0.0635)
38336AA050
1.625 (0.0640)
38336AA170
1.638 (0.0645)
38336AA060
1.650 (0.0650)
38336AA180
1.663 (0.0655)
38336AA070
1.675 (0.0659)
38336AA190
1.688 (0.0665)
38336AA080
1.700 (0.0669)
38336AA200
1.713 (0.0674)
38336AA090
1.725 (0.0679)
38336AA210
1.738 (0.0684)
38336AA100
1.750 (0.0689)
38336AA220
1.763 (0.0694)
38336AA110
1.775 (0.0699)
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)
0.05 0.15 (0.0020 0.0059)
803135011
0.925 0.950 (0.0364 0.0374)
803135012
0.950 0.975 (0.0374 0.0384)
803135013
0.975 1.000 (0.0384 0.0394)
803135014
1.000 1.025 (0.0394 0.0404)
803135015
1.025 1.050 (0.0404 0.0413)
Limit mm (in)
0.10 0.15 (0.0039 0.0059)
DI-6
General Description
DIFFERENTIALS
VA2-type
flange bolt hole)
N (kgf, lb)
12.7 32.4 (1.3 3.9, 2.9 7.3)

Part No.
31454AA250
31454AA260
31454AA270
31454AA280
31454AA290
31454AA300
31454AA310
31454AA320
31454AA330
Part No.
38336AA430
38336AA440
38336AA450
38336AA460
38336AA470
38336AA480
38336AA490
38336AA500
38336AA510
38336AA520
38336AA530
38336AA540
38336AA550
38336AA560
38336AA570
38336AA580
38336AA590
38336AA600
38336AA610
38336AA620
38336AA630
38336AA640
38336AA650
Part No.
32295AA350
32295AA360
32295AA370
32295AA380
32295AA390
32295AA400
Limit mm (in)
DI-7
Length mm (in)
51.05 (2.010)
51.25 (2.018)
51.35 (2.022)
51.45 (2.026)
51.55 (2.030)
51.65 (2.033)
51.75 (2.037)
51.85 (2.041)
52.05 (2.049)
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)
Thickness mm (in)
0.150 (0.0059)
0.175 (0.0069)
0.200 (0.0079)
0.225 (0.0089)
0.250 (0.0098)
0.275 (0.0108)
0.10 0.15 (0.0039 0.0059)
General Description
DIFFERENTIALS
B: COMPONENT
1. REAR DIFFERENTIAL WITHOUT LSD (T-TYPE)
(1)
(18)
(19)
(21)
(2)
(20)
(3)
(4)
(19)
(5)
(20)
(23)
(18)
( 1 ) (21)
(22)
(25)
(26)
T4
(27)
T1
(16)
(28)
T3
T3
(15)
(14)
(24)
T2
(23)
(30)
(13)
(17)
(31)
(29)
(6)
(7)
T1
(13)
(14)
(15)
(8)
(16)
(17)
(9)
(10)
(12)
T5
(11)
(1)
Hypoid driven gear and drive pinion set
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)

Rear bearing
Bearing preload adjusting collar
Bearing preload adjusting washer
Differential carrier
Front bearing
Collar
Pilot bearing
Front oil seal
Companion flange
Self-locking nut
DI-00260
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
Side bearing
O-ring
Side bearing retainer
Side oil seal
Side gear
Pinion mate gear
Pinion mate gear washer
Pinion shaft lock pin
Snap ring
Pinion mate shaft
Air breather cap
DI-8
(26)
(27)
(28)
(29)
(30)
(31)
Stud bolt
Oil filler plug
Oil drain plug
Rear cover
Differential case
Gasket

T1: 10.3 (1.05, 7.6)
T2: 29 (3.0, 21.7)
T3: 49 (5.0, 36.2)
T4: 105 (10.7, 77.4)
T5: 181 (18.5, 134)
General Description
DIFFERENTIALS
2. REAR DIFFERENTIAL WITH LSD (T-TYPE)

(1)
(2)
(3)
(4)
(5)
(1)
(21)
(23)
T4
T1
(22)
T3
(20)
(15)
(19)
(24)
(13)
T3
(17)
(18)
T2
(6)
(16)
(14)
(14)
(15)
(7)
(13)
T1
(16)
(17)
(8)
(10)
T5
(12)
(9)
(11)
DI-00002
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)

Rear bearing
Front bearing
Collar
Pilot bearing
Front oil seal
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
Companion flange
Self-locking nut
Side bearing
O-ring
Side bearing retainer
Side oil seal
Gasket
Differential case ASSY
Rear cover
Air breather cap
DI-9
(22)
(23)
(24)
Stud bolt
Oil filler plug
Oil drain plug

T1: 10.3 (1.05, 7.6)
T2: 29 (3.0, 21.7)
T3: 49 (5.0, 36.2)
T4: 105 (10.7, 77.4)
T5: 181 (18.5, 134)
General Description
DIFFERENTIALS
3. REAR DIFFERENTIAL (VA1-TYPE)

(18) (19)
(20)
(1)
(19)
(18)
(21)
(2)
(3)
(4)
T3
(5)
(17)
(16)
(23)
(22)
(15)
(14)
(25)
(30)
T2
(24)
(27)
T1
(26)
(13)
(28)
(6)
(26)
(7)
(29)
T1
(13)
T1
(14)
(15)
(8)
(16)
(17)
(9)
(10)
(12)
T4
(11)
DI-00296
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)

Rear bearing
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
Pinion mate gear
Pinion shaft lock pin
Differential case
Pinion mate shaft
Air breather cap
Stud bolt
DI-10
(26)
(27)
(28)
(29)
(30)
Gasket
Oil filler plug
Oil drain plug
Rear cover
Gasket

T1: 25 (2.5, 18.1)
T2: 34 (3.5, 25.3)
T3: 62 (6.3, 45.6)
T4: 191 (19.5, 141)
General Description
DIFFERENTIALS
4. REAR DIFFERENTIAL (VA2-TYPE)
(1)
(2)
(3)
(4)
T4
(5)
(17)
(16)
(18)
(15)
(14)
(20)
(25)
(19)
T1
(23)
(13)
T2
(22)
(21)
(21)
T3
(7)
(24)
(6)
(13)
T1
(14)
(15)
(16)
(8)
(10)
T5
(12)
(17)
(9)
(11)
DI-00349
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)

Rear bearing
Front bearing
Collar
Pilot bearing
Front oil seal
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
Companion flange
Self-locking nut
Lock plate
Side bearing
O-ring
Axle shaft holder
Side oil seal
Differential case ASSY
Air breather cap
Stud bolt
Gasket
DI-11
(22)
(23)
(24)
(25)
Oil filler plug

Oil drain plug
Rear cover
Gasket

T1: 25 (2.5, 18.1)
T2: 29 (3.0, 21.4)
T3: 34 (3.5, 25.3)
T4: 62 (6.3, 45.6)
T5: 191 (19.5, 141)
General Description
DIFFERENTIALS
5. REAR DIFFERENTIAL MOUNTING SYSTEM
(4)
T2
(5)
(3)
(2)
(5)
(1)
T3
(5)
T1
DI-00350
(1)
(2)
(3)
Rear differential front member

Rear differential member plate
Rear differential ASSY
(4)
(5)
Sub frame
Self-locking nut
DI-12

T1: 52 (5.3, 38)
T2: 70 (7.1, 51)
T3: 110 (11.2, 81)
General Description
DIFFERENTIALS
C: CAUTION
the equivalent. Do not mix gear oil, grease etc. with

points.
Before installing O-rings or snap rings, apply sufficient amount of gear oil to avoid damage and deformation.
or shop cloth between the part and the vice.
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
398477701
DESCRIPTION
HANDLE
REMARKS
Used for installing front and rear bearing cone.
398477702
DRIFT
Used for press-fitting the bearing race of differential carrier (front). (T-type)
Used for press-fitting the side bearing race.
(VA1-type)
Used for press-fitting the bearing race of differential carrier (Rear). (VA1-type)
398217700
ATTACHMENT SET
Stand for rear differential carrier disassembly

and assembly.
ST-398477701
ST-398477702
ST-398217700
DI-13
General Description
DIFFERENTIALS
ILLUSTRATION
TOOL NUMBER
498447120
DESCRIPTION
INSTALLER
REMARKS
Used for installing front oil seal.
498427200
FLANGE WRENCH
Used for stopping rotation of companion flange

when removing and tightening self-locking nut.
398467700
DRIFT
Used for removing pinion, pilot bearing and

front bearing cone.
For T-type and VA1-type
399780104
WEIGHT
Used for installing front bearing cone and pilot

bearing companion flange.
ST-498447120
ST-498427200
ST-398467700
ST-399780104
DI-14
General Description
DIFFERENTIALS
ILLUSTRATION
TOOL NUMBER
899580100
DESCRIPTION
INSTALLER
REMARKS
Used for press-fitting front bearing cone and pilot
bearing.
899904100
STRAIGHT PIN
REMOVER
Used for driving out differential pinion shaft lock

pin.
498247001
MAGNET BASE

498247100
DIAL GAUGE

ST-899580100
ST-899904100
ST-498247001
ST-498247100
DI-15
General Description
DIFFERENTIALS
ILLUSTRATION
TOOL NUMBER
398507704
DESCRIPTION
BLOCK
REMARKS
Used for adjusting pinion height and preload.
398177700
INSTALLER
Used for installing rear bearing cone.

398457700
ATTACHMENT
Used for removal of side bearing retainer.

For T-type
398477703
DRIFT 2
Used for press-fitting bearing race (rear) of differential carrier.

ST-398507704
ST-398177700
ST-398457700
ST-398477703
DI-16
General Description
DIFFERENTIALS
ILLUSTRATION
TOOL NUMBER
398437700
DESCRIPTION
DRIFT
REMARKS
Used for installing side oil seal.
398507702
DUMMY SHAFT

For T-type
398507703
DUMMY COLLAR

For T-type
398517700
REPLACER
Used for removing rear bearing cone.

ST-398437700
ST-398507702
ST-398507703
ST-398517700
DI-17
General Description
DIFFERENTIALS
ILLUSTRATION
TOOL NUMBER
398487700
DESCRIPTION
DRIFT
REMARKS
Used for press-fitting side bearing cone.
398417700
DRIFT PUNCH
Used for press-fitting side bearing race.

398507701
DIFFERENTIAL
CARRIER GAUGE
Used for adjusting pinion height.

For T-type
398527700
PULLER ASSY
Used for removing front oil seal.

Used for removing side bearing cup. (T-type)
ST-398487700
ST-398417700
ST-398507701
ST-398527700
DI-18
General Description
DIFFERENTIALS
ILLUSTRATION
TOOL NUMBER
28099PA090
DESCRIPTION
REMARKS
OIL SEAL PROTEC- Used for installing the rear drive shaft to rear
TOR
differential.
For oil seal protection
ST28099PA090
28099PA100
DRIVE SHAFT
REMOVER
Used for removing rear drive shaft from rear

differential.
For T-type
399703600
PULLER ASSY
Used for removing companion flange.
899874100
INSTALLER
Used for installing companion flange.
ST28099PA100
ST-399703600
ST-899874100
DI-19
General Description
DIFFERENTIALS
ILLUSTRATION
TOOL NUMBER
498077000
DESCRIPTION
REMOVER
REMARKS
Used for removing side bearing cone from differential.
For VA2-type
899864100
REMOVER
Used for removing differential side bearing.
499277200
INSTALLER
Used for installing front bearing cone.

For VA2-type
PULLER
Used for removing side bearing cup.

For VA2-type
ST-498077000
ST-899864100
ST-499277200
18758AA000
ST18758AA000
DI-20
General Description
DIFFERENTIALS
ILLUSTRATION
TOOL NUMBER
DESCRIPTION
18759AA000
PULLER ASSY
REMARKS
Used for removing differential from side bearing cone.
For T-type
18678AA000
DUMMY SHAFT

For VA2-type
18831AA010
DIFFERENTIAL
(Newly adopted tool) CARRIER GAUGE

For VA2-type
18630AA010
WRENCH ASSY
Used for removing and installing side oil seal

holder.
For VA2-type
NOTE:
Also available for VA1-type.
ST18759AA000
ST18678AA000
ST18831AA010
ST18630AA010
DI-21
General Description
DIFFERENTIALS
ILLUSTRATION
TOOL NUMBER
498175500
DESCRIPTION
INSTALLER
REMARKS
Used for installing rear bearing cone.
For VA1-type
499785500
WRENCH ASSY
Used for removing and installing side oil seal

holder.
For VA1-type
498447100
INSTALLER
Used for installing oil seal.

For VA1-type
399520105
SEAT
Used for removing side bearing cone.

Used with PULLER SET (899524100).
For VA-type
ST-498175500
ST-499785500
ST-498447100
ST-399520105
DI-22
General Description
DIFFERENTIALS
ILLUSTRATION
TOOL NUMBER
498485400
DESCRIPTION
DRIFT
REMARKS
Used for installing side bearing cone.
For VA1-type
498505501
DIFFERENTIAL
CARRIER GAUGE

For VA1-type
498447110
DRIFT
Used for press-fitting the bearing race (front)

of differential carrier.
For VA1-type
498447150
DUMMY SHAFT

For VA1-type
ST-498485400
ST-498505501
ST-498447110
ST-498447150
DI-23
General Description
DIFFERENTIALS
ILLUSTRATION
TOOL NUMBER
498515500
DESCRIPTION
REPLACER
REMARKS
Used for removing rear bearing cone.
For VA1-type
32285AA000
DUMMY COLLAR

For VA1-type
499705404
SEAT
Used for removing side bearing race.

Used with PULLER ASSY (499705401).
For VA1-type
499705401
PULLER ASSY
Used for removing side bearing race.

Used with SEAT (499705404).
For VA-type
ST-498515500
ST32285AA000
ST-499705404
ST-499705401
2. GENERAL PURPOSE TOOL

TOOL NAME
Transmission jack
Puller
Thickness gauge
Hexagon wrench
Tire lever
REMARKS
Used for assembly/disassembly of rear differential.
Used for removal of side bearing retainer.
Used for measuring clearance.
Used for installing and removing filler and drain plug.
Used for removal of rear drive shaft. (VA-type)
DI-24

DIFFERENTIALS
Except for VA2-type
A: INSPECTION
1) Remove the filler plug, and then check the gear
oil. If it is contaminated or deteriorated, replace the
gear oil. <Ref. to DI-25, REPLACEMENT, Differential Gear Oil.>
2) Check that the gear oil level is up to the bottom
of filler plug hole. If the level is low, refill up to the
bottom of filler plug hole.
Except for VA2-type
(A)
(B)
DI-00356
(A)
(A) Filler plug

(B) Drain plug
VA2-type
(A)
(B)
DI-00354
(A) Filler plug

(B) Drain plug
(B)
VA2-type
DI-00357
(A) Filler plug

(B) Drain plug
3) Tighten the oil drain plug.

NOTE:
Apply liquid gasket to the drain plug threads for
T-type.
(A)
(B)
Liquid gasket:
equivalent
Use a new aluminum gasket for VA1-type.
Use a new metal gasket for VA2-type.
DI-00355
(A) Filler plug

(B) Drain plug
B: REPLACEMENT
racks.
2) 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.
Tightening torque:
T-type:
49 Nm (5.0 kgf-m, 36.2 ft-lb)
VA1-type:
34 Nm (3.5 kgf-m, 25.3 ft-lb)
VA2-type:
29 Nm (3.0 kgf-m, 21.4 ft-lb)
4) Fill the differential carrier with gear oil to the bottom of filler plug.
NOTE:
Carefully refill oil while watching the level. Excessive or insufficient oil must be avoided.
DI-25

DIFFERENTIALS

<Ref. to DI-2, SPECIFICATION, General Description.>
Oil capacity:
0.8 2 (0.8 US qt, 0.7 Imp qt)
Except for VA2-type
(B)
(A)
DI-00391
(A) Filler plug

(B) Drain plug
VA2-type
(A)
(B)
DI-00355
(A) Filler plug

(B) Drain plug
5) Install the filler plug.

NOTE:
Apply liquid gasket to the filler plug threads for Ttype.
Liquid gasket:
equivalent
Tightening torque:
T-type:
49 Nm (5.0 kgf-m, 36.2 ft-lb)
VA1-type:
34 Nm (3.5 kgf-m, 25.3 ft-lb)
VA2-type:
29 Nm (3.0 kgf-m, 21.4 ft-lb)
DI-26

DIFFERENTIALS
3. Front Differential Assembly

A: NOTE
1. AT MODEL
4AT
For front differential of 4AT model, refer to 4AT
section. <Ref. to 4AT-115, Front Differential Assembly.>
5AT
For front differential of 5AT model, refer to 5AT
section. <Ref. to 5AT-94, Front Differential Assembly.>
2. MT MODEL
For front differential of manual transmission, refer
to 5MT section. <Ref. to 5MT-85, Front Differential Assembly.>
DI-27
Rear Differential (T-type)

DIFFERENTIALS
4. Rear Differential (T-type)
ST
28099PA100 DRIVE SHAFT REMOVER
A: REMOVAL
2) Move the select lever or gear shift lever to neutral.
4) Release the parking brake.
racks.
2.0 L SOHC and DOHC non-turbo model
<Ref. to EX(H4SO 2.0)-11, Rear Exhaust Pipe.>
<Ref. to EX(H4SO 2.0)-13, Muffler.>
2.0 L DOHC turbo model
<Ref. to EX(H4DOTC)-11, Rear Exhaust Pipe.>
9) Prepare the transmission jack and band.
ST
(A)
DI-00270
(A) Bolt
12) Remove the rear differential front member.
DI-00358
13) Support the rear differential with transmission

jack.
DI-00268
10) Loosen the self-locking nuts which hold the

rear differential to rear crossmember.
DI-00273
14) Secure the rear differential using band.

15) Remove the self-locking nuts which hold the
rear differential to crossmember.
16) Remove the rear differential stud bolt from rear
crossmember bushing.
DI-00269
11) Remove the DOJ of rear drive shaft from rear

differential using ST.
DI-28

DIFFERENTIALS
NOTE:
When removing the stud bolt, carefully adjust the
angle and location of transmission jack and jack
stand, if necessary.
20) Secure the rear drive shaft to lateral link using

wire.
DI-00277
21) Remove the rear differential member plate from

rear differential.
DI-00400
17) Lower the transmission jack stand after removing the rear differential stud bolt from rear crossmember. Rear drive shaft should not come into
contact with lateral link bolt.
(A)
DI-00359
(A) Rear differential member plate
B: INSTALLATION
DI-00392
1) Install the rear differential member plate to rear

differential.
18) Pull out the axle shaft from rear differential.

NOTE:
If it is difficult to remove the axle shaft from rear differential, remove it using ST.
ST 28099PA100 DRIVE SHAFT REMOVER
(A)
DI-00359
2) Set the rear differential to transmission jack.

DI-00276
NOTE:
Secure the rear differential to transmission jack using band.
DI-29

DIFFERENTIALS
8) After inserting the rear differential stud bolt into

rear crossmember bushing, lift up the transmission
jack and align the rear differential with its own position.
3) Install the ST to rear differential.

ST 28099PA090 OIL SEAL PROTECTOR
ST
DI-00279
4) Insert the spline shaft until the spline portion

comes inside the side oil seal.
DI-00283
9) Tighten the rear crossmember self-locking nut

temporarily.
DI-00280
5) Remove ST from rear differential.

6) Push the rear differential to insert the axle shaft
into rear differential.
DI-00269
10) Remove the band from rear differential. Lift up

the rear differential until the rear differential is separated from the transmission jack.
11) Install the rear differential front member.
Tightening torque:
T1: 52 Nm (5.3 kgf-m, 38 ft-lb)
T2: 110 Nm (11.2 kgf-m, 81 ft-lb)
T2
DI-00281
7) Adjust the transmission jack, if necessary, and

insert the rear differential stud bolt into rear crossmember bushing properly.
T1
DI-00284
DI-00393
DI-30

DIFFERENTIALS
12) Tighten the self-locking nut.
C: DISASSEMBLY
Tightening torque:
70 Nm (7.1 kgf-m, 51 ft-lb)
To detect the real cause of trouble, inspect the following items before disassembling.
Tooth contact of hypoid driven gear and drive
pinion, and backlash
Total preload of drive pinion
1) Set the ST on vise and install the differential assembly to ST.
ST 398217700
ATTACHMENT
DI-00269

17) After installing the rear differential carrier to the
vehicle, remove the filler plug, and refill the gear oil
to the bottom of plug hole.
Oil capacity:
0.8 2 (0.8 US qt, 0.7 Imp qt)
ST
DI-00061
2) Drain the gear oil by removing plug.

3) Remove the air breather cap.
NOTE:
Do not attempt to replace the air breather cap unless necessary.
Replace the air breather cap with a new one
when removing it.
(A)
(A)
(B)
DI-00285
(B)
(A) Filler plug

(B) Drain plug
DI-00062
18) Tighten the filler plug.

(A) Air breather cap
(B) Rear cover
NOTE:
Apply liquid gasket to the drain plug.
Liquid gasket:
equivalent
Tightening torque:
49.0 Nm (5.0 kgf-m, 36.2 ft-lb)
DI-31

DIFFERENTIALS
4) Remove the bolts, and then remove the rear

cover.
NOTE:
Remove it by tapping with plastic hammer.
7) When replacing the side bearing, remove the

bearing cup from side bearing retainer using ST.
ST 398527700
PULLER ASSY
(B)
ST
(A)
DI-00066
8) Extract the bearing cone with ST.
DI-00063
(A) Rear cover

(B) Differential carrier
5) Keep the side bearing retainers RH and LH separately for easier reassembly. Remove the side
bearing retainer attaching bolts, set the ST to differential case, and extract the side bearing retainers
RH and LH with a puller.
NOTE:
Do not attempt to disassemble the parts unless
necessary.
Set the puller so that its claws catch the edge of
the bearing cone.
Never mix up the bearing races RH and LH and
cones.
ST 18759AA000 PULLER ASSY
NOTE:
Each shim, which is installed to adjusted the side
bearing preload, should be kept together with its
mating retainer.
ST 398457700
ATTACHMENT
ST
ST
DI-00316
9) Remove the hypoid driven gear by loosening hypoid driven gear bolts.
DI-00064
6) Pull out the differential case assembly from differential carrier.

NOTE:
Be careful not to hit the teeth against the case.
DI-00068
10) Drive out the pinion shaft lock pin from hypoid
driven gear side (Model without LSD).
NOTE:
The lock pin is staked at the pin hole end on the differential carrier. Do not drive it out forcibly before
removing the stake.
DI-00065
DI-32

DIFFERENTIALS
ST
899904100
13) Extract the companion flange with a puller.
ST
DI-00237
DI-00072
11) Draw out the pinion mate shaft and remove pinion mate gears, side gears and thrust washers.
(Model without LSD)
14) Press the end of drive pinion shaft and extract it

together with rear bearing cone, pinion height adjust washer and washer.
NOTE:
The gears should be marked or kept separated
right and left, and front and rear as well as thrust
washers.
NOTE:
Hold the drive pinion so as not to drop it.
ST 398467700
DRIFT
ST
DI-00073
DI-00238
(A)
(B)
(C)
(D)
(E)
15) Remove the rear bearing cone from drive pinion by supporting the cone with ST.
Side gear
Pinion mate gear
Thrust washer
Differential case
Pinion mate shaft
NOTE:
Place the replacer so that its center-recessed side
faces the pinion gear.
ST 398517700
REPLACER
12) Hold the companion flange with ST and remove

the self-locking nut.
ST 498427200
FLANGE WRENCH
ST
DI-00074
ST
DI-00071
DI-33

DIFFERENTIALS
16) Remove the front oil seal from differential carrier using ST.
ST 398527700
PULLER ASSY
(A)
(B)
DI-00145
(A) Differential carrier

(B) Front oil seal
17) Remove the pilot bearing together with front

bearing cone and collar using ST.
ST 398467700
DRIFT
D: ASSEMBLY
NOTE:
Check and adjust each part during assembly.
Keep the shims and washers in order, so that
they are not improperly installed.
Thoroughly clean the surfaces on which the
shims, washers and bearings are to be installed.
Apply gear oil to the bearings and thrust washers
when installing them.
Be careful not to mix up the bearing races RH
and LH.
Use new O-rings and gasket.
Replace the oil seals with new ones at every disassembly. Apply grease to the lips when installing
the oil seals.
Be careful not to mix up the differential oil seal
RH and LH.
ST
(D)
(C)
(B)
DI-00078
(A)
DI-00076
(A)
(B)
(C)
(D)
Pilot bearing
Collar
Front bearing
Rear bearing cup
18) When replacing the bearings, hit out the front

bearing cup and rear bearing cup in this order out of
case using a brass bar.
1) Adjusting preload for front and rear bearings:

Adjust the bearing preload with collar 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 the rear bearing race into differential
carrier with ST1 and ST2.
ST2 398477703 DRIFT 2
(A)
ST2
ST1
(B)
(A) 2 cutouts along diagonal lines

(B) Hit out alternately with brass bar
DI-00077
DI-00079
(2) Install the front bearing race to differential

carrier using ST1 and ST2.
ST2 398477702 DRIFT
DI-34

DIFFERENTIALS
(3) Measure and record the thickness of pinion

height adjust washer.
NOTE:
If tooth contact (drive pinion, hypoid driven gear) is
normal in the inspection before disassembling, verify that the washer is not deformed, and then re-use
the used washer.
(4) Insert the ST1 into carrier with pinion height
adjusting washer and rear bearing cone fitted
onto it.
Measure the preload in direction of tangent to

flange.
ST1 398507702 DUMMY SHAFT
ST2 398507704 BLOCK
Tightening torque:
181 Nm (18.5 kgf-m, 134 ft-lb)
NOTE:
Use new rear bearing cone.
(5) Install the preload adjusting collar and
washer, front bearing cone, ST2, companion
flange, and washer and drive pinion nut.
ST2 398507703 DUMMY COLLAR
(A)
(B)
ST1
ST2
DI-00081

18.1 38.8 N (1.8 4.0 kgf, 4.1 8.7 lb)
at companion flange bolt hole
(C)
ST2
ST1
DI-00080
(A) Pinion height adjusting washer

(B) Preload adjusting collar
(C) Preload adjusting washer
DI-00117
(6) Turn the ST1 with hand to make it seated,

and tighten the self-locking nut while measuring
the preload with spring balance. Select the preload adjusting washer and collar so that the
specified preload is obtained when nut is tightened to the specified torque.
Preload adjusting
washer
DI-00117
NOTE:
Be careful not to give excessive preload.
When tightening the self-locking nut, lock ST1
with ST2 as shown in the figure.
DI-35
Part No.
383705200
383715200
383725200
383735200
383745200
383755200
383765200
383775200
383785200
383795200
383805200
383815200
383825200
383835200
383845200
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)

DIFFERENTIALS
Preload adjusting
collar
Part No.
383695201
383695202
383695203
383695204
383695205
383695206
NOTE:
Use copies of this page.
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)
T
To
2) Adjusting drive pinion height:

Adjust the drive pinion height with washer installed
between the rear bearing cone and the back of pinion gear.
(1) Install the ST2.
ST2 398507701 DIFFERENTIAL CARRIER
GAUGE
ST3
ST1
(A)
RH
LH
ST2
DI-00083
(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.
GAUGE
ST2
ST1
DI-00084
(3) Obtain the thickness of pinion height adjusting washer to be inserted from the following formula, and replace the temporarily installed
washer with this one.
T = To + N (H 0.01) 0.20 mm
DI-36
N
H
Memo:
Thickness of pinion height adjusting

washer mm (in)
Thickness of washer temporally
inserted mm (in)
Clearance of thickness gauge mm (in)
Figure marked on drive pinion head
(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 pinion height adjusting washer of part number 383605200.
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)

DIFFERENTIALS
3) Install the selected pinion height adjusting washer on drive pinion, and press the rear bearing cone
into position with ST.
ST 398177700
INSTALLER
6) Insert the collar, then press-fit the pilot bearing

with ST1 and ST2.
ST2
ST
ST1
DI-00085
DI-00088
4) Insert the drive pinion into differential carrier, install the selected bearing preload adjusting collar
and washer.
(A)
(B)
7) 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 to the oil seal lips.
ST 498447120
INSTALLER
(C)
ST
(D)
(A)
(B)
(C)
(D)
DI-00086
Drive pinion
DI-00089
5) Press-fit the front bearing cone into case with

ST1, ST2 and ST3.
8) Press-fit the companion flange with ST1 and

ST2.
NOTE:
Be careful not to damage the bearing.
ST1
ST3
ST1
ST2
ST2
DI-00090
DI-00087
DI-37

DIFFERENTIALS
9) Install a new self-locking nut and secure the

companion flange using ST and tighten the nut.
ST 498427200
FLANGE WRENCH
(1) Measure the side gear backlash.

Side gear backlash:
0.10 0.20 mm (0.0039 0.0079 in)
Tightening torque:
181 Nm (18.5 kgf-m, 134 ft-lb)
DI-00240
(2) Adjust the side gear backlash as specified

by selecting side gear thrust washer.
ST
DI-00091
10) Assembling differential case

Install the side gears and pinion mate gears, with
their thrust washers and pinion mate shaft, into differential case. (Model without LSD)
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.
Part No.
383445201
383445202
383445203

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)
(3) Check the condition of rotation after applying oil to the gear tooth surfaces and thrust surfaces.
(4) After inserting the pinion shaft lock pin into
differential case, stake the both sides of the hole
to prevent pin from falling off.
11) Install the hypoid driven gear to differential
case.
NOTE:
Before installing bolts, apply Lock Tite to bolt
threads.
Lock Tite:
Tighten diagonally while tapping the bolt heads.
Tightening torque:
105 Nm (10.7 kgf-m, 77.4 ft-lb)
DI-00239
DI-00068
DI-38

DIFFERENTIALS
12) Press the side bearing into differential case using ST.
ST 398487700
DRIFT

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)
ST
(4) Align the arrow mark on differential carrier

with the mark on side retainer during installation.
NOTE:
Be careful that side bearing outer race is not damaged by bearing roller.
DI-00095
13) Press-fit the side bearing cone to the side bearing retainer using ST.
ST 398417700
DRIFT
(A)
ST
DI-00097
(A) Arrow mark

DI-00324
(5) Tighten the side bearing retainer bolts.
14) Adjusting the side bearing retainer shims

(1) The hypoid driven gear backlash and side
bearing preload can be adjusted by the side
bearing retainer shim thickness.
(2) Install the differential assembly into differential carrier in the reverse order of disassembly.
Tightening torque:
10.3 Nm (1.05 kgf-m, 7.6 ft-lb)
DI-00098
DI-00065
(3) Install the side bearing retainer shims to retainers RH and LH from which they were removed.
NOTE:
Replace the broken or corroded side retainer shim
with a new one of same thickness.
DI-39
(6) Measure the hypoid driven gear to drive pinion backlash. Set the magnet base on differential carrier. Align the contact point of dial gauge
with tooth face of hypoid driven gear, and move
hypoid driven gear while holding drive pinion
still. Read the value indicated on dial gauge.
If the backlash exceeds 0.2 mm (0.08 in), reduce the thickness of shim on the back face of
hypoid driven gear and increase the thickness of
shim on the tooth face of hypoid driven gear. If
the backlash is less than 0.1 mm (0.004 in), increase the thickness of shim on the back face of
hypoid driven gear and reduce the thickness of
shim on the tooth face of hypoid driven gear.

DIFFERENTIALS
Hypoid driven gear runout on its back surface:

0.05 mm (0.0020 in)
Backlash:
0.10 0.20 mm (0.0039 0.0079 in)
DI-00099
DI-00101
(7) At the same time, measure the total preload

of drive pinion. Compared with the resistance
when differential case is not installed, if the total
preload is not within specification, adjust the
thickness of side bearing retainer shims, increasing/reducing by an even amount at a time.
Total preload:
20.7 54.4 N (2.1 5.5 kgf, 4.7 12.2 lb)
15) Recheck the hypoid driven gear to drive pinion
backlash.
Backlash:
0.10 0.20 mm (0.0039 0.0079 in)
17) Checking and adjusting the tooth contact of hypoid driven gear
(1) Apply an even coat of red lead on both sides
of three or four teeth on the hypoid driven gear.
Check the contact pattern after rotating the hypoid driven gear several revolutions back and
forth until a definite contact pattern appears on
the hypoid driven gear.
(2) When the contact pattern is incorrect, readjust.
NOTE:
Be sure to wipe off red lead completely after adjustment is completed.
shifted toward toe side under no-load rotation.
heel.]
(A)
DI-00099
16) Check the hypoid driven gear runout on its

back surface, and make sure that pinion and hypoid driven gear rotates smoothly.
If the hypoid driven gear runout on its back surface
exceed the specification, verify that there is any foreign material between hypoid driven gear and differential case, and they are not deformed.
DI-40
(B)
AT-00207
(A) Toe side

(B) Heel side

DIFFERENTIALS

Checking item: Contact areas is small
Contact pattern
Face contact
Contact pattern
AT-00208
AT-00210
Corrective action: Increase thickness of drive pinion height adjusting washer in order to bring drive
pinion close to hypoid driven gear.

height adjusting washer in order to bring drive pinion away from hypoid driven gear.
AT-00212
AT-00213

Contact pattern
Flank contact
Contact pattern
AT-00209
AT-00211

AT-00213
AT-00212
DI-41

DIFFERENTIALS
18) If proper tooth contact is not obtained, once

again adjust the drive pinion height by changing RH
and LH side bearing retainer shims and the hypoid
gear backlash.
19) Remove the RH and LH side bearing retainer.
20) Install a new O-ring to side bearing retainer of
both side.
21) Using the ST, install the oil seal to the side
bearing retainer of both side.
ST 398437700
DRIFT
22) Align the arrow mark on differential carrier with
the mark on side retainer during installation.
Tightening torque:
29 Nm (3.0 kgf-m, 21.7 ft-lb)
DI-00113
25) Install the breather cap.

26) Install the drain plug and filler plug.
(A)
Tightening torque:
49 Nm (5.0 kgf-m, 36.2 ft-lb)
E: INSPECTION
DI-00097
(A) Arrow mark
23) Apply liquid gasket to the bolt of arrow mark,

and install the side bearing retainer.
Liquid gasket:
equivalent
Tightening torque:
10.3 Nm (1.05 kgf-m, 7.6 ft-lb)
DI-00098
24) Install the new gasket and rear cover to the differential carrier, and tighten the bolts to specified
torque.
Wash all the disassembled parts clean, and examine them for wear, damage and other defects. Repair or replace the defective parts as necessary.
1) Hypoid driven gear and drive pinion
If abnormal tooth contact is evident, find out the
cause and adjust to give correct tooth contact. 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) Bearings
Replace if seizure, peeling, wear, rust, dragging
during rotation, 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.
DI-42

DIFFERENTIALS
1. SIDE GEAR BACKLASH

Using a dial gauge, check the backlash of the side
gear. (Model without LSD)
Side gear backlash:
0.1 0.2 mm (0.004 0.008 in)
If the side gear backlash is not within the specification, adjust it as specified by selecting side gear
thrust washer.
3. HYPOID DRIVEN GEAR RUNOUT ON ITS

BACK SURFACE
Using a dial gauge, check the hypoid driven gear
runout on its back surface.
Hypoid driven gear runout on its back surface:
0.05 mm (0.0020 in)
If the hypoid driven gear runout exceeds 0.05 mm
(0.0020 in), replace the hypoid driven gear.
DI-00315
DI-00101
2. HYPOID DRIVEN GEAR BACKLASH

Using a dial gauge, check the backlash of hypoid
driven gear.
Hypoid driven gear backlash:
0.1 0.2 mm (0.004 0.008 in)
If the hypoid driven gear backlash is not within the
specification, adjust the side bearing preload or repair if necessary.
4. TOOTH CONTACT BETWEEN HYPOID

DRIVEN GEAR AND DRIVE PINION
Inspect the tooth contact between hypoid driven
gear and drive pinion. <Ref. to DI-34, ASSEMBLY,
Rear Differential (T-type).>
5. TOTAL PRELOAD
Using a spring balance, check the total preload.
Total preload:
20.7 54.4 N (2.1 5.5 kgf, 4.7 12.2 lb)
If the total preload is not within the specification,
adjust the side bearing retainer shims.
DI-00099
DI-00117
DI-43

DIFFERENTIALS
6. COMPANION FLANGE
F: ADJUSTMENT
1) If rust or dirt is attached to the companion flange,

remove them.
2) Set a dial gauge at a companion flange surface
(mating surface of propeller shaft and companion
flange), and then measure the companion flange
runout.
Limit of runout:
0.08 mm (0.0031 in)
Adjust hypoid driven gear backlash.

<Ref. to DI-34, ASSEMBLY, Rear Differential (Ttype).>
Adjust the side gear backlash.


Adjust the tooth contact between hypoid driven
gear and drive pinion gear.
4. TOTAL PRELOAD
DI-00360
3) Set the gauge inside of the companion flange,

and measure the runout.
Adjust the side bearing shim.

Limit of runout:
0.08 mm (0.0031 in)
DI-00361
4) If either runout exceeds the limit, move the

phase of companion flange and drive pinion 90
each, and find the point where the runout is within
the limit.
5) If the runout exceeds the limit after changing the
phase, replace the companion flange and recheck
the runout.
6) If the runout exceeds the limit after replacing the
companion flange, the drive pinion may be assembled incorrectly or bearing is faulty.
DI-44
Rear Differential (VA-type)

DIFFERENTIALS
5. Rear Differential (VA-type)
12) Remove the DOJ of rear drive shaft from rear

differential.
A: REMOVAL
racks.
(A)
(B)
DI-00287
(A) Tire lever

(B) Bolt
13) Remove the nuts which hold the rear differential front member.
AT-01331

10) Prepare the transmission jack and band.
DI-00358
14) Support the rear differential with transmission

jack.
DI-00268
11) Loosen the self-locking nuts which hold the

DI-00273
15) Remove the rear differential front member.

16) Secure the rear differential using band.
17) Remove the self-locking nuts which hold the
DI-00269
DI-45

DIFFERENTIALS
18) Remove the rear differential stud bolt from rear

crossmember bushing.
22) Secure the rear drive shaft to lateral link using

wire.
NOTE:
When removing the stud bolt, carefully adjust the
angle and location of transmission jack and jack
stand, if necessary.
DI-00277
23) Remove the rear differential member plate from

rear differential.
(A)
DI-00400
19) Lower the transmission jack stand after removing the rear differential stud bolt from rear crossmember. Rear drive shaft should not come into
contact with lateral link bolt.
DI-00359
B: INSTALLATION
1) Insert the rear differential member plate into rear
differential.
DI-00392
(A)
20) Pull out the axle shaft from rear differential.

NOTE:
If it is difficult to remove the axle shaft from rear differential, remove it using tire lever.
DI-00359
2) Set the rear differential to transmission jack.

DI-00276
NOTE:
Secure the rear differential to transmission jack using band.
DI-46

DIFFERENTIALS
8) After inserting the rear differential stud bolt into

rear crossmember bushing, lift up the transmission
jack and align the rear differential to the height of
rear differential.
3) Install the ST to rear differential.

ST
DI-00300
4) Insert the spline shaft until the spline portion

comes inside the side oil seal.
DI-00283
9) Tighten a new self-locking nut temporarily to rear

crossmember.
ST
DI-00289
5) Remove ST from rear differential.

6) Push the rear differential to insert the axle shaft
into rear differential.
DI-00269
10) Remove the band from rear differential. Lift up

the rear differential until the rear differential is left
from the transmission jack.
11) Install the rear differential front member with a
new self-locking nut.
Tightening torque:
T1: 52 Nm (5.3 kgf-m, 38 ft-lb)
T2: 110 Nm (11.2 kgf-m, 81 ft-lb)
T2
DI-00281
7) Adjust the transmission jack, if necessary, and

insert the rear differential stud bolt into rear crossmember bushing properly.
T1
DI-00284
DI-00393
DI-47

DIFFERENTIALS
3) Remove the rear cover by loosening retaining

bolts.
12) Tighten the self-locking nut.

Tightening torque:
70 Nm (7.1 kgf-m, 51 ft-lb)
DI-00130
4) Remove the air breather cap.
DI-00269

14) Install the propeller shaft.
<Ref. to DS-11, INSTALLATION, Propeller Shaft.>
NOTE:
Do not attempt to remove the air breather cap
unless necessary.
When removing the air breather cap, replace it
with a new one.
C: DISASSEMBLY
(A)
1. VA1-TYPE
(B)
Tooth contact and backlash between hypoid driven gear and drive pinion
ST 398217700
ATTACHMENT
DI-00131
(A) Air breather cap

(B) Rear cover
5) Remove the lock plate RH and LH.
ST
DI-00129

DI-00132
DI-48

DIFFERENTIALS
6) Remove the holder RH and LH with ST.

ST 499785500
WRENCH ASSY
NOTE:
Perform this operation only when changing oil seal.
ST
DI-00133
DI-00136

NOTE:
10) Extract the bearing cone with ST1 and ST2.

NOTE:
necessary.
Set the puller so that its claws catch the edge of
the bearing cone.
cones.
ST2 399520105 SEAT
ST1
DI-00134
8) Remove the bearing race from holder RH and

LH with ST1 and ST2.
ST1 499705401 PULLER ASSY
ST2 499705404 SEAT
ST2
DI-00137
11) Remove the hypoid driven gear by loosening

hypoid driven gear bolts.
ST1
(A)
ST2
(B)
DI-00135
(A) Bearing race

(B) Holder
9) Remove the oil seal from holder RH and LH using screwdriver.
DI-00068
12) Drive out the pinion shaft lock pin from hypoid
driven 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.
DI-49

DIFFERENTIALS
ST
899904100

(A)
ST
(B)
DI-00237
13) Draw out the pinion mate shaft and remove pinion mate gears, side gears and thrust washers.
NOTE:
The gears should be marked or kept separated
right and left, and front and rear as well as thrust
washers.
DI-00142
(A) Companion flange

(B) Puller
16) Press the end of drive pinion shaft and extract it

together with rear bearing cone, pinion height adjust washer and washer.
NOTE:
Hold the drive pinion so as not to drop it.
ST 398467700
DRIFT
ST
DI-00238
(A)
(B)
(C)
(D)
(E)
Side gear
Pinion mate gear
Thrust washer
Differential case
Pinion mate shaft
DI-00073
17) Remove the rear bearing cone from drive pinion by supporting the cone with ST.
14) Support the companion flange with ST and remove self-locking nut.
ST 498427200
FLANGE WRENCH
NOTE:
ST 498515500
REPLACER
ST
ST
DI-00141
DI-00074
DI-50

DIFFERENTIALS
18) Remove the front oil seal from differential carrier using ST.
ST 398527700
PULLER SET
(A)
2. VA2-TYPE
Tooth contact and backlash between hypoid driven gear and drive pinion
ST 398217700
ATTACHMENT
(B)
DI-00145
(A) Differential carrier

(B) Front oil seal
19) Remove the pilot bearing together with front

bearing cone and collar using ST.
ST 398467700
DRIFT
ST
DI-00363

3) Remove the rear cover by loosening retaining
bolts.
ST
(D)
(C)
(B)
(A)
DI-00076
(A)
(B)
(C)
(D)
Pilot bearing
Collar
Front bearing
Rear bearing cup
DI-00388
4) Remove the lock plate RH and LH.

case by using a brass bar.
(A)
DI-00364
(B)
DI-00077

DI-51

DIFFERENTIALS
5) Remove the holder RH and LH with ST.

ST 18630AA010 WRENCH
Set the puller so that its claws catch the groove of

holder.
ST
ST
(A)
ST
(B)
DI-00367
DI-00365
(A) Groove
(B) Claw
NOTE:
(A)
ST
DI-00368
DI-00366
(A) Holder
7) Remove the bearing race from holder RH and

LH with ST1 and press.
ST 18758AA000 PULLER
8) Remove the oil seal from holder RH and LH using screwdriver.
NOTE:
Make sure the bolt of puller turn manually.
NOTE:
Perform this operation only when changing oil seal.
DI-00369
9) Extract the bearing cone with ST1, ST2 and

ST3.
NOTE:
necessary.
cones.
DI-52

DIFFERENTIALS
ST1
ST2
ST3
498077000
399520105
899864100
13) Removes the drive pinion shaft.

14) Remove the rear bearing cone from drive pinion by supporting cone with ST.
REMOVER
SEAT
REMOVER
NOTE:
ST 398517700
REPLACER
ST1
ST3
ST2
DI-00370
ST
10) Remove the hypoid driven gear by loosening

hypoid driven gear bolts.
DI-00373
15) Remove the front oil seal from differential carrier using screwdriver.
16) Remove the pilot bearing, front bearing cone
and collar.
DI-00371
11) Support the companion flange with ST and remove self-locking nut.
ST 498427200
FLANGE WRENCH
(D)
(B)
(C)
(A)
DI-00374
ST
(A)
(B)
(C)
(D)
DI-00372
Pilot bearing
Collar
Front bearing
Rear bearing cup

case by using a brass bar.
(A)
(A)
(B)
(B)
DI-00394

(A) Companion flange

(B) Puller
DI-53
DI-00077

DIFFERENTIALS
D: ASSEMBLY

ST2 498447110 DRIFT
(3) Insert the front bearing cone.
1. VA1-TYPE
NOTE:
Use a new gasket.
Apply gear oil when installing the bearings and
thrust washers.
and LH.
Replace the oil seal with a new one at every disassembly. Apply grease to the lips when installing
the oil seal.
RH and LH.
NOTE:
Use new front bearing cone.
height adjust washer.
NOTE:
the used washer.
(5) Insert the ST1 into the case with pinion
height adjusting washer and rear bearing cone
fitted onto it.
NOTE:
washer, front bearing cone, ST2, companion
flange, and washer and self-locking nut.
ST1 498447150
DUMMY SHAFT
ST2 32285AA000 DUMMY COLLAR
(A)
(B)
(C)
DI-00078

inserted.
(1) Install the rear bearing race into differential
ST2 398477702 DRIFT
ST1
ST2
ST1
DI-00150

(B) Preload adjusting collar
(C) Preload adjusting washer

ST2
DI-00149
(2) Install the front bearing race to differential

carrier using ST1 and ST2.
DI-00152
DI-54

DIFFERENTIALS
NOTE:
When tightening the self-locking nut, lock ST1
with ST2 as shown in the figure.
flange.
ST2 398507704 BLOCK
Tightening torque:
191 Nm (19.5 kgf-m, 141 ft-lb)
ST1
ST2
Preload adjusting
collar
Part No.
32288AA040
32288AA050
31454AA100
32288AA060
31454AA110
32288AA070
31454AA120
32288AA080
32288AA090
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)

ST1 498447150
DUMMY SHAFT
ST2 498505501
DIFFERENTIAL CARRIER
GAUGE
ST3 32285AA000 DUMMY COLLAR
ST3
DI-00081
ST1
RH
ST2

For new bearing:
12.7 32.2 N (1.3 3.3 kgf, 2.9 7.3 lb)
Measure at companion flange bolt hole
Preload adjusting
washer
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
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)
(A)
LH
DI-00083

thickness gauge.
NOTE:
and ST2.
GAUGE
ST2
ST1
DI-00084
DI-55

DIFFERENTIALS
4) Insert the drive pinion into differential carrier, install the selected bearing preload adjusting collar
and washer.
(A)
NOTE:
Adjust it using the 1 3 washers.
T = To + N 0.05 (mm)
T
To
N
Memo:
(B)
(C)

washer mm (in)
inserted mm (in)
(D)
To = 0.15 mm
N = 0.1 mm
T = 0.15 + 0.1 0.05 = 0.2 mm
Therefore use the pinion height adjusting washer of
part number 32295AA220.
(A)
(B)
(C)
(D)
Drive pinion
5) Press-fit the front

ST1, ST2 and ST3.
ST1 32285AA000
ST2 399780104
ST3 899580100

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)
DI-00156
bearing cone into carrier with

DUMMY COLLAR
WEIGHT
INSTALLER
ST3
ST1
ST2
ST 498175500
INSTALLER
DI-00087
6) Insert the collar, then press-fit the pilot bearing

with ST1 and ST2.
ST2
ST
DI-00085
ST1
DI-00088

NOTE:
DI-56

DIFFERENTIALS
ST
498447120
Insert the pinion mate shaft into the differential

case by aligning the lock pin holes.
INSTALLER
ST
DI-00089
8) Press-fit the companion flange with ST1 and

ST2.
NOTE:
ST1
DI-00239
(1) Measure the side gear backlash.

Side gear backlash:
0.05 0.15 mm (0.0020 0.0059 in)
ST2
DI-00090
9) Install a new self-locking nut, and secure the

companion flange using ST, and tighten the nut.
ST 498427200
FLANGE WRENCH
Tightening torque:
191 Nm (19.1 kgf-m, 141 ft-lb)
DI-00240
(2) Adjust the side gear backlash as specified

by selecting side gear thrust washer.
ST
DI-00161
10) Assembling differential case

Install the side gears and pinion mate gears, with
their thrust washers and pinion mate shaft, into differential case.
NOTE:
Apply gear oil to both sides of the washer and the
side gear shaft before installing.
DI-57
Part No.
803135011
803135012
803135013
803135014
803135015

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)
(3) Check the condition of rotation after applying oil to the gear tooth surfaces and thrust surfaces.
(4) After inserting the pinion shaft lock pin into
differential case, stake the both sides of the hole
to prevent pin from falling off.

DIFFERENTIALS
11) Install the hypoid driven gear on differential

case.
NOTE:
Before installing bolts, apply Lock Tite to bolt
threads.
Lock Tite:
(2) Install the bearing race into holder RH and

LH.
ST 398477702
DRIFT
CAUTION:
Make sure that the oil seal, bearing outer race
and cone are properly assembled.
Tightening torque:
62 Nm (6.3 kgf-m, 45.6 ft-lb)
ST
DI-00167
DI-00068
ST 498485400
DRIFT
DI-00134
ST
DI-00095
13) Assemble holders.

(1) Install the oil seal into holder RH and LH.
ST 498447100
INSTALLER
(4) Temporally tighten the side holder RH and

LH in differential carrier to install.
14) Perform the backlash adjustment between the
hypoid driven gear and drive pinion, and preload
adjustment of differential side bearing.
(1) Turn the drive pinion with ST for better fitting
of differential side bearing.
ST 498427200
FLANGE WRENCH
ST
ST
DI-00169
DI-00166
DI-58

DIFFERENTIALS
(2) Screw in the side holder LH until light contact is made with ST.
ST 499785500
WRENCH
Backlash:
0.10 0.15 mm (0.0039 0.0059 in)
ST
DI-00172
DI-00133
(3) Back off the side (hypoid driven gear side)

holder approx. 1 1/2 teeth of holder, and tighten
the other side holder by approx. 2 teeth (approx.
1 1/2 + 1/2 teeth). [Back off amount of side (hypoid driven gear side) holder + 1/2 tooth.]
This + 1/2 tooth gives preload.
(4) Temporarily tighten the lock plate.
15) Draw a matching mark on both differential carrier and holder. Remove the holder side at a time.
Replace in the original position after inserting an Oring and applying grease to threaded portion.
(A)
NOTE:
Turn over the lock plate to displace the holder 1/2
tooth.
(B)
DI-00173
(A) Alignment mark

(B) Holder
16) Tighten the bolt of lock plate to specified

torque.
DI-00132
(5) Measure the hypoid driven gear-to-drive

pinion backlash. Set the magnet base on differential carrier. Align the contact point of dial
gauge with tooth face of hypoid driven gear, and
move hypoid driven gear while holding drive pinion still. Read the value indicated on dial gauge.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
NOTE:
If measured backlash is not within specified range,
repeat the procedures for pinion driven gear set
backlash adjustment and differential side bearing
preload adjustment.
DI-59
DI-00132

DIFFERENTIALS
17) Recheck the hypoid driven gear to pinion backlash.

Backlash:
0.10 0.15 mm (0.0039 0.0059 in)
Face contact
Contact pattern
AT-00208
DI-00172
NOTE:
toward heel.]
AT-00212
Flank contact
Contact pattern
(A)
AT-00209
(B)
AT-00207

(A) Toe side

(B) Heel side
AT-00213
DI-60

DIFFERENTIALS

again adjust the drive pinion height and the differential side bearing preload (already mentioned)
and the hypoid gear backlash.
20) Install the new gasket and rear cover to differential carrier and tighten the bolts to specified
torque.

Contact pattern
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
(A)
AT-00210

DI-00189
(A) Rear cover
2. VA2-TYPE
NOTE:
Use a new gasket.
Apply gear oil when installing the bearings and
thrust washers.
and LH.
Replace the oil seal with a new one at every disassembly. Apply grease to the lips when installing
the oil seal.
RH and LH.
AT-00213

Contact pattern
AT-00211
DI-00078
AT-00212
DI-61

DIFFERENTIALS

inserted.
(1) Install the rear bearing race into differential
ST2 398477703 DRIFT 2
ST1
18678AA000 DUMMY SHAFT

(A)
(B)
(C)
(D)
ST1
ST1
(A)
(B)
(C)
(D)
DI-00377

Collar

ST2
DI-00375
(2) Using the ST, install the front bearing race to

the differential carrier.
ST 499277200
INSTALLER
ST
DI-00152
DI-00376
(3) Insert the front bearing cone.

NOTE:
Use new front bearing cone.
adjust washer.
NOTE:
the used washer.
(5) Insert the ST1 into carrier with pinion height
adjusting washer and rear bearing cone fitted
onto it.
NOTE:
When tightening the self-locking nut, lock companion flange with ST2 as shown in the figure.
flange.
ST1 18678AA000 DUMMY SHAFT
ST2 498427200
FLANGE WRENCH
NOTE:
washer, front bearing cone, collar, companion
flange, and washer and self-locking nut.
DI-62

DIFFERENTIALS
Tightening torque:
191 Nm (19.5 kgf-m, 141 ft-lb)

ST2 18831AA010 DIFFERENTIAL CARRIER
GAUGE
ST2
ST1
RH
ST2
DI-00398

12.7 32.4 N (1.3 3.3 kgf, 2.9 7.3 lb)
(at companion flange bolt hole)
Preload adjusting
washer
Preload adjusting
collar
Part No.
38336AA430
38336AA440
38336AA450
38336AA460
38336AA470
38336AA480
38336AA490
38336AA500
38336AA510
38336AA520
38336AA530
38336AA540
38336AA550
38336AA560
38336AA570
38336AA580
38336AA590
38336AA600
38336AA610
38336AA620
38336AA630
38336AA640
38336AA650
Part No.
31454AA250
31454AA260
31454AA270
31454AA280
31454AA290
31454AA300
31454AA310
31454AA320
31454AA330
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)
51.05 (2.010)
51.25 (2.018)
51.35 (2.022)
51.45 (2.026)
51.55 (2.030)
51.65 (2.033)
51.75 (2.037)
51.85 (2.041)
52.05 (2.049)
(A)
LH
DI-00379
(2) Install the side holder LH to the left side of

differential carrier in reverse direction.
DI-00380

thickness gauge.
NOTE:
and ST2.
ST2 18831AA010 DIFFERENTIAL CARRIER
GAUGE
ST2
ST1
DI-00381
DI-63

DIFFERENTIALS
4) Insert the drive pinion into differential carrier, install the previously selected bearing preload adjusting collar and washer.
(A)
NOTE:
Adjust it using the 1 3 washers.
T = To + N 0.05 (mm)
T
To
N
Memo:
(B)
(C)

washer mm (in)
inserted mm (in)
(D)
To = 0.15 mm
N = 0.1 mm
T = 0.15 + 0.1 0.05 = 0.2 mm
Therefore use the pinion height adjusting washer of
part number 32295AA370.
(A)
(B)
(C)
(D)
DI-00382
Drive pinion
5) Set ST and differential carrier to the press and

install the front bearing cone.
ST 399780104
WEIGHT

Part No.
Thickness mm (in)
32295AA350
0.150 (0.0059)
32295AA360
0.175 (0.0069)
32295AA370
0.200 (0.0079)
32295AA380
0.225 (0.0089)
32295AA390
0.250 (0.0098)
32295AA400
0.275 (0.0108)
ST
DI-00383
ST 398177700
INSTALLER
NOTE:
Set the carrier to the press until the companion
flange is installed.
6) Insert the collar, then install the pilot bearing.
(A)
(B)
ST
DI-00389
DI-00085
(A) Pilot bearing

(B) Collar
DI-64

DIFFERENTIALS

NOTE:
ST 499277200
INSTALLER
10) Install the hypoid driven gear on differential

case.
NOTE:
Set a cushioning such as wooden block, aluminum plate or shop cloth between vise and differential case if the side gear comes into contact with
vise.
Tightening torque:
62 Nm (6.3 kgf-m, 45.6 ft-lb)
ST
DI-00089
8) Press-fit the companion flange with ST.

NOTE:
ST 899874100
INSTALLER
DI-00371
ST 398227700
DRIFT
ST
ST
DI-00384
9) Install a new self-locking nut, and secure the

companion flange using ST, and tighten the nut.
ST 498427200
FLANGE WRENCH
DI-00095
12) Assemble holders.

(1) Install the new oil seal into holder RH and
LH.
ST 498447100
INSTALLER
Tightening torque:
191 Nm (19.1 kgf-m, 141 ft-lb)
ST
ST
DI-00372
DI-00166
DI-65

DIFFERENTIALS
(2) Install the bearing race into holder RH and

LH.
ST 398487700
DRIFT
(2) Screw in the side holder LH until light contact is made with ST.
ST 18630AA010 WRENCH
CAUTION:
Make sure that the oil seal, bearing outer race
and cone are properly assembled.
ST
ST
DI-00399
(3) Back off the side (hypoid driven gear side)

holder approx.1 1/2 teeth of holder, and tighten
the other side holder by approx. 2 teeth (approx.
1 1/2 + 1/2 teeth). [Back off amount of side (hypoid driven gear side) holder + 1/2 tooth.]
This + 1/2 tooth gives preload.
(4) Temporarily tighten the lock plate.
DI-00167
NOTE:
Turn over the lock plate to displace the holder 1/2
tooth.
DI-00366
(4) Temporally tighten the side holder RH and

LH in differential carrier to install.
13) Perform the backlash adjustment between the
hypoid driven gear and drive pinion, and preload
adjustment of differential side bearing.
(1) Turn the drive pinion with ST for better fitting
of differential side bearing.
ST 498427200
FLANGE WRENCH
DI-00364
(5) Measure the hypoid driven gear-to-drive

pinion backlash. Set the magnet base on differential carrier. Align the contact point of dial
gauge with tooth face of hypoid driven gear, and
move hypoid driven gear while holding drive pinion still. Read the value indicated on dial gauge.
NOTE:
If measured backlash is not within specified range,
repeat the procedures for pinion driven gear set
backlash adjustment and differential side bearing
preload adjustment.
ST
DI-00385
DI-66

DIFFERENTIALS
Backlash:
0.10 0.15 mm (0.0039 0.0059 in)
16) Recheck the hypoid driven gear to pinion backlash.

Backlash:
0.10 0.15 mm (0.0039 0.0059 in)
DI-00172
14) Draw a matching mark on both differential carrier and holder. Remove the holder side at a time.
Replace in the original position after inserting an Oring and applying grease to threaded portion.
(A)
(B)
DI-00386
(A) Alignment mark

(B) Holder
15) Tighten the bolt of lock plate to specified

torque.
DI-00172
NOTE:
shifted toward toe side under no-load rotation.
heel.]
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
(A)
(B)
AT-00207
(A) Toe side

(B) Heel side
DI-00364
DI-67

DIFFERENTIALS

Contact pattern
Face contact
Contact pattern
AT-00208
AT-00210

AT-00212
AT-00213

Contact pattern
Flank contact
Contact pattern
AT-00209
AT-00211

AT-00213
AT-00212
DI-68

DIFFERENTIALS

again adjust the drive pinion height and the differential side bearing preload (already mentioned)
and the hypoid gear backlash.
19) Install the new gasket and rear cover to differential carrier and tighten the bolts to specified
torque.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)

Using a dial gauge, check the backlash of the side
gear. (VA1-type only)
Side gear backlash:
0.05 0.15 mm (0.0020 0.0059 in)
If the side gear backlash is not within the specification, adjust it as specified by selecting side gear
thrust washer.
DI-00240
DI-00387
E: INSPECTION
Wash all the disassembled parts clean, and examine them for wear, damage and other defects. Repair or replace the defective parts as necessary.
1) Hypoid driven gear and drive pinion
If abnormal tooth contact is evident, find out the
cause and adjust to give correct tooth contact. 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) Bearings
Replace if seizure, peeling, wear, rust, dragging
during rotation, 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.
Using a dial gauge, check the backlash of hypoid

driven gear.
Hypoid driven gear backlash:
0.10 0.15 mm (0.0039 0.0059 in)
If the hypoid driven gear backlash is not within the
specification, adjust the side bearing preload or repair if necessary.
DI-00099

Inspect the tooth contact between hypoid driven
gear and drive pinion. <Ref. to DI-54, ASSEMBLY,
Rear Differential (VA-type).>
4. COMPANION FLANGE
1) If rust or dirt is attached to the companion flange,
remove them.
2) Set a dial gauge at a companion flange surface
(mating surface of propeller shaft and companion
flange), and then measure the companion flange
runout.
DI-69

DIFFERENTIALS

Limit of runout:
0.08 mm (0.003 in)
Adjust the tooth contact between hypoid driven

gear and drive pinion gear.
<Ref. to DI-54, ASSEMBLY, Rear Differential (VAtype).>
DI-00360
3) Set the gauge inside of the companion flange,

and measure the runout.
Limit of runout:
0.08 mm (0.003 in)
DI-00361
4) If either runout exceeds the limit, move the

phase of companion flange and drive pinion 90
each, and find the point that the runout is within the
limit.
5) If the runout exceeds the limit after changing the
phase, replace the companion flange and recheck
the runout.
6) If the runout exceeds the limit after replacing the
companion flange, the drive pinion may be assembled incorrectly or bearing is faulty.
F: ADJUSTMENT
Adjust the side gear backlash. (VA1-type)

Adjust hypoid driven gear backlash.
DI-70
Rear Differential Front Oil Seal

DIFFERENTIALS
6. Rear Differential Front Oil

Seal
A: INSPECTION
Make sure that there is no leakage from front oil
seal portion. If there is any leakage, replace the oil
seal and inspect the propeller shaft.
B: REPLACEMENT
4) Remove the oil drain plug, and drain gear oil.
Except for VA2-type
Tightening torque:
T-type:
49 Nm (5.0 kgf-m, 36.2 ft-lb)
VA1-type:
34 Nm (3.5 kgf-m, 25.3 ft-lb)
For VA2-type:
29 Nm (3.0 kgf-m, 21.4 ft-lb)
6) Jack-up the rear wheel and support the body
with rigid racks.
9) Remove the self-locking nut while holding the
companion flange with ST.
ST 498427200
FLANGE WRENCH
(A)
ST
(B)
DI-00356
DI-00194
10) Extract the companion flange using ST.

ST 399703600
PULLER ASSY
(A) Filler plug

(B) Drain plug
VA2-type
ST
(A)
(B)
DI-00196
11) Remove the oil seal using ST or screwdriver.

ST 398527700
PULLER ASSY
DI-00357
(A) Filler plug

(B) Drain plug
5) Install the oil drain plug.

NOTE:
Apply liquid gasket to the oil drain plug for T-type.
Liquid gasket:
equivalent
ST
DI-00197
DI-71
Rear Differential Front Oil Seal

DIFFERENTIALS
12) Install a new oil seal with ST.

ST 498447120
OIL SEAL INSTALLER
ST
DI-00292
13) Install the companion flange.

NOTE:
Use a plastic hammer to install companion flange.
14) Tighten the self-locking nut within the specified
torque range so that the turning resistance of companion flange becomes the same as that of before
oil seal replacement.
ST 498427200
FLANGE WRENCH
NOTE:
Tightening torque:
T-type:
181 Nm (18.5 kgf-m, 134 ft-lb)
VA-type:
191 Nm (19.5 kgf-m, 141 ft-lb)
ST
DI-00194
15) Hereafter, reassemble in the reverse order of

disassembly.
DI-72
Rear Differential Side Oil Seal

DIFFERENTIALS
7. Rear Differential Side Oil Seal

A: INSPECTION
Make sure that there is no leakage from side oil
seal. If there is any leakage, replace the oil seal.
B: REPLACEMENT
1) Remove the rear differential. <Ref. to DI-28, REMOVAL, Rear Differential (T-type).> <Ref. to DI-45,
REMOVAL, Rear Differential (VA-type).>
2) Remove the rear differential side oil seal using a
screwdriver wrapped with vinyl tape to prevent the
side retainer from scratches.
3) Using the ST, install the oil seal to the side retainer.
T-type and VA2-type
ST 398437700
DRIFT
ST
DI-00209
VA1-type
ST 498447100
INSTALLER
ST
DI-00221
4) Install the rear differential. <Ref. to DI-29, INSTALLATION, Rear Differential (T-type).> <Ref. to
DI-46, INSTALLATION, Rear Differential (VAtype).>
DI-73
Rear Differential Front Member

DIFFERENTIALS
8. Rear Differential Front Member

A: REMOVAL
3) Support the rear differential using transmission
jack, and then remove the rear differential front
member.
(A)
DI-00293
(A) Rear differential front member
B: INSTALLATION
Install the rear differential front member with a new
self-locking nut.
Tightening torque:
T1: 52 Nm (5.3 kgf-m, 38 ft-lb)
T2: 110 Nm (11.2 kgf-m, 81 ft-lb)
T2
T1
DI-00294
C: INSPECTION
1) Check the rear differential front member for
damage, bend and corrosion.
If damage, bend or corrosion is excessive, replace
the rear differential front member.
2) Check the bushings of rear differential member
for cracking, hardening and damage.
If cracking, hardening or damage is excessive, replace rear differential front member.
DI-74

DIFFERENTIALS

A: INSPECTION
Symptom or trouble
1. Oil leakage
Possible cause
(1) Worn, scratched or incorrectly seated
front or side oil seal. Scored, battered or
excessively worn sliding surface of companion flange.
(2) Clogged or damaged air breather.
(3) Loose bolts on differential spindle or
side retainer, or incorrectly fitted O-ring.
(4) Loose rear cover attaching bolts or
damaged gasket.
(5) Loose oil filler or drain plug.
(6) Wear, damage or incorrectly fitting for
spindle, side retainer and oil seal.
2. Seizure
(1) Insufficient backlash for hypoid gear.
NOTE:
(2) Excessive preload for side, rear or
Seized or damaged parts should be re- front bearing.
placed, and also other parts should be
(3) Insufficient or improper oil used.
thoroughly checked for any defect and
should be repaired or replaced as required.
(1) Improper backlash for hypoid gear.
3. Damage
NOTE:
(2) Insufficient or excessive preload for
Damaged parts should be replaced, and side, rear or front bearing.
also other parts should be thoroughly
(3) Excessive backlash for differential
checked for any defect and should be regear.
paired or replaced as required.
(4) Loose bolts and nuts such as hypoid
driven gear bolt.
(5) Damage due to overloading.
4. Noises when starting or shifting
(1) Excessive backlash for hypoid gear.
gears
(2) Excessive backlash for differential
NOTE:
gear.
Noises may be caused by differential as(3) Insufficient preload for front or rear
sembly, universal joint, wheel bearing,
bearing.
etc. Find out what is actually making noise
(4) Loose drive pinion nut.
before disassembling.
(5) Loose bolts and nuts such as side
bearing retainer attaching bolt.
5. Noises when cornering
(1) Damaged differential gear.
(2) Excessive wear or damage of thrust
washer.
(3) Broken pinion mate shaft.
(4) Seized or damaged side bearing.
DI-75
Remedy
Correct or replace.

Tighten the bolts to specified torque.
Replace the O-ring.
Tighten the bolts to specified torque.
Replace gasket and apply liquid gasket.
Retighten and apply liquid gasket.
Correct or replace.
Readjust or replace.
Replace seized part and fill with specified
oil to specified level.
Replace.
Replace gear or thrust washer.
Retightening.
Replace.
Readjust.
Replace gear or thrust washer.
Readjust.
Replace.
Replace.
Replace.
Replace.

DIFFERENTIALS
Symptom or trouble
6. Gear noise
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.
Possible cause
(1) Improper tooth contact of hypoid gear.
(2) Improper backlash for hypoid gear.
(3) Scored or chipped teeth of hypoid
gear.
(4) Seized hypoid gear.
(5) Improper preload for front or rear
bearings.
(6) Seized, scored or chipped front or
rear bearing.
(7) Seized, scored or chipped side bearing.
(8) Vibrating differential carrier.
DI-76
Remedy
Readjust or replace hypoid gear set.
Readjust.
Replace hypoid gear set.
Replace hypoid gear set.
Readjust.
Replace.
Replace.
Replace.
TRANSFER CASE
TC
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Page
Transfer Case and Extension Case Assembly............................................3
Transfer Clutch............................................................................................4
Extension Case ...........................................................................................5
Extension Case and Intermediate Case......................................................6
Oil Seal........................................................................................................7
Transfer Drive Gear ....................................................................................8
Transfer Driven Gear ..................................................................................9
Reduction Drive Gear................................................................................10
Center Differential Carrier .........................................................................11
Center Differential .....................................................................................13
General Description
TRANSFER CASE
A: NOTE
For general description, refer to 4AT, 5AT or
5MT section.
4AT model:
<Ref. to 4AT-2, General Description.>
5AT model:
<Ref. to 5AT-2, General Description.>
5MT model:
<Ref. to 5MT-2, General Description.>
TC-2

TRANSFER CASE
2. Transfer Case and Extension

Case Assembly
A: NOTE
For removal, installation and inspection, refer to
5MT section. <Ref. to 5MT-44, Transfer Case and
Extension Case Assembly.>
TC-3
Transfer Clutch
TRANSFER CASE
3. Transfer Clutch
A: NOTE
4AT or 5AT section.
4AT model:
<Ref. to 4AT-88, Transfer Clutch.>
5AT model:
<Ref. to 5AT-74, Transfer Clutch.>
TC-4
Extension Case
TRANSFER CASE
4. Extension Case
A: NOTE
4AT section. <Ref. to 4AT-84, Extension Case.>
TC-5

TRANSFER CASE
5. Extension Case and Intermediate Case

A: NOTE
5AT section. <Ref. to 5AT-72, Extension Case
and Intermediate Case.>
TC-6
Oil Seal
TRANSFER CASE
6. Oil Seal
A: NOTE
For replacement and inspection, refer to 4AT,
5AT or 5MT section.
4AT model:
<Ref. to 4AT-50, Extension Case Oil Seal.> <Ref.
to 4AT-51, Differential Side Retainer Oil Seal.>
5AT model:
<Ref. to 5AT-50, Extension Case Oil Seal.> <Ref.
to 5AT-51, Differential Side Retainer Oil Seal.>
5MT model:
<Ref. to 5MT-39, Oil Seal.> <Ref. to 5MT-40, Differential Side Retainer Oil Seal.>
TC-7
Transfer Drive Gear

TRANSFER CASE
7. Transfer Drive Gear

A: NOTE
5MT section. <Ref. to 5MT-48, Transfer Drive
Gear.>
TC-8

TRANSFER CASE
8. Transfer Driven Gear

A: NOTE
5MT section. <Ref. to 5MT-50, Transfer Driven
Gear.>
TC-9

TRANSFER CASE
9. Reduction Drive Gear

A: NOTE
4AT section. <Ref. to 4AT-98, Reduction Drive
Gear.>
TC-10

TRANSFER CASE

A: NOTE
4AT or 5AT section.
4AT model:
<Ref. to 4AT-100, Center Differential Carrier.>
5AT model:
<Ref. to 5AT-80, Center Differential Carrier.>
TC-11

TRANSFER CASE

A: NOTE
4AT or 5AT section.
4AT model:
<Ref. to 4AT-96, Reduction Driven Gear.>
5AT model:
<Ref. to 5AT-78, Reduction Driven Gear.>
TC-12
Center Differential
TRANSFER CASE
12.Center Differential
A: NOTE
5MT section. <Ref. to 5MT-52, Center Differential.>
TC-13

TRANSFER CASE
13.Transfer Clutch Pressure

Test
A: NOTE
For inspection, refer to 4AT or 5AT section.
4AT model:
<Ref. to 4AT-39, Transfer Clutch Pressure Test.>
5AT model:
<Ref. to 5AT-37, Transfer Clutch Pressure Test.>
TC-14
DRIVE SHAFT SYSTEM
DS
1.
2.
3.
4.
5.
6.
7.
8.
Page
Propeller Shaft ..........................................................................................10
Front Axle..................................................................................................13
Front Hub Unit Bearing .............................................................................17
Rear Hub Unit Bearing ..............................................................................19
Front Drive Shaft .......................................................................................22
Rear Drive Shaft........................................................................................26
General Description
DRIVE SHAFT SYSTEM
A: SPECIFICATION
1. PROPELLER SHAFT
Model
Propeller shaft type
Propeller shaft length: L
Front propeller shaft Joint-to-joint length: L1
5MT
Rear propeller shaft Joint-to-Joint length: L2

Outer diameter of tube:
mm (in)
mm (in)
1490 (58.66)
4AT
EDJ
1430 (56.30)
mm (in)
735 (28.9)
675 (26.6)
mm (in)
755 (29.7)
D1
63.5 (2.50)
D2
57.5 (2.26)
L1
5AT
1317 (51.85)
562 (22.1)
L2
D1
D2
DS-00226
DS-2
General Description
DRIVE SHAFT SYSTEM
2. FRONT DRIVE SHAFT ASSEMBLY

Model
Type of drive shaft
Turbo AT, 3.0 L

Except turbo AT, 3.0 L
EBJ87+PTJ82
EBJ87+PTJ82
Axle diameter D
mm (in)
32 (1.3)
26 (1.0)
Axle length L
mm (in)
349.6 (13.76)
349.6 (13.76)
(B)
(A)
DS-00227
(A)
Axle diameter
(B)
Axle length
3. REAR DRIVE SHAFT ASSEMBLY

Model
Type of drive shaft
2.0 L Non-turbo AT
Except 2.0 L Non-turbo AT
BJ75+DOJ75
EBJ82+DOJ79
Axle diameter D
mm (in)
22 (0.87)
22 (0.87)
Axle length L
mm (in)
366.5 (14.43)
375.1 (14.77)
(B)
(A)
DS-00228
(A)
Axle diameter
(B)
Axle length
DS-3
General Description
DRIVE SHAFT SYSTEM
B: COMPONENT
1. PROPELLER SHAFT
(1)
(2)
(3)
(2)
T1
T2
(4)
T1
(5)
T1
DS-00229
(1)
(2)
(3)
Propeller shaft
Bushing
Rear differential (VA1-type)
(4)
(5)
Rear differential (T-type)

Rear differential (VA2-type)
DS-4

T1: 31 (3.2, 23.1)
T2: 52 (5.3, 38.3)
General Description
DRIVE SHAFT SYSTEM
2. FRONT AXLE
(1)
(2)
(3)
(4)
(5)
(6)
(8)
(10)
(9)
(7)
T2
(14)
(11)
T1
(12)
(13)
DS-00232
(1)
(2)
(3)
(4)
(5)
(6)
Circlip
Baffle plate
Outer race (PTJ)
Snap ring
Trunnion
Snap ring
(7)
(8)
(9)
(10)
(11)
(12)
Boot band
Boot (PTJ)
Boot (EBJ)
EBJ shaft ASSY
Housing
Hub bolt
DS-5
(13)
(14)

Axle nut

T1: 220 (22.4, 162)
T2: 65 (6.6, 47.9)
General Description
DRIVE SHAFT SYSTEM
3. REAR AXLE
(1)
(2)
(3)
(5)
(6)
(7)
(8)
(8)
(10)
(4)
(9)
(8)
(11)
(13)
(12)
(14)
T2
T1
DS-00233
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Baffle plate (DOJ)

Outer race (DOJ)
Snap ring
Inner race
Ball
Cage
Snap ring
(8)
(9)
(10)
(11)
Boot band
Boot (DOJ)
Boot (BJ)
BJ shaft ASSY (2.0 L Non-turbo
AT model)
EBJ shaft ASSY (Except 2.0 L
Non-turbo AT model)
DS-6
(12)
(13)
(14)

Hub bolt
Axle nut (olive color)

T1: 65 (6.6, 47.9)
T2: 190 (19.4, 140)
General Description
DRIVE SHAFT SYSTEM
C: CAUTION
Use SUBARU genuine grease etc. or the equivalent. Do not mix grease, etc. with that of another
points.
Before installing 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.
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
922431000
DESCRIPTION
AXLE SHAFT
INSTALLER
REMARKS
Used for installing axle shaft into housing.
Used with ADAPTER (927390000).
925091000
BAND TIGHTENING
TOOL
Used for tightening boot band.

(A) Jig for band
(B) Ratchet wrench
926470000
AXLE SHAFT
PULLER
Used for removing axle shaft.
ST-922431000
(A)
(B)
ST-925091000
ST-926470000
DS-7
General Description
DRIVE SHAFT SYSTEM
ILLUSTRATION
TOOL NUMBER
18675AA000
DESCRIPTION
DIFFERENTIAL
SIDE OIL SEAL
INSTALLER
REMARKS
seal.
927080000
HUB STAND
Used for assembling hub bolt in hub.
927140000
AXLE SHAFT
PULLER PLATE
Same as plate 2 included in AXLE SHAFT

PULLER (926470000).
ST18675AA000
ST-927080000
ST-927140000
28099PA090
OIL SEAL PROTEC- Used for installing rear drive shaft into rear difTOR
ferential.
For protecting oil seal.
ST28099PA090
DS-8
General Description
DRIVE SHAFT SYSTEM
ILLUSTRATION
TOOL NUMBER
28399SA010
DESCRIPTION
REMARKS
OIL SEAL PROTEC- Used for installing front drive shaft into front
TOR
differential.
For protecting oil seal.
ST28399SA010
28399AG000
(New adopted tool)
HUB STAND
Used for extracting hub bolt.
ST28399AG000
2. GENERAL TOOL
DESCRIPTION
Puller
Dial gauge
Extension cap
Bar
REMARKS
Used for removing ball joint from knuckle arm.
Used for inspecting propeller shaft run-out.
Used for preventing leak of gear oil or ATF.
Used for extracting drive shaft.
DS-9
Propeller Shaft
DRIVE SHAFT SYSTEM
2. Propeller Shaft
8) Make matching marks on the flange yoke and

rear differential before removal.
A: REMOVAL
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.
(A)
DS-00028
(A) Alignment mark
9) Remove the three bolts which hold propeller

shaft to rear differential.
10) Remove the remaining bolt.
11) Remove the two bolts which hold center bearing to vehicle body.
DS-00239

2) Shift the select lever or gear shift lever to neutral.
DS-00141
12) Remove the propeller shaft from transmission.
(A)
DS-00230
CAUTION:
Be careful not to damage oil seals and 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:
Use a container to catch ATF or oil flowing from
propeller shaft.
(A) Heat shield cover
DS-00030
DS-10
Propeller Shaft
DRIVE SHAFT SYSTEM
13) 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.
(A)
DS-00031
(A) Extension cap

C: INSPECTION
NOTE:
Do not disassemble propeller shaft. Check the following and replace if necessary.
Tube surface for dents of cracks
Splines for deformation or abnormal wear
Joints for non-smooth operation or abnormal
noise
Center bearing for free play, noise or nonsmooth operation.
Oil seals for abnormal wear or damage
Center bearing for breakage
Check the following points with propeller shaft installed in vehicle.
1. JOINTS AND CONNECTIONS
B: INSTALLATION
1) Insert the sleeve yoke into the transmission and
attach center bearing to body.
Tightening torque:
52 Nm (5.3 kgf-m, 38.3 ft-lb)

3) Check for any looseness of the yoke flange
mounting bolts which connect to rear differential
and center bearing bracket mounting bolts.
2. SPLINES AND BEARING

4) Turn the 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.
DS-00141
2) Align the matching marks and connect the flange

yoke and rear differential.
Tightening torque:
31 Nm (3.2 kgf-m, 23.1 ft-lb)
DS-00035
3. RUNOUT OF PROPELLER SHAFT

(A)
DS-00028

4) Set the dial gauge with its indicator stem at center of propeller shaft tube.
(A) Alignment mark

DS-11
Propeller Shaft
DRIVE SHAFT SYSTEM
5) Turn the propeller shaft slowly by hands to check

for runout of propeller shaft.
Runout:
Service limit 0.6 mm (0.024 in)
(A)
(B)
DS-00036
(A) Propeller shaft

(B) Dial gauge
4. CENTER BEARING FREE PLAY

4) Move the propeller shaft near center bearing up
and down, and left and right with your hand to
check for any abnormal bearing free play.
DS-00037
DS-12
Front Axle
DRIVE SHAFT SYSTEM
3. Front Axle
8) Remove the cotter pin and castle nut which secure tie-rod end to housing knuckle arm.
A: REMOVAL
(A)

3) Unlock the axle nut.
(B)
(C)
DS-00042
(A) Cotter pin

(B) Castle nut
(C) Tie-rod
DS-00038
4) Remove the axle nut using a socket wrench

while depressing the brake pedal.
9) Using a puller, remove the tie-rod ball joint from

knuckle arm.
CAUTION:
Remove the wheel before loosening the axle
nut. Failure to follow this rule may damage the
wheel bearings.
DS-00043
10) Remove the ABS wheel speed sensor assembly and harness.
DS-00143
6) Remove the disc brake caliper from housing,

and suspend it from strut using a wire.
7) Remove the disc rotor from hub.
NOTE:
If the disc rotor seizes up within hub, drive disc rotor
out by installing an 8-mm bolt in screw hole on rotor.
DS-00249
11) Remove the bolts which secure sensor harness

to strut.
DS-00041
DS-00144
DS-13
Front Axle
DRIVE SHAFT SYSTEM
12) Remove the front arm ball joint from housing.
3) Install the front arm ball joint to housing.

Tightening torque:
49 Nm (5.0 kgf-m, 36 ft-lb)
4) Install the ABS wheel speed sensor harness to
strut.
5) Install the ABS wheel speed sensor on housing.
Tightening torque:
32 Nm (3.3 kgf-m, 23.9 ft-lb)
6) Install the disc rotor on hub.
7) Install the disc brake caliper on housing.
DS-00045
13) Remove the PTJ from transmission.

14) Remove the front drive shaft assembly from
hub. If it is hard to remove, use STs.
ST1 926470000 AXLE SHAFT PULLER
PLATE
Tightening torque:
78 Nm (8.0 kgf-m, 57.9 ft-lb)
8) Install the stabilizer link.
9) Connect the tie-rod end ball joint to the knuckle
arm with a castle nut.
Tightening torque:
27.0 Nm (2.75 kgf-m, 19.9 ft-lb)
CAUTION:
When connecting, do not hit the cap at bottom
of tie-rod end with hammer.
10) Tighten the castle nut to specified torque and
tighten further within 60 until the pin hole is aligned
with the slot in nut. Bend the cotter pin to lock.
ST1
ST2
(A)
DS-00145
15) After scribing an alignment mark on camber adjusting bolt head, remove the bolts which connect
housing and strut, and disconnect the housing from
strut.
(B)
(C)
DS-00042
(A) Cotter pin

(B) Castle nut
(C) Tie-rod
11) While depressing the brake pedal, tighten a

new axle nut (olive color) to specified torque and
lock it securely.
DS-00046
B: INSTALLATION
1) While aligning the alignment mark on the camber adjusting bolt head, tighten the housing and
strut using a new self-locking nut.
Tightening torque:
177 Nm (18.0 kgf-m, 130 ft-lb)
Tightening torque:
220 Nm (22.4 kgf-m, 162 ft-lb)
CAUTION:
Install the wheel after installation of axle nut.
Failure to follow this rule may damage the
wheel bearing.
Be sure to tighten the axle nut to specified
torque. Do not overtighten it as this may damage wheel bearing.
DS-14
Front Axle
DRIVE SHAFT SYSTEM
D: ASSEMBLY
12) After tightening the axle nut, lock it securely.
1) Assemble the front hub unit bearing. <Ref. to

DS-18, ASSEMBLY, Front Hub Unit Bearing.>
2) Place the disc cover between housing and front
hub unit, and tighten the four bolts.
Tightening torque:
65 Nm (6.6 kgf-m, 47.9 ft-lb)
DS-00048
(A)
13) Install the wheel and tighten the wheel nuts to

specified torque.
Tightening torque:
90 Nm (9.2 kgf-m, 66 ft-lb)
C: DISASSEMBLY
DS-00231
1) Remove the four bolts from housing, and remove the front hub unit bearing and disc cover.
(A) Housing
CAUTION:
Do not get closer the tool which charged
magnetism to magnetic encorder.
Be careful not to damage the magnetic encoder.
(A)
(2)
(1)
DS-00231
(A) Housing
CAUTION:
DS-00250
(1) Magnetic encoder

(2) Front hub unit bearing
(2)
E: INSPECTION
(1)
1) Moving the front tire up and down by hand,

check there is no backlash in bearing, and check
the wheel rotates smoothly.
DS-00250

2) Disassemble the front hub unit bearing. <Ref. to

DS-18, DISASSEMBLY, Front Hub Unit Bearing.>
DS-00061
DS-15
Front Axle
DRIVE SHAFT SYSTEM
2) Inspect the lean of axis direction using a dial

gauge. Replace the bearing if the load range exceeds the limitation.
Service limit:
Maximum: 0.05 mm (0.0020 in)
DS-00062
DS-16
Front Hub Unit Bearing

DRIVE SHAFT SYSTEM
4. Front Hub Unit Bearing

A: REMOVAL
CAUTION:
(2)
(1)
DS-00250
DS-00038


CAUTION:
wheel bearings.
5) Remove the disc brake caliper from housing,
and suspend it from strut using a wire.
8) Remove the front hub unit bearing. If it is hard to

remove, use STs.
PLATE
NOTE:
If the disc rotor seizes up within hub, drive disc rotor
out by installing an 8-mm bolt in screw hole on rotor.
ST1
ST2
DS-00145
B: INSTALLATION
1) Place the disc cover between housing and front
hub unit, and tighten the four bolts.
DS-00041
Tightening torque:
65 Nm (6.6 kgf-m, 47.9 ft-lb)
7) Remove four bolts from housing.

(A)
(A)
DS-00231
DS-00231
(A) Housing
(A) Housing
DS-17
Front Hub Unit Bearing

DRIVE SHAFT SYSTEM
3) Tighten the axle nut temporarily.
5) Install the disc brake caliper on the housing.
NOTE:
Since the hub unit bearing can not be disassembled, only hub bolts can be removed.
(1)
Tightening torque:
78 Nm (8.0 kgf-m, 57.9 ft-lb)
6) While depressing the brake pedal, tighten a new
axle nut (olive color) to specified torque and lock it
securely.
ST
Tightening torque:
220 Nm (22.4 kgf-m, 162 ft-lb)
CAUTION:
Install the wheel after installation of the axle
wheel bearing.
DS-00252
D: ASSEMBLY
1) Attach the hub to ST securely.
ST 927080000
HUB STAND
(1)
ST
DS-00253
DS-00048

specified torque.
2) Using a press, press new hub bolts until their

seating surfaces contact the hub.
Tightening torque:
90 Nm (9.2 kgf-m, 66 ft-lb)
NOTE:
Use 12 mm (0.47 in) dia. holes in HUB STAND to
prevent bolts from tilting.
C: DISASSEMBLY
Using the ST and a hydraulic press, drive hub bolts
out.
ST 28399AG000 HUB STAND
E: INSPECTION
CAUTION:
Be careful not to hammer the hub bolts. This
may deform the hub.
Do not reuse the hub bolt.
CAUTION:
If there is any fault in the bearing, replace hub
unit bearing.
Refer to FRONT AXLE for inspection procedures.

<Ref. to DS-15, INSPECTION, Front Axle.>
DS-18
Rear Hub Unit Bearing

DRIVE SHAFT SYSTEM
5. Rear Hub Unit Bearing

A: REMOVAL
wheels.
If the disc rotor seizes up within hub, drive the

disc rotor out by installing an 8-mm bolt in screw
hole on rotor.
9) Remove the four bolts from rear arm.
DS-00149
10) Remove the hub unit bearing.

DS-00038
4) While applying the parking brake, remove the

axle nut using the socket wrench.
CAUTION:
wheel bearings.
6) Remove the rear ABS wheel speed sensor.
CAUTION:
(2)
(1)
DS-00251

(2) Rear hub unit bearing
DS-00147
7) Remove the disc brake caliper from back plate,

and suspend it from stabilizer using wire.
DS-00150
DS-00148

NOTE:
Mark the mating surface of hub and disc rotor before removing the disc rotor to avoid confusing
when installing.
DS-19

DRIVE SHAFT SYSTEM
2) Tighten the four bolts to the back plate.
NOTE:
If it is hard to remove, use STs.
PLATE
ST1
Tightening torque:
65 Nm (6.6 kgf-m, 47.9 ft-lb)
ST2
DS-00149
3) Remove the axle nut.

4) Draw the rear drive shaft into specified position.
5) Tighten the new axle nut temporarily.
DS-00122
B: INSTALLATION
1) Aligning the hub unit bearing to the mounting
hole of the back plate, install the hub unit assembly
and back plate. Tighten the axle nut temporarily.
CAUTION:
CAUTION:
Use a new axle nut (olive color).
7) Install the disc brake caliper on back plate.
Tightening torque:
52 Nm (5.3 kgf-m, 38.3 ft-lb)
(2)
(1)
DS-00152
DS-00251

8) Install the rear ABS wheel speed sensor and

brake cable bracket.
DS-00147
DS-00151
9) Adjust the parking brake lever stroke by turning

adjuster. <Ref. to PB-5, ADJUSTMENT, Parking
Brake Lever.>
DS-20

DRIVE SHAFT SYSTEM
10) While applying the parking brake and depressing the brake pedal, tighten a new axle nut (olive
color) to the specified torque and lock it securely.
D: ASSEMBLY
1) Attach the hub to ST securely.
ST 927080000
HUB STAND
Tightening torque:
190 Nm (19.4 kgf-m, 140 ft-lb)
(1)
CAUTION:
wheel bearing.
ST
DS-00255
2) Using a press, press the new 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.
E: INSPECTION
DS-00048

specified torque.
1) Moving the rear tire up and down by hand, check

there is no backlash in bearing, and check the
wheel rotates smoothly.
Tightening torque:
90 Nm (9.2 kgf-m, 66 ft-lb)
C: DISASSEMBLY
Using the ST and a hydraulic press, drive hub bolts
out.
ST 28399AG000 HUB STAND
CAUTION:
Be careful not to hammer the hub bolts. This
may deform the hub.
Do not reuse the hub bolt.
NOTE:
Since the hub unit bearing can not be disassembled, only hub bolts can be removed.
DS-00183
2) Inspect the lean of axis direction using a dial

gauge. Replace the hub bearing if the lean range
exceed the limitation.
Service limit:
Maximum: 0.05 mm (0.0020 in)
(1)
ST
DS-00254
DS-00062
DS-21
Front Drive Shaft

DRIVE SHAFT SYSTEM
6. Front Drive Shaft
8) Using a bar, remove the front drive shaft from

transmission.
A: REMOVAL
CAUTION:
Be careful not to allow the bar to damage holder
area.
B: INSTALLATION
1) Using the ST, replace the differential side retainer oil seal with a new one.
SEAL INSTALLER
NOTE:
After pulling out the drive shaft, be sure to replace
with a new oil seal.
DS-00038
ST

CAUTION:
wheel bearings.
5) Remove the stabilizer link from front arm.
6) Disconnect the front arm ball joint from housing.
MT-00103
2) Insert the EBJ into hub splines.

3) Draw the drive shaft into specified position.
CAUTION:
Do not hammer drive shaft when installing it.
5) Using the ST, install the front drive shaft to transmission.
FS-00106
7) Remove the front drive shaft assembly. If it is

hard to remove, use ST1 and ST2.
PLATE
ST
AT-00110
6) Connect the front arm ball joint to housing.

Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
7) Install the stabilizer link.
ST1
ST2
DS-00145
CAUTION:
Be sure to use a new self-locking nut.
Tightening torque:
45 Nm (4.6 kgf-m, 33.2 ft-lb)
DS-22
Front Drive Shaft

DRIVE SHAFT SYSTEM
8) While depressing the brake pedal, tighten a new

axle nut (olive color) to the specified torque and
lock it securely.
4) Remove the PTJ outer race from shaft assembly.

5) Wipe off grease.
Tightening torque:
220 Nm (22.4 kgf-m, 162 ft-lb)
CAUTION:
The grease is a special grease. Do not confuse
with other greases.
6) Place alignment marks on the roller kit and trunnion.
CAUTION:
wheel bearing.
Be sure to tighten axle nut to specified
9) After tightening axle nut, lock it securely.
C: DISASSEMBLY
1) Place alignment marks on the shaft and outer
race.
DS-00106
2) Remove the PTJ boot band and boot.

DS-00109
CAUTION:
Be careful not to damage boot.
7) Remove the roller kit from trunnion.

CAUTION:
Be careful with the roller kit position.
8) Place alignment marks on the trunnion and
shaft.
DS-00107
3) Remove the snap ring from PTJ outer race.
DS-00110
DS-00108
DS-23
Front Drive Shaft

DRIVE SHAFT SYSTEM
6) Align alignment marks on roller kit and trunnion

and install the roller kit.
9) Remove the snap ring and trunnion.
CAUTION:
Be careful with the roller kit position.
DS-00111
CAUTION:
Be sure to wrap shaft splines with vinyl tape to
prevent boot from scratches.
10) Remove the PTJ boot.
NOTE:
Further disassembly of axle is impossible because
the BJ cannot be disassembled.
D: ASSEMBLY
NOTE:
Use specified grease.
PTJ side:
NSG301 (Part No. 28395AG020)
1) Place the PTJ boot at the center of shaft.
2) Align alignment marks and install the trunnion on
the shaft.
DS-00109
7) Align alignment marks on the shaft and outer

race, and install outer race.
DS-00106
DS-00110
3) Install the snap ring to shaft.

CAUTION:
Confirm that the snap ring is completely fitted
in shaft groove.
4) Fill 100 to 110 g (3.53 to 3.88 oz.) of specified
grease into the interior of PTJ outer race.
5) Apply a thin coat of specified grease to the roller
kit and trunnion.
8) Install the snap ring in the groove on PTJ outer

race.
CAUTION:
Pull the shaft lightly and assure that the snap
ring is completely fitted in the groove.
9) 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.
10) Install the PTJ boot taking care not to twist it.
CAUTION:
The large end of PTJ boot and the boot
groove shall be cleaned completely so as to be
free from grease and other substances.
When installing PTJ boot, position outer race
of PTJ at center of its travel.
DS-24
Front Drive Shaft

DRIVE SHAFT SYSTEM
11) Put a new band through the clip and wind twice
in alignment with band groove of boot.
12) Pinch the end of band with pliers. Hold the clip
and tighten securely.
NOTE:
When tightening boot, use care so that the air within the boot is appropriate.
13) Tighten the band using ST.
ST 925091000
BAND TIGHTENING TOOL
NOTE:
Tighten the band until it cannot be moved by hand.
EBJ (high-efficiency compact ball fixed joint)

Check for seizure, corrosion, damage and excessive play.
Shaft
Check for excessive bending, twisting, damage
and wear.
Boot
Check for wear, warping, breakage and scratches.
Grease
Check for discoloration and fluidity.
DS-00132
14) Tap on the clip with the punch provided at the

end of ST.
ST 925091000
CAUTION:
Tap to an extent that the boot underneath is not
damaged.
DS-00133
15) Cut off the 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.
16) Extend and retract the PTJ to provide equal
grease coating.
E: INSPECTION
Check the removed parts for damage, wear, corrosion etc. If faulty, repair or replace.
PTJ (pillow tripod joint)
Check for seizure, corrosion, damage, wear and
excessive play.
DS-25
Rear Drive Shaft

DRIVE SHAFT SYSTEM
7. Rear Drive Shaft
B: INSTALLATION
A: REMOVAL
1) Insert the BJ or EBJ into rear hub splines.

wheels.
CAUTION:
(2)
(1)
DS-00038
DS-00251
4) While applying the parking brake, remove the

axle nut using the socket wrench.
CAUTION:
wheel bearings.
5) Remove the rear differential assembly.
T-type
<Ref. to DI-28, REMOVAL, Rear Differential (Ttype).>
VA-type
<Ref. to DI-45, REMOVAL, Rear Differential (VAtype).>
6) Remove the axle nut and rear drive shaft. If it is
hard to remove, use ST1 and ST2.
PLATE
CAUTION:
Do not hammer drive shaft when removing.
Do not damage the oil seal and magnetic encoder.
ST1
ST2

2) Draw the rear drive shaft into specified position.

CAUTION:
Do not hammer drive shaft when installing it.
4) Install the rear differential assembly.
T-type
(T-type).>
VA-type
(VA-type).>
5) While applying the parking brake and depressing the brake pedal, tighten a new axle nut (olive
color) to specified torque and lock it securely.
Tightening torque:
190 Nm (19.4 kgf-m, 140 ft-lb)
CAUTION:
wheel bearing.
DS-00122
DS-26
Rear Drive Shaft

DRIVE SHAFT SYSTEM
6) Lock the axle nut securely.
7) Wipe off the 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).
DS-00048
(A)
7) Install the wheel.
(B)
Tightening torque:
90 Nm (9.2 kgf-m, 66 ft-lb)
C: DISASSEMBLY
1) Straighten the bent claw of larger end of DOJ
boot.
2) Loosen the band by means of screwdriver or pliers.
CAUTION:
Be careful not to damage boot.
DS-00126
(A) Outer race

(B) Grease
8) To remove the cage from inner race, turn the

cage by a half pitch to the track groove of inner race
and shift the cage.
9) Remove the snap ring, which fixes inner race to
shaft, using pliers.
10) Take out the DOJ inner race.
11) Take off the DOJ cage from shaft and remove
DOJ boot.
DS-00124
3) Remove the 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 the round circlip located at the
neck of DOJ outer race with a screwdriver.
CAUTION:
12) Remove the BJ boot or EBJ boot in the same
procedure as DOJ boot.
NOTE:
Further disassembly of axle is impossible because
the BJ and EBJ cannot be disassembled.
D: ASSEMBLY
NOTE:
Use specified grease.
BJ side:
NTG2218-M (Part No. 28395AG010)
EBJ side:
NTG2218-M (Part No. 28395AG010)
DS-00125
6) Take out the DOJ outer race from shaft assembly.
DOJ side:
NKG205 (Part No. 28495AG000)
1) Install the BJ or EBJ boot in specified position,
and fill it with 60 to 70 g (2.12 to 2.47 oz.) of specified grease.
DS-27
Rear Drive Shaft

DRIVE SHAFT SYSTEM
2) Place the DOJ boot at the center of shaft.
5) Install the cage to inner race fixed upon shaft.
CAUTION:
3) Insert the DOJ cage onto shaft.
NOTE:
Fit the cage with the protruded part aligned with the
track on the inner race and then turn by a half pitch.
NOTE:
Insert the cage with the cut-out portion facing the
shaft end, since the cage has an orientation.
(B)
(A)
(A)
DS-00129
(A) Inner race

(B) Cage
(B)
DS-00127
(A) Cage
(B) Cutout
4) Install the DOJ inner race on shaft and fit the

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 the shaft, inner race, cage and balls in the
original positions and then fit outer race.
(A)
(B)
DS-00126
(A) Outer race

(B) Grease
DS-00128
10) Install the snap ring 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.
Use care not to place the matched position of
snap ring in the ball groove of outer race.
DS-28
Rear Drive Shaft

DRIVE SHAFT SYSTEM
Pull the shaft lightly and assure that the circlip is

completely fitted in the groove.
16) Tap on the clip with the punch provided at the

end of ST.
ST 925091000
NOTE:
Tap to an extent that the boot underneath is not
damaged.
DS-00125
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 the DOJ boot taking care not to twist it.
DS-00133
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 new band through the clip and wind twice
in alignment with band groove of boot.
14) Pinch the end of band with pliers. Hold the clip
and tighten securely.
17) Cut off the band with an allowance of about 10

mm (0.39 in) left from the clip and bend this allowance over the clip.
NOTE:
When tightening boot, exercise care so that the air
within the boot is appropriate.
15) Tighten the band by using ST.
ST 925091000
E: INSPECTION
NOTE:
Tighten the band until it cannot be moved by hand.
DS-00132
NOTE:
Be careful so that the end of the band is in close
contact with clip.
18) Install the BJ boot or EBJ boot in the same procedure as DOJ boot.
19) Extend and retract the DOJ to provide equal
grease coating.
Check the removed parts for damage, wear, corrosion etc. Repair or replace if defective.
DOJ (Double Offset Joint)
excessive play.
EBJ (high-efficiency compact ball fixed joint)
excessive play.
Shaft
Check for excessive bending, twisting, damage
and wear.
BJ (Bell Joint)
Check for seizure, corrosion, damage and excessive play.
Boot
Check for wear, warping, breakage and scratches.
Grease
Check for discoloration and fluidity.
DS-29

DRIVE SHAFT SYSTEM

A: INSPECTION
NOTE:
Vibration while cruising may be caused by an unbalanced tire, improper tire inflation pressure, improper
wheel alignment, etc.
Symptom
Noise or vibration from propeller shaft
Possible cause
Center bearing
Runout of propeller shaft
Loose or free play of connection
Abnormal wheel vibration
Wheel is out of balance.

Front strut
Rear shock absorber
Front drive shaft
Rear drive shaft
Noise from the underbody
Wheel is out of balance.

Front strut
Rear shock absorber
DS-30
Corrective action
Check the center bearing. <Ref. to DS-12, CENTER BEARING FREE PLAY, INSPECTION,
Propeller Shaft.>
Check the vibration of propeller shaft. <Ref. to
DS-11, RUNOUT OF PROPELLER SHAFT,
INSPECTION, Propeller Shaft.>
Check joint and connector. <Ref. to DS-11,
JOINTS AND CONNECTIONS, INSPECTION,
Propeller Shaft.>
Check splines and bearing. <Ref. to DS-11,
SPLINES AND BEARING, INSPECTION, Propeller Shaft.>
Check the wheel balance. <Ref. to WT-7,
ADJUSTMENT, Wheel Balancing.>
Check the front wheel alignment. <Ref. to FS-8,
INSPECTION, Wheel Alignment.>
Check the rear wheel alignment. <Ref. to RS-8,
Check the front strut. <Ref. to FS-24, INSPECTION, Front Strut.>
Check the rear shock absorber. <Ref. to RS-16,
INSPECTION, Rear Shock Absorber.>
Check the front drive shaft. <Ref. to DS-25,
INSPECTION, Front Drive Shaft.>
Check the rear drive shaft. <Ref. to DS-29,
INSPECTION, Rear Drive Shaft.>
Check the front hub unit bearing. <Ref. to DS-18,
INSPECTION, Front Hub Unit Bearing.>
Check the rear hub unit bearing. <Ref. to DS-21,
INSPECTION, Rear Hub Unit Bearing.>
Check the wheel balance. <Ref. to WT-7,
ADJUSTMENT, Wheel Balancing.>
Check the front wheel alignment. <Ref. to FS-8,
Check the rear wheel alignment. <Ref. to RS-8,
Check the front strut. <Ref. to FS-24, INSPECTION, Front Strut.>
Check the rear shock absorber. <Ref. to RS-16,
INSPECTION, Rear Shock Absorber.>
ABS
ABS
1.
2.
3.
4.
5.
6.
7.
8.
Page
ABS Control Module and Hydraulic Control Unit (ABSCM&H/U)................6
ABS Sequence Control .............................................................................10
Front ABS Wheel Speed Sensor...............................................................13
Rear ABS Wheel Speed Sensor ...............................................................15
Front Magnetic Encoder............................................................................16
Rear Magnetic Encoder ............................................................................17
G Sensor ...................................................................................................18
General Description
ABS
A: SPECIFICATION
Item
ABS wheel speed sensor gap (for reference)
ABS wheel speed sensor
Front
Marks of harness (Marks, Color)
Rear
G sensor
ABSCM&H/U identification
G sensor voltage
AT (Except for OUTBACK)
MT (Except for OUTBACK)
AT (OUTBACK)
MT (OUTBACK)
ABS-2
Front
Rear
RH
LH
RH
LH
Standard value or identification

0.77 1.43 mm (0.030 0.056 in)
0.64 1.56 mm (0.025 0.061 in)
K1 (White)
K2 (Yellow)
K5 (White)
K6 (Yellow)
2.30.2 V
J1
J2
J3
J4
General Description
ABS
B: COMPONENT
1. ABS WHEEL SPEED SENSOR
T1
T1
(1)
T2
(4)
T2
(6)
(5)
T1
(3)
(2)
T2
ABS00380
(1)
(2)
(3)
G sensor
Front ABS wheel speed sensor LH
Front housing
(4)
(5)
(6)
Rear ABS wheel speed sensor LH Tightening torque: Nm (kgf-m, ft-lb)

Hub unit bearing
T1: 7.5 (0.76, 5.5)
Magnetic encoder
T2: 33 (3.3, 24)
ABS-3
General Description
ABS
2. ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U)

(3)
(4)
(5)
(2)
(7)
(6)
(1)
T2
(9)
(8)
T1
(10)
(11)
T2
T2
ABS00381
(1)
ABS control module and hydraulic

control unit (ABSCM&H/U)
(2)
(3)
(4)
(5)
Front outlet RH
Rear outlet LH
Rear outlet RH
Front outlet LH
(6)
(7)
(8)
(9)
(10)
Primary inlet
Secondary inlet
Damper
Spacer
Damper
C: CAUTION
cable from battery.
points.
ABS-4
(11)
Bracket

T1: 7.5 (0.76, 5.5)
T2: 33 (3.3, 24)
General Description
ABS
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
24082AA230
DESCRIPTION
CARTRIDGE
REMARKS
22771AA030
SUBARU SELECT
MONITOR KIT

ST24082AA230
ST22771AA030
2. GENERAL TOOL
Circuit tester
Pressure gauge
Oscilloscope
TOOL NAME
REMARKS
TORX BIT E5
Used for replacing ABS control module.
ABS-5
ABS Control Module and Hydraulic Control Unit (ABSCM&H/U)

ABS
2. ABS Control Module and Hydraulic Control Unit (ABSCM&H/U)

A: REMOVAL
2) Use compressed air to get rid of water around
the ABSCM&H/U.
NOTE:
When dust and dirt are attached to the terminal,
they may cause poor contact.
3) Disconnect the ABSCM&H/U connector pulling
up the lock lever.
8) Remove the ABSCM&H/U bracket.
B: INSTALLATION
1) Install the ABSCM&H/U bracket.
Tightening torque:
33 Nm (3.3 kgf-m, 24 ft-lb)
2) Install the ABSCM&H/U aligning the groove of
damper on ABSCM&H/U side with the pawl of
bracket.
NOTE:
Check the identification mark of ABSCM&H/U.
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
CAUTION:
Do not pull the harness when disconnecting
connector.
ABS00383
3) Connect the brake pipes to their correct ABSCM&H/U positions.

ABS00382
4) Remove the harness clip.

5) Disconnect the brake pipes from ABSCM&H/U.
6) Wrap the brake pipe using a vinyl bag not to spill
the brake fluid on the vehicle body.
CAUTION:
When brake fluid is attached to the vehicle
body, wash it off with water and wipe the water.
7) Remove the nuts and remove the ABSCM&H/U.
CAUTION:
Do not drop or bump the ABSCM&H/U.
Do not turn ABSCM&H/U upside down or
place it sideways for storage.
Be careful that no foreign objects are mixed
in ABSCM&H/U.
Be careful that no water enters inside the
connectors.
Tightening torque:
15 Nm (1.5 kgf-m, 10.8 ft-lb)
4) Using a harness clip, secure the ABSCM&H/U
harness to bracket.
NOTE:
Be sure to remove all foreign matters from inside
the connector before connecting.
Ensure the ABSCM&H/U connector is securely
locked.
6) Bleed air from the brake system.
C: INSPECTION
1) Check the connected and fixed condition of connector.
2) Check the mark used for ABSCM&H/U identification.
ABS00383
ABS-6

ABS
Refer to SPECIFICATION for mark. <Ref. to

ABS-2, SPECIFICATION, General Description.>
(1)
that the kick-back is normal, and tightness is normal.
Initial value
When
decompressed
When compressed
ABS00384
(1) Mark
1. CHECKING THE HYDRAULIC UNIT ABS

OPERATION BY PRESSURE GAUGE
1) Lift-up the vehicle, and then remove the 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 use the pressure gauge for the measurement of transmission oil pressure since
the piston seal may be expanded and deformed.
NOTE:
Wrap a sealing tape around the pressure gauge.
Front wheel
3,500 kPa
(36 kgf/cm2, 511 psi)
500 kPa
(5 kgf/cm2, 73 psi)
or less
3,500 kPa
(36 kgf/cm2, 511 psi)
or more
Rear wheel
3,500 kPa
(36 kgf/cm2, 511 psi)
500 kPa
(5 kgf/cm2, 73 psi)
or less
3,500 kPa
(36 kgf/cm2, 511 psi)
or more
8) Remove the pressure gauges from the FL and

FR caliper bodies.
9) Connect the air bleeder screws of the FL and FR
caliper bodies.
10) Remove the air bleeder screws from the RL
and RR caliper bodies.
11) Connect two pressure gauges to the RL and
RR caliper bodies.
13) Bleed air from the pressure gauges and the RL
14) Perform ABS sequence control.
<Ref. to ABS-10, ABS Sequence Control.>
15) When the hydraulic unit begins to work, first the
RR side performs decompression, holding and
compression, and then the RL side performs decompression, holding and compression.
16) Read values indicated on the pressure gauge
and check if the fluctuation of the values between
decompression and compression meets the standard values. Depress the brake pedal and check
that the kick-back is normal, and tightness is normal.
17) Remove the pressure gauge from the RL and
RR caliper bodies.
18) Connect the air bleeder screws of the RL and
RR caliper bodies.
ABS00134
4) Bleed air from the pressure gauges and the FL

and FR caliper bodies.
FL side performs decompression, holding and
compression, and then the FR side performs decompression, holding and compression.
ABS-7

ABS

OPERATION WITH BRAKE TESTER
1) Install the spare fuse to the FWD connector located in the main fuse box for the model without AT
VTD.
(1)
(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.
8) Read values indicated on the brake tester and
check if the fluctuation of the values between decompression and compression meets the standard
values.
Initial value
(2)
When
decompressed
ABS00392
When compressed
(1) Main fuse box

(2) FWD connector
2) Since the MT model and AT VTD model cannot

cut off the AWD circuit forcibly, set the wheels other
than measured one onto free rollers.
3) Prepare for the ABS sequence control.
4) Set the front wheels or rear wheels on the brake
tester and set the select lever to neutral.
(1)
ABS00136
Front wheel
1,000 N
(102 kgf, 225 lb)
500 N
(51 kgf, 112 lb)
or less
1,000 N
(102 kgf, 225 lb)
or more
Rear wheel
1,000 N
(102 kgf, 225 lb)
500 N
(51 kgf, 112 lb)
or less
1,000 N
(102 kgf, 225 lb)
or more
9) After the inspection, depress the brake pedal

and check that it is not abnormally hard, and tightness is normal.
D: REPLACEMENT
CAUTION:
Because the seal of ABSCM cannot be replaced, do not pull or peel it with lifting up.
Because the screw part of H/U deteriorates in
every replacement procedure, do not perform
the replacement more than five times on it.
When the malfunction is found though the replacement that performed is less than five
times, replace the H/U body.
Use new screws for installation of ABSCM.
When the sealing surface of ABSCM or H/U is
dirty or damaged and it cannot be removed or
repaired, replace it with new one.
1) Remove the ABSCM&H/U. <Ref. to ABS-6, REMOVAL, ABS Control Module and Hydraulic Control Unit (ABSCM&H/U).>
2) To prevent entering foreign matter and brake fluid leakage, plug the oil pressure port of ABSCM&H/
U using screw plug and etc.
3) Set the pump motor part of removed ABSCM&H/
U faces down on a vise.
(1)
ABS00137
(1) Brake tester
5) Operate the brake tester.

7) When the hydraulic unit begins to work, check
the following working sequence.
ABS-8

ABS
NOTE:
Before securing a part on a vice, place cushioning
material such as wood blocks, aluminum plate or
cloth between the part and vice.
CAUTION:
Always use new screws.
Tightening torque:
1.5 Nm (0.15 kgf-m, 1.1 ft-lb)
(1)
(3)
(1)
(2)
(4)
ABS00430
(2)
ABS00432
(1) Aluminum plate or etc.

(2) Vise
4) Using TORX BIT E5, remove the four screws of

ABSCM.
10) Check that there is no foreign matter in aligning

part between ABSCM and H/U.
11) Using TORX BIT E5, tighten the screws stepwise in the order of (1) through (4) again.
Tightening torque:
3 Nm (0.3 kgf-m, 2.2 ft-lb)
12) Check that there is no clearance in aligning part
between ABSCM and H/U.
13) Install the ABSCM&H/U to vehicle.
NOTE:
Always use new screws.
ABS00431
5) Slowly remove the ABSCM upward from H/U.

NOTE:
To prevent damaging of coil part, remove the ABSCM straightly from H/U.
6) Ensure there are no dirt or damage on sealing
surface of H/U.
CAUTION:
Do not clean the ABSCM & H/U with applying
compressed air.
Do not repair the damages of H/U sealing surface using file or metal scraper. To remove the
sealing, use resin scraper. Do not use the
chemical materials (thinner and etc.).
7) Position the coil of new ABSCM to align H/U
valve.
8) To prevent deforming of ABSCM housing cover,
hold the corner of ABSCM and install it to the H/U
without tilting.
9) Using TORX BIT E5, tighten the screws stepwise in the order of (1) through (4).
ABS-9
ABS Sequence Control

ABS
3. ABS Sequence Control

A: OPERATION
1) While the ABS sequence control is performed,
the operation of the hydraulic unit can be checked
using the brake tester or pressure gauge after the
hydraulic unit solenoid valve operation.
2) ABS sequence control can be started by diagnosis connector or Subaru Select Monitor.
1. ABS SEQUENCE CONTROL WITH DIAGNOSIS CONNECTOR

NOTE:
In the event of any trouble, the ABS sequence control is not operated.
1) Turn the ignition switch to OFF at the vehicle stationary mode.
2) Take out the diagnosis connector from the inside
of instrument panel lower cover on the drivers side,
and connect one of ground terminal to connector
terminal No. 8.
5) When the Function check sequence is selected, the ABS sequence control will start.
6) Execute the following operations when the message Press the brake pedal so that the brake pedal force is between 100 and 150 kgf is displayed.
(1) When the brake tester is used, press brake
pedal pad with a force of 1,000 N (102 kgf, 225
lb).
(2) When using the pressure gauge, press the
brake pedal so as to make the pressure gauge
indicate 3,500 kPa (36 kg/cm2, 511 psi).
7) Press the [YES] key will be displayed. Press
the [YES] key.
8) The brake line being operated is displayed on
the Subaru Select Monitor.
B82
1 2
3
4 5 6 7 8
ABS00466
3) Turn the ignition switch to ON without depressing the brake pedal.

4) After the ABS warning light is turned off, perform
the brake pedal operation as follows; press it within
3 seconds, release it, press it again, release it again, and then press it.
NOTE:
Engine must not start.
5) After completion of ABS sequence control, turn
2. ABS SEQUENCE CONTROL WITH SUBARU SELECT MONITOR

NOTE:
In the event of any trouble, the ABS sequence control is not operated.
connector under the drivers side instrument panel
lower cover.
3) Set the Subaru Select Monitor switch to ON.
4) Set the Subaru Select Monitor to Brake Control
mode.
ABS-10

ABS
3. CONDITIONS FOR ABS SEQUENCE CONTROL
V max < 4 km/h (2.5 MPH)

V max < 10 km/h (6 MPH)
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(16)
OFF
(19)
(17)
ON
(18)
(20)
(19)
OFF
OFF
(22)
(21)
(23)
(22)
(23)
(24)
(20)
(19)
(20)
(19)
ON
ON
(25)
OFF
(22)
ON
OFF
ON
(25)
(9)
OFF
(10)
OFF
(11)
OFF
(12)
(13)
(14)
(15)
ON
(22)
ON
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
(26)
(27)
(28)
(29)
(30)
(31)
(32)
ABS00385
ABS-11

ABS
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
All wheel speed

DL terminal
Ignition key
ABS warning light
Stop light switch
Valve relay
FL decompression valve
FL compression valve
FR decompression valve
FR compression valve
RR decompression valve
RR compression valve
(13)
(14)
(15)
(16)
RL decompression valve
RL compression valve
Pump motor
Diagnosis connector and connection
(17)
When using the Subaru Select

Monitor, both connection and nonconnection of diagnosis connector
are acceptable.
(18)
(19)
(20)
1.5 seconds
Light OFF
Light ON
NOTE:
When using the Subaru Select Monitor, the control
operation starts from point A. The patterns from ignition key ON to the point A show that operation is
started by diagnosis connector. (However, it is required to turn the stop light switch to ON before
point A.)
B: SPECIFICATION
1. CONDITIONS FOR COMPLETION OF
ABS SEQUENCE CONTROL
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 the diagnosis connector is disconnected.
(Without Subaru Select Monitor)
3) When the brake pedal is released during ABS
sequence control and the stop light switch goes
OFF.
4) When the brake pedal is depressed after the ignition key is turned to ON, but before ABS warning
light goes out. (Without Subaru Select Monitor)
5) When the ignition key is turned to ON, but the
brake pedal is not depressed within 3 seconds after
ABS warning light goes OFF. (Without Subaru Select Monitor)
6) After completion of ABS sequence control.
7) When malfunction is detected.
ABS-12
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
Within 3 seconds
1.0 second
1.4 seconds
0.6 second
0.4 second
Point A
Reset
Master cylinder pressure
FL wheel cylinder pressure
FR wheel cylinder pressure
RR wheel cylinder pressure
RL wheel cylinder pressure
Front ABS Wheel Speed Sensor

ABS
4. Front ABS Wheel Speed Sensor
Do not apply excessive force to the sensor

harness.
A: REMOVAL
2) Disconnect the ABS wheel speed sensor connector located next to the front strut mounting
house in engine compartment.
3) Separate the sensor connector and vehicle securing clip. Apply force in the direction of (2) to unlock the pawl, and then slide the connector in the
direction of (3). Pull out the connector to the tire
side from grommet hole.
CAUTION:
Clip would break when removing the clip without separating sensor connector and clip.
(3)
ABS00387
B: INSTALLATION
Tightening torque:
Sensor:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
Bracket:
33 Nm (3.3 kgf-m, 24 ft-lb)
CAUTION:
Be careful not to damage the sensor portion.
NOTE:
Check the identification (mark) on the harness to
make sure that no warp exists. (RH: K1 (White),
LH: K2 (Yellow))
Check if the harness is not pulled and does not
come in contact with the suspension or body during
steering wheel effort.
(1)
(2)
ABS00434
(1) Pawl
4) Remove the sensor harness bracket.
C: INSPECTION
(1)
1. INSPECTION WITH SUBARU SELECT

MONITOR
(2)
ABS00386
(1) To front ABS wheel speed sensor connector

(2) Sensor harness bracket
5) Remove the bolts which secure sensor harness

to front strut.
6) Remove the front ABS wheel speed sensor from
housing.

connector.
2) Select {Current Data Display & Save}. Check if
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.
3) If the speed indicated on the display does not
change, check the ABS wheel speed sensor. <Ref.
to ABS-14, ABS WHEEL SPEED SENSOR, INSPECTION, Front ABS Wheel Speed Sensor.>
CAUTION:
ABS-13

ABS

1) Check the pole piece of the ABS wheel speed
sensor for foreign particles or damage. If necessary, clean the pole piece or replace the ABS wheel
speed sensor.
2) Charge a 12 V power supply to the No. 2 terminal of sensor connector as shown in the figure, and
then install the resistance to No. 1 terminal. Rotate
the wheel about 2.75 km/h (2 MPH) or equivalent,
measure the voltage using oscilloscope.
Standard value of output voltage:
0.7 1.4 V
1.4 V
0.7 V
(1)
12 V
1
(2)
2
2
1
100
ABS00388
(1) Oscilloscope
(2) ABS wheel speed sensor
NOTE:
Check the ABS wheel speed sensor cable for discontinuity. If necessary, replace with a new one.
ABS-14
Rear ABS Wheel Speed Sensor

ABS
5. Rear ABS Wheel Speed Sensor

A: REMOVAL
CAUTION:
Do not apply excessive force to the sensor
harness.

speed sensor.
ABS00390
B: INSTALLATION
ABS00389
3) Remove the sensor harness bracket from rear

arm.
CAUTION:
Tightening torque:
Sensor:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
Bracket:
33 Nm (3.3 kgf-m, 24 ft-lb)
NOTE:
Check the identification (mark) on the harness to
make sure that no warp exists. (RH:K5(White),
LH:K6(Yellow))
C: INSPECTION
ABS00166

<Ref. to ABS-14, ABS WHEEL SPEED SENSOR,
INSPECTION, Front ABS Wheel Speed Sensor.>
ABS00167
ABS00168
4) Remove the rear ABS wheel speed sensor from

rear arm.
ABS-15
Front Magnetic Encoder

ABS
6. Front Magnetic Encoder

A: REMOVAL
Refer to Front Hub Bearing for removal, because
the front magnetic encoder is integrated with front
hub bearing.
<Ref. to DS-17, REMOVAL, Front Hub Unit Bearing.>
B: INSTALLATION
Refer to Front Hub Bearing for installation, because the front magnetic encoder is integrated with
front hub bearing.
<Ref. to DS-17, INSTALLATION, Front Hub Unit
Bearing.>
C: INSPECTION
Visually check the magnetic encoder for any damage. If necessary, replace with a new hub unit bearing.
NOTE:
Replace the hub unit bearing with a new one if
there is any defect found on the magnetic encoder,
since the magnetic encoder is integrated with hub
unit bearing assembly.
ABS-16
Rear Magnetic Encoder

ABS
7. Rear Magnetic Encoder

A: REMOVAL
Refer to Rear Hub Unit Bearing for removal, because the rear magnetic encoder is integrated with
rear hub unit bearing.
<Ref. to DS-19, REMOVAL, Rear Hub Unit Bearing.>
B: INSTALLATION
Refer to Rear Hub Unit Bearing for installation,
because the rear magnetic encoder is integrated
with rear hub unit bearing.
<Ref. to DS-20, INSTALLATION, Rear Hub Unit
Bearing.>
C: INSPECTION
Visually check the magnetic encoder for any damage. If necessary, replace with a new hub unit bearing.
NOTE:
Replace the hub unit bearing with a new one if
there is any defect found on the magnetic encoder,
since the magnetic encoder is integrated with hub
unit bearing assembly.
ABS-17
G Sensor
ABS
8. G Sensor
A: REMOVAL
<Ref. to EI-53, REMOVAL, Console Box.>
3) Disconnect the connector from G sensor.
4) Remove the G sensor from body.
CAUTION:
Do not drop or bump the G sensor.
Since G sensor is a unit with the bracket, do
not disassemble them.
ABS00463
B: INSTALLATION
CAUTION:
Do not drop or bump the G sensor.
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
ABS-18
G Sensor
ABS
C: INSPECTION
1
Step
CHECK G SENSOR.
link connector.
3) Set the Subaru Select Monitor to the {Brake
Control} mode.
4) Set the display in the {Current Data Display
& Save} mode.
5) Read the G sensor output value.
CHECK G SENSOR.
2) Remove the G sensor from vehicle. (Do not
disconnect connector.)
CHECK G SENSOR.
Check
Is the value 1.2 1.2 m/s
when the vehicle is in horizontal position?
2
Is the value 8.1 11.2 m/s2

when G sensor is inclined forward to 90?
Yes
Go to step 2.
No
between G sensor
and ABSCM&H/U.
Or replace G sensor.
Go to step 3.

between G sensor
and ABSCM&H/U.
between G sensor
and ABSCM&H/U.
Is the value 8.1 11.2 m/s2 G sensor is normal.

when G sensor is inclined
backward to 90?
ABS-19
G Sensor
ABS
ABS-20
ABS (DIAGNOSTICS)
ABS(diag)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Page
Electrical Component Location .................................................................10
Control Module I/O Signal .........................................................................12
Inspection Mode........................................................................................26
ABS Warning Light / Brake Warning Light Illumination Pattern ................28

ABS (DIAGNOSTICS)

A: PROCEDURE
CAUTION:
Remove foreign matters (dust, water, oil, etc.) from the ABSCM&H/U connector during removal and
installation.
NOTE:
To check harness for broken wires or short circuits, shake trouble spot or connector.
Refer to Check List for Interview. <Ref. to ABS(diag)-4, Check List for Interview.>
Step
1) Ask the customer when and how the trouble occurred using interview checklist. <Ref. to
ABS(diag)-4, Check List for Interview.>
2) Before performing diagnostics, check the
component which might affect ABS problems.
<Ref. to ABS(diag)-8, INSPECTION, General
Description.>
CHECK INDICATION OF DTC ON SCREEN.
link connector.
3) Turn the ignition switch to ON and Subaru
Select Monitor to ON.
Check
Is the component that might
influence the ABS problem
normal?
Yes
Go to step 2.
No
Repair or replace
each unit.
Is DTC displayed?
Go to step 4.
Go to step 3.
NOTE:
ABS(diag)-18, COMMUNICATION FOR INITIALIZING IMPOSSIBLE, INSPECTION, Subaru Select Monitor.>
4) Read the DTC. <Ref. to ABS(diag)-25,
OPERATION, Read Diagnostic Trouble Code
(DTC).>
5) Record all DTCs and Freeze Frame Data.
PERFORM THE GENERAL DIAGNOSTICS. Does the ABS warning light go Finish the diagno1) Inspect using General Diagnostic Table. off after turning the ignition
sis.
<Ref. to ABS(diag)-81, General Diagnostic
switch to ON?
Table.>
ABS(diag)-17, CLEAR MEMORY MODE,
ABS(diag)-26, Inspection Mode.>
READ DIAGNOSTIC TROUBLE CODE (DTC),
Check the DTC does not displayed.
ABS(diag)-2
Check in accordance with Diagnostic Procedure

for ABS. <Ref. to
ABS(diag)-21,
WITHOUT DTC,
INSPECTION,
Subaru Select
Monitor.>

ABS (DIAGNOSTICS)
Step
Check
Is DTC displayed?
1) Refer to the List of Diagnostic Trouble
Code (DTC). <Ref. to ABS(diag)-39, LIST, List
2) Fix the wrong part.
ABS(diag)-26, Inspection Mode.>
ABS(diag)-3
Yes
No
Repeat step 1 to 4 Finish the diagnountil DTC is not
sis.
shown.

ABS (DIAGNOSTICS)

A: CHECK
Check the following items about the vehicles state.
1. STATE OF ABS WARNING LIGHT

ABS warning light
comes on.
Ignition key position
Timing
Always
Sometimes
Only once
Not come on
When / how long does it come on?
LOCK
ACC
ON (before starting engine)
START
ON (after Engine starting, engine is running)
ON (after Engine starting, engine is at a standstill)
Immediately after turning the ignition to ON
Immediately after turning the ignition to START
When accelerating
km/h
When driving at a constant speed

When decelerating
When turning to the right
Steering angle:
Steering time:
Steering angle:
Steering time:
When turning to the left

When operating other electrical parts
Parts name:
Operating condition:
2. STATE OF BRAKE WARNING LIGHT

Brake warning light
comes on.
Always
Sometimes
Only once
Not come on
When pulling the parking brake lever up.
When releasing the parking brake lever down.
When / how long does it come on?
LOCK
ACC
START
ABS(diag)-4
km/h
MPH
MPH
km/h
MPH
deg
Sec.
deg
Sec.

ABS (DIAGNOSTICS)
Timing

When accelerating
km/h

When decelerating
Steering angle:
Steering time:
Steering angle:
Steering time:
km/h
MPH
MPH
km/h
MPH
deg
Sec.
deg
Sec.

Parts name:
3. SYMPTOMS
ABS operating condi- Does not move.
tion
Operates only when applying an abrupt brake.
How to step on brake pedal:
a) Operating time:
b) Operating noise: Occurs. / Does not occur.
What kind of noise?
Vehicle speed:
Sec.
Knocking
Gong gong
Bong
Buzz
Gong gong buzz
Others:
c) Reaction force of brake pedal

Stick
Weak pedal resistance
Strong pedal resistance
Others:
ABS(diag)-5
km/h
MPH

ABS (DIAGNOSTICS)
Behavior of vehicle
a) Directional stability cannot be obtained or the steering refuses to work when applying brakes:
Yes / No
When:
When spinning
Others:
a) Directional stability cannot be obtained or the steering refuses to work when accelerating:
Yes / No
When:
When spinning
Others:
c) Poor brake performance: Yes / No
What kind:
Long braking/stopping distance
Brakes lock or drag
Long pedal stroke
Pedal sticks.
Others:
d) Poor acceleration: Yes / No
What kind:
Not accelerate
Engine stalls.
Others:
e) Occurrence of vibration: Yes / No
Where
What kind:
Where
What kind:
g) Other troubles occurred: Yes / No
What kind:
4. CONDITIONS UNDER WHICH TROUBLE OCCURS

Environment
Fine
Cloudy
Rainy
Snowy
Others:
a) Weather
C (F)
b) Ambient temperature
c) Road
Inner city
Suburbs
Highway
Local street
Uphill
Downhill
Paved road
Gravel road
Muddy road
Sandy place
Others:
Dried
Wet
Covered with fresh snow
Covered with hardened snow
Frozen slope
Others:
d) Road surface
ABS(diag)-6

ABS (DIAGNOSTICS)
Condition
a) Brakes
Deceleration:
Intermittent / Temporary
Acceleration:
Intermittent / Temporary
km/h
Advancing
When accelerating
When decelerating
At low speed
When 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:
b) Accelerator
c) Vehicle speed
d) Tire inflation pressure
e) Degree of wear
f) Genuine parts are used.: Yes / No

g) Tire chain is attached.: Yes / No
h) T-type tire is used.: Yes / No
i) Condition of suspension alignment:
j) Loading state:
k) Repair parts are used.: Yes / No
Contents:
l) Others:
ABS(diag)-7
G
G
MPH
kPa
kPa
kPa
kPa
General Description
ABS (DIAGNOSTICS)
6. BRAKE PAD AND ROTOR
A: CAUTION
Check the brake pad and rotor.

FRONT <Ref. to BR-18, INSPECTION, Front
Brake Pad.> <Ref. to BR-19, INSPECTION, Front
Disc Rotor.>
REAR <Ref. to BR-25, INSPECTION, Rear
Brake Pad.> <Ref. to BR-26, INSPECTION, Rear
Disc Rotor.>
1. SUPPLEMENTAL RESTRAINT SYSTEM

AIRBAG
Airbag system wiring harness is routed near the
ABS wheel speed sensor and ABSCM&H/U.
CAUTION:
All airbag system wiring harness and connectors are colored yellow. Do not use the electrical test equipment on these circuits.
wiring harness when servicing the ABS wheel
speed sensor and ABSCM&H/U.
7. TIRE
Check the tire specifications, tire wear and air pressure. <Ref. to WT-2, SPECIFICATION, General
Description.>
B: INSPECTION
Before performing diagnosis, check the following
items which might affect ABS problems.
1. BATTERY
Measure battery voltage and check electrolyte.
2. GROUND
Check the tightening torque of ABS ground (GB-7)
bolt.
Tightening torque:
33 Nm (3.4 kgf-m, 24.3 ft-lb)
3. BRAKE FLUID
1) Check the brake fluid level.
2) Check the brake fluid for leaks.
4. HYDRAULIC UNIT
Check the hydraulic unit.
With brake tester <Ref. to ABS-8, 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-7, CHECKING THE HYDRAULIC UNIT ABS OPERATION
BY PRESSURE GAUGE, INSPECTION, ABS
Control Module and Hydraulic Control Unit (ABSCM&H/U).>
5. BRAKE DRAG
Check for brake drag.
ABS(diag)-8
General Description
ABS (DIAGNOSTICS)
C: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
24082AA230
DESCRIPTION
CARTRIDGE
REMARKS
22771AA030
SUBARU SELECT
MONITOR KIT

ST24082AA230
ST22771AA030
2. GENERAL TOOL
TOOL NAME
Circuit tester
Oscilloscope
REMARKS
ABS(diag)-9

ABS (DIAGNOSTICS)

A: LOCATION
(13)
(4)
(5)
(3)
(2)
(1)
(9)
(7)
(8)
(10)
(6)
(11)
(12)
(7)
(8)
(9)
ABS00458
(1)

(5)
Data link connector

(For Subaru Select Monitor)
(2)
(3)
Two-way connector
Diagnosis connector (Used for
ABS sequence control.)
(6)

(TCM) (AT model)
(4)
ABS warning light
(7)
(8)
Magnetic encoder seal

ABS(diag)-10
(9)
(10)
(11)
(12)
(13)
Caliper body
G sensor
Stop light switch
Master cylinder
Brake and EBD warning light

ABS (DIAGNOSTICS)
(1)
(3)
ABS00405
ABS00106
(13)
(5)
(4)
ABS00438
ABS00464
(8)
(8)
FRONT
REAR
(7)
(7)
ABS00408
(10)
ABS00406
ABS(diag)-11
(7)
(7)
ABS00407
Control Module I/O Signal

ABS (DIAGNOSTICS)
5. Control Module I/O Signal

(1)
B301
12 13 14 15
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
ABS00409
(1)

control unit (ABSCM&H/U) connector
NOTE:
Terminal numbers in ABSCM&H/U connector are as shown in the figure.
ABS warning light is illuminates when the connector is removed from ABSCM&H/U.
ABS(diag)-12

ABS (DIAGNOSTICS)
Terminal
No.
(+) ()
Measured value and measuring conditions
16 15
4.5 16.5 V
5.9 16.8 mA: Rectangle waveform
5 15
4.5 16.5 V
2 15
4.5 16.5 V
17
3 15
4.5 16.5 V
CAN communication line (+)

CAN communication line ()
Valve relay power supply *1
Motor relay power supply *1
Power supply
G sensor
Ground
Output
4
26
11
14 15
13 15
24 10
10
21 10
Stop light switch *1
20 15
ABS warning light
22 15
Brake warning light (EBD warning light)
8 15
7 15
ABS diagnosis connector

Power supply *1
Grounding line
Vehicle speed output signal
25 15
18 15
15
23 15

2.5 1.5 V pulse signal
10 15 V
10 15 V
4.75 5.25 V
2.1 2.5 V when the vehicle is on a level surface

Less than 1.5 V when the stop light is OFF; otherwise,
10 15 V when the stop light is ON.
After turning the ignition switch to ON, 10 15 V during
1.5 seconds and less than 1.5 V after 1.5 seconds
passed.
passed.
Less than 1.5 V when no data is received.
0 12 V pulse (in communication)
When the ignition switch is ON, 10 15 V.
0 5 V pulse
Description
Front LH wheel

(Wheel speed sensor)
Front RH wheel
Rear LH wheel
Rear RH wheel
Power
supply
Signal
Power
supply
Signal
Power
supply
Signal
Power
supply
Signal
Input/Output signal
*1: Measure the I/O signal voltage after removing the connector from the ABSCM&H/U terminal.
ABS(diag)-13

ABS (DIAGNOSTICS)
B: WIRING DIAGRAM
(3)
(16)
(30)
(1)
(5)
(31)
(17)
(18)
(19)
(2)
(6)
(20)
(28)
(29)
(4)
(21)
M
(22)
(7)
(8)
(9)
(23)
(10)
(11)
(12)
(24)
(13)
(25)
(14)
(26)
(15)
(27)
ABS00470
(1)
(2)
(3)
Battery
Ignition switch
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
ABS control module

Valve relay
Motor relay
Motor
Front inlet solenoid valve LH
Front outlet solenoid valve LH
Front inlet solenoid valve RH
Front outlet solenoid valve RH
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
Rear inlet solenoid valve LH

Rear outlet solenoid valve LH
Rear inlet solenoid valve RH
Rear outlet solenoid valve RH
Diagnosis connector
Data link connector
ABS warning light
Brake warning light
Stop light switch
Stop light
G sensor
ABS(diag)-14
(24)
(25)

Front ABS wheel speed sensor
RH
(26)
(27)
Rear ABS wheel speed sensor LH

Rear ABS wheel speed sensor
RH
(28)
(29)
(30)
(31)
Parking brake switch

Brake fluid level switch
(TCM)

ABS (DIAGNOSTICS)

A: OPERATION
(DTC)
CAUTION:
turn the Subaru Select Monitor switch to ON.

ABS(diag)-9, SPECIAL TOOL, PREPARATION
(1)
ABS00114
(1) Power switch

ABS00111

Monitor.
<Ref. to ABS(diag)-9, SPECIAL TOOL, PREPARATION TOOL, General Description.>
ABS00112

connector.
side).
(1)

screen, select the {Brake Control} and press the
[YES] key.
8) Press the [YES] key after the {ABS} is displayed.
9) On the ABS Diagnosis display screen, select
the {DTC Display} and press the [YES] key.
NOTE:
Diagnostic Trouble Code (DTC). <Ref. to ABS(diag)-39, List of Diagnostic Trouble Code (DTC).>
DTCs are displayed up to three in detected order.
If a particular DTC is not properly stored in memory (due to a drop in ABSCM&H/U power supply,
etc.) on the occurrence of a problem, the DTC
which is suffixed with a question mark ? appears
on the Subaru Select Monitor display. This shows it
may be an unreliable reading.
10) If ABS and Subaru Select Monitor cannot communicate, check the communication circuit. <Ref.
to ABS(diag)-18, COMMUNICATION FOR INITIALIZING IMPOSSIBLE, INSPECTION, Subaru
Select Monitor.>
ABS00465

connector.
ABS(diag)-15

ABS (DIAGNOSTICS)
11) When DTC is not displayed, check the meter

circuit or CAN communication circuit. <Ref. to
ABS(diag)-21, WITHOUT DTC, INSPECTION,
Display
Current
Old
Older
Before 3
Contents to be monitored
Indicate the latest DTC on the Subaru
Indicate the latest DTC in previous trouble on the Subaru Select Monitor display.
Indicate the latest DTC in second previous trouble on the Subaru Select Monitor
display.
Indicate the latest DTC in third previous
trouble on the Subaru Select Monitor display.

2) On the System Selection Menu display screen, select the {Brake Control} and press the [YES] key.
4) On the Brake Control Diagnosis screen, select the {Current Data Display/Save}, and then press the
[YES] key.
5) On the Data Display Menu screen, select the data display style and press the [YES] key.
6) Using a scroll key, move the display screen up or down until necessary data is shown.
Display
BLS Signal
Wheel speed detected by front ABS wheel speed sensor RH is displayed.
Wheel speed detected by front ABS wheel speed sensor LH is displayed.
Wheel speed detected by rear ABS wheel speed sensor RH is displayed.
Wheel speed detected by rear ABS wheel speed sensor LH is displayed.
Brake ON/OFF is displayed.
G Sensor
Vehicle acceleration detected by analog G sensor is displayed.
Valve Relay Signal

ABS Warning Light
EBD Warning Light
Motor Relay Monitor
IG power supply voltage
ABS Control Flag
ABS OK B Signal
Valve relay operation signal is displayed.

ON operation of the ABS warning light is displayed.
ON operation of the EBD warning light is displayed.
Motor relay monitor voltage is displayed.
Voltage supplied to ABSCM&H/U is displayed.
ABS control condition is displayed.
ABS system normal/abnormal is displayed.
FR Wheel Speed
FL Wheel Speed
RR Wheel Speed
RL Wheel Speed
Unit of measure
km/h or MPH
km/h or MPH
km/h or MPH
km/h or MPH
ON or OFF
m/s (m/s2)
ON or OFF
ON or OFF
ON or OFF
V
V
ON or OFF
OK or NG
NOTE:
ABS(diag)-16

ABS (DIAGNOSTICS)

{2. Each System Check} and press the [YES] key.
[YES] key.
4) On the Brake Control Diagnosis display
[YES] key.
Display
Clear memory?
Function of clearing DTC.
5) When Done and Turn ignition switch OFF are

shown on the display screen, turn the Subaru Select Monitor and ignition switch to OFF.
Display
IG power supply
voltage
G Sensor
Motor relay monMotor relay condition is displayed.

itor
BLS Signal
Vehicle speed calculated by ABS control
Vehicle speed
module is displayed.
ABS Control
Flag
Whether abnormal voltage occurred or
Power Supply
Failure
not is displayed during malfunction.
NOTE:
MANUAL.
4. ABS SEQUENCE CONTROL

Display
ABS
sequence
control
Operate the valve and
pump motor continuously
to perform the ABS
sequence control.
Index No.
<Ref. to ABS10, ABS
Sequence Control.>
5. FREEZE FRAME DATA

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.
Freeze frame data will be memorized up to three.
If a Freeze Frame Data is not properly stored in
memory (due to a drop in ABS control module power supply, etc.), the DTC which is suffixed with a
question mark ? appears on the Subaru Select
Monitor display. This shows it may be an unreliable
reading.
Display
FR Wheel
FL Wheel
RR Wheel
RL Wheel
Voltage supplied (V) to ABSCM&H/U is
displayed.
Vehicle acceleration detected by analog
G sensor is displayed.
Wheel speed detected by the Front ABS
wheel speed sensor RH is displayed in
km/h or MPH.
Wheel speed detected by the Front ABS
wheel speed sensor LH is displayed in
km/h or MPH.
Wheel speed detected by the Rear ABS
km/h or MPH.
Wheel speed detected by the Rear ABS
km/h or MPH.
ABS(diag)-17

ABS (DIAGNOSTICS)
B: INSPECTION
1. COMMUNICATION FOR INITIALIZING IMPOSSIBLE
Defective harness connector
TROUBLE SYMPTOM:
Communication is impossible between ABS and Subaru Select Monitor.
WIRING DIAGRAM:
SBF-1
BATTERY
No.13
SBF-7
IGNITION
SWITCH
DATA LINK
CONNECTOR
1
10
No.33
B40
B301
ABSCM & H/U
B40
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
15
18
B301
12 13 14 15
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
ABS00411
ABS(diag)-18

ABS (DIAGNOSTICS)
10
Step
Check
Yes
Does the ignition switch turn to Go to step 2.
ON?
CHECK BATTERY.
2) Measure the battery voltage.
Is there poor contact at battery Repair or tighten

terminal?
the battery terminal.
CHECK SUBARU SELECT MONITOR COM- Is the system name and model Go to step 8.
MUNICATION.
year displayed on Subaru
Select Monitor?
2) Using Subaru Select Monitor, check
whether communication to other system can
be executed normally.
CHECK SUBARU SELECT MONITOR COM- Is the system name and model Replace
MUNICATION.
year displayed on Subaru
ABSCM&H/U.
Select Monitor?
<Ref. to ABS-6,
2) Disconnect the ABSCM&H/U connector.
ABS Control Mod3) Turn the ignition switch to ON.
ule and Hydraulic
4) Check whether communication to other
Control Unit
(ABSCM&H/U).>
EACH CONTROL MODULE AND DATA LINK M?
CONNECTOR.
2) Disconnect ABSCM&H/U, ECM and TCM.
3) Measure the resistance between data link
Go to step 8.
CHECK OUTPUT SIGNAL FOR ABSCM&H/ Is the voltage less than 1 V?
U.
2) Measure the voltage between data link connector and chassis ground.
CHECK HARNESS CONNECTOR BETWEEN Is the resistance less than 0.5 Go to step 9.
ABSCM&H/U AND DATA LINK CONNEC?
TOR.
Measure the resistance between ABSCM&H/U
connector and data link connector.
(B301) No. 7 (B40) No. 10:
CHECK INSTALLATION OF ABSCM&H/U
Is the ABSCM&H/U connector Go to step 10.
CONNECTOR.
inserted into ABSCM&H/U until
it is locked by clamps?
Go to step 11.
CHECK POWER SUPPLY CIRCUIT.
OFF)
between ABSCM&H/U connector and chassis
ground.
ABS(diag)-19
No
Turn the ignition
switch to ON, and
select ABS mode
using Subaru
Select Monitor.
Charge or replace
the battery.
Go to step 4.
Go to step 5.
Go to step 6.
Repair the harness and connector between each

control module

control module
Repair the harness and connector between
ABSCM&H/U and
Insert ABSCM&H/
U connector into
ABSCM&H/U.
Repair the open
circuit in harness
between
ABSCM&H/U and
battery.

ABS (DIAGNOSTICS)
11
12
Step
Check
Yes
ABSCM&H/U AND CHASSIS GROUND.
?
2) Disconnect the connector from ABSCM&H/
U.
between ABSCM&H/U connector and chassis
ground.
CHECK POOR CONTACT IN CONNECTOR. Is there poor contact in control Repair the conmodule power supply, ground nector.
circuit and data link connector?
ABS(diag)-20
No
Repair the open
circuit in harness
between
ABSCM&H/U and
inhibitor side connector, and poor
Replace the
ABSCM only.
<Ref. to ABS-8,
REPLACEMENT,
ABS Control Module and Hydraulic
Control Unit
(ABSCM&H/U).>

ABS (DIAGNOSTICS)
2. WITHOUT DTC
Defective combination meter
Open in harness
TROUBLE SYMPTOM:
ABS warning light does not go off.
NO TROUBLE CODE will be displayed on the Subaru Select Monitor.
NOTE:
When the ABS warning light is OFF and NO TROUBLE CODE is displayed on Subaru Select Monitor, the
system is in normal condition.
ABS(diag)-21

ABS (DIAGNOSTICS)
WIRING DIAGRAM:
LHD model
BATTERY
SBF-7
SBF-1
E
IGNITION
SWITCH
No.33
No.5
BRAKE
WARNING
LIGHT
ABS
WARNING
LIGHT
COMBINATION
METER
A:
GROUND
TERMINAL
i10
B82
8
i3
20
B81
B301
A:
12 13 14 15
15
ABSCM & H/U
B301
i10
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
25
22
18
B38
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
B38
B82
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
2
1
3 4 5 6
ABS00459
ABS(diag)-22

ABS (DIAGNOSTICS)
RHD model
BATTERY
SBF-7
SBF-1
E
IGNITION
SWITCH
No.33
No.5
BRAKE
WARNING
LIGHT
ABS
WARNING
LIGHT
COMBINATION
METER
A:
GROUND
TERMINAL
i10
B82
8
B81
i1
B301
A:
12 13 14 15
15
ABSCM & H/U
B301
i10
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
25
22
18
B36
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
i1
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
B82
2
1
3 4 5 6
ABS00440
ABS(diag)-23

ABS (DIAGNOSTICS)
Step
Check
DATA CHECK SUBARU SELECT MONITOR. Is ON indicated?
2) Read the condition of ABS warning light.
Yes
No
Replace the
Go to step 2.
ABSCM only.
<Ref. to ABS-8,
REPLACEMENT,
Control Unit
(ABSCM&H/U).>
CHECK WIRING HARNESS.
Is the resistance less than 0.5 Go to step 3.
Repair the harMeasure the resistance between ABSCM con- ?
ness and connecnector and combination meter connector.
tor between
ABSCM&H/U and
(i10) No. 5 (B301) No. 22:
combination meter
connector.
CHECK POOR CONTACT IN CONNECTOR. Is there poor contact in
Repair the conCheck the combiABSCM connector and combinector.
nation meter.
nation meter connector?
ABS(diag)-24

ABS (DIAGNOSTICS)

Code (DTC)
A: OPERATION
For details about reading of DTCs, refer to Subaru
Select Monitor. <Ref. to ABS(diag)-15, Subaru Select Monitor.>
ABS(diag)-25
Inspection Mode
ABS (DIAGNOSTICS)
8. Inspection Mode
A: PROCEDURE
Reproduce the malfunction occurrence condition
as possible.
Drive the vehicle at a speed more than 40 km/h (25
MPH) for at least one minute.
ABS(diag)-26
Clear Memory Mode

ABS (DIAGNOSTICS)

A: OPERATION
For details concerning DTC clear operation, refer to
Subaru Select Monitor. <Ref. to ABS(diag)-15,
ABS(diag)-27
ABS Warning Light / Brake Warning Light Illumination Pattern

ABS (DIAGNOSTICS)
10.ABS Warning Light / Brake Warning Light Illumination Pattern

A: INSPECTION
(4)
(3)
(3)
(2)
(1)
(7)
(6)
(6)
(5)
(8)
(7)
(6)
(6)
(9)
(10)
(11)
ABS00442
(1)
(2)
(3)
(4)
Ignition switch
OFF
ON
Engine start
(5)
(6)
(7)
(8)
ABS warning light

Light OFF
Light ON
1.5 seconds
ABS(diag)-28
(9)
Brake warning light (EBD warning

light)
(10)
(11)
Parking brake
Released

ABS (DIAGNOSTICS)
1) When the ABS warning light and brake warning light do not illuminate in accordance with this illumination
pattern, there must be an electrical malfunction.
2) When ABS warning light remains constantly OFF, check the combination meter circuit. <Ref. to ABS(diag)-30, ABS WARNING LIGHT DOES NOT COME ON, ABS Warning Light / Brake Warning Light Illumination Pattern.>
3) When ABS warning light does not go off, check the combination meter circuit. <Ref. to ABS(diag)-33, ABS
WARNING LIGHT DOES NOT GO OFF, ABS Warning Light / Brake Warning Light Illumination Pattern.>
4) When brake warning light does not go off, check the brake warning light circuit, combination meter circuit.
<Ref. to ABS(diag)-36, BRAKE WARNING LIGHT DOES NOT GO OFF, ABS Warning Light / Brake Warning
Light Illumination Pattern.>
NOTE:
Even though the ABS warning light does not go off after 1.5 seconds from ABS warning light illumination, the
ABS function operates normally when the warning light goes off while driving at approximately 12km/h (7
MPH). However, the ABS function does not operate while the ABS warning light is illuminated.
ABS(diag)-29

ABS (DIAGNOSTICS)
B: ABS WARNING LIGHT DOES NOT COME ON

Defective harness
TROUBLE SYMPTOM:
When the ignition switch is turned to ON (engine OFF), ABS warning light does not come on.
WIRING DIAGRAM:
LHD model
BATTERY
SBF-7
SBF-1
E
IGNITION
SWITCH
No.33
No.5
BRAKE
WARNING
LIGHT
ABS
WARNING
LIGHT
COMBINATION
METER
A:
GROUND
TERMINAL
i10
B82
8
i3
20
B81
B301
A:
12 13 14 15
15
ABSCM & H/U
B301
i10
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
25
22
18
B38
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
B38
B82
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
2
1
3 4 5 6
ABS00459
ABS(diag)-30

ABS (DIAGNOSTICS)
RHD model
BATTERY
SBF-7
SBF-1
E
IGNITION
SWITCH
No.33
No.5
BRAKE
WARNING
LIGHT
ABS
WARNING
LIGHT
COMBINATION
METER
A:
GROUND
TERMINAL
i10
B82
8
B81
i1
B301
A:
12 13 14 15
15
ABSCM & H/U
B301
i10
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
25
22
18
B36
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
i1
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
B82
2
1
3 4 5 6
ABS00440
ABS(diag)-31

ABS (DIAGNOSTICS)
1
2
Step
CHECK ILLUMINATION OF OTHER LIGHTS.
Turn the ignition switch to ON. (engine OFF)
READ DTC.
Read the DTC. <Ref. to ABS(diag)-25, Read
2) Disconnect the connector (B301) from
ABSCM&H/U.
3) Disconnect the connector (i10) from the
combination meter.
4) Measure the resistance between ABSCM
CHECK ABSCM.
1) Connect the connector (B301) to the
ABSCM&H/U.
2) Turn the ignition to ON.
3) Immediately after turning ignition switch to
ON (within 1.5 seconds), measure the resistance of harness between the combination
(i10) No. 5 Chassis ground:
Check
Do other warning lights illuminate?
Is DTC displayed?
Yes
Go to step 2.
No
Go to step 3.

M?

DTC.
Go to step 4.
ABSCM&H/U and
combination meter
connector.

M?
ABS(diag)-32
Replace the
ABSCM only.
<Ref. to ABS-8,
REPLACEMENT,
Control Unit
(ABSCM&H/U).>

ABS (DIAGNOSTICS)
C: ABS WARNING LIGHT DOES NOT GO OFF

Open in harness
TROUBLE SYMPTOM:
When starting the engine, the ABS warning light is kept on.
WIRING DIAGRAM:
LHD model
BATTERY
SBF-7
SBF-1
E
IGNITION
SWITCH
No.33
No.5
BRAKE
WARNING
LIGHT
ABS
WARNING
LIGHT
COMBINATION
METER
A:
GROUND
TERMINAL
i10
B82
8
i3
20
B81
B301
A:
12 13 14 15
15
ABSCM & H/U
B301
i10
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
25
22
18
B38
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
B38
B82
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
2
1
3 4 5 6
ABS00459
ABS(diag)-33

ABS (DIAGNOSTICS)
RHD model
BATTERY
SBF-7
SBF-1
E
IGNITION
SWITCH
No.33
No.5
BRAKE
WARNING
LIGHT
ABS
WARNING
LIGHT
COMBINATION
METER
A:
GROUND
TERMINAL
i10
B82
8
B81
i1
B301
A:
12 13 14 15
15
ABSCM & H/U
B301
i10
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
25
22
18
B36
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
i1
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
B82
2
1
3 4 5 6
ABS00440
ABS(diag)-34

ABS (DIAGNOSTICS)
3
4
Step
READ DTC.
ABSCM&H/U.
combination meter.
connector and combination meter connector.
(B301) No. 22 (i10) No. 5:
Check poor contact in all connectors.
CHECK ABSCM.
1) Connect the connector (B301) to the
ABSCM&H/U.
3) Measure the resistance between combination meter connector and chassis ground.
Check
Is DTC displayed?
Yes
No
nosis according to
DTC.
Repair the har?
ness and connector between
ABSCM&H/U and
combination meter
connector.

Is the resistance less than 0.5 Check the combi?
nation meter.
ABS(diag)-35
Go to step 4.
Replace the
ABSCM only.
<Ref. to ABS-8,
REPLACEMENT,
Control Unit
(ABSCM&H/U).>

ABS (DIAGNOSTICS)
D: BRAKE WARNING LIGHT DOES NOT GO OFF

Brake warning light circuit is shorted.
Defective sensor/connector
TROUBLE SYMPTOM:
After starting the engine, the brake warning light is kept on though the parking lever is released.
WIRING DIAGRAM:
LHD model
BATTERY
SBF-7
SBF-1
IGNITION
SWITCH
A3
BRAKE
WARNING
LIGHT
BRAKE FLUID
LEVEL SWITCH
20
16
i1
i10
A7
A8
A:
B36
A4
No.5
i3
B301
B38
ABSCM & H/U
1
2
B97
B16
B229
R1
R4
B16
1
2
B229
1 2
PARKING
BRAKE
SWITCH
i1
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
B301
12 13 14 15
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
A:
i10
1 2 3 4 5
11 12 13 14 15 16
B38
B97
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
6 7 8 9 10
17 18 19 20 21 22
ABS00460
ABS(diag)-36

ABS (DIAGNOSTICS)
RHD model
BATTERY
SBF-7
SBF-1
IGNITION
SWITCH
A3
BRAKE
WARNING
LIGHT
A4
NO.5
16
i10
A7
BRAKE FLUID
LEVEL SWITCH
i1
A8
A:
B301
B36
ABSCM & H/U
1
2
B16
B97
B229
R1
R4
PARKING
BRAKE
SWITCH
B16
1
2
B229
1 2
i1
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
B301
12 13 14 15
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
A:
i10
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
B97
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
ABS00412
ABS(diag)-37

ABS (DIAGNOSTICS)
8
9
Step
CHECK INSTALLATION OF ABSCM&H/U
CONNECTOR.
2) Check that the ABSCM&H/U connector is
inserted to ABSCM&H/U until the clamp locks
onto it.
READ DTC.
CHECK THE BRAKE FLUID AMOUNT.
Check the amount of brake fluid in the reservoir tank of master cylinder.
CHECK BRAKE FLUID LEVEL SWITCH.
1) Disconnect the level switch connector (B16)
from master cylinder.
2) Measure the resistance of master cylinder
terminals.
Terminals
No. 1 No. 2:
CHECK PARKING BRAKE SWITCH.
1) Disconnect the connector (R4) from parking brake switch.
3) Measure the resistance between parking
brake switch terminal and chassis ground.
1) Disconnect the connector (i10) from combination meter.
CHECK HARNESS.
ABSCM&H/U.
combination meter.
3) Measure the resistance between
ABSCM&H/U connector and combination
meter connector.
(B301) No. 8 (i10) No. 7:
CHECK ABSCM.
1) Connect the connector to the ABSCM&H/U.
Check
Is the connector correctly
inserted?
Yes
Go to step 2.
No
Insert the
ABSCM&H/U connector until the
clamp locks onto
it.
Is DTC displayed?

nosis according to
DTC.
Is the amount of brake fluid
Go to step 4.
Replenish brake
between the lines of MAX and
fluid to the speciMIN?
fied value.
Replace the masM?
ter cylinder.

M?
Go to step 6.
Replace the parking brake switch.

M?
Go to step 7.

parking brake
switch.

?
Repair harness
between
ABSCM&H/U and
combination meter
connector.
Go to step 9.

nation meter.
ABS(diag)-38
Replace the
ABSCM only.
<Ref. to ABS-8,
REPLACEMENT,
Control Unit
(ABSCM&H/U).>

ABS (DIAGNOSTICS)

A: LIST
DTC
C0101
Rear ABS wheel

speed sensor RH
C0102
Rear ABS wheel

speed sensor LH
Display
ABS wheel speed sensor malfunction (Broken wire, short)

C0103
Front ABS wheel

speed sensor RH
C0104
Front ABS wheel

speed sensor LH
C0105
Abnormal signal of
rear ABS wheel speed
sensor RH
C0106
C0107
Abnormal signal of
rear ABS wheel speed
ABS wheel speed sensensor LH
sor malfunction (ABS
wheel speed sensor
abnormal signal)
Abnormal signal of
front ABS wheel speed
sensor RH
Abnormal signal of
front ABS wheel speed
sensor LH
C0108
C0109
Power voltage malfunction
C0110
ABS control module malfunction
C0111
Motor/motor relay on failure
C0114
Valve relay on failure
Reference target
<Ref. to ABS(diag)-42, DTC C0101 ABS
Rear Right ABS SenWHEEL SPEED SENSOR RR SENSOR
sor Circuit Open or
(BROKEN WIRE, INPUT VOLTAGE TOO
HIGH), Diagnostic Procedure with DiagnosShorted Battery
tic Trouble Code (DTC).>
Rear Left ABS Sensor WHEEL SPEED SENSOR RL SENSOR
Circuit Open or
Shorted Battery
HIGH), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
Front Right ABS Sen- WHEEL SPEED SENSOR FR SENSOR
sor Circuit Open or
Shorted Battery
Front Left ABS Sensor WHEEL SPEED SENSOR FL SENSOR
Circuit Open or
Shorted Battery
WHEEL SPEED SENSOR RH MALFUNCRear Right ABS SenTION (ABS WHEEL SPEED SENSOR
sor Signal
ABNORMAL SIGNAL), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
WHEEL SPEED SENSOR LH MALFUNCRear Left ABS Sensor
TION (ABS WHEEL SPEED SENSOR
Signal
WHEEL SPEED SENSOR RH MALFUNCFront Right ABS SenTION (ABS WHEEL SPEED SENSOR
sor Signal
WHEEL SPEED SENSOR LH MALFUNCFront Left ABS Sensor
TION (ABS WHEEL SPEED SENSOR
Signal
<Ref. to ABS(diag)-65, DTC C0109 POWER
Power Supply Voltage VOLTAGE MALFUNCTION, Diagnostic ProFailure
cedure with Diagnostic Trouble Code
(DTC).>
CONTROL MODULE MALFUNCTION,
ECM
<Ref. to ABS(diag)-71, DTC C0111
MOTOR/MOTOR RELAY MALFUNCTION,
Motor and Motor Relay
<Ref. to ABS(diag)-69, DTC C0114 VALVE
Valve Relay
RELAY MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
ABS(diag)-39

ABS (DIAGNOSTICS)
DTC
Display
C0115
ABS wheel speed senAbnormal ABS wheel

sor malfunction (ABS
speed sensor on any
wheel speed sensor
one of four sensors
abnormal signal)
Any One of Four ABS

Sensors Signal
C0116
Stop light switch signal circuit malfunction
Brake Light Switch
C0118
Faulty G sensor output voltage
G Sensor Failure
C0119
Abnormal G sensor output voltage
G Sensor Signal
C0120
Inlet valve malfunction

in hydraulic unit
Front inlet valve LH
FL Hold Valve malfunction
C0121
Outlet valve malfunction in hydraulic unit
Front outlet valve LH
FL Pressure Reducing
Valve malfunction
C0122

in hydraulic unit
Front inlet valve RH
FR Hold Valve malfunction
C0123
Front outlet valve RH
FR Pressure Reducing
Valve malfunction
C0124

in hydraulic unit
Rear inlet valve LH
RL Hold Valve malfunction
C0125
Rear outlet valve LH
RL Pressure Reducing Valve malfunction
C0126

in hydraulic unit
Rear inlet valve RH
RR Hold Valve malfunction
ABS(diag)-40
Reference target
WHEEL SPEED SENSOR SIGNAL MALFUNCTION IN ONE OF FOUR WHEELS,
<Ref. to ABS(diag)-73, DTC C0116 FAULTY
STOP LIGHT SWITCH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to ABS(diag)-75, DTC C0118 G SENSOR OUTPUT VOLTAGE MALFUNCTION,
<Ref. to ABS(diag)-78, DTC C0119 G SENSOR OUTPUT VOLTAGE MALFUNCTION,
<Ref. to ABS(diag)-55, DTC C0120 FRONT
INLET SOLENOID VALVE LH MALFUNCTION IN ABS CONTROL MODULE AND
HYDRAULIC CONTROL UNIT (ABSCM&H/
U), Diagnostic Procedure with Diagnostic
OUTLET SOLENOID VALVE LH MALFUNCTION IN ABS CONTROL MODULE
AND HYDRAULIC CONTROL UNIT
(ABSCM&H/U), Diagnostic Procedure with
INLET SOLENOID VALVE RH MALFUNCTION IN ABS CONTROL MODULE AND
OUTLET SOLENOID VALVE RH MALFUNCTION IN ABS CONTROL MODULE
<Ref. to ABS(diag)-55, DTC C0124 REAR
INLET SOLENOID VALVE LH MALFUNCTION IN ABS CONTROL MODULE AND
OUTLET SOLENOID VALVE LH MALFUNCTION IN ABS CONTROL MODULE
INLET SOLENOID VALVE RH MALFUNCTION IN ABS CONTROL MODULE AND

ABS (DIAGNOSTICS)
DTC
C0127
C0140
CAN communication malfunction
Display
Rear outlet valve RH
RR Pressure Reducing Valve malfunction
Improper CAN communication
ABS(diag)-41
Reference target
OUTLET SOLENOID VALVE RH MALFUNCTION IN ABS CONTROL MODULE
<Ref. to ABS(diag)-68, DTC C0140 CAN
COMMUNICATION MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>

ABS (DIAGNOSTICS)

A: DTC C0101 ABS WHEEL SPEED SENSOR RR SENSOR (BROKEN WIRE, INPUT VOLTAGE TOO HIGH)
NOTE:
For the diagnostic procedure, refer to DTC C0104. <Ref. to ABS(diag)-43, DTC C0104 ABS WHEEL SPEED
SENSOR FL SENSOR (BROKEN WIRE, INPUT VOLTAGE TOO HIGH), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
B: DTC C0102 ABS WHEEL SPEED SENSOR RL SENSOR (BROKEN WIRE, INPUT VOLTAGE TOO HIGH)
NOTE:
C: DTC C0103 ABS WHEEL SPEED SENSOR FR SENSOR (BROKEN WIRE, INPUT VOLTAGE TOO HIGH)
NOTE:
ABS(diag)-42

ABS (DIAGNOSTICS)
D: DTC C0104 ABS WHEEL SPEED SENSOR FL SENSOR (BROKEN WIRE, INPUT VOLTAGE TOO HIGH)
Defective ABS wheel speed sensor (broken wire, input voltage too high)
TROUBLE SYMPTOM:
ABS does not operate.
WIRING DIAGRAM:
LHD model
6
15
15
3
4
2
17
ABSCM & H/U
5
14
5
6
16
1
B301
B98
B6
1
2
R72
1
2
R73
1
2
1
2
B15
TWISTED WIRE
TWISTED WIRE
TWISTED WIRE
TWISTED WIRE
R2
E
FRONT ABS
WHEEL SPEED
SENSOR LH
B6
R72
B15
R73
1 2
FRONT ABS
WHEEL SPEED
SENSOR RH
REAR ABS
WHEEL SPEED
SENSOR LH
B98
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
REAR ABS
WHEEL SPEED
SENSOR RH
B301
12 13 14 15
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
ABS00461
ABS(diag)-43

ABS (DIAGNOSTICS)
RHD model
8
19
15
3
4
2
17
ABSCM & H/U
7
18
5
6
16
1
B301
B97
B6
1
2
R72
1
2
R73
1
2
1
2
B15
TWISTED WIRE
TWISTED WIRE
TWISTED WIRE
TWISTED WIRE
R1
E
FRONT ABS
WHEEL SPEED
SENSOR LH
B6
R72
B15
R73
1 2
FRONT ABS
WHEEL SPEED
SENSOR RH
REAR ABS
WHEEL SPEED
SENSOR LH
B97
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
REAR ABS
WHEEL SPEED
SENSOR RH
B301
12 13 14 15
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
ABS00413
ABS(diag)-44

ABS (DIAGNOSTICS)
Step
Check the poor contact between ABSCM&H/U
and ABS wheel speed sensor.
ABSCM&H/U AND ABS WHEEL SPEED
SENSOR.
ABSCM&H/U.
2) Disconnect the connector from ABS wheel
speed sensor.
ABSCM&H/U connector and ABS wheel speed
sensor connector.
DTC C0101
(B301) No. 3 (R72) No. 1:
(B301) No. 4 (R72) No. 2:
DTC C0102
(B301) No. 2 (R73) No. 1:
(B301) No. 17 (R73) No. 2:
DTC C0103
(B301) No. 5 (B6) No. 1:
(B301) No. 6 (B6) No. 2:
DTC C0104
(B301) No. 16 (B15) No. 1:
(B301) No. 1 (B15) No. 2:
DTC C0101
DTC C0102
DTC C0103
DTC C0104
CHECK ABS WHEEL SPEED SENSOR POWER SUPPLY CIRCUIT.
1) Connect the ABSCM&H/U connector.
3) Measure the voltage between ABS wheel
speed sensor connector and chassis ground.
DTC C0101
(R72) No. 1 Chassis ground ():
DTC C0102
(R73) No. 1 Chassis ground ():
DTC C0103
DTC C0104
Check
Yes
No
Go to step 2.

?

between
ABSCM&H/U and
ABS wheel speed
sensor.

M?
Go to step 4.

between
ABSCM&H/U and
ABS wheel speed
sensor.
Go to step 6.
Go to step 5.
ABS(diag)-45

ABS (DIAGNOSTICS)
Step
CHECK ABSCM&H/U POWER SUPPLY CIRCUIT.
2) Disconnect the ABSCM&H/U connector.
4) Measure the voltage between ABSCM&H/
U connector and chassis ground.
(B301) No. 18 (+) (B301) No. 15 ():
CHECK ABS WHEEL SPEED SENSOR SIGNAL.
1) Install the ABS wheel speed sensor.
2) Prepare an oscilloscope.
3) Check ABS wheel speed sensor. <Ref. to
ABS-14, ABS WHEEL SPEED SENSOR,
CHECK ABSCM&H/U.
4) Read the DTC.
Check
Yes
Go to step 7.
No
Check the generator, battery,
ABSCM&H/U
power circuit.
Is the pattern the same waveform as shown in the figure?
Go to step 7.
Replace the speed

sensor.
Go to step 8.
Replace the
ABSCM only.
<Ref. to ABS-8,
REPLACEMENT,
Control Unit
(ABSCM&H/U).>
DTC.
It results from a
temporary noise
interference.
E: DTC C0105 ABS WHEEL SPEED SENSOR RH MALFUNCTION (ABS WHEEL

SPEED SENSOR ABNORMAL SIGNAL)
NOTE:
SENSOR LH MALFUNCTION (ABS WHEEL SPEED SENSOR ABNORMAL SIGNAL), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
F: DTC C0106 ABS WHEEL SPEED SENSOR LH MALFUNCTION (ABS WHEEL

NOTE:
G: DTC C0107 ABS WHEEL SPEED SENSOR RH MALFUNCTION (ABS WHEEL

NOTE:
ABS(diag)-46

ABS (DIAGNOSTICS)
H: DTC C0108 ABS WHEEL SPEED SENSOR LH MALFUNCTION (ABS WHEEL

Defective ABS wheel speed sensor signal (noise, abnormal signal, etc.)
TROUBLE SYMPTOM:
WIRING DIAGRAM:
LHD model
6
15
15
3
4
2
17
ABSCM & H/U
5
14
5
6
16
1
B301
B98
B6
1
2
R72
1
2
R73
1
2
1
2
B15
TWISTED WIRE
TWISTED WIRE
TWISTED WIRE
TWISTED WIRE
R2
E
FRONT ABS
WHEEL SPEED
SENSOR LH
B6
R72
B15
R73
1 2
FRONT ABS
WHEEL SPEED
SENSOR RH
REAR ABS
WHEEL SPEED
SENSOR LH
B98
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
REAR ABS
WHEEL SPEED
SENSOR RH
B301
12 13 14 15
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
ABS00461
ABS(diag)-47

ABS (DIAGNOSTICS)
RHD model
8
19
15
3
4
2
17
ABSCM & H/U
7
18
5
6
16
1
B301
B97
B6
1
2
R72
1
2
R73
1
2
1
2
B15
TWISTED WIRE
TWISTED WIRE
TWISTED WIRE
TWISTED WIRE
R1
E
FRONT ABS
WHEEL SPEED
SENSOR LH
B6
R72
B15
R73
1 2
FRONT ABS
WHEEL SPEED
SENSOR RH
REAR ABS
WHEEL SPEED
SENSOR LH
B97
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
REAR ABS
WHEEL SPEED
SENSOR RH
B301
12 13 14 15
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
ABS00413
ABS(diag)-48

ABS (DIAGNOSTICS)
Step
CHECK OUTPUT OF ABS WHEEL SPEED
SENSOR USING SUBARU SELECT MONITOR.
2) Read the ABS wheel speed sensor output
corresponding to the faulty wheel in Subaru
Select Monitor data display mode.
CHECK SOURCES OF SIGNAL NOISE.
Make sure the car phone, radio wave device
like radio and etc., electric components are
installed correctly.
Check that the noise sources are (such as an
antenna) installed near the sensor harness.
Check
Yes
Does the speed indicated on
Go to step 2.
the display change in response
to the speedometer reading
during acceleration/deceleration when the steering wheel is
in the straight-ahead position?
No
Go to step 7.
Is there poor contact in connectors between ABSCM&H/U

and ABS wheel speed sensor?
Is the car phone, radio wave
device like radio and etc., electric components installed correctly?
Is the noise sources installed?
Go to step 3.
Go to step 4.
Install the radio

wave device and
electric components properly.
Go to step 5.
CHECK ABSCM&H/U.
4) Read the DTC.
CHECK INSTALLATION OF ABS WHEEL

SPEED SENSOR.
Is the ABS wheel speed sensor installation bolt tightened

7.5 Nm (0.76 kgf-m, 5.5 ft-lb)?

10
Does the oscilloscope indicate

the waveform pattern like
shown in the figure when the
tire is slowly turned? Does the
oscilloscope indication repeat
tire is slowly turned in equal
speed for more one rotation?
CHECK ABS WHEEL SPEED SENSOR AND Is there foreign particles,
MAGNETIC ENCODER.
breakage or damage in the
pole piece of ABS wheel speed
sensor or magnetic encoder?

like CB and etc., electric components are
Install the noise

sources apart from
the sensor harness.
Replace the
ABSCM only.
<Ref. to ABS-8,
REPLACEMENT,
Control Unit
(ABSCM&H/U).>
DTC.
Go to step 8.
Go to step 10.
Go to step 6.
It results from a
temporary noise
interference.
Tighten the ABS
wheel speed sensor installation
bolts.
Go to step 9.
Remove dirt com- Go to step 10.

pletely. Replace
the ABS wheel
speed sensor or
magnetic encoder
as a unit with hub
unit bearing when
it is broken or
damaged.
Go to step 11.
Install the radio
wave device and
device like radio and etc., elecelectric compotric components installed cornents properly.
rectly?
ABS(diag)-49

ABS (DIAGNOSTICS)
Step
Check if the noise sources are (such as an
Check
Are noise sources installed?
Yes
Go to step 12.
12
CHECK ABSCM&H/U.
4) Read the DTC.
13
Replace the
ABSCM only.
<Ref. to ABS-8,
REPLACEMENT,
Control Unit
(ABSCM&H/U).>
Perform the diag- It results from a
nosis according to temporary noise
DTC.
interference.
11
No
Install the noise
sources apart from
the sensor harness.
Go to step 13.
NOTE:
Though ABS warning light remains to
illuminate at this
time, it is normal.
Drive the vehicle at
more than 12 km/h
(7 MPH) in order to
make ABS warning
light go off. Be sure
to drive the vehicle
and check the
warning light goes
off.
ABS(diag)-50

ABS (DIAGNOSTICS)
I:
DTC C0115 ABS WHEEL SPEED SENSOR SIGNAL MALFUNCTION IN ONE

OF FOUR WHEELS

Defective ABS wheel speed sensor signal (noise, abnormal signal, etc.)
Defective magnetic encoder
When a wheel is turned freely for a long time
TROUBLE SYMPTOM:
EBD does not operate.
NOTE:
Brake warning light comes on as well as ABS warning light.
ABS(diag)-51

ABS (DIAGNOSTICS)
WIRING DIAGRAM:
LHD model
6
15
15
3
4
2
17
ABSCM & H/U
5
14
5
6
16
1
B301
B98
B6
1
2
R72
1
2
R73
1
2
1
2
B15
TWISTED WIRE
TWISTED WIRE
TWISTED WIRE
TWISTED WIRE
R2
E
FRONT ABS
WHEEL SPEED
SENSOR LH
B6
R72
B15
R73
1 2
FRONT ABS
WHEEL SPEED
SENSOR RH
REAR ABS
WHEEL SPEED
SENSOR LH
B98
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
REAR ABS
WHEEL SPEED
SENSOR RH
B301
12 13 14 15
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
ABS00461
ABS(diag)-52

ABS (DIAGNOSTICS)
RHD model
8
19
15
3
4
2
17
ABSCM & H/U
7
18
5
6
16
1
B301
B97
B6
1
2
R72
1
2
R73
1
2
1
2
B15
TWISTED WIRE
TWISTED WIRE
TWISTED WIRE
TWISTED WIRE
R1
E
FRONT ABS
WHEEL SPEED
SENSOR LH
B6
R72
B15
R73
1 2
FRONT ABS
WHEEL SPEED
SENSOR RH
REAR ABS
WHEEL SPEED
SENSOR LH
B97
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
REAR ABS
WHEEL SPEED
SENSOR RH
B301
12 13 14 15
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
ABS00413
ABS(diag)-53

ABS (DIAGNOSTICS)
2
3
4
5
Step
Check
WHETHER A WHEEL TURNED FREELY OR Did the wheels turn freely?
NOT.
Check if the wheels have been turned freely for
more than one minute, such as when the vehicle is jacked-up, under full-lock cornering or
when the wheels are not in contact with road
surface.
CHECK TIRE SPECIFICATIONS.

CHECK WEAR OF TIRE.
CHECK TIRE INFLATION PRESSURE.
Are the tire specifications correct?

Is the tire worn excessively?
Is the tire pressure correct?

SPEED SENSOR.

7.5 Nm (0.76 kgf-m, 5.5 ft-lb)?
(four of them)
CHECK ABS WHEEL SPEED SENSOR SIG- Does the oscilloscope indicate
NAL.
tire is slowly turned? Does the
3) Check ABS wheel speed sensor. <Ref. to oscilloscope indication repeat
INSPECTION, Front ABS Wheel Speed Sen- shown in the figure when the
sor.>
tire is slowly turned in equal
speed for more one rotation?
CHECK ABS WHEEL SPEED SENSOR AND Is there foreign particles,
MAGNETIC ENCODER.
pole piece of ABS wheel speed
CHECK ABSCM&H/U.
4) Read the DTC.
ABS(diag)-54
Yes
No
ABS is normal.
Go to step 2.
Erase the memory.
NOTE:
When the wheels
turn freely for a
long time, such as
when the vehicle is
towed or jackedup, or when steering wheel is continuously turned all
the way, this diagnostic trouble code
may
sometimes
occur.
Go to step 3.
Replace the tire.
Replace the tire.
Go to step 5.
Go to step 6.
Go to step 8.
Go to step 4.
Adjust the tire
pressure.
Tighten the ABS
bolts.
Go to step 7.
Remove dirt com- Go to step 8.

pletely. Replace
the ABS wheel
speed sensor or
magnetic encoder
as a unit with hub
unit bearing when
it is broken or
damaged.
Replace the
Go to step 9.
ABSCM only.
<Ref. to ABS-8,
REPLACEMENT,
Control Unit
(ABSCM&H/U).>

ABS (DIAGNOSTICS)
Step
Check
Yes
No
DTC.
interference.
NOTE:
illuminate at this
time, it is normal.
more than 12 km/h
(7 MPH) in order to
make ABS warning
and check the
warning light goes
off.
J: DTC C0120 FRONT INLET SOLENOID VALVE LH MALFUNCTION IN ABS

CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U)
NOTE:
For the diagnostic procedure, refer to DTC C0126. <Ref. to ABS(diag)-56, DTC C0126 REAR INLET SOLENOID VALVE RH MALFUNCTION IN ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT (ABSCM&H/U), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
K: DTC C0122 FRONT INLET SOLENOID VALVE RH MALFUNCTION IN ABS

NOTE:
L: DTC C0124 REAR INLET SOLENOID VALVE LH MALFUNCTION IN ABS

NOTE:
ABS(diag)-55

ABS (DIAGNOSTICS)
M: DTC C0126 REAR INLET SOLENOID VALVE RH MALFUNCTION IN ABS

Defective inlet solenoid valve in ABSCM&H/U
TROUBLE SYMPTOM:
NOTE:
ABS(diag)-56

ABS (DIAGNOSTICS)
WIRING DIAGRAM:
SBF-1
BATTERY
SBF-7
GENERATOR
No.33
IGNITION
SWITCH
15
18
B301
ABSCM & H/U
B301
12 13 14 15
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
ABS00414
ABS(diag)-57

ABS (DIAGNOSTICS)
Step
CHECK INPUT VOLTAGE OF ABSCM&H/U.
U.
CHECK GROUND CIRCUIT OF ABSCM&H/U.
ABSCM&H/U connector and chassis ground.
CHECK ABSCM&H/U.
4) Read the DTC.
Check
Yes
Go to step 2.
No
Repair the
ABSCM&H/U
power circuit.

?
Repair the
ABSCM&H/U
ground harness.
Is there poor contact in conRepair the connector between generator, bat- nector.
tery and ABSCM&H/U?
Replace
ABSCM&H/U.
<Ref. to ABS-6,
Control Unit
(ABSCM&H/U).>
Inspect the DTC
Code (DTC).
<Ref. to
ABS(diag)-39, List
Go to step 4.
ABS(diag)-58
Go to step 5.
Temporary poor
contact occurs.

ABS (DIAGNOSTICS)
N: DTC C0121 FRONT OUTLET SOLENOID VALVE LH MALFUNCTION IN ABS

NOTE:
For the diagnostic procedure, refer to DTC C0127. <Ref. to ABS(diag)-60, DTC C0127 REAR OUTLET SOLENOID VALVE RH MALFUNCTION IN ABS CONTROL MODULE AND HYDRAULIC CONTROL UNIT
(ABSCM&H/U), Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
O: DTC C0123 FRONT OUTLET SOLENOID VALVE RH MALFUNCTION IN ABS

NOTE:
P: DTC C0125 REAR OUTLET SOLENOID VALVE LH MALFUNCTION IN ABS

NOTE:
ABS(diag)-59

ABS (DIAGNOSTICS)
Q: DTC C0127 REAR OUTLET SOLENOID VALVE RH MALFUNCTION IN ABS

Defective outlet solenoid valve in ABSCM&H/U
TROUBLE SYMPTOM:
NOTE:
ABS(diag)-60

ABS (DIAGNOSTICS)
WIRING DIAGRAM:
SBF-1
BATTERY
SBF-7
GENERATOR
No.33
IGNITION
SWITCH
15
18
B301
ABSCM & H/U
B301
12 13 14 15
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
ABS00414
ABS(diag)-61

ABS (DIAGNOSTICS)
Step
U.
CHECK ABSCM&H/U.
4) Read the DTC.
Check
Yes
Go to step 2.
No
Repair the
ABSCM&H/U
power circuit.

?
Repair the
ABSCM&H/U
ground harness.
tery and ABSCM&H/U?
Replace
ABSCM&H/U.
<Ref. to ABS-6,
Control Unit
(ABSCM&H/U).>
Inspect the DTC
Code (DTC).
<Ref. to
ABS(diag)-39, List
Go to step 4.
ABS(diag)-62
Go to step 5.
Temporary poor
contact occurs.

ABS (DIAGNOSTICS)
R: DTC C0110 ABS CONTROL MODULE MALFUNCTION

Defective ABSCM&H/U
TROUBLE SYMPTOM:
NOTE:
WIRING DIAGRAM:
ABSCM & H/U
15
B301
B301
12 13 14 15
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
ABS00415
ABS(diag)-63

ABS (DIAGNOSTICS)
Step
Check
CHECK GROUND CIRCUIT OF ABSCM&H/U. Is the resistance less than 0.5
?
U.
ABSCM&H/U and chassis ground.
CHECK POOR CONTACT IN CONNECTOR. Is there poor contact in connectors between battery, ignition switch and ABSCM&H/U?
Is the car telephone or the
radio properly installed?
CHECK ABSCM&H/U.
4) Read the DTC.
Yes
Go to step 2.
No
Repair the
ABSCM&H/U
ground harness.
Go to step 3.
Go to step 4.
Properly install the

car telephone or
the wireless transmitter.
Go to step 5.
Are noise sources (such as an Install the noise

antenna) installed near the
sources apart from
sensor harness?
the sensor harness.
Replace the
Go to step 6.
ABSCM only.
<Ref. to ABS-8,
REPLACEMENT,
Control Unit
(ABSCM&H/U).>
Inspect the DTC
Temporary poor
using List of Diag- contact occurs.
nostic Trouble
Code (DTC).
<Ref. to
ABS(diag)-39, List
ABS(diag)-64

ABS (DIAGNOSTICS)
S: DTC C0109 POWER VOLTAGE MALFUNCTION

Power voltage of the ABSCM&H/U is too low or too high.
TROUBLE SYMPTOM:
EBD may not operate.
NOTE:
If EBD does not operate, brake warning light comes on as well as ABS warning light. Both warning lights go
off if voltage returns.
ABS(diag)-65

ABS (DIAGNOSTICS)
WIRING DIAGRAM:
SBF-1
BATTERY
SBF-7
GENERATOR
No.33
IGNITION
SWITCH
15
18
B301
ABSCM & H/U
B301
12 13 14 15
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
ABS00414
ABS(diag)-66

ABS (DIAGNOSTICS)
Step
CHECK GENERATOR.
Terminals
ground ():
Check

tightly?
CHECK INPUT VOLTAGE OF ABSCM&H/U. Is the voltage 10 15 V?
U.
3) Operate the devices such as headlights, air
conditioner, defogger, etc. which produce
much electrical loading.
CHECK GROUND CIRCUIT OF ABSCM&H/U. Is the resistance less than 0.5
?
CHECK POOR CONTACT IN CONNECTOR. Is there poor contact in connector between generator, battery and ABSCM&H/U?
CHECK ABSCM&H/U.
4) Read the DTC.
ABS(diag)-67
Yes
Go to step 2.
No
Repair the generator.
Go to step 3.
Tighten the terminal.
Go to step 4.
Repair the
ABSCM&H/U
power circuit.
Go to step 5.
Repair the
ABSCM&H/U
ground harness.
Go to step 6.
Replace the
Go to step 7.
ABSCM only.
<Ref. to ABS-8,
REPLACEMENT,
Control Unit
(ABSCM&H/U).>
Inspect the DTC
Temporary poor
nostic Trouble
Code (DTC).
<Ref. to
ABS(diag)-39, List

ABS (DIAGNOSTICS)
T: DTC C0140 CAN COMMUNICATION MALFUNCTION

Defective CAN communication
TROUBLE SYMPTOM:
Possibly the vehicle speed cannot output on CAN.
Step
Check
CHECK LAN SYSTEM.
Is there any fault in LAN sysPerform the diagnosis for LAN system. <Ref. to tem?
LAN(diag)-24, OPERATION, Read Diagnostic
ABS(diag)-68
Yes
No
Repair it according Replace the
to DTC of LAN
ABSCM only.
system.
<Ref. to ABS-8,
REPLACEMENT,
Control Unit
(ABSCM&H/U).>

ABS (DIAGNOSTICS)
U: DTC C0114 VALVE RELAY MALFUNCTION

Defective valve relay
TROUBLE SYMPTOM:
EBD does not operate depending on the trouble contents.
NOTE:
Brake warning light comes on as well as ABS warning light when EBD does not operate.
WIRING DIAGRAM:
BATTERY
No.1
SBF-7
SBF-1
IGNITION
SWITCH
PUMP MOTOR
RR INLET
RR OUTLET
RL INLET
RL OUTLET
FR INLET
FR OUTLET
FL INLET
VALVE
RELAY
FL OUTLET
18
SOLENOID
VALVE
MOTOR RELAY
ABSCM & H/U
14
B301
15
No.33
B301
12 13 14 15
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
ABS00746
ABS(diag)-69

ABS (DIAGNOSTICS)
Step
U.
CHECK VALVE RELAY IN ABSCM&H/U.
terminals.
Terminals
No. 14 No. 15:
Check
Yes
Go to step 2.
No
between battery
and ABSCM&H/U.

?
Repair the
ABSCM&H/U
ground harness.

M?
Replace the
ABSCM only.
<Ref. to ABS-8,
REPLACEMENT,
Control Unit
(ABSCM&H/U).>
Go to step 5.
CHECK POOR CONTACT IN CONNECTOR. Is there poor contact in connector between generator, battery and ABSCM&H/U?
CHECK ABSCM&H/U.
4) Read the DTC.
ABS(diag)-70
Go to step 4.
Replace the
Go to step 6.
ABSCM only.
<Ref. to ABS-8,
REPLACEMENT,
Control Unit
(ABSCM&H/U).>
Inspect the DTC
Temporary poor
nostic Trouble
Code (DTC).
<Ref. to
ABS(diag)-39, List

ABS (DIAGNOSTICS)
V: DTC C0111 MOTOR/MOTOR RELAY MALFUNCTION

Defective motor
Defective motor relay
TROUBLE SYMPTOM:
WIRING DIAGRAM:
BATTERY
SBF-1
SBF-7
SBF-2
IGNITION
SWITCH
PUMP MOTOR
15
RR INLET
RR OUTLET
RL INLET
RL OUTLET
FR INLET
FR OUTLET
FL INLET
VALVE
RELAY
FL OUTLET
18
SOLENOID
VALVE
MOTOR RELAY
ABSCM & H/U
13
B301
12
No.33
B301
12 13 14 15
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
ABS00747
ABS(diag)-71

ABS (DIAGNOSTICS)
Step
U.
CHECK GROUND CIRCUIT OF MOTOR.
CHECK ABSCM&H/U.
4) Read the DTC.
Check
Yes
Go to step 2.
No
between battery
and ABSCM&H/U.

?
Repair the
ABSCM&H/U
ground harness.

between battery,
ignition switch and
ABSCM&H/U.
Go to step 4.

?
Repair the
ABSCM&H/U
ground harness.
tery and ABSCM&H/U?
Replace
ABSCM&H/U.
<Ref. to ABS-6,
Control Unit
(ABSCM&H/U).>
Inspect the DTC
Code (DTC).
<Ref. to
ABS(diag)-39, List
Go to step 6.
ABS(diag)-72
Go to step 7.
Temporary poor
contact occurs.
NOTE:
illuminate at this
time, it is normal.
more than 12 km/h
(7 MPH) in order to
make ABS warning
and check the
warning light goes
off.

ABS (DIAGNOSTICS)
W: DTC C0116 FAULTY STOP LIGHT SWITCH

Defective stop light switch
WIRING DIAGRAM:
SBF-1
BATTERY
No.8
SBF-3
STOP LIGHT SWITCH
OC WC
1
2
2
3
B64
OC
B65
WC
B159
: WITH CRUISE CONTROL
OC
: WITHOUT CRUISE CONTROL
20
WC
B301
B64
B65
1 2
1 2
3 4
ABSCM & H/U
B159
1
5
2
6
B301
3
8
4
9
12 13 14 15
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
ABS00462
ABS(diag)-73

ABS (DIAGNOSTICS)
3
4
Step
CHECK OUTPUT OF STOP LIGHT SWITCH
2) Release the brake pedal.
3) Read the stop light switch signal in Subaru
Select Monitor.
2) Read the stop light switch output in Subaru
Select Monitor.
CHECK IF STOP LIGHTS COME ON.
Depress the brake pedal.
CHECK OPEN CIRCUIT IN HARNESS.
U.
CHECK ABSCM&H/U.
4) Read the DTC.
Check
Is OFF displayed on the display?
Yes
Go to step 2.
No
Go to step 3.
Is ON displayed on the display?
Go to step 5.
Go to step 3.
Does the stop light illuminate? Go to step 4.

Go to step 5.
Is there poor contact in connector between stop light

switch and ABSCM&H/U?
Go to step 6.
ABS(diag)-74
Repair the stop

lights circuit.
Repair harness
between stop light
switch and
ABSCM&H/U connector.
Replace the
Go to step 7.
ABSCM only.
<Ref. to ABS-8,
REPLACEMENT,
Control Unit
(ABSCM&H/U).>
Inspect the DTC
Temporary poor
nostic Trouble
Code (DTC).
<Ref. to
ABS(diag)-39, List

ABS (DIAGNOSTICS)
X: DTC C0118 G SENSOR OUTPUT VOLTAGE MALFUNCTION

Defective G sensor
TROUBLE SYMPTOM:
WIRING DIAGRAM:
ABSCM & H/U
15
24
21
10
B301
1
2
3
B292
E
ABS G SENSOR
B301
B292
1 2 3
12 13 14 15
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
ABS00419
ABS(diag)-75

ABS (DIAGNOSTICS)
Step
CHECK OUTPUT OF G SENSOR USING
2) Read the G sensor output on Subaru
Select Monitor.
Check
Yes
Is the reading indicated on dis- Go to step 2.
play 1.2 1.2 m/s when G
sensor is horizontal?
No
Go to step 5.
Is there poor contact in connector between ABSCM&H/U

and G sensor?
Go to step 3.
Replace the
ABSCM only.
<Ref. to ABS-8,
REPLACEMENT,
Control Unit
(ABSCM&H/U).>
Inspect the DTC
Code (DTC).
<Ref. to
ABS(diag)-39, List
Go to step 6.
Go to step 4.
CHECK ABSCM&H/U.
4) Read the DTC.
CHECK INPUT VOLTAGE OF G SENSOR.

5) Measure the voltage between G sensor
(B292) No. 1 (+) No. 3 ():
CHECK OPEN CIRCUIT IN G SENSOR OUTPUT HARNESS AND GROUND HARNESS.
U.
ABSCM&H/U connector terminals.
(B301) No. 21 No. 10:
CHECK GROUND SHORT IN G SENSOR
OUTPUT HARNESS.
1) Disconnect the connector from G sensor.
CHECK G SENSOR.
1) Connect the connector to G sensor.
(B292) No. 2 (+) No. 3 ():
Temporary poor
contact occurs.

between G sensor
and ABSCM&H/U.

k?
Go to step 7.

between G sensor
and ABSCM&H/U.

M?
Go to step 8.
Repair the harness between G

sensor and
ABSCM&H/U.

when G sensor is on a level?
Go to step 9.
Replace G sensor. <Ref. to ABS18, G Sensor.>
ABS(diag)-76

ABS (DIAGNOSTICS)
10
11
Step
CHECK G SENSOR.
Measure the voltage between G sensor connector terminals.
(B292) No. 2 (+) No. 3 ():
CHECK G SENSOR.
(B292) No. 2 (+) No. 3 ():
12
CHECK ABSCM&H/U.
4) Read the DTC.
13
Check
when G sensor is inclined forwards to 90?
Yes
Go to step 10.
No

backward to 90?
Go to step 11.
Is there poor contact in connector between ABSCM&H/U

and G sensor?
Go to step 12.
ABS(diag)-77
Replace the
Go to step 13.
ABSCM only.
<Ref. to ABS-8,
REPLACEMENT,
Control Unit
(ABSCM&H/U).>
Inspect the DTC
Temporary poor
nostic Trouble
Code (DTC).
<Ref. to
ABS(diag)-39, List

ABS (DIAGNOSTICS)
Y: DTC C0119 G SENSOR OUTPUT VOLTAGE MALFUNCTION

Defective G sensor output signal
TROUBLE SYMPTOM:
WIRING DIAGRAM:
ABSCM & H/U
15
24
21
10
B301
1
2
3
B292
E
ABS G SENSOR
B301
B292
1 2 3
12 13 14 15
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
ABS00419
ABS(diag)-78

ABS (DIAGNOSTICS)
Step
Check
WHETHER A WHEEL TURNED FREELY OR Have the wheels been turned
NOT.
freely when the vehicle is lifted
up or drove on a rolling road?
Is the reading indicated on disSUBARU SELECT MONITOR.
sensor is on a level?
sensor is inclined forward to
90?
sensor is inclined backward to
90?
nector between ABSCM&H/U
and G sensor?
CHECK ABSCM&H/U.
4) Read the DTC.
CHECK OPEN CIRCUIT IN G SENSOR OUTPUT HARNESS AND GROUND HARNESS.

U.
ABSCM&H/U connector terminals.
(B301) No. 21 No. 10:

k?

M?
ABS(diag)-79
Yes
No
ABS is normal.
Go to step 2.
Erase the memory.
Go to step 3.
Go to step 8.
Go to step 4.
Go to step 5.
Go to step 6.
Replace the
ABSCM only.
<Ref. to ABS-8,
REPLACEMENT,
Control Unit
(ABSCM&H/U).>
Inspect the DTC
Code (DTC).
<Ref. to
ABS(diag)-39, List
Go to step 9.
Go to step 7.
Go to step 10.
Temporary poor
contact occurs.

between G sensor
and ABSCM&H/U.

between G sensor
and ABSCM&H/U.

ABS (DIAGNOSTICS)
10
11
12
13
14
Step
CHECK G SENSOR.
2) Remove the G sensor from vehicle.
3) Connect the connector to G sensor.
(B292) No. 2 (+) No. 3 ():
CHECK G SENSOR.
(B292) No. 2 (+) No. 3 ():
CHECK G SENSOR.
(B292) No. 2 (+) No. 3 ():
CHECK ABSCM&H/U.
5) Read the DTC.
Check
when G sensor is on a level?
Yes
Go to step 11.
No

when G sensor is inclined forwards to 90?
Go to step 12.

backward to 90?
Go to step 13.
Replace the
Go to step 14.
ABSCM only.
<Ref. to ABS-8,
REPLACEMENT,
Control Unit
(ABSCM&H/U).>
Inspect the DTC
Temporary poor
nostic Trouble
Code (DTC).
<Ref. to
ABS(diag)-39, List
ABS(diag)-80

ABS (DIAGNOSTICS)

A: INSPECTION
Symptom
Vehicle is pulled to either right or

left side.
Vehicle instability during braking
Vehicle spins.
Long braking/stopping distance
Wheel locks.
Brake drag
Poor brake performance
Long brake pedal stroke

Vehicle vertical 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
ABS(diag)-81
Problem parts
ABSCM&H/U (solenoid valve)
Brake (caliper, piston and pads)
Wheel Alignment
Tire specifications, tire wear and air pressures
Incorrect wiring or piping connections
Road surface (uneven, camber)
Brake (pads)
Brake (pads)
Air in brake line
ABSCM&H/U (solenoid valve, motor)
Master cylinder
Brake (caliper and piston)
Parking Brake
Axle and wheels
Brake pedal play
Air in brake line
Brake pedal play
Suspension play or fatigue (reduced damping)
Road surface (uneven)
Brake (caliper, piston and pads)
ABSCM&H/U (mount bushing)
Brake line
ABSCM&H/U (mount bushing)
Master cylinder
Brake (caliper, piston, pads and rotor)
Brake line
Brake booster and check valve
Suspension play or fatigue
Brake (caliper, piston, pads and rotor)
Parking Brake
Brake line
Suspension play or fatigue

ABS (DIAGNOSTICS)
ABS(diag)-82
VEHICLE DYNAMICS CONTROL

(VDC)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
VDC
Page
VDC Control Module and Hydraulic Control Unit (VDCCM&H/U) ...............7
ABS Sequence Control .............................................................................11
VDC Sequence Control.............................................................................12
Yaw Rate and Lateral G Sensor ...............................................................15
Steering Angle Sensor ..............................................................................17
Front ABS Wheel Speed Sensor...............................................................19
Rear ABS Wheel Speed Sensor ...............................................................20
Front Magnetic Encoder............................................................................21
Rear Magnetic Encoder ............................................................................22
VDC OFF Switch.......................................................................................23
General Description
A: SPECIFICATION
Item
gap (for reference)
ABS wheel speed
sensor
Yaw rate & lateral G

sensor
Marks of VDCCM&H/U
Marks of harness
(Marks, Color)
Front
Rear
Front
Rear
RH
LH
RH
LH
Lateral G sensor voltage
Standard values or identification

0.77 1.43 mm (0.030 0.056 in)
0.64 1.56 mm (0.025 0.061 in)
K1 (White)
K2 (Yellow)
K5 (White)
K6 (Yellow)
2.50.2 V
Wagon 2.5 i
Sedan 2.5 i
Wagon 3.0 R
Sedan 3.0 R
OUTBACK 3.0 R
VDC-2
G3
G9
G4
GA
G2
General Description
B: COMPONENT
T1
T2
(3)
T2
(5)
T1
(2)
(4)
(1)
T2
VDC00194
(1)
(2)
(3)

Front housing
(4)
(5)
Hub unit bearing

Magnetic encoder
VDC-3

T1: 7.5 (0.76, 5.5)
T2: 33 (3.4, 24)
General Description
2. YAW RATE & LATERAL G SENSOR
(1)
(2)
VDC00195
(1)
Yaw rate & lateral G sensor
(2)

T: 7.5 (0.76, 5.5)
Bracket
3. STEERING ANGLE SENSOR
(1)
VDC00196
(1) Steering angle sensor
VDC-4
General Description
4. VDC CONTROL MODULE & HYDRAULIC CONTROL UNIT (VDCCM&H/U)

(6)
(5)
(8) (7)
(9)
(4)
(10)
(3)
(1)
(11)
(2)
T
VDC00197
(1)
VDC control module and hydraulic

control unit (VDCCM&H/U)
(2)
(3)
(4)
Clip
Bracket
Rear RH outlet
(5)
(6)
(7)
(8)
(9)
Rear LH outlet
Secondary inlet
Primary inlet
Front LH outlet
Front RH outlet
VDC-5
(10)
(11)
Pressure sensor
Damper

T: 33 (3.4, 24)
General Description
C: CAUTION
cable from battery.

points.
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
24082AA230
DESCRIPTION
CARTRIDGE
REMARKS
22771AA030
SUBARU SELECT
MONITOR KIT

ST24082AA230
ST22771AA030
2. GENERAL TOOL
TOOL NAME
Circuit tester
Pressure gauge
Oscilloscope
REMARKS
VDC-6
VDC Control Module and Hydraulic Control Unit (VDCCM&H/U)

2. VDC Control Module and Hydraulic Control Unit (VDCCM&H/U)
7) Remove the clips, and then remove the VDCCM&H/U.
A: REMOVAL
2) Use compressed air to get rid of water and dust
around the VDCCM&H/U.
NOTE:
When dust and dirt are attached to the terminal,
they may cause poor contact.
3) Disconnect the pressure sensor connector.
VDC00201
CAUTION:
VDCCM&H/U cannot be disassembled. Do
not attempt to loosen the bolts and nuts.
Do not drop or bump the VDCCM&H/U.
Do not turn VDCCM&H/U upside down or
place it sideways for storage.
Be careful that no foreign objects are mixed
in VDCCM&H/U.
Be careful that no water enters connectors.
VDC00198
4) Disconnect the VDCCM&H/U connector with

pulling up the lock lever.
CAUTION:
Do not pull the harness when disconnecting
connector.
VDC00200
8) Remove the VDCCM&H/U bracket.
B: INSTALLATION
1) Install the VDCCM&H/U bracket.
VDC00199
5) Disconnect the brake pipes from VDCCM&H/U.

6) Wrap the brake pipe using a vinyl bag not to spill
the brake fluid on the vehicle body.
Tightening torque:
33 Nm (3.3 kgf-m, 24 ft-lb)
2) Install the VDCCM&H/U to bracket.
3) Install the clip.
CAUTION:
When the brake fluid is attached to vehicle
body, wash it off with water and wipe the water.
VDC00201
NOTE:
Hook the clip on the pawl of bracket securely.
VDC-7

4) Connect the brake pipes to their specified VDCCM&H/U positions.

Tightening torque:
T1: 15 Nm (1.5 kgf-m, 11.1 ft-lb)
T2: 19 Nm (1.9 kgf-m, 14 ft-lb)
<Ref. to ABS-7, CHECKING THE HYDRAULIC

UNIT ABS OPERATION BY PRESSURE GAUGE,
INSPECTION, ABS Control Module and Hydraulic
Control Unit (ABSCM&H/U).>
T2
T1

OPERATION WITH BRAKE TESTER
<Ref. to ABS-8, CHECKING THE HYDRAULIC
UNIT ABS OPERATION WITH BRAKE TESTER,
INSPECTION, ABS Control Module and Hydraulic
Control Unit (ABSCM&H/U).>
3. CHECKING THE HYDRAULIC UNIT VDC

T2
T1
VDC00311
5) Connect the connector to VDCCM&H/U.

NOTE:
Be sure to remove all foreign matters from inside
the connector before connecting.
Ensure that the VDCCM&H/U connector is securely locked.
6) Connect the pressure sensor connector.
C: INSPECTION
1) Check the connected and fixed condition of connector.
2) Check the mark used for VDCCM&H/U identification.
Refer to SPECIFICATION for mark. <Ref. to
VDC-2, SPECIFICATION, General Description.>
1) Lift-up the vehicle, and then remove the wheels.

2) Remove 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 use the pressure gauge for the measurement of transmission oil pressure since
the piston seal may be expanded and deformed.
NOTE:
Wrap a sealing tape around the pressure gauge.
(1)
ABS00134
VDC00202
(1) Mark
4) Bleed air from the pressure gauges.

5) Perform VDC sequence control.
<Ref. to VDC-12, VDC Sequence Control.>
FL side performs compression, holding, and decompression, and then the FR side performs compression, holding, and decompression.
that it is not abnormally hard, and tightness is normal.
VDC-8

When compressed
When decompressed
Front wheel
3,000 kPa
(31 kgf/cm2, 441
psi)
or more
500 kPa
(5 kgf/cm2, 73 psi)
or less
3) Set the front wheels or rear wheels on the brake

tester and set the select lever position to N range.
Rear wheel
2,000 kPa
(20 kgf/cm2, 284
psi)
or more
500 kPa
(5 kgf/cm2, 73 psi)
or less
8) Disconnect the pressure gauges from FL and FR

caliper bodies.
9) Install the air bleeder screws of FL and FR caliper bodies.
10) Remove the air bleeder screws from the RL
11) Connect two pressure gauges to the RL and
RR caliper bodies.
12) Bleed air from the pressure gauges and the RL
RR side performs compression, holding, and decompression, and then the RL side performs compression, holding, and decompression.
15) Read the values indicated on the pressure
gauges and check it within specified. Depress the
brake pedal and check that it is not abnormally
hard, and tightness is normal.
16) Disconnect the pressure gauge from the RL
17) Install the air bleeder screws of RL and RR caliper bodies.
18) Bleed air from the brake line.
4. CHECK HYDRAULIC UNIT VDC OPERATION WITH BRAKE TESTER

1) Set the wheels other than the measured one on
free rollers.
2) Prepare for operating the VDC sequence control.
(1)
ABS00136
(1)
ABS00137
(1) Brake tester
4) Operate the brake tester.

6) When the hydraulic unit begins to work; check
the following working sequence.
(1) The FL wheel performs compression, holding and decompression in sequence, and subsequently the FR wheel repeats the cycle.
(2) The RR wheel performs compression, holding and decompression in sequence, and subsequently the RL wheel repeats the cycle.
7) Read values indicated on the brake tester and
check if the fluctuation of the values between decompression and compression meets the standard
values.
When compressed
When decompressed
Front wheel
2,000 N
(203 kgf, 447 lb)
or more
500 N
(51 kgf, 112 lb)
or less
Rear wheel
1,000 N
(102 kgf, 225 lb)
or more
500 N
(51 kgf, 112 lb)
or less
8) After the inspection, depress the brake pedal

and check that it is not abnormally hard, and tightness is normal.
VDC-9

D: ADJUSTMENT
When the following replacement, removal and installation is performed, be sure to perform the centering setting of steering angle sensor and zero
point setting of yaw rate & lateral G sensor.
VDCCM&H/U
Steering angle sensor
Steering wheel parts (Including airbag)
Suspension parts
Wheel alignment adjustment
1) Park the vehicle straight on a level surface. (Engine operation on P or N range)
2) Check that steering wheels are positioned in
center. (When the center position is not correct, adjust the wheel alignment.)
3) Set the Subaru Select Monitor to vehicle, select
the {Set up mode for Neutral of Steering Angle
Sensor & Lateral G Sensor 0 point} on Function
check sequence display. (Follow the step on display.)
4) On the Brake Control System display screen,
select the {Current Data Display & Save}, and
check that the steering angle sensor is displayed 0
deg.
5) When the 0 deg is not displayed, repeat the
above steps and check that the 0 deg is displayed.
6) Drive the vehicle for 10 minutes, and check that
the ABS and VDC warning light is not illuminated.
7) Check that the unnecessary operation of VDC,
or losing control of steering is not occurred. And
when the malfunction occurred, repeat the above
steps.
VDC-10

3. ABS Sequence Control

A: OPERATION
<Ref. to ABS-10, OPERATION, ABS Sequence
Control.>
1. ABS SEQUENCE CONTROL WITH DIAGNOSIS CONNECTOR

<Ref. to ABS-10, ABS SEQUENCE CONTROL
WITH DIAGNOSIS CONNECTOR, OPERATION,
ABS Sequence Control.>
2. ABS SEQUENCE CONTROL WITH SUBARU SELECT MONITOR

<Ref. to ABS-10, ABS SEQUENCE CONTROL
WITH SUBARU SELECT MONITOR, OPERATION, ABS Sequence Control.>
3. CONDITIONS FOR ABS SEQUENCE

CONTROL
<Ref. to ABS-11, CONDITIONS FOR ABS SEQUENCE CONTROL, OPERATION, ABS Sequence Control.>
B: SPECIFICATION
ABS SEQUENCE CONTROL
<Ref. to ABS-12, CONDITIONS FOR COMPLETION OF ABS SEQUENCE CONTROL, SPECIFICATION, ABS Sequence Control.>
VDC-11
VDC Sequence Control

4. VDC Sequence Control

A: OPERATION
1) While the VDC sequence control is performed,
the operation of the hydraulic unit can be checked
using the brake tester or pressure gauge after the
hydraulic unit solenoid valve is operated.
2) VDC sequence control can be started by diagnosis connector or Subaru Select Monitor.
5) When the VDC Inspection Mode is selected

from the Function check sequence menu, the
VDC sequence control will start.
6) Since Press the [YES] key is displayed, press
the YES key.
7) Operation points will be displayed on the Subaru
Select Monitor.
1. VDC SEQUENCE CONTROL WITH DIAGNOSIS CONNECTOR

NOTE:
In the event of any trouble, the VDC sequence control is not operated.
1) Turn the ignition switch to OFF at the vehicle stationary mode.
2) Take out the diagnosis connector from the inside
of instrument panel lower cover on the drivers side
and connect one of the ground terminals to connector terminal No. 8.
B82
1 2
3
4 5 6 7 8
ABS00466
3) Turn the ignition switch to ON and start the engine immediately without pressing the brake pedal.
4) After VDC warning light goes out and starting the
engine, perform the brake pedal operation as follows; depress it within 3 seconds, release it,
depress it again, release it again.
5) After completion of VDC sequence control, turn
2. VDC SEQUENCE CONTROL WITH SUBARU SELECT MONITOR

NOTE:
In the event of any trouble, the sequence control
may not be operative.
connector under the drivers side instrument panel
lower cover.
3) Set the Subaru Select Monitor switch to ON.
4) Set the Subaru Select Monitor to the Brake
Control mode.
VDC-12

3. CONDITIONS FOR VDC SEQUENCE CONTROL

V max < 4 km/h (2.5 MPH)
V max < 10 km/h (6 MPH)
(1)
(2)
(3)
(4)
(21)
OFF
(25)
(35)
(22)
ON (23)
(26)
(25)
(24)
(27)
(28)
(27)
(29)
(26)
(25)
(26)
(25)
(5)
(6)
(7)
(8)
VDC
OFF
OFF
ON
ON
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(32) (28) (33) (34)
OFF
(32) (28) (33) (34)
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
ON
(30)
(31)
(36)
(37)
(38)
(39)
(40)
VDC00203
VDC-13

(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
All wheel speed

DL terminal
Ignition key
ABS warning light
VDC warning light
Stop light switch
Valve relay
VDC switching valve 1 FL
VDC switching valve 1 FR
VDC switching valve 2 FL
VDC switching valve 2 FR
FL decompression valve
FL compression valve
FR decompression valve
FR compression valve
(16)
(17)
(18)
(19)
(20)
(21)
RR decompression valve
RR compression valve
RL decompression valve
RL compression valve
Pump motor
Diagnosis connector and connection
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
1.5 sec.
Approx. 3 sec.
Within 3 sec.
Light OFF
Light ON
3.4 sec.
1 sec.
1.6 sec.
NOTE:
When using the Subaru Select Monitor, the control
operation starts from point A. The patterns from ignition key ON to the point A show that operation is
started by diagnosis connector.
B: SPECIFICATION
VDC SEQUENCE CONTROL
When the following conditions develop, the VDC
sequence control stops and VDC 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 the diagnosis connector is disconnected.
(Without Subaru Select Monitor)
3) When the brake pedal is pressed during sequence control and the stop light switch is set to
ON.
4) When the brake pedal is pressed after the ignition key is turned to ON, and before VDC warning
light goes out. (Without Subaru Select Monitor)
5) Turn the ignition key to ON and when 3 seconds
or more have elapsed after the VDC warning light
goes OFF.
6) After completion of VDC sequence control.
7) When malfunction is detected.
VDC-14
(30)
(31)
(32)
(33)
(34)
(35)
Point A
Reset
0.8 sec.
1.2 sec.
0.4 sec.
When using the Subaru Select
Monitor, both connection and nonconnection of diagnosis connector
are acceptable.
(36)
(37)
(38)
(39)
(40)
Master cylinder pressure

FR wheel cylinder pressure
FL wheel cylinder pressure
RL wheel cylinder pressure
RR wheel cylinder pressure
Yaw Rate and Lateral G Sensor

5. Yaw Rate and Lateral G Sensor

A: REMOVAL
<Ref. to EI-53, Console Box.>
3) Disconnect the connector from the yaw rate &
lateral G sensor.
4) Remove the yaw rate & lateral G sensor.
CAUTION:
Do not drop or bump the yaw rate & lateral G
sensor.
CAUTION:
After completion of installation, set the following two positions.
Positioning to the center of steering angle
sensor
Positioning of the yaw rate & lateral G sensor
to zero
The above procedure is required VDCCM&H/U
to identify the vehicle position afterward. For
the setting procedure of step 2 above, refer to
VDC Control Module and Hydraulic Control
Unit. <Ref. to VDC-10, ADJUSTMENT, VDC
Control Module and Hydraulic Control Unit (VDCCM&H/U).>
VDC00204
B: INSTALLATION
NOTE:
Install the yaw rate & lateral G sensor to body with
directing the arrow mark on sensors to vehicle
front.
VDC00205
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)
VDC-15
Yaw Rate and Lateral G Sensor

C: INSPECTION
1. YAW RATE & LATERAL G SENSOR SIGNAL
Step
CHECK YAW RATE & LATERAL G SENSOR.
2) Connect the Subaru Select Monitor connector to data link connector.
4) Set the Subaru Select Monitor connector to
the {Brake Control} mode.
5) Select {Current Data Display & Save}.
6) Read the output voltage of yaw rate & lateral G sensor.
2) Remove the yaw rate & lateral G sensor
from vehicle. (Do not disconnect the connector.)
3) Read the display of Subaru Select Monitor.
Check
Yes
Are the indicated values when Go to step 2.
the vehicle is placed horizontally
Lateral G sensor: 1.5 1.5
m/s
Yaw rate sensor: 4 4 deg/
s?
No
between yaw rate
& lateral G sensor
and VDCCM&H/U.
Or replace the yaw
rate & lateral G
sensor.
Is the value 6.8 12.8 m/s

when the yaw rate & lateral G
sensor are inclined rightward
to 90?

between yaw rate
& lateral G sensor
and VDCCM&H/U.
Or replace the yaw
rate & lateral G
sensor.
Go to step 3.
NOTE:
When the yaw rate & lateral G sensor is moved
with its power supply on, DTC of yaw rate & lateral G sensor may be recorded.
Is the value 6.8 12.8 m/s Yaw rate & lateral
Read the display of Subaru Select Monitor.
when the yaw rate & lateral G G sensor is norsensor are inclined leftward to mal.
NOTE:
When the yaw rate & lateral G sensor is moved 90?
with its power supply on, DTC of yaw rate & lateral G sensor may be recorded.
VDC-16

between yaw rate
& lateral G sensor
and VDCCM&H/U.
Or replace the yaw
rate & lateral G
sensor.
Steering Angle Sensor

6. Steering Angle Sensor
9) Remove the steering angle sensor from roll connector.
A: REPLACEMENT
CAUTION:
Do not perform the removal except when the
replacement.
When replacing more than three times, replace the combination switch as assembly to
protect screw part.
1) Set the steering wheel in a wheel-forward position.
3) Remove the airbag module.
<Ref. to AB-15, REMOVAL, Drivers Airbag Module.>
WARNING:
Always refer to Airbag System when performing the airbag module repair service.
<Ref. to AB-4, CAUTION, General Description.>
4) Remove the steering wheel.
<Ref. to PS-20, REMOVAL, Steering Wheel.>
5) Remove the screws and detach the steering column lower cover.
6) Remove the two screws securing the steering
column upper cover.
7) Unlock the harness band and disconnect the
connector of steering angle sensor.
VDC00208
10) Turn the protrusion portion of new steering angle sensor to match the alignment mark of inspection hole.
(1)
(2)
(3)
VDC00209
(1) Protrusion portion

(2) Inspection hole
(3) Alignment mark
CAUTION:
Be careful not to allow foreign particles to enter
from inspection hole.
11) Align the center of roll connector.
<Ref. to AB-24, INSTALLATION, Roll Connector.>
(1)
(2)
VDC00093
(1) Harness band

(2) Connector
8) Remove the screws which secure the roll connector to steering column.
VDC00207
VDC-17

12) Apply thin coat of grease which is enclosed

with new part to the protruding parts (four) of steering angle sensor.
(1)
ABS00435
(1) Apply grease.

CAUTION:
After completion of installation, adjust the following two positions.
Positioning to the center of steering angle
sensor
Positioning of the yaw rate & lateral G sensor
to zero
The above procedure is required for VDCCM to
identify the vehicle position afterward. For the
setting procedure of step 2 above, refer to
VDC Control Module and Hydraulic Control
Unit. <Ref. to VDC-10, ADJUSTMENT, VDC
13) Align the position of protrusion portion and install the roll connector to the steering angle sensor.
Tightening torque:
0.5 Nm (0.05 kgf-m, 0.36 ft-lb)
VDC00208
14) Install the roll connector to combination switch.
VDC00207
15) Install the steering wheel.

<Ref. to PS-20, INSTALLATION, Steering Wheel.>
Tightening torque:
44 Nm (4.5 kgf-m, 32.5 ft-lb)
16) Install the airbag module to steering wheel.
<Ref. to AB-15, INSTALLATION, Drivers Airbag
Module.>
WARNING:
Always refer to Airbag System before performing the service operation.
VDC-18

7. Front ABS Wheel Speed Sensor

A: NOTE
For the vehicle equipped with VDC, it has the same
ABS wheel speed sensor as installed to the vehicle
equipped with ABS. For removal, installation and
inspection procedure, refer to ABS section.
<Ref. to ABS-13, Front ABS Wheel Speed Sensor.>
VDC-19
Rear ABS Wheel Speed Sensor

8. Rear ABS Wheel Speed Sensor

A: NOTE
ABS wheel speed sensor as installed to the vehicle
<Ref. to ABS-15, Rear ABS Wheel Speed Sensor.>
VDC-20
Front Magnetic Encoder

9. Front Magnetic Encoder

A: NOTE
magnetic encoder as installed to the vehicle
<Ref. to ABS-16, Front Magnetic Encoder.>
VDC-21
Rear Magnetic Encoder

10.Rear Magnetic Encoder

A: NOTE
magnetic encoder as installed to the vehicle
<Ref. to ABS-17, Rear Magnetic Encoder.>
VDC-22
VDC OFF Switch

11.VDC OFF Switch

A: REMOVAL
2) Remove the screws, and then remove the VDC
OFF switch.
RHD model
4 3 2 1
VDC00210
LHD model
7 6 5
4 3 2 1
15 14 13 12 11 10
9 8
VDC00240
B: INSTALLATION
C: INSPECTION
Measure the resistance between VDC OFF switch
terminals.
RHD model
Switch position
OFF
ON
Terminal No.
23
23
Standard
More than 1 M
Less than 1
Terminal No.
2 15
2 15
Standard
More than 1 M
Less than 1
LHD model
Switch position
OFF
ON
If NG, replace the VDC OFF switch.
VDC-23
VDC OFF Switch

VDC-24

(DIAGNOSTICS)
VDC(diag)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Page
Control Module I/O Signal .........................................................................12
Inspection Mode........................................................................................23
Warning Light Illumination Pattern ............................................................25

VEHICLE DYNAMICS CONTROL (VDC) (DIAGNOSTICS)

A: PROCEDURE
CAUTION:
When the Subaru Select Monitor is communicating (except when displaying the data), the ABS warning light flashes and VDC warning light illuminates in the combination meter. Do not communicate
with the Subaru Select Monitor while driving, because the ABS and VDC functions are disabled. Carefully drive the vehicle, when you have to communicate with the Subaru Select Monitor. When the data
is displayed by the {Current Data Display & Save} menu, both the ABS and VDC warning lights are
turned off and ABS and VDC functions are enabled.
NOTE:
To check the harness for broken wires or short circuits, shake problem spot or connector.
Refer to Check List for Interview. <Ref. to VDC(diag)-4, Check List for Interview.>
Step
<Ref. to VDC(diag)-4, Check List for Interview.>
2) Before performing diagnostics, check the
component which might affect VDC problems.
<Ref. to VDC(diag)-8, INSPECTION, General
Description.>
link connector.
4) Read the DTC. <Ref. to VDC(diag)-22,
(DTC).>
Check
influence the VDC problem
normal?
Yes
Go to step 2.
No
Repair or replace
each component.
Is DTC displayed?
Go to step 4.
Go to step 3.
NOTE:
VDC(diag)-19, COMMUNICATION FOR INITIALIZING IMPOSSIBLE, INSPECTION, Subaru Select Monitor.>
5) Record all DTCs and freeze frame data.
PERFORM GENERAL DIAGNOSTICS.
Do the VDC warning light and
1) Inspect using General Diagnostic Table. ABS warning light go off after
<Ref. to VDC(diag)-129, INSPECTION, Gen- starting the engine?
eral Diagnostic Table.>
VDC(diag)-24, OPERATION, Clear Memory
Mode.>
VDC(diag)-23, PROCEDURE, Inspection
Mode.>
(DTC).>
5) Check the DTC does not displayed.
VDC(diag)-2
Finish the diagno- Check the combisis.

nation meter circuit. <Ref. to
VDC(diag)-30,
ABS WARNING
LIGHT DOES
NOT GO OFF,
Warning Light Illumination Pattern.>
<Ref. to
VDC(diag)-33,
VDC WARNING
LIGHT AND VDC
OFF INDICATOR
LIGHT DO NOT
GO OFF, Warning
Light Illumination
Pattern.>

Step
PERFORM DIAGNOSIS.
1) Refer to List of Diagnostic Trouble Code
(DTC).
Check
Is DTC displayed?
NOTE:
For the DTC list, refer to List of Diagnostic
Trouble Code (DTC). <Ref. to VDC(diag)-37,
LIST, List of Diagnostic Trouble Code (DTC).>
VDC(diag)-24, OPERATION, Clear Memory
Mode.>
Mode.>
(DTC).>
VDC(diag)-3
Yes
No
Repeat step 4 until Finish the diagnoDTC is not shown. sis.


A: CHECK
Check the following items about the vehicles state.
1. STATE OF ABS WARNING LIGHT

ABS warning light
come on.
Timing
Always
Sometimes
Only once
Not come on
When / How long does it come on?
LOCK
ACC
START
ON (after engine starting, engine is running)
ON (after engine starting, engine is at a standstill)
Immediately after turning the ignition switch to ON
Immediately after turning the ignition switch to START
When accelerating
km/h

When decelerating
Steering angle:
Steering time:
Steering angle:
Steering time:

Part name:
VDC(diag)-4
km/h
MPH
MPH
km/h
MPH
deg
Sec.
deg
Sec.

2. STATE OF VDC WARNING LIGHT AND VDC OFF INDICATOR LIGHT

VDC warning light
and VDC OFF indicator light come on.
Timing
Always
Sometimes
Only once
Not come on
LOCK
ACC
START
When accelerating
When decelerating
km/h
km/h
MPH
MPH
km/h
MPH
deg
Sec.
deg
Sec.
km/h
km/h
MPH
MPH
km/h
MPH
deg
Sec.
deg
Sec.
Steering angle:
Steering time:
Steering angle:
Steering time:

Part name:
3. STATE OF VDC INDICATOR LIGHT

VDC operation indicator light comes on.
Timing
Always
Sometimes
Only once
Not come on
LOCK
ACC
START
When accelerating
When decelerating
Steering angle:
Steering time:
Steering angle:
Steering time:

Part name:
VDC(diag)-5


Environment
Fine
Cloudy
Rainy
Snowy
Others:
a) Weather
C (F)
b) Ambient temperature
c) Road
Inner city
Suburbs
Highway
Local street
Uphill
Downhill
Paved road
Gravel road
Muddy road
Sandy place
Straight road
Sharp curve
Gentle curve
S-curve
Road with a slope on both sides
Others:
Dried
Wet
Covered with fresh snow
Covered with hardened snow
Frozen slope
Others:
d) Road surface
VDC(diag)-6

Condition
a) Brakes
Deceleration:
continuous / intermittent
Acceleration:
continuous / intermittent
km/h
Advancing
When accelerating
When decelerating
At low speed
When 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:
Sharp turning
Gentle turning
Straight forward motion
Gentle return
Sharp return
Specified size
Except specification (
Summer tire
Studless tire (Brand:
b) Accelerator
c) Vehicle speed
d) Tire inflation pressure
e) Degree of wear
f) Steering wheel
g) Tire/Wheel size
h) Tire variation
i) Tire chains are fitted: Yes / No
j) T-type tire is used: Yes / No
k) Condition of suspension alignment:
l) Loading state:
m) Repair parts are used: Yes / No
Contents:
n) Others:
VDC(diag)-7
G
G
MPH
kPa
kPa
kPa
kPa
)
)
General Description
6. BRAKE PAD AND ROTOR
A: CAUTION
Check the brake pad and rotor.

FRONT <Ref. to BR-18, INSPECTION, Front
Brake Pad.> <Ref. to BR-19, INSPECTION, Front
Disc Rotor.>
REAR <Ref. to BR-25, INSPECTION, Rear
Brake Pad.> <Ref. to BR-26, INSPECTION, Rear
Disc Rotor.>
1. SUPPLEMENTAL RESTRAINT SYSTEM

AIRBAG
ABS wheel speed sensor and VDCCM&H/U.
CAUTION:
wiring harness when servicing the ABS wheel
speed sensor and VDCCM&H/U.
7. TIRE
Check the tire specifications, tire wear and air pressure. <Ref. to WT-2, SPECIFICATION, General
Description.>
B: INSPECTION
Before performing diagnosis, check the following
items which might affect VDC problems.
1. BATTERY
Measure battery voltage and check electrolyte.
2. GROUND
Check the tightening torque of VDC ground (GB-5)
bolt.
Tightening torque:
33 Nm (3.4 kgf-m, 24.3 ft-lb)
3. BRAKE FLUID
1) Check the brake fluid level.
2) Check the brake fluid for leaks.
4. HYDRAULIC UNIT
Check the hydraulic unit.
With brake tester <Ref. to VDC-8, CHECKING
THE HYDRAULIC UNIT ABS OPERATION WITH
BRAKE TESTER, INSPECTION, VDC Control
Module and Hydraulic Control Unit (VDCCM&H/
U).>
Without brake tester <Ref. to VDC-8, CHECKING THE HYDRAULIC UNIT ABS OPERATION
BY PRESSURE GAUGE, INSPECTION, VDC
5. BRAKE DRAG
Check for brake drag.
VDC(diag)-8
General Description
C: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
24082AA230
DESCRIPTION
CARTRIDGE
REMARKS
22771AA030
SUBARU SELECT
MONITOR KIT

ST24082AA230
ST22771AA030
2. GENERAL TOOL
TOOL NAME
Circuit tester
Oscilloscope
REMARKS
VDC(diag)-9


A: LOCATION
(8)
(9)
(7)
(4) (5) (6)
(15)
(1)
(2)
(12)
(13)
(11)
(10)
(14)
(3)
(16)
(10)
(11)
VDC00241
(1)

(2)
(3)
Pressure sensor
(TCM)
light)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
ABS warning light

VDC indicator light
VDC warning light and VDC OFF
indicator light
VDC OFF switch
Magnetic encoder
VDC(diag)-10
(11)
(12)
(13)
(14)
(15)
(16)

Data link connector
Diagnosis connector (Used for
ABS sequence control)
Stop light switch

(4)
(2)
(1)
(5)
(7)
(6)
VDC00251
VDC00231
(11)
(8)
(10)
(10)
VDC00235
VDC00234
(12)
(13)
VDC00250
(14)
VDC00230
VDC(diag)-11
VDC00242


B310
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
VDC00211
NOTE:
Terminal numbers in VDCCM&H/U connector are as shown in the figure.
When the connector is removed from VDCCM&H/U, the ABS warning light and VDC warning light illuminate.
VDC(diag)-12

Content
Power supply
Yaw rate & lateral G

sensor
Input/Output signal
41 6
4.5 16.5 V
25
22 6
4.5 16.5 V
21
24 6
4.5 16.5 V
40
Measured value and measuring conditions
Power
supply
Signal
Power
supply
Front RH wheel
Signal
Power
supply
Rear LH wheel
Signal
Power
supply
Rear RH wheel
Signal
Output (Lateral G sensor)
Power supply
23 6
4.5 16.5 V
38
3 16
30 16
Output (Yaw rate sensor)
28 16
Standard (Yaw rate sensor)
1 16
Test
2 16

When the vehicle is on level, 2.35 2.65 V.
Waveform
<Ref. to VDC(diag)-15, WAVEFORM, MEASUREMENT, Control Module I/O Signal.>
2.1 2.9 V
5 1 V cycle for 40 ms pulse signal.

When the ignition switch is ON, 4.75 5.25 V.
0.48 0.72 V (when releasing the brake pedal)

passed.
passed.
Less than 1.5 V when the stop light is OFF; otherwise,
10 15 V when the stop light is ON.
0 12 V pulse (in communication)
0 5 V pulse
Front LH wheel
Terminal
No.
(+) ()
14 6
Ground
CAN communication line (+)
CAN communication line ()
Valve relay power supply
Motor relay power supply
Power supply
Pressure sensor
Output voltage
Ground
16
13
29
56
9 10
27 12
11 12
12
ABS warning light
35 6
Brake warning light (EBD warning light)
20 6
Stop light switch
37 6
Diagnosis connector
Vehicle speed output signal
Ground
17
26 6
36
6
VDC(diag)-13

B: WIRING DIAGRAM
(3)
(5)
(20)
(1)
(21)
(22)
(23)
(24)
(2)
(25)
(6)
(26)
(27)
(4)
(30)
(28) (29)
(31)
(32)
(33)
(7)
(8)
(34)
(9)
(35)
(10)
(11)
(36)
(12)
(13)
(37)
(14)
(15)
(38)
(16)
(17)
(39)
(40)
(18)
(19)
(41)
VDC00236
(1)
(2)
(3)
Battery
Ignition switch
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
VDC control module

Valve relay
Motor relay
Motor
Front inlet solenoid valve LH
Front outlet solenoid valve LH
Front inlet solenoid valve RH
Front outlet solenoid valve RH
Rear inlet solenoid valve LH
Rear outlet solenoid valve LH
Rear inlet solenoid valve RH
Rear outlet solenoid valve RH
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
Primary cut solenoid valve

Primary suction solenoid valve
Secondary cut solenoid valve
Secondary suction solenoid valve
Diagnosis connector
Data link connector
VDC OFF switch
Combination meter
VDC indicator light
indicator light
(26)
(27)
(28)
(29)
ABS warning light

Brake warning light
Brake fluid level switch
VDC(diag)-14
(30)
(31)
(32)
(33)
(34)
Stop light switch

Stop light
(TCM)
(35)
(36)
(37)
(38)
(39)

Pressure sensor
RH
(40)
(41)
Rear ABS wheel speed sensor LH

RH

C: MEASUREMENT
Measure input and output signal voltage.
1. WAVEFORM
(V)
(1)
(2)
28 16
2
10
2.1 2.9 V
(3)
5.0 V
(2)
2 16
0
0
20 ms
VDC00212
(1)
Yaw rate sensor
(2)
Terminal No.
VDC(diag)-15
(3)
Vehicle is at a standstill.


A: OPERATION
CAUTION:
When the Subaru Select Monitor is communicating (except when displaying the data), the
ABS warning light flashes and VDC warning
light illuminates in the combination meter. Do
not communicate with the Subaru Select Monitor while driving, because the ABS and VDC
functions are disabled. Carefully drive the vehicle, when you have to communicate with the
Subaru Select Monitor. When the data is displayed by the {Current Data Display & Save}
menu, both the ABS and VDC warning lights are
turned off and ABS and VDC functions are enabled.

(DTC)
VDC(diag)-9, SPECIAL TOOL, PREPARATION
(1)
ABS00465

connector.
CAUTION:
(1)
ABS00114
ABS00111

Monitor.
<Ref. to VDC(diag)-9, SPECIAL TOOL, PREPARATION TOOL, General Description.>
ABS00112

connector.
(1) Power switch

[YES] key.
8) Press the [YES] key after the {VDC AWD AT} is
displayed.
9) On the VDC Diagnosis display screen, select
the {Diagnostic Code(s) Display}, and then press
the [YES] key.
NOTE:
For details concerning operation procedure, refer to SUBARU SELECT MONITOR OPERATION
MANUAL.
For details concerning DTCs, refer to List of Diagnostic Trouble Code (DTC). <Ref. to VDC(diag)-37, List of Diagnostic Trouble Code (DTC).>
DTCs are displayed up to three in detected order.
VDC(diag)-16

If a particular DTC is not properly stored in memory (due to a drop in VDCCM&H/U power supply,
etc.) on the occurrence of a problem, the DTC
which is suffixed with a question mark ? appears
on the Subaru Select Monitor display. This shows it
may be an unreliable reading.
10) If VDC and Subaru Select Monitor cannot communicate, check the communication circuit. <Ref.
to VDC(diag)-19, COMMUNICATION FOR INITIALIZING IMPOSSIBLE, INSPECTION, Subaru
Select Monitor.>
Display
Current
Old
Older
Before 3
Indicate the latest DTC on the Subaru
Indicate the latest DTC in previous trouble on the Subaru Select Monitor display.
Indicate the latest DTC in second previous trouble on the Subaru Select Monitor
display.
Indicate the latest DTC in third previous
trouble on the Subaru Select Monitor display.

2) On the System Selection Menu display screen, select the {Brake Control} and press the [YES] key.
3) Press the [YES] key after {VDC 4WD AT} is displayed.
4) On the Brake Control Diagnosis display screen, select the {Current Data Display/Save}, and then press
the [YES] key.
5) On the Data Display Menu display screen, select the display method, and press the [YES] key.
6) Using a scroll key, scroll the display screen up or down until necessary data is shown.
Display
FR Wheel Speed
FL Wheel Speed
RR Wheel Speed
RL Wheel Speed
Yaw Rate Sensor
Pressure Sensor
Lateral G Sensor
EAM signal
TCS Operation Light
VDC Operation Light
VDC OFF Light
EBD Warning Light
ABS Warning Light
VDC Warning Light
VDC OK-B signal
Valve Relay Signal
Motor Relay Signal
Motor Relay Monitor
PATA Signal
BLS Signal
Gear position
Engine Speed
PW Signal
Wheel speed detected by front ABS wheel speed sensor RH is displayed.
Wheel speed detected by front ABS wheel speed sensor LH is displayed.
Wheel speed detected by rear ABS wheel speed sensor RH is displayed.
Wheel speed detected by rear ABS wheel speed sensor LH is displayed.
Steering angle detected by steering angle sensor is displayed.
Vehicle angular speed detected by yaw rate sensor is displayed.
Brake fluid pressure detected by pressure sensor is displayed.
Vehicle lateral acceleration detected by lateral G sensor is displayed.
Voltage supplied to VDCCM&H/U is displayed.
Engine control command signal is displayed.
TCS operation condition is displayed.
VDC operation condition is displayed.
ON/OFF condition of VDC OFF indicator light is displayed.
ON operation of the EBD warning light is displayed.
ON operation of the ABS warning light is displayed.
ON operation of the VDC warning light is displayed.
Malfunction of VDC sensor (except for vehicle speed sensor) is
displayed.
Motor relay operation signal is displayed.
Motor relay monitor signal is displayed.
Operation condition of VDC OFF switch is displayed.
Present gear position is displayed.
Current engine speed is displayed.
Acceleration opening is displayed.
VDC(diag)-17
Unit of measure
km/h or MPH
km/h or MPH
km/h or MPH
km/h or MPH
deg
deg/s
bar
m/s (m/s^2)
V
1 or 0
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
1 or 0
ON or OFF
ON or OFF
ON or OFF
ON or OFF
ON or OFF
rpm
%

NOTE:
to SUBARU SELECT MONITOR OPERATION
MANUAL.
Display
Steering angle
sensor
Yaw rate sensor

[YES] key.
3) Press the [YES] key after {VDC 4WD AT} is displayed.
4) On the Brake Control Diagnosis display
screen, select the {Memory Clear} and press the
[YES] key.
Display
Clear memory?
DTC deleting function
Lateral G sensor
Pressure sensor
Vehicle Speed
FR Wheel
Speed
FL Wheel Speed
RR Wheel
Speed
5) When Done and Turn ignition switch OFF are

shown on the display screen, turn the Subaru Select Monitor and ignition switch to OFF.
NOTE:
MANUAL.
4. ABS SEQUENCE CONTROL
RL Wheel
Speed
Required torque
Current torque
Target torque
PW signal
Engine Speed
Display
ABS
sequence
control
VDC confirmation
mode
to perform the ABS
sequence control.
to perform the VDC
sequence control.
Reference target
<Ref. to ABS10, ABS
Sequence Control.>
<Ref. to VDC12, VDC
Sequence Control.>

NOTE:
shown on display.
Each time trouble occurs, the latest information
is stored in the freeze frame data in memory.
If a freeze frame data is not properly stored in
memory (due to a drop in VDC control module power supply, etc.), the DTC which is suffixed with a
question mark ? appears on the Subaru Select
Monitor display. This shows it may be an unreliable
reading.
Gear position
IG power supply
voltage
Absolute angle
recognition flag
Decreasing
required torque
EAM signal
VDC O control
flag
VDC U control
flag
BMR control flag
AMR control flag
ABS control flag
VDC OFF light
Valve Relay Signal
Motor Relay
Monitor
BLS signal
VDC(diag)-18
Steering angle detected by steering
angle sensor is displayed.
Vehicle angular speed detected by yaw
rate sensor is displayed.
Vehicle lateral acceleration detected by
lateral G sensor is displayed.
Brake fluid pressure detected by pressure sensor is displayed.
Vehicle speed calculated by VDC control
module is displayed.
Wheel speed detected by front ABS
km/h or MPH.
Wheel speed detected by front ABS
km/h or MPH.
Wheel speed detected by rear ABS
km/h or MPH.
Wheel speed detected by rear ABS
km/h or MPH.
Engine required torque is displayed.
Current engine torque on malfunction
occurrence is displayed.
Engine target torque is displayed.
Acceleration opening is displayed.
Engine speed on malfunction occurrence is displayed.
Gear position on malfunction occurrence
is displayed.
Voltage supplied to VDC control module
is displayed.
Whether the absolute angle was determined is displayed.
Whether the torque decrease is required
to engine is displayed.
Engine control command signal is displayed.
VDC oversteer control condition is displayed.
VDC understeer control condition is displayed.
Brake control condition is displayed.
Engine control condition is displayed.
ON/OFF condition of VDC OFF indicator
light is displayed.
Motor relay monitor signal is displayed.

B: INSPECTION
1. COMMUNICATION FOR INITIALIZING IMPOSSIBLE
TROUBLE SYMPTOM:
Communication is impossible between VDC and Subaru Select Monitor.
WIRING DIAGRAM:
SBF-1
BATTERY
SBF-7
DATA LINK
CONNECTOR
IGNITION
SWITCH
1
10
No.33
B40
B310
VDCCM & H/U
B40
B310
1 2 3 4 5 6 7 8
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
9 10 11 12 13 14 15 16
26
14
VDC00244
VDC(diag)-19

Step
Check
Is the ignition switch ON?
Yes
Go to step 2.
CHECK BATTERY.

terminal?
CHECK SUBARU SELECT MONITOR COM- Are the system name and
Go to step 8.
MUNICATION.
model year displayed on Sub1) Turn the ignition switch to ON.
aru Select Monitor?
whether communication to other system can
CHECK SUBARU SELECT MONITOR COM- Are the system name and
Replace the
MUNICATION.
model year displayed on Sub- VDCCM&H/U.
aru Select Monitor?
<Ref. to VDC-7,
2) Disconnect the VDCCM&H/U connector.
VDC Control Mod3) Turn the ignition switch to ON.
ule and Hydraulic
Control Unit
(VDCCM&H/U).>
EACH CONTROL MODULE AND DATA LINK M?
CONNECTOR.
2) Disconnect the VDCCM&H/U, ECM and
TCM.
Go to step 8.
CHECK OUTPUT SIGNAL FOR VDCCM&H/ Is the voltage less than 1 V?
U.
2) Measure the voltage between VDCCM&H/
U and chassis ground.
VDCCM&H/U AND DATA LINK CONNEC?
TOR.
Measure the resistance between VDCCM&H/U
connector and data link connector.
(B310) No. 26 (B40) No. 10:
CHECK INSTALLATION OF VDCCM&H/U
Is the VDCCM&H/U connector Go to step 10.
CONNECTOR.
inserted into VDCCM&H/U
until the clamp locks onto it?
VDC(diag)-20
No
Turn the ignition
switch to ON, and
select VDC mode
using Subaru
Select Monitor.
Charge or replace
the battery.
Go to step 4.
Go to step 5.
Go to step 6.

control module

control module
VDCCM&H/U and
Insert the
VDCCM&H/U connector into
VDCCM&H/U.

10
11
12
Step
OFF)
between VDCCM&H/U connector and chassis
ground.
VDCCM&H/U AND CHASSIS GROUND.
2) Disconnect the connector from VDCCM&H/
U.
between VDCCM&H/U and chassis ground.
Check
Yes
Go to step 11.
No
Repair the open
circuit in harness
between
VDCCM&H/U and
battery.

?
Repair the open

circuit in harness
between
VDCCM&H/U and
inhibitor side connector, and poor
Is there poor contact in control Repair the conmodule power supply, ground nector.
circuit and data link connector?
Replace the
VDCCM&H/U.
<Ref. to VDC-7,
VDC Control Module and Hydraulic
Control Unit
(VDCCM&H/U).>
VDC(diag)-21


Code (DTC)
A: OPERATION
For details concerning DTC reading procedure, refer to Subaru Select Monitor. <Ref. to VDC(diag)16, Subaru Select Monitor.>
VDC(diag)-22
Inspection Mode
8. Inspection Mode
A: PROCEDURE
Reproduce the malfunction occurrence condition
as possible.
Drive the vehicle at least ten minutes.
NOTE:
Make sure the vehicle is not dragged to one side
under usual driving condition.
VDC(diag)-23
Clear Memory Mode


A: OPERATION
For details concerning DTC clear operation, refer to
Subaru Select Monitor. <Ref. to VDC(diag)-16,
VDC(diag)-24
Warning Light Illumination Pattern

10.Warning Light Illumination Pattern

A: INSPECTION
(4)
(3)
(1)
(3)
(2)
(7)
(5)
(6)
(8)
(6)
(7)
(9)
(6)
(6)
(7)
(10)
(6)
(6)
(11)
(7)
(6)
(12)
(13)
(14)
VDC00214
(1)
(2)
(3)
(4)
(5)
(6)
Ignition switch
OFF
ON
Engine start
ABS warning light
Light OFF
(7)
(8)
(9)
(10)
Light ON
1.5 sec.
VDC indicator light
indicator light
(11)
Several seconds (depending on

engine coolant temperature)
(12)

light)
(13)
(14)
Parking brake
Released
1) When warning lights or indicator lights do not illuminate in accordance with this illumination pattern, there
must be an electrical malfunction.
2) When warning lights or indicator lights remain constantly OFF, check the combination meter circuit or CAN
communication circuit. <Ref. to VDC(diag)-26, VDC WARNING LIGHT, VDC OFF INDICATOR LIGHT AND
VDC INDICATOR LIGHT DO NOT COME ON, Warning Light Illumination Pattern.>
3) When ABS warning light does not go off, check the combination meter circuit. <Ref. to VDC(diag)-30, ABS
WARNING LIGHT DOES NOT GO OFF, Warning Light Illumination Pattern.>
4) When the VDC indicator light, VDC warning light and VDC OFF indicator light do not go off, check the combination meter circuit or CAN communication circuit. <Ref. to VDC(diag)-32, VDC INDICATOR LIGHT DOES
NOT GO OFF, Warning Light Illumination Pattern.>
NOTE:
Even though the ABS warning light does not go off after 1.5 seconds from ABS warning light illumination,
the ABS system operates normally when the warning light goes off while driving at approximately 12 km/h (7
MPH). However, the ABS system does not work while the ABS warning light is illuminated.
It may take several minutes before VDC warning light and VDC OFF indicator light goes off if the vehicle
is parked under low temperature for a specified time. This is not defective because it is resulted from low engine coolant temperature.
VDC(diag)-25

With the vehicle jack-up/lift-up or set on free rollers, when the wheels lock or spin after starting the engine,
ABS warning light, VDC warning light and VDC OFF indicator light may illuminate because VDCCM&H/U detects the abnormal conditions from ABS wheel speed sensors. In this case, this is not a malfunction. Perform
the clear memory mode.
B: VDC WARNING LIGHT, VDC OFF INDICATOR LIGHT AND VDC INDICATOR
LIGHT DO NOT COME ON
TROUBLE SYMPTOM:
When the ignition switch is turned to ON (engine OFF), VDC indicator light, VDC warning light and VDC OFF
indicator light do not come on.
NOTE:
When pressing VDC OFF switch for more than 10 seconds, VDC OFF indicator light goes off and cannot operate any more. When turning the ignition switch from OFF to ON, the OFF operation enabled status is restored.
Step
CHECK OTHER INDICATOR LIGHT.
Check
Does other indicator light illuminate soon after ON?
Yes
Go to step 2.
CHECK VDCCM.
When the engine does not start, display the
current data of VDCCM using Subaru Select
Monitor.
CHECK LAN SYSTEM.
Perform the diagnosis for LAN system. <Ref. to
Is VDC warning light output

set to ON?
Go to step 3.
Is there any fault in LAN system?

nosis according to
DTC for LAN system.
Replace the
Repair the combiVDCCM&H/U.
nation meter
assembly.
Is combination meter OK?
VDC(diag)-26
No
Replace the
VDCCM&H/U.

C: ABS WARNING LIGHT DOES NOT COME ON

Defective harness
TROUBLE SYMPTOM:
When the ignition switch is turned to ON (engine OFF), ABS warning light does not come on.
WIRING DIAGRAM:
LHD model
BATTERY
SBF-7
SBF-1
IGNITION
SWITCH
A3
A:
B36
35
20
i3
16
i1
20
A5
A7
A8
BRAKE FLUID
LEVEL SWITCH
i10
ABS
WARNING
LIGHT
BRAKE
WARNING
LIGHT
A4
NO.5
B38
B310
VDCCM & H/U
1
2
B16
B97
B229
R1
R4
PARKING
BRAKE
SWITCH
B16
1
2
B229
1 2
i1
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
B310
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
A:
i10
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
B38
B97
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
VDC00245
VDC(diag)-27

RHD model
BATTERY
SBF-7
SBF-1
IGNITION
SWITCH
i10
35
A5
3
A:
20
A7
4
ABS
WARNING
LIGHT
A3
A8
BRAKE FLUID
LEVEL SWITCH
16
BRAKE
WARNING
LIGHT
A4
NO.5
i1
B310
B36
VDCCM & H/U
1
2
B16
B97
B229
R1
R4
PARKING
BRAKE
SWITCH
B16
1
2
B229
1 2
i1
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
B310
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
A:
i10
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
B97
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
VDC00238
VDC(diag)-28

1
2
Step
CHECK OTHER LIGHTS TURN ON.
Turn the ignition switch to ON. (engine OFF)
READ DTC.
Read the DTC. <Ref. to VDC(diag)-22, Read
CHECK GROUND SHORT CIRCUIT OF HARNESS.
VDCCM&H/U.
VDCCM&H/U connector and chassis ground.
CHECK VDCCM.
1) Connect the connector (B310) to
VDCCM&H/U.
3) Measure the resistance between the combination meter connector and chassis ground
soon after the ignition switch is turned to ON
(within 1.5 seconds).
(i10) No. A5 Chassis ground:
Check
Do other warning lights illuminate?
Is DTC displayed?
Yes
Go to step 2.
No
Go to step 3.

M?

DTC.
Go to step 4.
between
VDCCM&H/U and
combination
meter.

M?
VDC(diag)-29
Replace
VDCCM&H/U.

D: ABS WARNING LIGHT DOES NOT GO OFF

Open in harness
TROUBLE SYMPTOM:
When starting the engine, the ABS warning light is kept ON.
WIRING DIAGRAM:
LHD model
BATTERY
SBF-7
SBF-1
IGNITION
SWITCH
A3
A:
B36
35
20
i3
16
i1
20
A5
A7
A8
BRAKE FLUID
LEVEL SWITCH
i10
ABS
WARNING
LIGHT
BRAKE
WARNING
LIGHT
A4
NO.5
B38
B310
VDCCM & H/U
1
2
B16
B97
B229
R1
R4
PARKING
BRAKE
SWITCH
B16
1
2
B229
1 2
i1
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
B310
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
A:
i10
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
B38
B97
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
VDC00245
VDC(diag)-30

RHD model
BATTERY
SBF-7
SBF-1
IGNITION
SWITCH
i10
35
A5
3
A:
20
A7
4
ABS
WARNING
LIGHT
A3
A8
BRAKE FLUID
LEVEL SWITCH
16
BRAKE
WARNING
LIGHT
A4
NO.5
i1
B310
B36
VDCCM & H/U
1
2
B16
B97
B229
R1
R4
PARKING
BRAKE
SWITCH
B16
1
2
B229
1 2
i1
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
B310
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
A:
i10
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
B97
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
VDC00238
VDC(diag)-31

3
4
Step
READ DTC.
VDCCM&H/U.
VDCCM&H/U connector and combination
meter connector.
(B310) No. 35 (i10) No. A5:
CHECK VDCCM.
1) Connect the connector to VDCCM&H/U
(B310).
Check
Is DTC displayed?
Yes
No
nosis according to
DTC.
Repair the har?
ness connector
between
VDCCM&H/U and
combination
meter.

nation meter.
Go to step 4.
Replace the
VDCCM&H/U.
E: VDC INDICATOR LIGHT DOES NOT GO OFF

TROUBLE SYMPTOM:
When starting the engine, VDC indicator light is kept ON.
Step
READ DTC.
CHECK LAN SYSTEM.
Perform the diagnosis for LAN system. <Ref. to
Check
Is DTC displayed?
Is there any fault in LAN system?
VDC(diag)-32
Yes
DTC.
DTC for LAN system.
Replace the
VDCCM&H/U.
No
Go to step 2.
Go to step 3.
Repair the combination meter.

F: VDC WARNING LIGHT AND VDC OFF INDICATOR LIGHT DO NOT GO OFF
Defective engine
VDC OFF switch is shorted.
TROUBLE SYMPTOM:
When starting the engine, VDC OFF indicator light is kept ON.
NOTE:
When pressing the VDC OFF switch for more than 10 seconds, the VDC OFF indicator light goes off and cannot operate any more. When turning the ignition switch from OFF to ON, the OFF operation enabled status
is restored.
Step
2
3
4
5
Check
Is DTC displayed?
Yes
No
READ DTC.
nosis according to
DTC.
CHECK ENGINE.
Does the malfunction indicator Repair the engine. Go to step 3.
light illuminate?
CHECK ENGINE COOLANT.
When the engine coolant tem- Normal Operation Go to step 4.
Warm up the engine and check if VDC warning perature is too low, VDC warnlight and VDC OFF indicator light illumination ing light and VDC OFF
condition changes.
indicator light illuminate. Does
the lights go off when the
engine is warmed-up?
CHECK VDC OFF SWITCH.
Is VDC OFF switch normal?
Go to step 5.
Replace the VDC
Remove and check VDC OFF switch.
OFF switch.
CHECK LAN SYSTEM.
Is there any fault in LAN sys- Perform the diag- Go to step 6.
Perform the diagnosis for LAN system. <Ref. to tem?
nosis according to
DTC for LAN sysTrouble Code (DTC).>
tem.
Replace the
Repair the combiCheck the combination meter.
VDCCM&H/U.
nation meter.
VDC(diag)-33

G: BRAKE WARNING LIGHT DOES NOT GO OFF

Brake warning light circuit is shorted.
Defective sensor/connector
TROUBLE SYMPTOM:
After starting the engine, the brake warning light is kept on though the parking lever is released.
WIRING DIAGRAM:
LHD model
BATTERY
SBF-7
SBF-1
IGNITION
SWITCH
A3
A:
B36
35
20
i3
16
i1
20
A5
A7
A8
BRAKE FLUID
LEVEL SWITCH
i10
ABS
WARNING
LIGHT
BRAKE
WARNING
LIGHT
A4
NO.5
B38
B310
VDCCM & H/U
1
2
B16
B97
B229
R1
R4
PARKING
BRAKE
SWITCH
B16
1
2
B229
1 2
i1
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
B310
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
A:
i10
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
B38
B97
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
VDC00245
VDC(diag)-34

RHD model
BATTERY
SBF-7
SBF-1
IGNITION
SWITCH
i10
35
A5
3
A:
20
A7
4
ABS
WARNING
LIGHT
A3
A8
BRAKE FLUID
LEVEL SWITCH
16
BRAKE
WARNING
LIGHT
A4
NO.5
i1
B310
B36
VDCCM & H/U
1
2
B16
B97
B229
R1
R4
PARKING
BRAKE
SWITCH
B16
1
2
B229
1 2
i1
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
B310
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
A:
i10
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
B97
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
VDC00238
VDC(diag)-35

8
9
Step
CHECK INSTALLATION OF VDCCM&H/U
CONNECTOR.
2) Check that VDCCM&H/U connector is
inserted until it is locked by clamp.
READ DTC.
CHECK BRAKE FLUID AMOUNT.
Check the amount of brake fluid in the reservoir tank of master cylinder.
CHECK BRAKE FLUID LEVEL SWITCH.
2) Disconnect the level switch connector (B16)
from master cylinder.
3) Measure the resistance of master cylinder
terminals.
Terminals
No. 1 No. 2:
CHECK PARKING BRAKE SWITCH.
1) Disconnect the connector (R4) from parking brake switch.
3) Measure the resistance between parking
brake switch terminal and chassis ground.
CHECK HARNESS CONNECTOR.
VDCCM&H/U.
VDCCM&H/U connector and combination connector.
(B310) No. 20 (i10) No. A7:
CHECK VDCCM.
1) Connect the connector (B310) to
VDCCM&H/U.
Check
Is the connector firmly
inserted?
Yes
Go to step 2.
Is DTC displayed?

nosis according to
DTC.
Go to step 4.
Replenish brake
fluid to the specified value.
Go to step 5.
Replace the master cylinder.
Is the amount of brake fluid

between the lines of MAX
and MIN?
M?
No
Insert the
VDCCM&H/U connector until it is
locked by clamp.

M?
Go to step 6.
Replace the parking brake switch.

M?
Go to step 7.

between combination meter brake
fluid level switch
and parking brake
switch.
between
VDCCM&H/U and
combination
meter.

?

nation meter.
VDC(diag)-36
Go to step 9.
Replace the
VDCCM&H/U.


A: LIST
DTC
Detailed
code
Display
698XH
FR sensor power supply

failure
Abnormal power supply of front ABS wheel

speed sensor RH
6A0XH
Front Right ABS Sensor

Circuit Open or Shorted
Battery
Open/high input of front

ABS wheel speed sensor RH
68CXH
68EXH
690XH
694XH
696XH
Front Right ABS Sensor

Signal
Front ABS wheel speed

sensor RH signal malfunction
618XH
FL sensor power supply failure

sensor LH power supply malfunction
620XH
Front Left ABS Sensor

Battery
Open/high input of front

ABS wheel speed sensor LH
60CXH
60EXH
610XH
614XH
616XH
Front Left ABS Sensor

Signal

sensor LH signal malfunction
658XH
RR sensor power supply failure
Rear ABS wheel speed

sensor RH power supply malfunction
660XH
Rear Right ABS Sensor

Battery
Open/high input of rear

ABS wheel speed sensor RH
64CXH
64EXH
650XH
654XH
656XH
Rear Right ABS Sensor

Signal

sensor RH signal malfunction
6D8XH
RL sensor power supply

failure

sensor LH power supply malfunction
6E0XH
Rear Left ABS Sensor

Battery
Open/high input of rear

ABS wheel speed sensor LH
6CCXH
6CEXH
6D0XH
6D4XH
6D6XH
Rear Left ABS Sensor

Signal

sensor LH signal malfunction
C0021
C0022
C0023
C0024
C0025
C0026
C0027
C0028
VDC(diag)-37
Reference target
<Ref. to VDC(diag)-43, DTC C0021 FRONT ABS
WHEEL SPEED SENSOR RH POWER SUPPLY
MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to VDC(diag)-46, DTC C0021 OPEN/HIGH
INPUT OF FRONT ABS WHEEL SPEED SENSOR RH, Diagnostic Procedure with Diagnostic
WHEEL SPEED SENSOR RH SIGNAL MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
WHEEL SPEED SENSOR LH POWER SUPPLY
INPUT OF FRONT ABS WHEEL SPEED SENSOR LH, Diagnostic Procedure with Diagnostic
WHEEL SPEED SENSOR LH SIGNAL MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to VDC(diag)-43, DTC C0025 REAR ABS
WHEEL SPEED SENSOR RH POWER SUPPLY
INPUT OF REAR ABS WHEEL SPEED SENSOR
RH, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
WHEEL SPEED SENSOR RH SIGNAL MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
WHEEL SPEED SENSOR LH POWER SUPPLY
INPUT OF REAR ABS WHEEL SPEED SENSOR
LH, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
WHEEL SPEED SENSOR LH SIGNAL MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>

DTC
C0029
Detailed
code
608XH
648XH
688XH
6C8XH
704XH
606XH
646XH
686XH
6C6XH
702XH
604XH
644XH
684XH
6C4XH
70CXH
720XH
710XH
Display
Reference target
Any One of Four ABS

Sensors Signal
ABS wheel speed sensor signal malfunction

in one of four wheels
<Ref. to VDC(diag)-57, DTC C0029 ABS WHEEL

SPEED SENSOR SIGNAL MALFUNCTION IN
ONE OF FOUR WHEELS, Diagnostic Procedure
Front inlet solenoid

valve RH malfunction in
VDCCM&H/U
C0031
320XH
FR hold valve malfunction
C0032
360XH
FR pressure reducing
valve malfunction
Front outlet solenoid

VDCCM&H/U
C0033
220XH
FL hold valve malfunction
Front inlet solenoid

valve LH malfunction in
VDCCM&H/U
C0034
260XH
FL pressure reducing
valve malfunction
Front outlet solenoid

VDCCM&H/U
C0035
2A0XH
RR hold valve malfunction
Rear inlet solenoid

VDCCM&H/U
C0036
2E0XH
RR pressure reducing
valve malfunction
Rear outlet solenoid

VDCCM&H/U
C0037
3A0XH
RL hold valve malfunction
Rear inlet solenoid

VDCCM&H/U
C0038
3E0XH
RL pressure reducing
valve malfunction
Rear outlet solenoid

VDCCM&H/U
C0061
4A0XH
Normal opening valve 1

malfunction
Secondary cut valve

malfunction in
VDCCM&H/U
C0062
4E0XH
Normal opening valve 2

malfunction
Primary cut valve malfunction in VDCCM&H/

U
VDC(diag)-38
<Ref. to VDC(diag)-61, DTC C0031 FRONT

INLET SOLENOID VALVE RH MALFUNCTION
IN VDCCM&H/U, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to VDC(diag)-61, DTC C0032 FRONT OUTLET SOLENOID VALVE RH MALFUNCTION IN
VDCCM&H/U, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to VDC(diag)-61, DTC C0033 FRONT
INLET SOLENOID VALVE LH MALFUNCTION IN
<Ref. to VDC(diag)-61, DTC C0034 FRONT OUTLET SOLENOID VALVE LH MALFUNCTION IN
<Ref. to VDC(diag)-61, DTC C0035 REAR INLET
SOLENOID VALVE RH MALFUNCTION IN
<Ref. to VDC(diag)-62, DTC C0036 REAR OUTLET SOLENOID VALVE RH MALFUNCTION IN
<Ref. to VDC(diag)-62, DTC C0037 REAR INLET
SOLENOID VALVE LH MALFUNCTION IN
<Ref. to VDC(diag)-62, DTC C0038 REAR OUTLET SOLENOID VALVE LH MALFUNCTION IN
<Ref. to VDC(diag)-62, DTC C0061 SECONDARY CUT VALVE MALFUNCTION IN
<Ref. to VDC(diag)-62, DTC C0062 PRIMARY
CUT VALVE MALFUNCTION IN VDCCM&H/U,
Code (DTC).>

DTC
Detailed
code
Display
Secondary suction
valve malfunction in
VDCCM&H/U
C0063
520XH
Normal closing valve 1

malfunction
C0064
560XH
Normal closing valve 2

malfunction
Primary suction valve

malfunction in
VDCCM&H/U
C0041
000XH
002XH
004XH
006XH
010XH
012XH
014XH
016XH
018XH
01AXH
01EXH
024XH
026XH
028XH
02AXH
02CXH
02EXH
030XH
03AXH
03CXH
03DXH
03EXH
034XH
036XH
038XH
ECM
VDC control module

(VDCCM) malfunction
7CEXH
7D0XH
Power supply voltage

failure
Power voltage malfunction
7CCXH
Speed sen. power supply failure
9A0XH
TCM communication
circuit
970XH
822XH
Incorrect VDC Control

Module specifications
972XH
TCM malfunction
788XH
78CXH
7A0XH
7A4XH
C0042
C0044
C0045
C0047
Reference target
<Ref. to VDC(diag)-62, DTC C0063 SECONDARY SUCTION VALVE MALFUNCTION IN
<Ref. to VDC(diag)-63, DTC C0064 PRIMARY
SUCTION VALVE MALFUNCTION IN
<Ref. to VDC(diag)-65, DTC C0041 VDC CONTROL MODULE MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to VDC(diag)-67, DTC C0042 POWER

VOLTAGE MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to VDC(diag)-70, DTC C0042 ABS WHEEL
ABS wheel speed sen- SPEED SENSOR POWER MALFUNCTION,
sor power malfunction
Code (DTC).>
CAN communication
<Ref. to VDC(diag)-70, DTC C0044 AT COMMUmalfunction of transmis- NICATION, Diagnostic Procedure with Diagnossion control module
tic Trouble Code (DTC).>
<Ref. to VDC(diag)-71, DTC C0045 DIFFERENT
Different VDC control
VDC CONTROL MODULE SPECIFICATION,
module specification
Code (DTC).>
<Ref. to VDC(diag)-72, DTC C0045 AT CONAT control module malTROL MODULE MALFUNCTION, Diagnostic Profunction
VDC(diag)-39
<Ref. to VDC(diag)-73, DTC C0047 IMPROPER

CAN COMMUNICATION, Diagnostic Procedure

DTC
Detailed
code
Display
048XH
Valve relay OFF failure
Valve relay OFF malfunction
04AXH
04CXH
Valve relay
Valve relay system
06AXH
Valve relay test failure
Valve relay test malfunction
00DXH
Valve relay ON failure
Valve relay ON malfunction
58AXH
Motor and motor relay
Motor/motor relay system
5A0XH

OFF failure
Motor/motor relay OFF

malfunction
58EXH

ON failure
Motor/motor relay ON
malfunction
58CXH
Motor malfunction
Motor
0A0XH
Brake Light Switch
BLS open circuit
08CXH
BLS ON malfunction
BLS ON malfunction
820XH
EGI communication circuit
CAN communication
malfunction of engine
control module
C0051
C0052
C0054
C0057
VDC(diag)-40
Reference target
<Ref. to VDC(diag)-75, DTC C0051 VALVE
RELAY OFF MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
RELAY MALFUNCTION, Diagnostic Procedure
RELAY TEST MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
RELAY ON MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to VDC(diag)-83, DTC C0052 MOTOR/
MOTOR RELAY MALFUNCTION, Diagnostic
MOTOR RELAY OFF MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code
(DTC).>
MOTOR RELAY ON MALFUNCTION, Diagnostic
<Ref. to VDC(diag)-88, DTC C0052 MOTOR,
Code (DTC).>
<Ref. to VDC(diag)-89, DTC C0054 BLS OPEN
CIRCUIT, Diagnostic Procedure with Diagnostic
<Ref. to VDC(diag)-91, DTC C0054 BLS ON
<Ref. to VDC(diag)-92, DTC C0057 ECM COMMUNICATION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>

DTC
C0071
Detailed
code
Reference target
<Ref. to VDC(diag)-93, DTC C0071 EXCESSIVE

Excessive steering
STEERING ANGLE SENSOR OUTPUT OFFSET,
angle sensor output offDiagnostic Procedure with Diagnostic Trouble
set
Code (DTC).>
<Ref. to VDC(diag)-95, DTC C0071 EXCESSIVE
Excessive variation
VARIATION AMOUNT OF STEERING ANGLE
amount of steering
SENSOR OUTPUT, Diagnostic Procedure with
angle sensor output
148XH

offset is too big
14AXH
Change range of steering angle sensor is too

big
142XH
144XH
146XH
14EXH
158XH
15AXH
15CXH
15EXH
14CXH
164XH
166XH
16AXH
16CXH
16EXH
170XH

malfunction

output
160XH
No signal from steering

angle sensor

communication
764XH

malfunction

power supply malfunction
Abnormal yaw rate sensor output
Yaw rate sensor output
192XH
1A0XH
18BXH
Voltage inputted to yaw

rate sensor exceeds
specification
19CXH
Abnormal yaw rate sensor reference voltage
18CXH
Change range of yaw

rate sensor signal is too
big
184XH
188XH
18EXH
180XH
182XH
186XH
190XH
194XH
196XH
198XH
19AXH
C0072
Display
<Ref. to VDC(diag)-97, DTC C0071 STEERING

ANGLE SENSOR OUTPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>

ANGLE SENSOR COMMUNICATION, Diagnostic
ANGLE SENSOR POWER SUPPLY MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to VDC(diag)-104, DTC C0072 YAW RATE


Yaw rate sensor power
SENSOR POWER/OUTPUT, Diagnostic Procesupply/output
dure with Diagnostic Trouble Code (DTC).>
Yaw rate sensor referSENSOR REFERENCE, Diagnostic Procedure
ence
<Ref. to VDC(diag)-112, DTC C0072 EXCESExcessive variation
SIVE VARIATION AMOUNT OF YAW RATE
amount of yaw rate senSENSOR OUTPUT, Diagnostic Procedure with
sor output
VDC(diag)-41

DTC
Detailed
code
Display
1C8XH
1CAXH
Lateral G sensor offset

is too big
1C0XH
1C6XH
1D8XH
C0073
1CCXH
1D2XH
1E0XH
118XH
110XH
C0074
120XH
113XH
102XH
108XH
124XH
C0081
746XH
Reference target
<Ref. to VDC(diag)-115, DTC C0073 EXCESSIVE AMOUNT OF LATERAL G SENSOR OUTPUT OFFSET, Diagnostic Procedure with
<Ref. to VDC(diag)-115, DTC C0073 LATERAL G
Abnormal lateral G senLateral G sensor output SENSOR OUTPUT, Diagnostic Procedure with
sor output
<Ref. to VDC(diag)-115, DTC C0073 EXCESExcessive variation
Change range of lateral
SIVE VARIATION AMOUNT OF LATERAL G
amount of lateral G
G sensor is too big
sensor output
<Ref. to VDC(diag)-116, DTC C0073 EXCESExcessive lateral G sen- Excessive lateral G
SIVE LATERAL G SENSOR OUTPUT, Diagnostic
sor signal
sensor output
Voltage inputted to lat<Ref. to VDC(diag)-118, DTC C0073 LATERAL G
Lateral G sensor power/
eral G sensor exceeds
SENSOR POWER/OUTPUT, Diagnostic Proceoutput
specification
<Ref. to VDC(diag)-121, DTC C0074 PRESSURE
Pressure sensor test
Pressure sensor test
SENSOR TEST MALFUNCTION, Diagnostic Profailure
malfunction
<Ref. to VDC(diag)-123, DTC C0074 EXCESPressure sensor offset
Excessive pressure
SIVE PRESSURE SENSOR OUTPUT OFFSET,
is too big
sensor output offset
Code (DTC).>
Pressure sensor power/ Pressure sensor power/
SENSOR POWER/OUTPUT, Diagnostic Proceoutput
output
Pressure sensor output Pressure sensor output SENSOR OUTPUT, Diagnostic Procedure with
Pressure sensor power Pressure sensor power
SENSOR POWER MALFUNCTION, Diagnostic
supply malfunction
supply malfunction
<Ref. to VDC(diag)-128, DTC C0081 SYSTEM
System failure
System malfunction
Excessive amount of
lateral G sensor output
offset
VDC(diag)-42


A: DTC C0021 FRONT ABS WHEEL SPEED SENSOR RH POWER SUPPLY
MALFUNCTION
NOTE:
For the diagnostic procedure, refer to DTC C0027 REAR ABS WHEEL SPEED SENSOR LH POWER SUPPLY MALFUNCTION. <Ref. to VDC(diag)-44, DTC C0027 REAR ABS WHEEL SPEED SENSOR LH POWER SUPPLY MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
B: DTC C0023 FRONT ABS WHEEL SPEED SENSOR LH POWER SUPPLY

MALFUNCTION
NOTE:
C: DTC C0025 REAR ABS WHEEL SPEED SENSOR RH POWER SUPPLY MALFUNCTION
NOTE:
VDC(diag)-43

D: DTC C0027 REAR ABS WHEEL SPEED SENSOR LH POWER SUPPLY MALFUNCTION
Defective ABS wheel speed sensor
TROUBLE SYMPTOM:
VDC does not operate.
WIRING DIAGRAM:
SBF-1
BATTERY
SBF-7
GENERATOR
No.33
IGNITION
SWITCH
14
B310
VDCCM & H/U
B310
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
VDC00216
VDC(diag)-44

Step
Check if there is poor contact in VDCCM&H/U
CHECK VDCCM&H/U POWER SUPPLY CIRCUIT.
U connector terminals.
Terminals
(B310) No. 14 (+) (B310) No. 6 ():
CHECK VDCCM&H/U.
4) Read the DTC.
Check
Yes
No
Go to step 2.
Go to step 3.
Check the generator, battery and

VDCCM&H/U
Replace the
VDCCM&H/U.
Go to step 4.

DTC.
interference.
VDC(diag)-45

E: DTC C0021 OPEN/HIGH INPUT OF FRONT ABS WHEEL SPEED SENSOR RH

NOTE:
For the diagnostic procedure, refer to DTC C0027 OPEN/HIGH INPUT OF REAR ABS WHEEL SPEED
SENSOR LH. <Ref. to VDC(diag)-47, DTC C0027 OPEN/HIGH INPUT OF REAR ABS WHEEL SPEED
SENSOR LH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
F: DTC C0023 OPEN/HIGH INPUT OF FRONT ABS WHEEL SPEED SENSOR LH

NOTE:
G: DTC C0025 OPEN/HIGH INPUT OF REAR ABS WHEEL SPEED SENSOR RH

NOTE:
VDC(diag)-46

H: DTC C0027 OPEN/HIGH INPUT OF REAR ABS WHEEL SPEED SENSOR LH

Defective ABS wheel speed sensor (broken wire, input voltage too high)
TROUBLE SYMPTOM:
WIRING DIAGRAM:
LHD model
23
38
22
21
24
40
VDCCM & H/U
5
14
6
15
TWISTED WIRE
TWISTED WIRE
41
25
B310
B98
B6
1
2
R72
1
2
R73
1
2
1
2
B15
TWISTED WIRE
TWISTED WIRE
R2
E
FRONT ABS
WHEEL SPEED
SENSOR LH
B6
R72
B15
R73
1 2
FRONT ABS
WHEEL SPEED
SENSOR RH
REAR ABS
WHEEL SPEED
SENSOR LH
REAR ABS
WHEEL SPEED
SENSOR RH
B98
B310
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
1 2 3 4
5
6
7
8
9
10
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
VDC00246
VDC(diag)-47

RHD model
23
38
22
21
24
40
VDCCM & H/U
7
18
8
19
TWISTED WIRE
TWISTED WIRE
41
25
B310
B97
B6
1
2
R72
1
2
R73
1
2
1
2
B15
TWISTED WIRE
TWISTED WIRE
R1
E
FRONT ABS
WHEEL SPEED
SENSOR LH
B6
R72
B15
R73
FRONT ABS
WHEEL SPEED
SENSOR RH
REAR ABS
WHEEL SPEED
SENSOR LH
REAR ABS
WHEEL SPEED
SENSOR RH
B310
B97
1 2
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
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
VDC00215
VDC(diag)-48

Step
Check if there is poor contact between
VDCCM&H/U and ABS wheel speed sensor.
VDCCM&H/U AND ABS WHEEL SPEED
SENSOR.
VDCCM&H/U.
2) Disconnect the connector from ABS wheel
speed sensor.
VDCCM&H/U connector and ABS wheel
speed sensor connector.
DTC C0021
(B310) No. 22 (B6) No. 1:
(B310) No. 21 (B6) No. 2:
DTC C0023
(B310) No. 41 (B15) No. 1:
(B310) No. 25 (B15) No. 2:
DTC C0025
(B310) No. 23 (R72) No. 1:
(B310) No. 38 (R72) No. 2:
DTC C0027
(B310) No. 24 (R73) No. 1:
(B310) No. 40 (R73) No. 2:
DTC C0021
DTC C0023
DTC C0025
DTC C0027
CHECK ABS WHEEL SPEED SENSOR POWER SUPPLY CIRCUIT.
1) Connect the VDCCM&H/U connector.
3) Measure the voltage between ABS wheel
speed sensor connector and chassis ground.
DTC C0021
DTC C0023
DTC C0025
DTC C0027
Check
Yes
No
Go to step 2.

?

between
VDCCM&H/U and
ABS wheel speed
sensor.

M?
Go to step 4.

between
VDCCM&H/U and
ABS wheel speed
sensor.
Go to step 6.
Go to step 5.
VDC(diag)-49

Step
CHECK VDCCM&H/U POWER SUPPLY CIRCUIT.
(B310) No. 14 (+) (B310) No. 6 ():
3) Check the ABS wheel speed sensor. <Ref.
to ABS-15, ABS WHEEL SPEED SENSOR,
INSPECTION, Rear ABS Wheel Speed Sensor.>
CHECK VDCCM&H/U.
Mode.>
4) Read the DTC.
Check
Yes
Go to step 7.
No
Check the generator, battery and
VDCCM&H/U
Is waveform pattern same as

Go to step 7.
Replace the ABS

wheel speed sensor.
Replace the
VDCCM&H/U.
<Ref. to VDC-7,
Control Unit
(VDCCM&H/U).>
DTC.
Go to step 8.
VDC(diag)-50
It results from a
temporary noise
interference.

I:
DTC C0022 FRONT ABS WHEEL SPEED SENSOR RH SIGNAL MALFUNCTION
NOTE:
For the diagnostic procedure, refer to DTC C0028 REAR ABS WHEEL SPEED SENSOR LH SIGNAL MALFUNCTION. <Ref. to VDC(diag)-52, DTC C0028 REAR ABS WHEEL SPEED SENSOR LH SIGNAL MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
J: DTC C0024 FRONT ABS WHEEL SPEED SENSOR LH SIGNAL MALFUNCTION

NOTE:
K: DTC C0026 REAR ABS WHEEL SPEED SENSOR RH SIGNAL MALFUNCTION

NOTE:
VDC(diag)-51

L: DTC C0028 REAR ABS WHEEL SPEED SENSOR LH SIGNAL MALFUNCTION

Defective ABS wheel speed sensor signal (noise, irregular signal, etc.)
TROUBLE SYMPTOM:
VDC(diag)-52

WIRING DIAGRAM:
LHD model
23
38
22
21
24
40
VDCCM & H/U
5
14
6
15
TWISTED WIRE
TWISTED WIRE
41
25
B310
B98
B6
1
2
R72
1
2
R73
1
2
1
2
B15
TWISTED WIRE
TWISTED WIRE
R2
E
FRONT ABS
WHEEL SPEED
SENSOR LH
B6
R72
B15
R73
1 2
FRONT ABS
WHEEL SPEED
SENSOR RH
REAR ABS
WHEEL SPEED
SENSOR LH
REAR ABS
WHEEL SPEED
SENSOR RH
B98
B310
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
1 2 3 4
5
6
7
8
9
10
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
VDC00246
VDC(diag)-53

RHD model
23
38
22
21
24
40
VDCCM & H/U
7
18
8
19
TWISTED WIRE
TWISTED WIRE
41
25
B310
B97
B6
1
2
R72
1
2
R73
1
2
1
2
B15
TWISTED WIRE
TWISTED WIRE
R1
E
FRONT ABS
WHEEL SPEED
SENSOR LH
B6
R72
B15
R73
FRONT ABS
WHEEL SPEED
SENSOR RH
REAR ABS
WHEEL SPEED
SENSOR LH
REAR ABS
WHEEL SPEED
SENSOR RH
B310
B97
1 2
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
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
VDC00215
VDC(diag)-54

Step
CHECK OUTPUT OF ABS WHEEL SPEED
SENSOR USING SUBARU SELECT MONITOR.
2) Read the ABS wheel speed sensor output
corresponding to the faulty wheel in Subaru
Select Monitor data display mode.
like radio and etc., or electric device are
Check if the noise sources (such as an
antenna) are installed near the sensor harness.
CHECK VDCCM&H/U.
Mode.>
4) Read the DTC.
Check
Yes
Does the speed indicated on
Go to step 2.
the display change in response
to the speedometer reading
during acceleration/deceleration when the steering wheel is
in the straight-ahead position?
No
Go to step 7.
Is there poor contact in connectors between VDCCM&H/U

and ABS wheel speed sensor?
Are the car phone, radio wave
device like radio and etc., or
electric device installed correctly?
Go to step 3.
Go to step 4.
Install the radio

wave device and
electric device
properly.
Go to step 5.

SPEED SENSOR.

7.5 Nm (0.76 kgf-m, 5.5 ft-lb)?

CHECK ABS WHEEL SPEED SENSOR OR

MAGNETIC ENCODER.
Is the oscilloscope pattern the

same waveform as shown in
the figure when the tire is
rotated? Is the pattern as
shown in the figure displayed
regularly in the oscilloscope
when the tire is slowly rotated
more than one revolution with
even speed?
Are there foreign materials,
protrusion of ABS wheel speed
10

like radio and etc., or electric device are
Check if the noise sources are (such as an
11

device like radio and etc., or
electric device installed correctly?
VDC(diag)-55
Install the noise

sources apart from
the sensor harness.
Replace the
VDCCM&H/U.
<Ref. to VDC-7,
Control Unit
(VDCCM&H/U).>
DTC.
Go to step 8.
Go to step 10.
Go to step 6.
It results from a
temporary noise
interference.
Tighten the ABS
bolts.
Go to step 9.
Remove dirt thor- Go to step 10.

oughly. Replace
the ABS wheel
speed sensor or
magnetic encoder
as a unit with hub
unit bearing when
it is broken or
damaged.
Go to step 11.
Install the radio
wave device and
electric device
properly.
Go to step 12.
Install the noise
sources apart from
the sensor harness.

12
13
Step
CHECK VDCCM&H/U.
Mode.>
4) Read the DTC.
Check
Yes
Replace the
VDCCM&H/U.
<Ref. to VDC-7,
Control Unit
(VDCCM&H/U).>
DTC.
No
Go to step 13.
It results from a
temporary noise
interference.
NOTE:
Though the ABS
warning light remains on at this
time, it is normal.
more than 12 km/h
(7 MPH) in order to
turn ABS warning
light off. Be sure to
drive the vehicle
and check the
warning light goes
off.
VDC(diag)-56

M: DTC C0029 ABS WHEEL SPEED SENSOR SIGNAL MALFUNCTION IN ONE

OF FOUR WHEELS
Defective ABS wheel speed sensor signal (noise, irregular signal, etc.)
Defective magnetic encoder
When a wheel is turned freely for a long time
TROUBLE SYMPTOM:
NOTE:
Brake warning light comes on as well as ABS warning light when EBD does not operate.
VDC(diag)-57

WIRING DIAGRAM:
LHD model
23
38
22
21
24
40
VDCCM & H/U
5
14
6
15
TWISTED WIRE
TWISTED WIRE
41
25
B310
B98
B6
1
2
R72
1
2
R73
1
2
1
2
B15
TWISTED WIRE
TWISTED WIRE
R2
E
FRONT ABS
WHEEL SPEED
SENSOR LH
B6
R72
B15
R73
1 2
FRONT ABS
WHEEL SPEED
SENSOR RH
REAR ABS
WHEEL SPEED
SENSOR LH
REAR ABS
WHEEL SPEED
SENSOR RH
B98
B310
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
1 2 3 4
5
6
7
8
9
10
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
VDC00246
VDC(diag)-58

RHD model
23
38
22
21
24
40
VDCCM & H/U
7
18
8
19
TWISTED WIRE
TWISTED WIRE
41
25
B310
B97
B6
1
2
R72
1
2
R73
1
2
1
2
B15
TWISTED WIRE
TWISTED WIRE
R1
E
FRONT ABS
WHEEL SPEED
SENSOR LH
B6
R72
B15
R73
FRONT ABS
WHEEL SPEED
SENSOR RH
REAR ABS
WHEEL SPEED
SENSOR LH
REAR ABS
WHEEL SPEED
SENSOR RH
B310
B97
1 2
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
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
VDC00215
VDC(diag)-59

2
3
4
5
Step
Check
WHETHER A WHEEL TURNED FREELY OR Did the wheels turn freely?
NOT.
Check if the wheels have been turned freely for
more than one minute, such as when the vehicle is jacked-up, under full-lock cornering or
when the wheels are not in contact with road
surface.
CHECK TIRE SPECIFICATIONS.

CHECK WEAR OF TIRE.
CHECK TIRE INFLATION PRESSURE.
Are the tire specifications correct?

Is the tire worn excessively?
Is the tire pressure correct?

SPEED SENSOR.
Are the ABS wheel speed sensor installation bolts tightened

to 7.5 Nm (0.76 kgf-m, 5.5 ftlb)? (For four wheels)
CHECK ABS WHEEL SPEED SENSOR SIG- Is the oscilloscope pattern the
NAL.
the figure when the tire is
rotated? Is the pattern as
3) Check the ABS wheel speed sensor. <Ref. shown in the figure displayed
to ABS-14, ABS WHEEL SPEED SENSOR,
regularly in the oscilloscope
INSPECTION, Front ABS Wheel Speed Sen- when the tire is slowly rotated
sor.>
more than one revolution with
even speed?
CHECK ABS WHEEL SPEED SENSOR OR Are there foreign materials,
MAGNETIC ENCODER.
protrusion of ABS wheel speed
CHECK VDCCM&H/U.
Mode.>
4) Read the DTC.
VDC(diag)-60
Yes
No
VDC is normal.
Go to step 2.
Erase the memory.
NOTE:
When the wheels
turn freely for a
long time, such as
when the vehicle is
towed or jackedup, or when steering wheel is continuously turned all
the way, this diagnostic trouble code
may
sometimes
occur.
Go to step 3.
Replace the tire.
Replace the tire.
Go to step 5.
Go to step 6.
Go to step 8.
Go to step 4.
Adjust the tire
pressure.
Tighten the ABS
bolts.
Go to step 7.
Remove dirt thor- Go to step 8.

oughly. Replace
the ABS wheel
speed sensor or
magnetic encoder
as a unit with hub
unit bearing if
there is breakage
or damage.
Replace the
Go to step 9.
VDCCM&H/U.
<Ref. to VDC-7,
Control Unit
(VDCCM&H/U).>

Step
Check
Yes
No
DTC.
interference.
NOTE:
Though the ABS
time, it is normal.
more than 12 km/h
(7 MPH) in order to
turn off the ABS
warning light. Be
sure to drive the
vehicle and check
the warning light
goes off.
N: DTC C0031 FRONT INLET SOLENOID VALVE RH MALFUNCTION IN VDCCM&H/U

NOTE:
For the diagnostic procedure, refer to DTC C0064 PRIMARY SUCTION VALVE MALFUNCTION IN VDCCM&H/U. <Ref. to VDC(diag)-63, DTC C0064 PRIMARY SUCTION VALVE MALFUNCTION IN VDCCM&H/U, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
O: DTC C0032 FRONT OUTLET SOLENOID VALVE RH MALFUNCTION IN VDCCM&H/U

NOTE:
P: DTC C0033 FRONT INLET SOLENOID VALVE LH MALFUNCTION IN VDCCM&H/U

NOTE:
Q: DTC C0034 FRONT OUTLET SOLENOID VALVE LH MALFUNCTION IN VDCCM&H/U

NOTE:
R: DTC C0035 REAR INLET SOLENOID VALVE RH MALFUNCTION IN VDCCM&H/U

NOTE:
VDC(diag)-61

S: DTC C0036 REAR OUTLET SOLENOID VALVE RH MALFUNCTION IN VDCCM&H/U

NOTE:
T: DTC C0037 REAR INLET SOLENOID VALVE LH MALFUNCTION IN VDCCM&H/U

NOTE:
U: DTC C0038 REAR OUTLET SOLENOID VALVE LH MALFUNCTION IN VDCCM&H/U

NOTE:
V: DTC C0061 SECONDARY CUT VALVE MALFUNCTION IN VDCCM&H/U

NOTE:
W: DTC C0062 PRIMARY CUT VALVE MALFUNCTION IN VDCCM&H/U

NOTE:
X: DTC C0063 SECONDARY SUCTION VALVE MALFUNCTION IN VDCCM&H/U

NOTE:
VDC(diag)-62

Y: DTC C0064 PRIMARY SUCTION VALVE MALFUNCTION IN VDCCM&H/U

Defective VDCH/U solenoid valve
TROUBLE SYMPTOM:
WIRING DIAGRAM:
SBF-1
BATTERY
SBF-7
GENERATOR
No.33
IGNITION
SWITCH
14
B310
VDCCM & H/U
B310
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
VDC00216
VDC(diag)-63

Step
CHECK INPUT VOLTAGE FOR VDCCM&H/
U.
U.
CHECK GROUND CIRCUIT FOR VDCCM&H/
U.
CHECK VDCCM&H/U.
4) Read the DTC.
Check
Yes
Go to step 2.
No
Repair the power
supply circuit.

?
Repair the
VDCCM&H/U
ground harness.
tery and VDCCM&H/U?
Replace the
VDCCM&H/U.
<Ref. to VDC-7,
Control Unit
(VDCCM&H/U).>
DTC.
Go to step 4.
VDC(diag)-64
Go to step 5.
Temporary poor
contact occurs.

Z: DTC C0041 VDC CONTROL MODULE MALFUNCTION

Defective VDCCM&H/U
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B310
VDCCM & H/U
B310
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
VDC00217
VDC(diag)-65

Step
Check
CHECK GROUND CIRCUIT FOR VDCCM&H/ Is the resistance less than 0.5
U.
?
U.
VDCCM&H/U and chassis ground.
CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in connectors between battery, ignition switch and VDCCM&H/U?
Is the car phone or radio properly installed?
CHECK VDCCM&H/U.
4) Read the DTC.
Yes
Go to step 2.
No
Repair the
VDCCM&H/U
ground harness.
Go to step 3.
Go to step 4.
Install the car

phone or radio
properly.
Go to step 5.
Are noise sources (such as an Install the noise

antenna) installed near the
sources apart from
sensor harness?
the sensor harness.
Replace the
Go to step 6.
VDCCM&H/U.
<Ref. to VDC-7,
Control Unit
(VDCCM&H/U).>
DTC. <Ref. to
VDC(diag)-37, List
VDC(diag)-66

AA:DTC C0042 POWER VOLTAGE MALFUNCTION

Defective VDCCM&H/U power voltage
TROUBLE SYMPTOM:
NOTE:
Warning lights go off if voltage returns.
VDC(diag)-67

WIRING DIAGRAM:
SBF-1
BATTERY
SBF-7
GENERATOR
No.33
IGNITION
SWITCH
14
B310
VDCCM & H/U
B310
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
VDC00216
VDC(diag)-68

Step
CHECK GENERATOR.
Terminals
ground ():
Check
Yes
Go to step 2.
No
SC(H4SO 2.0)-14,
Generator.>

tightly?
Go to step 3.
Tighten the terminal.
Go to step 4.
Repair the power

supply circuit.
Go to step 5.
Repair the
VDCCM&H/U
ground harness.
Go to step 6.

U.
U.
3) Operate the devices such as headlights, air
conditioner, defogger, etc. which produce
much electrical loading.
U.
?
CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in connector between generator, battery and VDCCM&H/U?
CHECK VDCCM&H/U.
4) Read the DTC.
VDC(diag)-69
Replace the
Go to step 7.
VDCCM&H/U.
<Ref. to VDC-7,
Control Unit
(VDCCM&H/U).>
DTC. <Ref. to
VDC(diag)-37, List

AB:DTC C0042 ABS WHEEL SPEED SENSOR POWER MALFUNCTION

NOTE:
For the diagnostic procedure, refer to DTC C0042 POWER VOLTAGE MALFUNCTION. <Ref. to VDC(diag)-67, DTC C0042 POWER VOLTAGE MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
AC:DTC C0044 AT COMMUNICATION

No CAN signal from TCM.
TROUBLE SYMPTOM:
2
3
Step
Check
CHECK LAN SYSTEM.
CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in TCM
connector?
CHECK TCM.
Is the TCM normal?
CHECK VDCCM&H/U.
4) Read the DTC.
VDC(diag)-70
Yes
No
nosis according to
DTC for LAN system.
Repair the conGo to step 3.
nector.
Go to step 4.
Replace the TCM.
<Ref. to 4AT-67,
(TCM).> <Ref. to
5AT-62, Transmission Control Module (TCM).>
Replace the
Go to step 5.
VDCCM&H/U.

interference.
DTC.

AD:DTC C0045 DIFFERENT VDC CONTROL MODULE SPECIFICATION

Different control module specification
TROUBLE SYMPTOM:
Step
CHECK VDCCM&H/U SPECIFICATION.
Check the identification mark of VDCCM&H/U.
Identification mark of VDCCM&H/U
OUTBACK 3.0 R: G2
Wagon model 2.5 i: G3
Wagon model 3.0 R: G4
Sedan model 2.5 i: G9
Sedan model 3.0 R: GA
CHECK TCM SPECIFICATION.
Check the TCM specification.
Check
Is the identification mark of
VDCCM&H/U the same as
vehicle specification?
Yes
Go to step 2.
No
Replace the
VDCCM&H/U.
<Ref. to VDC-7,
Control Unit
(VDCCM&H/U).>
CHECK AT SYSTEM.
2) Check the DTC in AT system.
CHECK ECM SPECIFICATION.
Check the ECM specification.
Is DTC of AT system displayed?
CHECK VDCCM&H/U.
4) Read the DTC.
Replace the
VDCCM&H/U.

DTC.
interference.
Is the specification of TCM

Go to step 3.
same as vehicle specification?
Replace the TCM.

<Ref. to 4AT-67,
(TCM).> <Ref. to
Repair the AT sys- Go to step 4.
tem.
Is the specification of ECM

Go to step 5.
same as vehicle specification?
VDC(diag)-71
Replace the ECM.

<Ref. to FU(H4SO
2.0)-34, Engine
Control Module
(ECM).> <Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
<Ref. to
FU(H6DO)-34,
Engine Control
Module (ECM).>
Go to step 6.

AE:DTC C0045 AT CONTROL MODULE MALFUNCTION

Defective TCM
TROUBLE SYMPTOM:
Step
CHECK AT SYSTEM.
2) Check the DTC in AT system.
CHECK VDCCM&H/U.
4) Read the DTC.
Check
Is DTC of AT system displayed?
Yes
No
Repair the AT sys- Go to step 2.
tem.
Replace the
VDCCM&H/U.

DTC.
interference.
VDC(diag)-72
Go to step 3.

AF:DTC C0047 IMPROPER CAN COMMUNICATION

CAN communication line circuit is open or shorted.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
13
29
30
4
TWISTED WIRE
VDCCM & H/U
B310
B231
STEERING
ANGLE SENSOR
B231
B310
1 2 3 4
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
VDC00247
VDC(diag)-73

2
3
Step
Check
CHECK LAN SYSTEM.
CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in
VDCCM&H/U connector?
CHECK VDCCM&H/U.
4) Read the DTC.
VDC(diag)-74
Yes
DTC for LAN system.
Replace the
VDCCM&H/U.
<Ref. to VDC-7,
Control Unit
(VDCCM&H/U).>
No
Go to step 2.
Go to step 3.
Temporary poor
contact occurs.

AG:DTC C0051 VALVE RELAY OFF MALFUNCTION

TROUBLE SYMPTOM:
WIRING DIAGRAM:
BATTERY
No.21
SBF-7
SBF-1
IGNITION
SWITCH
No.33
PUMP MOTOR
6
SECONDARY CUT
SECONDARY SUCTION
PRIMARY CUT
PRIMARY SUCTION
RR INLET
RR OUTLET
RL INLET
RL OUTLET
FR INLET
FR OUTLET
FL INLET
FL OUTLET
VALVE RELAY
SOLENOID
VALVE
VDCCM & H/U
MOTOR RELAY
14
B310
B310
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
VDC00328
VDC(diag)-75

Step
U.
U.
U.
CHECK VDCCM&H/U.
4) Read the DTC.
Check
Yes
Go to step 2.
No
between battery
and VDCCM&H/U.

?
Repair the
VDCCM&H/U
ground harness.
tery and VDCCM&H/U?
Replace the
VDCCM&H/U.
<Ref. to VDC-7,
Control Unit
(VDCCM&H/U).>
DTC.
Go to step 4.
VDC(diag)-76
Go to step 5.
Temporary poor
contact occurs.

AH:DTC C0051 VALVE RELAY MALFUNCTION

TROUBLE SYMPTOM:
WIRING DIAGRAM:
BATTERY
No.21
SBF-7
SBF-1
IGNITION
SWITCH
No.33
PUMP MOTOR
6
SECONDARY CUT
SECONDARY SUCTION
PRIMARY CUT
PRIMARY SUCTION
RR INLET
RR OUTLET
RL INLET
RL OUTLET
FR INLET
FR OUTLET
FL INLET
FL OUTLET
VALVE RELAY
SOLENOID
VALVE
VDCCM & H/U
MOTOR RELAY
14
B310
B310
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
VDC00328
VDC(diag)-77

Step
U.
U.
U.
Calculate the voltage difference measured in
step 1.
A:(B310) No. 14 (+) Chassis ground ():
B:(B310) No. 5 (+) Chassis ground ():
U.
CHECK VALVE RELAY FOR VDCCM&H/U.
(B310) No. 5 (B310) No. 6:
CHECK VDCCM&H/U.
4) Read the DTC.
Check
Yes
Go to step 2.
No
Repair the power
supply circuit.
Is the voltage difference

Repair the power
between A and B more than 2 supply circuit.
V?
Go to step 3.

?
Repair the
VDCCM&H/U
ground harness.

M?
Replace the
VDCCM&H/U.
Go to step 5.
tery and VDCCM&H/U?
Replace the
VDCCM&H/U.
<Ref. to VDC-7,
Control Unit
(VDCCM&H/U).>
DTC.
VDC(diag)-78
Go to step 6.
Go to step 7.
Temporary poor
contact occurs.

AI: DTC C0051 VALVE RELAY TEST MALFUNCTION

TROUBLE SYMPTOM:
WIRING DIAGRAM:
BATTERY
No.21
SBF-7
SBF-1
IGNITION
SWITCH
No.33
PUMP MOTOR
6
SECONDARY CUT
SECONDARY SUCTION
PRIMARY CUT
PRIMARY SUCTION
RR INLET
RR OUTLET
RL INLET
RL OUTLET
FR INLET
FR OUTLET
FL INLET
FL OUTLET
VALVE RELAY
SOLENOID
VALVE
VDCCM & H/U
MOTOR RELAY
14
B310
B310
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
VDC00328
VDC(diag)-79

Step
U.
U.
U.
CHECK VALVE RELAY FOR VDCCM&H/U.
(B310) No. 5 (B310) No. 6:
CHECK VDCCM&H/U.
4) Read the DTC.
Check
Yes
Go to step 2.
No
Repair the power
supply circuit in
VDCCM&H/U.

?
Repair the ground

circuit in
VDCCM&H/U.

M?
Replace the
VDCCM&H/U.
Go to step 4.
Repair the conIs there poor contact in connector between generator, bat- nector.
tery and VDCCM&H/U?
Replace the
VDCCM&H/U.
<Ref. to VDC-7,
Control Unit
(VDCCM&H/U).>
DTC.
VDC(diag)-80
Go to step 5.
Go to step 6.
Temporary poor
contact occurs.

AJ:DTC C0051 VALVE RELAY ON MALFUNCTION

TROUBLE SYMPTOM:
WIRING DIAGRAM:
BATTERY
No.21
SBF-7
SBF-1
IGNITION
SWITCH
No.33
PUMP MOTOR
6
SECONDARY CUT
SECONDARY SUCTION
PRIMARY CUT
PRIMARY SUCTION
RR INLET
RR OUTLET
RL INLET
RL OUTLET
FR INLET
FR OUTLET
FL INLET
FL OUTLET
VALVE RELAY
SOLENOID
VALVE
VDCCM & H/U
MOTOR RELAY
14
B310
B310
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
VDC00328
VDC(diag)-81

Step
Check
CHECK VALVE RELAY FOR VDCCM&H/U. Is the resistance more than 1
1) Disconnect the connector from VDCCM&H/ M?
U.
VDCCM&H/U connector terminals.
Terminals
No. 5 No. 6:
CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in connector between generator, battery and VDCCM&H/U?
CHECK VDCCM&H/U.
4) Read the DTC.
VDC(diag)-82
Yes
Go to step 2.
No
Replace the
VDCCM&H/U.
<Ref. to VDC-7,
Control Unit
(VDCCM&H/U).>
Go to step 3.
Replace the
Go to step 4.
VDCCM&H/U.
<Ref. to VDC-7,
Control Unit
(VDCCM&H/U).>
DTC. <Ref. to
VDC(diag)-37, List

AK:DTC C0052 MOTOR/MOTOR RELAY MALFUNCTION

Defective motor and motor relay
TROUBLE SYMPTOM:
WIRING DIAGRAM:
BATTERY
SBF-1
SBF-7
SBF-2
IGNITION
SWITCH
PUMP MOTOR
6
SECONDARY CUT
SECONDARY SUCTION
PRIMARY CUT
PRIMARY SUCTION
RR INLET
RR OUTLET
RL INLET
RL OUTLET
FR INLET
FR OUTLET
FL INLET
FL OUTLET
VALVE RELAY
SOLENOID
VALVE
VDCCM & H/U
MOTOR RELAY
14
B310
10
No.33
B310
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
VDC00329
VDC(diag)-83

Step
U.
U.
U.
CHECK MOTOR RELAY FOR VDCCM&H/U.
Terminals
No. 9 No. 10:
CHECK VDCCM&H/U.
4) Read the DTC.
Check
Yes
Go to step 2.
No
Repair the power
supply circuit in
VDCCM&H/U.

?
Repair the
VDCCM&H/U
ground harness.

M?
Replace the
VDCCM&H/U.
Go to step 4.
tery and VDCCM&H/U?
Replace the
VDCCM&H/U.
<Ref. to VDC-7,
Control Unit
(VDCCM&H/U).>
DTC. <Ref. to
VDC(diag)-37, List
VDC(diag)-84
Go to step 5.
Go to step 6.
Temporary poor
contact occurs.
NOTE:
Though the ABS
time, it is normal.
more than 12 km/h
(7 MPH) in order to
turn ABS warning
drive the vehicle
and check the
warning light goes
off.

AL:DTC C0052 MOTOR/MOTOR RELAY OFF MALFUNCTION

TROUBLE SYMPTOM:
NOTE:
For the diagnostic procedure, refer to DTC C0052 MOTOR/MOTOR RELAY MALFUNCTION <Ref. to
VDC(diag)-83, DTC C0052 MOTOR/MOTOR RELAY MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
VDC(diag)-85

AM:DTC C0052 MOTOR/MOTOR RELAY ON MALFUNCTION

TROUBLE SYMPTOM:
WIRING DIAGRAM:
BATTERY
SBF-1
SBF-7
SBF-2
IGNITION
SWITCH
PUMP MOTOR
6
SECONDARY CUT
SECONDARY SUCTION
PRIMARY CUT
PRIMARY SUCTION
RR INLET
RR OUTLET
RL INLET
RL OUTLET
FR INLET
FR OUTLET
FL INLET
FL OUTLET
VALVE RELAY
SOLENOID
VALVE
VDCCM & H/U
MOTOR RELAY
14
B310
10
No.33
B310
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
VDC00329
VDC(diag)-86

Step
Check
CHECK MOTOR RELAY FOR VDCCM&H/U. Is the resistance more than 1
1) Disconnect the connector from VDCCM&H/ M?
U.
VDCCM&H/U connector terminals.
Terminals
No. 9 No. 10:
CHECK VDCCM&H/U.
4) Read the DTC.
VDC(diag)-87
Yes
Go to step 2.
Replace the
VDCCM&H/U.
<Ref. to VDC-7,
Control Unit
(VDCCM&H/U).>
DTC. <Ref. to
VDC(diag)-37, List
No
Replace the
VDCCM&H/U.
<Ref. to VDC-7,
Control Unit
(VDCCM&H/U).>
Go to step 3.
Temporary poor
contact occurs.
NOTE:
Though the ABS
time, it is normal.
more than 12 km/h
(7 MPH) in order to
turn ABS warning
drive the vehicle
and check the
warning light goes
off.

AN:DTC C0052 MOTOR

Defective motor
TROUBLE SYMPTOM:
NOTE:
For the diagnostic procedure, refer to DTC C0052 MOTOR/MOTOR RELAY MALFUNCTION <Ref. to
VDC(diag)-83, DTC C0052 MOTOR/MOTOR RELAY MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
VDC(diag)-88

AO:DTC C0054 BLS OPEN CIRCUIT

TROUBLE SYMPTOM:
WIRING DIAGRAM:
SBF-1
BATTERY
No.8
SBF-3
STOP LIGHT SWITCH

OC WC
1
2
2
3
:
OC
B65
WC
OC
B64
WC
37
B159
B310
VDCCM & H/U
B64
B65
1 2
1 2
3 4
B310
B159
1
5
2
6
3
8
4
9
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
VDC00221
VDC(diag)-89

3
4
Step
WITH SUBARU SELECT MONITOR.
2) Release the brake pedal.
Select Monitor.
WITH SUBARU SELECT MONITOR.
Select Monitor.
CHECK IF STOP LIGHTS COME ON.
Depress the brake pedal.
CHECK OPEN CIRCUIT OF HARNESS.
U.
CHECK VDCCM&H/U.
4) Read the DTC.
Check
Is OFF displayed on the display?
Yes
Go to step 2.
No
Go to step 3.
Is ON displayed on the display?
Go to step 5.
Go to step 3.
Does the stop light illuminate? Go to step 4.

Go to step 5.
Is there poor contact in connector between stop light

switch and VDCCM&H/U?
Go to step 6.
VDC(diag)-90
Repair the stop

lights circuit.
Repair the harness between stop
light switch and
VDCCM&H/U connector.
Replace the
Go to step 7.
VDCCM&H/U.
<Ref. to VDC-7,
Control Unit
(VDCCM&H/U).>
DTC.

AP:DTC C0054 BLS ON MALFUNCTION

TROUBLE SYMPTOM:
WIRING DIAGRAM:
SBF-1
BATTERY
No.8
SBF-3
STOP LIGHT SWITCH

OC WC
1
2
2
3
:
OC
B65
WC
OC
B64
WC
37
B159
B310
VDCCM & H/U
B64
B65
1 2
1 2
3 4
B310
B159
1
5
2
6
3
8
4
9
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
VDC00221
VDC(diag)-91

Step
2) Disconnect the stop light switch connector.
3) Measure the resistance of stop light switch
terminals.
INTERVIEWING CUSTOMERS.
Make sure that the operation was performed in
which accelerator pedal and brake pedal were
depressed simultaneously (with depressing
brake pedal with left foot).
CHECK VDCCM&H/U.
4) Read the DTC.
Check
Yes
M when switch is OFF (when
pedal is not depressed)?
No
Replace the stop
light switch.
Were the acceleration pedal

System is in good
and brake pedal depressed
order. (DTC may
simultaneously during driving? be recorded while
brake is applied
during driving.)
Replace the
VDCCM&H/U.
<Ref. to VDC-7,
Control Unit
(VDCCM&H/U).>
DTC. <Ref. to
VDC(diag)-37, List
Go to step 3.
Go to step 4.
Temporary poor
contact occurs.
AQ:DTC C0057 ECM COMMUNICATION

No CAN signal from ECM.
TROUBLE SYMPTOM:
2
3
4
Step
Check
CHECK LAN SYSTEM.
CHECK POOR CONTACT IN CONNECTORS. Is the poor contact in ECM
connector?
CHECK ECM.
Is ECM normal?
CHECK VDCCM&H/U.
4) Read the DTC.
VDC(diag)-92
Yes
DTC for LAN system.
Go to step 4.
Replace the
VDCCM&H/U.
<Ref. to VDC-7,
Control Unit
(VDCCM&H/U).>
DTC.
No
Go to step 2.
Go to step 3.
Replace the ECM.
Go to step 5.
It results from a
temporary noise
interference.

AR:DTC C0071 EXCESSIVE STEERING ANGLE SENSOR OUTPUT OFFSET

Defective steering angle sensor
TROUBLE SYMPTOM:
WIRING DIAGRAM:
13
29
30
4
TWISTED WIRE
VDCCM & H/U
B310
B231
STEERING
ANGLE SENSOR
B231
B310
1 2 3 4
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
VDC00247
VDC(diag)-93

Step
Check
CHECK STEERING WHEEL.
Is the deviation from the center
1) Drive the vehicle on a flat road.
of steering wheel less than 5?
2) Park the vehicle straight.
3) Check the steering wheel for deviation from
center.
CHECK VDCCM&H/U.
5) Read the DTC.
VDC(diag)-94
Yes
Go to step 2.
No
Perform the centering adjustment
of steering wheel.
Replace the
Go to step 3.
VDCCM&H/U.
<Ref. to VDC-7,
Control Unit
(VDCCM&H/U).>
DTC. <Ref. to
VDC(diag)-37, List

AS:DTC C0071 EXCESSIVE VARIATION AMOUNT OF STEERING ANGLE SENSOR OUTPUT

TROUBLE SYMPTOM:
WIRING DIAGRAM:
13
29
30
4
TWISTED WIRE
VDCCM & H/U
B310
B231
STEERING
ANGLE SENSOR
B231
B310
1 2 3 4
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
VDC00247
VDC(diag)-95

Step
CHECK VDCCM&H/U.
5) Read the DTC.
Check
VDC(diag)-96
Yes
No
Replace the
Go to step 2.
VDCCM&H/U.
<Ref. to VDC-7,
Control Unit
(VDCCM&H/U).>
DTC. <Ref. to
VDC(diag)-37, List

AT:DTC C0071 STEERING ANGLE SENSOR OUTPUT

TROUBLE SYMPTOM:
WIRING DIAGRAM:
13
29
30
4
TWISTED WIRE
VDCCM & H/U
B310
B231
STEERING
ANGLE SENSOR
B231
B310
1 2 3 4
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
VDC00247
VDC(diag)-97

Step
CHECK STEERING WHEEL.
3) Check the steering wheel for deviation from
center.
CHECK DRIVING PLACE.
Check if the vehicle ran the road with banks or
sandy surface (which does not mean a dirt
road).
Check
Yes
Is the deviation from the center Go to step 2.
of steering wheel less than 5?
Did the vehicle run the road

with banks or sandy surface
(which does not mean a dirt
road)?
No
Perform the centering adjustment
of steering wheel.
VDCCM&H/U may Go to step 3.

record DTC when
the vehicle ran the
road with banks or
sandy surface
(which does not
mean a dirt road).
CHECK OUTPUT OF STEERING ANGLE
Does the steering angle sensor Go to step 4.
Replace the steerSENSOR WITH SUBARU SELECT MONIoutput value on the display
ing angle sensor.
TOR.
vary in accordance with steer1) Select {Current Data Display & Save} in
ing operation when turning the
steering wheel to the right or
2) Read the steering angle sensor output dis- left?
played on display.
Replace the
CHECK VDCCM&H/U.
Go to step 5.
VDCCM&H/U.
<Ref. to VDC-7,
VDC Control Mod3) Erase the memory.
ule and Hydraulic
Control Unit
5) Read the DTC.
(VDCCM&H/U).>
DTC.
VDC(diag)-98

AU:DTC C0071 STEERING ANGLE SENSOR COMMUNICATION

Signal does not come from the steering angle sensor.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
13
29
30
4
TWISTED WIRE
VDCCM & H/U
B310
B231
STEERING
ANGLE SENSOR
B231
B310
1 2 3 4
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
VDC00247
VDC(diag)-99

3
4
Step
Check
CHECK POWER SUPPLY FOR STEERING Is the voltage 10 15 V?
ANGLE SENSOR.
2) Disconnect the connector from steering
angle sensor.
4) Measure the voltage between steering
angle sensor and chassis ground.
CHECK OUTPUT VOLTAGE OF VDCCM&H/ Is the voltage 10 15 V?
U.
Measure the voltage between VDCCM&H/U
and chassis ground.
CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in connector?
CHECK GROUND CIRCUIT FOR STEERING Is the resistance less than 0.5
ANGLE SENSOR.
?
Measure the resistance between steering
CHECK STEERING ANGLE SENSOR HAR- Is the resistance less than 0.5
NESS.
?
U.
VDCCM&H/U and steering angle sensor.
(B231) No. 1 (B310) No. 29:
(B231) No. 2 (B310) No. 13:
CHECK GROUND SHORT CIRCUIT OF
STEERING ANGLE SENSOR HARNESS.
M?
(B231 No. 2 Chassis ground:
CHECK STEERING ANGLE SENSOR.
5) Read the DTC.
CHECK VDCCM&H/U.
2) Replace the steering angle sensor.
5) Read the DTC.
VDC(diag)-100
Yes
Go to step 4.
No
Go to step 2.
Repair the harness between

steering angle
sensor and
VDCCM&H/U.
Go to step 3.
Correct or replace Go to step 9.

the connector.
Go to step 5.
Repair ground circuit in the steering
angle sensor.
Go to step 6.

steering angle
sensor and
VDCCM&H/U.
Go to step 7.

steering angle
sensor and
VDCCM&H/U.
Go to step 8.
Go to step 10.
Replace the
Go to step 11.
VDCCM&H/U.
<Ref. to VDC-7,
Control Unit
(VDCCM&H/U).>

Step
5) Read the DTC.
Check
10
11
Yes
Replace the
VDCCM&H/U.
<Ref. to VDC-7,
Control Unit
(VDCCM&H/U).>
DTC.
DTC.
No
Go to step 10.
Temporary poor
contact occurs.
Original steering
angle sensor malfunction
AV:DTC C0071 STEERING ANGLE SENSOR POWER SUPPLY MALFUNCTION

TROUBLE SYMPTOM:
NOTE:
Warning light does not illuminate though problem is detected.
The ABS and VDC operate normally if voltage returns.
VDC(diag)-101

WIRING DIAGRAM:
13
29
30
4
TWISTED WIRE
VDCCM & H/U
B310
B231
STEERING
ANGLE SENSOR
B231
B310
1 2 3 4
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
VDC00247
VDC(diag)-102

3
4
Step
Check
CHECK POWER SUPPLY FOR STEERING Is the voltage 10 15 V?
ANGLE SENSOR.
2) Disconnect the connector from steering
angle sensor.
4) Measure the voltage between steering
U.
and chassis ground.
CHECK GROUND CIRCUIT FOR STEERING Is the resistance less than 0.5
ANGLE SENSOR.
?
5) Read the DTC.
CHECK VDCCM&H/U.
2) Replace the steering angle sensor.
5) Read the DTC.

5) Read the DTC.
VDC(diag)-103
Yes
Go to step 4.
No
Go to step 2.

steering angle
sensor and
VDCCM&H/U.
Go to step 3.

the connector.
Go to step 5.
Repair ground circuit in the steering
angle sensor.
Go to step 6.
Go to step 8.
Replace the
VDCCM&H/U.
<Ref. to VDC-7,
Control Unit
(VDCCM&H/U).>
Replace the
VDCCM&H/U.
<Ref. to VDC-7,
Control Unit
(VDCCM&H/U).>
DTC.
DTC.
Go to step 9.
Go to step 8.
Temporary poor
contact occurs.
Original steering
angle sensor malfunction

AW:DTC C0072 YAW RATE SENSOR OUTPUT

Defective yaw rate sensor
TROUBLE SYMPTOM:
WIRING DIAGRAM:
VDCCM & H/U
16
28
30
B310
B312
B347
B230
YAW RATE &

LATERAL G SENSOR
B230
1 2 3
4 5 6
B310
B312
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
1 2
VDC00222
VDC(diag)-104

Step
road).
Check
road)?
Yes
No
record DTC when
the vehicle ran the
road with banks or
sandy surface
(which does not
mean a dirt road).
CHECK YAW RATE & LATERAL G SENSOR Is the yaw rate & lateral G sen- Go to step 3.
Tighten the yaw
INSTALLATION.
sor installation bolt tightened to
rate & lateral G
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)?
sensor installation
bolt.
CHECK OUTPUT OF YAW RATE & LATER- Is the reading indicated on
Go to step 4.
Replace the yaw
AL G SENSOR WITH SUBARU SELECT
monitor display 4 4 deg/s?
rate & lateral G
MONITOR.
sensor.
4) Read the yaw rate output displayed on display.
CHECK OUTPUT OF STEERING ANGLE
Is the reading indicated on
Go to step 5.
Perform the cenSENSOR WITH SUBARU SELECT MONImonitor display 5 5?
tering adjustment
TOR.
of steering wheel.
4) Read the steering angle sensor output displayed on display.
CHECK YAW RATE & LATERAL G SENSOR. Is the same DTC displayed?
Go to step 6.
Go to step 7.
5) Read the DTC.
CHECK VDCCM&H/U.
Replace the
Go to step 8.
VDCCM&H/U.
2) Replace the yaw rate & lateral G sensor.
<Ref. to VDC-7,
VDC Control Mod4) Perform the inspection mode.
ule and Hydraulic
5) Read the DTC.
Control Unit
(VDCCM&H/U).>
DTC.
Perform the diag- Malfunction is
nosis according to found in original
DTC.
yaw rate & lateral
G sensor.
VDC(diag)-105

AX:DTC C0072 YAW RATE SENSOR POWER/OUTPUT

TROUBLE SYMPTOM:
WIRING DIAGRAM:
VDCCM & H/U
16
28
30
B310
B312
B347
B230
YAW RATE &

LATERAL G SENSOR
B230
1 2 3
4 5 6
B310
B312
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
1 2
VDC00222
VDC(diag)-106

3
4
6
7
Step
Check
CHECK YAW RATE & LATERAL G SENSOR Is the voltage 10 15 V?
POWER SUPPLY.
2) Disconnect the connector from the yaw rate
& lateral G sensor.
4) Measure the voltage between yaw rate &
lateral G sensor and chassis ground.
U.
and chassis ground.
CHECK GROUND CIRCUIT OF YAW RATE & Is the resistance less than 0.5
LATERAL G SENSOR.
?
Measure the resistance between yaw rate &
U.
?
and chassis ground.
CHECK YAW RATE & LATERAL G SENSOR Is the resistance less than 0.5
HARNESS.
?
U.
VDCCM&H/U and yaw rate & lateral G sensor.
(B310) No. 28 (B230) No. 4:
Measure the resistance between VDCCM&H/U M?
CHECK YAW RATE & LATERAL G SENSOR. Is the oscilloscope pattern the
the figure?
3) Check the signal pattern of oscilloscope
between VDCCM&H/U connector terminals.
(B310) No. 2 No. 16:
(B310) No. 28 No. 16:
VDC(diag)-107
Yes
Go to step 4.
No
Go to step 2.
Go to step 3.
Repair the harness between yaw
rate & lateral G
sensor and
VDCCM&H/U.
the connector.
Go to step 7.
Go to step 5.

ness between yaw
rate & lateral G
sensor and
VDCCM&H/U.
the connector.
Go to step 8.
rate & lateral G
sensor and
VDCCM&H/U.
Go to step 9.
Go to step 10.

rate & lateral G
sensor and
VDCCM&H/U.
Replace the yaw
rate & lateral G
sensor.

10
11
Step
Check
5) Read the DTC.
VDC(diag)-108
Yes
No
Replace the
Go to step 11.
VDCCM&H/U.
<Ref. to VDC-7,
Control Unit
(VDCCM&H/U).>
DTC.

AY:DTC C0072 YAW RATE SENSOR REFERENCE

TROUBLE SYMPTOM:
WIRING DIAGRAM:
VDCCM & H/U
16
28
30
B310
B312
B347
B230
YAW RATE &

LATERAL G SENSOR
B230
1 2 3
4 5 6
B310
B312
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
1 2
VDC00222
VDC(diag)-109

5
6
Step
CHECK POWER SUPPLY FOR YAW RATE &
LATERAL G SENSOR.
2) Disconnect the connector from yaw rate &
lateral G sensor.
CHECK OUTPUT VOLTAGE OF VDCCM&H/
U.
and chassis ground.
CHECK GROUND CIRCUIT OF YAW RATE &
LATERAL G SENSOR.
U.
and chassis ground.
Check
Yes
Go to step 3.
Go to step 5.
rate & lateral G
sensor and
VDCCM&H/U.

?
No
Go to step 2.
Go to step 4.
Is the resistance less than 0.5 Repair the harGo to step 5.

?
ness between yaw
rate & lateral G
sensor and
VDCCM&H/U.
Is there poor contact in conCorrect or replace

nector?
the connector.
CHECK HARNESS OF YAW RATE & LATER- Is the resistance less than 0.5 Go to step 7.
AL G SENSOR.
?
U.
(B310) No. 1 (B230) No. 1:
CHECK GROUND SHORT CIRCUIT OF HAR- Is the resistance more than 1 Go to step 8.
M?
NESS.
and chassis ground.
Go to step 9.
CHECK THE YAW RATE & LATERAL G SEN- Is the voltage 2.1 2.9 V?
SOR.
2) Install the yaw rate & lateral G sensor to
body.
(B310) No. 1 (+) No. 16 ():
VDC(diag)-110
Go to step 9.
rate & lateral G
sensor and
VDCCM&H/U.

rate & lateral G
sensor and
VDCCM&H/U.
Replace the yaw
rate & lateral G
sensor. <Ref. to
VDC-15, Yaw Rate
and Lateral G Sensor.>

10
Step
CHECK VDCCM&H/U.
5) Read the DTC.
Check
VDC(diag)-111
Yes
No
Replace the
Go to step 10.
VDCCM&H/U.
<Ref. to VDC-7,
Control Unit
(VDCCM&H/U).>
DTC.

AZ:DTC C0072 EXCESSIVE VARIATION AMOUNT OF YAW RATE SENSOR

OUTPUT
TROUBLE SYMPTOM:
WIRING DIAGRAM:
VDCCM & H/U
16
28
30
B310
B312
B347
B230
YAW RATE &

LATERAL G SENSOR
B230
1 2 3
4 5 6
B310
B312
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
1 2
VDC00222
VDC(diag)-112

7
8
Step
road).
Check
road)?
Yes
No
record DTC when
the vehicle ran the
road with banks or
sandy surface
(which does not
mean a dirt road).
Tighten the yaw
INSTALLATION.
rate & lateral G
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)?
sensor installation
bolt.
Go to step 5.
Go to step 4.
POWER SUPPLY.
lateral G sensor.
U.
ness between yaw
rate & lateral G
and chassis ground.
sensor and
VDCCM&H/U.
Go to step 6.
CHECK GROUND CIRCUIT OF YAW RATE & Is the resistance less than 0.5 Go to step 8.
LATERAL G SENSOR.
?
CHECK GROUND CIRCUIT FOR VDCCM&H/ Is the resistance less than 0.5 Repair the harGo to step 7.
U.
?
ness between yaw
rate & lateral G
and chassis ground.
sensor and
VDCCM&H/U.
CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in conCorrect or replace Go to step 14.
nector?
the connector.
CHECK HARNESS OF YAW RATE & LATER- Is the resistance less than 0.5 Go to step 9.
Repair the harAL G SENSOR.
?
ness between yaw
rate & lateral G
U.
sensor and
VDCCM&H/U.
(B310) No. 1 (B230) No. 1:
(B310) No. 2 (B230) No. 2:
(B310) No. 28 (B230) No. 4:
CHECK GROUND SHORT CIRCUIT OF HAR- Is the resistance more than 1 Go to step 10.
Repair the harNESS.
M?
ness between yaw
rate & lateral G
sensor and
VDCCM&H/U.
VDC(diag)-113

10
11
12
13
Step
(B310) No. 1 (+) No. 16 ():
2) Check the signal pattern of oscilloscope
between VDCCM&H/U connector terminals.
(B310) No. 2 No. 16:
(B310) No. 28 No. 16:
5) Read the DTC.
CHECK VDCCM&H/U.
5) Read the DTC.
Check
Yes
Go to step 11.
No
Replace the yaw
rate & lateral G
sensor.
Is the oscilloscope pattern the Go to step 12.

the figure?
Replace the yaw

rate & lateral G
sensor.
Go to step 13.
Go to step 15.
Replace the
VDCCM&H/U.
<Ref. to VDC-7,
Control Unit
(VDCCM&H/U).>
Replace the
VDCCM&H/U.
<Ref. to VDC-7,
Control Unit
(VDCCM&H/U).>
DTC.
DTC.
Go to step 16.
14
5) Read the DTC.
15
16
VDC(diag)-114
Go to step 15.
Temporary poor
contact occurs.
Malfunction is
found in original
yaw rate & lateral
G sensor.

BA:DTC C0073 EXCESSIVE AMOUNT OF LATERAL G SENSOR OUTPUT OFFSET

NOTE:
For the diagnostic procedure, refer to DTC C0073. <Ref. to VDC(diag)-116, DTC C0073 EXCESSIVE LATERAL G SENSOR OUTPUT, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
BB:DTC C0073 LATERAL G SENSOR OUTPUT

NOTE:
BC:DTC C0073 EXCESSIVE VARIATION AMOUNT OF LATERAL G SENSOR

OUTPUT
NOTE:
VDC(diag)-115

BD:DTC C0073 EXCESSIVE LATERAL G SENSOR OUTPUT

Defective lateral G sensor
TROUBLE SYMPTOM:
WIRING DIAGRAM:
VDCCM & H/U
16
28
30
B310
B312
B347
B230
YAW RATE &

LATERAL G SENSOR
B230
1 2 3
4 5 6
B310
B312
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
1 2
VDC00222
VDC(diag)-116

Step
Check
Yes
INSTALLATION.
7.5 Nm (0.76 kgf-m, 5.5 ft-lb)?
CHECK LATERAL G SENSOR OUTPUT.
3) Read the lateral G sensor output displayed
on display.
from vehicle.
3) Turn the ignition switch to ON, and select
{Current Data Display & Save} in Subaru
Select Monitor.
on display.
Read the lateral G sensor output displayed on
screen.
Is the indicated reading on the Go to step 3.

monitor display 1.5 1.5
m/s2?
When the yaw rate & lateral G Go to step 4.

sensor is inclined 90 to the
right, is the indicated value 6.8
12.8 m/s2?
Replace the yaw

rate & lateral G
sensor.
Go to step 5.
Replace the yaw

rate & lateral G
sensor.
Go to step 6.
When the yaw rate & lateral G

sensor is inclined 90 to the
left, is the indicated value 6.8
12.8 m/s2?
CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in conTurn the ignition switch to OFF.
nector between VDCCM&H/U
and yaw rate & lateral G sensor?
CHECK VDCCM&H/U.
4) Read the DTC.
No
Tighten the yaw
rate & lateral G
sensor installation
bolt.
Replace the yaw
rate & lateral G
sensor.
VDC(diag)-117
Replace the
Go to step 7.
VDCCM&H/U.
<Ref. to VDC-7,
Control Unit
(VDCCM&H/U).>
DTC.

BE:DTC C0073 LATERAL G SENSOR POWER/OUTPUT

Defective lateral G sensor
WIRING DIAGRAM:
VDCCM & H/U
16
28
30
B310
B312
B347
B230
YAW RATE &

LATERAL G SENSOR
B230
1 2 3
4 5 6
B310
B312
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
1 2
VDC00222
VDC(diag)-118

5
6
Step
on display.
Check
Yes
Is the indicated reading on the Go to step 2.
monitor display 1.5 1.5
m/s2?
Is there poor contact in connector between VDCCM&H/U

POWER SUPPLY.
lateral G sensor.
U.
and chassis ground.
CHECK POOR CONTACT IN CONNECTORS Is there poor contact in connector?
CHECK OPEN CIRCUIT IN LATERAL G SEN- Is the resistance less than 0.5
SOR OUTPUT HARNESS.
?
lateral G sensor.
U.
(B310) No. 3 (B230) No. 5:
CHECK GROUND SHORT CIRCUIT FOR
YAW RATE & LATERAL G SENSOR HARM?
NESS.
when yaw rate & lateral G sen1) Turn the ignition switch to OFF.
sor is on level?
from vehicle.
3) Connect the connector to the yaw rate &
lateral G sensor.
4) Connect the connector to VDCCM&H/U.
lateral G sensor connector terminals.
(B230) No. 5 (+) No. 6 ():
VDC(diag)-119
No
Go to step 3.
Go to step 10.
Go to step 6.
Go to step 4.

ness between yaw
rate & lateral G
sensor and
VDCCM&H/U.
the connector.
Go to step 7.
between yaw rate
& lateral G sensor
and VDCCM&H/U.
Go to step 8.

between yaw rate
& lateral G sensor
and VDCCM&H/U.
Go to step 9.
Replace the yaw

rate & lateral G
sensor.

10
11
Step
Check
CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in connector between VDCCM&H/U
CHECK VDCCM&H/U.
4) Read the DTC.
VDC(diag)-120
Yes
No
Go to step 10.
Replace the
Go to step 11.
VDCCM&H/U.
<Ref. to VDC-7,
Control Unit
(VDCCM&H/U).>
DTC.

BF:DTC C0074 PRESSURE SENSOR TEST MALFUNCTION

Defective pressure sensor
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B310
1
2
3
12
11
27
VDCCM & H/U
B348
PRESSURE SENSOR
B310
B348
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
1
3
2
VDC00223
VDC(diag)-121

3
4
6
7
10
Step
Check
CHECK PRESSURE SENSOR POWER SUP- Is the voltage 4.75 5.25 V?
PLY.
2) Disconnect the connector from pressure
sensor.
4) Measure the voltage between pressure
CHECK OUTPUT VOLTAGE OF VDCCM&H/ Is the voltage 4.75 5.25 V?
U.
and chassis ground.
CHECK GROUND CIRCUIT OF PRESSURE Is the resistance less than 0.5
SENSOR.
?
Measure the resistance between pressure
sensor and chassis ground.
CHECK GROUND CIRCUIT OF VDCCM&H/U. Is the resistance less than 0.5
Measure the resistance between VDCCM&H/U ?
and chassis ground.
CHECK PRESSURE SENSOR HARNESS.
Is the resistance less than 0.5
?
U.
VDCCM&H/U and pressure sensor.
(B310) No. 11 (B348) No. 2:
CHECK VDCCM&H/U.
Is DTC displayed?
4) Read the DTC.
VDC(diag)-122
Yes
Go to step 4.
No
Go to step 2.
Go to step 3.
pressure sensor
and VDCCM&H/U.

the connector.
Go to step 7.
Go to step 5.

ness between
pressure sensor
and VDCCM&H/U.
the connector.
Go to step 8.
pressure sensor
and VDCCM&H/U.
Go to step 9.

pressure sensor
and VDCCM&H/U.
Replace the
Go to step 10.
VDCCM&H/U.
<Ref. to VDC-7,
Control Unit
(VDCCM&H/U).>
DTC.

BG:DTC C0074 EXCESSIVE PRESSURE SENSOR OUTPUT OFFSET

TROUBLE SYMPTOM:
WIRING DIAGRAM:
B310
1
2
3
12
11
27
VDCCM & H/U
B348
PRESSURE SENSOR
B310
B348
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
1
3
2
VDC00223
VDC(diag)-123

Step
Check stop light switch open circuit.
CHECK VDCCM&H/U.
4) Read the DTC.
Check
Is the stop light switch circuit
OK?
Yes
Go to step 2.
No
Repair the stop
light switch circuit.
Go to step 3.
Replace the
VDCCM&H/U.
<Ref. to VDC-7,
Control Unit
(VDCCM&H/U).>
DTC. <Ref. to
VDC(diag)-37, List
BH:DTC C0074 PRESSURE SENSOR POWER/OUTPUT

TROUBLE SYMPTOM:
NOTE:
For the diagnostic procedure, refer to DTC C0074 PRESSURE SENSOR TEST MALFUNCTION. <Ref. to
VDC(diag)-121, DTC C0074 PRESSURE SENSOR TEST MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
VDC(diag)-124

BI: DTC C0074 PRESSURE SENSOR OUTPUT

TROUBLE SYMPTOM:
WIRING DIAGRAM:
B310
1
2
3
12
11
27
VDCCM & H/U
B348
PRESSURE SENSOR
B310
B348
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
1
3
2
VDC00223
Step
Check stop light switch open circuit.
Check
Is the stop light switch circuit
OK?
VDC(diag)-125
Yes
Go to step 2.
No
If there is malfunction in the stop
light switch circuit,
DTC may be
recorded in the
memory.

4
5
7
8
10
11
Step
Check
CHECK PRESSURE SENSOR POWER SUP- Is the voltage 4.75 5.25 V?
PLY.
2) Disconnect the connector from pressure
sensor.
CHECK OUTPUT VOLTAGE OF VDCCM&H/ Is the voltage 4.75 5.25 V?
U.
and chassis ground.
CHECK GROUND CIRCUIT OF PRESSURE Is the resistance less than 0.5
SENSOR.
?
Measure the resistance between pressure
sensor and chassis ground.
CHECK GROUND CIRCUIT OF VDCCM&H/U. Is the resistance less than 0.5
Measure the resistance between VDCCM&H/U ?
and chassis ground.
CHECK PRESSURE SENSOR HARNESS.
Is the resistance less than 0.5
?
U.
VDCCM&H/U and pressure sensor.
(B310) No. 11 (B348) No. 2:
CHECK VDCCM&H/U.
Is DTC displayed?
4) Read the DTC.
VDC(diag)-126
Yes
Go to step 5.
No
Go to step 3.
Go to step 4.
pressure sensor
and VDCCM&H/U.

the connector.
Go to step 8.
Go to step 6.

ness between
pressure sensor
and VDCCM&H/U.
the connector.
Go to step 9.
pressure sensor
and VDCCM&H/U.
Go to step 10.

pressure sensor
and VDCCM&H/U.
Replace the
Go to step 11.
VDCCM&H/U.
<Ref. to VDC-7,
Control Unit
(VDCCM&H/U).>
DTC.

BJ:DTC C0074 PRESSURE SENSOR POWER MALFUNCTION

TROUBLE SYMPTOM:
WIRING DIAGRAM:
SBF-1
BATTERY
SBF-7
GENERATOR
No.33
IGNITION
SWITCH
14
B310
VDCCM & H/U
B310
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
VDC00216
VDC(diag)-127

Step
Check
CHECK POOR CONTACT IN CONNECTORS. Is there poor contact?
Check if there is poor contact in VDCCM&H/U
CHECK VDCCM&H/U POWER SUPPLY CIR- Is the voltage 10 15 V?
CUIT.
(B310) No. 14 (+) (B310) No. 6 ():
CHECK VDCCM&H/U.
4) Read the DTC.
Yes
No
Go to step 2.
Go to step 3.
Check the power

supply circuit in
VDCCM&H/U.
Replace the
VDCCM&H/U.
<Ref. to VDC-7,
Control Unit
(VDCCM&H/U).>
DTC.
Go to step 4.
It results from a
temporary noise
interference.
BK:DTC C0081 SYSTEM MALFUNCTION

VDC long time sequential control
TROUBLE SYMPTOM:
Step
Check
CHECK POOR CONTACT IN CONNECTOR. Is there poor contact in the
VDCCM&H/U and yaw rate &
lateral G sensor connector?
CHECK VDCCM&H/U.
5) Read the DTC.
VDC(diag)-128
Yes
No
Go to step 2.
Replace the
VDCCM&H/U.
Malfunction is
found in original
yaw rate & lateral
G sensor.


A: INSPECTION
Symptom
Poor brake per- Long braking/
formance
stopping distance
Wheel lock
VDCCM&H/U
Defective ABS wheel speed sensor or
sensor gap
Brake drag
VDCCM&H/U
sensor gap
Master cylinder
Brake caliper
Parking brake
Axle and wheels
Brake pedal play
Aeration to brake line
Brake pedal play
Long brake
pedal stroke
Poor brake performance
Main probable cause

VDCCM&H/U
Brake pad
Aeration to brake line
Tire specifications, tire wear and air
pressures
Vehicle vertical
pitching
VDCCM&H/U
Suspension play or fatigue (reduced
damping)
Unstable or
uneven braking
VDCCM&H/U
sensor gap
Brake caliper
Brake pad
pressures
VDC(diag)-129
Other probable cause

Defective ABS wheel speed sensor or sensor
gap
Defective steering angle sensor or improper
neutral position
Defective yaw rate & lateral G sensor or
improper installation
Master cylinder
Brake caliper
Disc rotor
Brake pipe
Brake booster
neutral position
Brake caliper
Brake pipe
neutral position
Brake pad
Brake pipe
VDCCM&H/U
Master cylinder
Brake caliper
Brake pad
Brake pipe
Brake booster
gap
neutral position
gap
neutral position
Master cylinder
Disc rotor
Brake pipe
Axle and wheels
Road with crowns or banks
Suspension play or fatigue (poor damping)

Symptom
Vibration or
Excessive
noise
brake pedal
When brakvibration
ing suddenly
Strange noise
When accel- from VDCH/U
erating suddenly
While driving
on a slippery
Noise from the
road
front side of
vehicle
Main probable cause

VDCCM&H/U (mount bushing)
sensor gap
Brake pipe
VDCCM&H/U (mount bushing)
sensor gap
Master cylinder
Brake caliper
Brake pad
Disc rotor
Brake pipe
Brake booster
Noise inside
passenger seat
Noise from the

rear side of
vehicle
Engine does not accelerate or

goes into a stall when accelerating suddenly or driving on a slippery surface.

sensor gap
Brake caliper
Brake pad
Disc rotor
Parking brake
Brake pipe
VDCCM&H/U
sensor gap
Master cylinder
Brake caliper
Parking brake
Incorrect wiring or piping
VDC(diag)-130

VDCCM&H/U
Brake booster
VDCCM&H/U
neutral position
Axle and wheels
VDCCM&H/U
neutral position
Axle and wheels

neutral position
Brake pad
Brake pipe

Symptom
Poor changeDeviation to
direction-opera- right or left
tion stability of
direction
TCS
Vehicle spin
Steering wheel drag while driving
VDC operates while driving normally.
Main probable cause

VDCCM&H/U
sensor gap
Defective steering angle sensor or
improper neutral position
Defective yaw rate & lateral G sensor
or improper installation
Brake caliper
Brake pad
Wheel alignment
pressures
VDCCM&H/U
sensor gap
Brake pad
pressures
VDCCM&H/U
sensor gap
Power steering system
VDCCM&H/U
sensor gap
Wheel alignment
pressures
Power steering system
VDC(diag)-131

Disc rotor
Brake pipe
Axle and wheels
Brake caliper
Brake pipe
Brake caliper
Brake pad
Disc rotor
Wheel alignment

Symptom
Main probable cause
VDC OFF indicator light does not Harness
come on when the VDC OFF
Indicator light bulb
switch is depressed.
VDC OFF switch
NOTE:
When pressing VDC OFF switch
for more than 10 seconds, VDC
OFF indicator light goes off and
cannot operate any more. When
turning the ignition switch from
OFF to ON, the previous status is
restored.
VDC(diag)-132
BRAKE
BR
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Page
Front Brake Pad ........................................................................................16
Front Disc Rotor ........................................................................................19
Front Disc Brake Assembly.......................................................................20
Rear Brake Pad.........................................................................................25
Rear Disc Rotor.........................................................................................26
Rear Disc Brake Assembly .......................................................................28
Master Cylinder .........................................................................................30
Brake Booster ...........................................................................................32
Brake Fluid ................................................................................................36
Air Bleeding...............................................................................................38
Brake Hose ...............................................................................................40
Brake Pipe.................................................................................................42
Brake Pedal...............................................................................................43
Stop Light Switch ......................................................................................45
General Description
BRAKE
A: SPECIFICATION
Model
Front disc
brake
Size
Type
Effective disc diameter
mm (in)
Disc thickness Outer
mm (in)
diameter
Effective cylinder diameter
Pad dimensions
(length width thickmm (in)
ness)
Clearance adjustment
Size
Master
cylinder
Effective disc diameter

Disc thickness Outer
diameter
Effective cylinder
diameter
Pad dimensions
(length width thickness)
Type
Effective diameter
Reservoir type
Brake fluid reservoir
capacity
Brake
booster
24 277 (0.94 10.91)
24 294 (0.94 11.57)
15-inch type
2.0 GT, 3.0 R

17-inch type
261 (10.28)
30 316 (1.18 12.44)
42.8 (1.685) 2
117.8 50.5 11.0 (4.638 1.988 0.433)
130.0 53.5 11.0

(5.118 2.106 0.433)
Automatic adjustment
15-inch type
mm (in)
238 (9.37)
Disc (Floating type, ventilated)

254 (10.0)
mm (in)
10 274 (0.39 10.79)
18 290 (0.71 11.42)
Type
Rear disc
brake
228 (8.98)
OUTBACK 2.5 i,
OUTBACK 3.0 R
16-inch type
Disc (Floating type, ventilated)
244 (4.61)
2.0 i, 2.5 i
Disc (Floating type, solid)
mm (in)
mm (in)
38.1 (1.500)
92.0 33.0 9.0 (3.622 1.299 0.354)
82.4 33.7 9.0

(3.244 1.327 0.354)
Automatic adjustment
Tandem
23.8 (15/16)
Sealed type
mm (in)
cm3
(cu in)
205 (12.51)
Type
Effective diameter
Vacuum suspended
208 + 229 (8.19 + 9.02)
Dual circuit system
mm (in)
Brake line
Brake fluid
CAUTION:
Avoid mixing brake fluid of different
brands to prevent fluid performance from
degrading.
When brake fluid is supplemented, be
careful not to allow any dust into the reservoir.
Use fresh SUBARU genuine brake fluid
when replacing or refilling the fluid.
FMVSS No. 116, DOT3
NOTE:
Refer to PB section for parking brake specifications. <Ref. to PB-2, SPECIFICATION, General Description.>
BR-2
General Description
BRAKE
Item
Pad thickness
mm (in)
Front brake
Disc thickness
mm (in)
Disc runout
Pad thickness
mm (in)
Rear brake (Disc

type)
Parking brake
Disc thickness
mm (in)
Disc runout
Inside diameter
Lining thickness
Lever stroke
Except 17-inch
type
17-inch type
Except 17-inch
type
17-inch type
mm (in)
Solid disc
Ventilated disc
Solid disc
Ventilated disc
mm (in)
mm (in)
mm (in)
Brake
Booster
Brake pedal
Brake fluid pressure with

engine running and vacuum
at 66.7 kPa (500 mmHg,
19.69 inHg)
Limit
11 (0.43)
1.5 (0.059)
11 (0.43)
1.5 (0.059)
24 (0.94)
22 (0.87)
30 (1.18)
28 (1.10)
0.05 (0.0020)
9.0 (0.354)
1.5 (0.059)
9.0 (0.354)
1.5 (0.059)
10 (0.39)
8.5 (0.335)
18 (0.71)
16 (0.63)
0.05 (0.0020)
170 (6.69)
171 (6.73)
3.2 (0.126)
1.5 (0.059)
5 6 notches/200 N (20 kgf, 45 lb)
147 (15, 33)

294 (30, 66)
147 (15, 33)
Fluid pressure kPa (kg/cm2, psi)

15-inch type
16-inch type
17-inch type
545 (6, 79)
1,564 (16, 227)
6,003 (61, 871)
5,381 (55, 780)
4,963 (51, 720)
294 (30, 66)
11,273 (115, 1,635) 10,982 (112, 1,593) 10,055 (103, 1,458)
Brake pedal force

N (kgf, lb)
Brake fluid pressure without
engine running
Standard value
Free play
0.5 2 (0.02 0.08)
mm (in) [When pulling the brake pedal upward with a force of less than 10 N (1 kgf, 2 lb).]
BR-3
General Description
BRAKE
B: COMPONENT
1. FRONT DISK BRAKE
Except for EC, EK, OUTBACK model
T1
T2
(2)
(3)
(4)
(1)
T3
(5)
(6)
(7)
(A )
(9)
(8)
(17)
(10)
(1 1 )
(4)
(1 2 )
(B)
(1 4 )
(13)
(12)
(11)
(11)
( 16)
(12)
(14)
(1 5 )
(13)
(12)
(11 )
BR-00332
(A)
(B)
15, 16-inch type

17-inch type
(1)
(2)
(3)
(4)
(5)
(6)
Caliper body
Air bleeder screw
Guide pin (Green)
Pin boot
Piston seal
Piston
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
Piston boot
Lock pin (Yellow)
Support
Pad clip
Outer shim
Inner shim
Pad (Outside)
Pad (Inside)
Disc rotor
BR-4
(16)
(17)
Disc cover
Bushing

T1: 8 (0.8, 5.8)
T2: 27 (2.8, 19.9)
T3: 80 (8.2, 59)
General Description
BRAKE
EC, EK, OUTBACK model
T1
T2
(2)
(3)
(4)
(1)
T3
(5)
(6)
(7)
(9)
(8)
(17)
(10)
(4)
(1 1 )
(1 2 )
(14)
(13)
(11)
( 16)
(15)
BR-00373
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Caliper body
Air bleeder screw
Guide pin (Green)
Pin boot
Piston seal
Piston
Piston boot
Lock pin (Yellow)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
Support
Pad clip
Outer shim
Inner shim
Pad (Outside)
Pad (Inside)
Disc rotor
Disc cover
BR-5
(17)
Bushing

T1: 8 (0.8, 5.8)
T2: 27 (2.8, 19.9)
T3: 80 (8.2, 59)
General Description
BRAKE
2. REAR DISC BRAKE

(34)
T1
(2)
T2
(3)
(4)
T3
(3 5 )
(1)
(5)
(6)
(7)
(8)
(14)
(14)
(12)
(9)
(10)
(4)
(11)
(14)
T4
(17)
(1 6 )
(11)
(13)
(18)
(19)
(20)
(21)
(23)
(24)
(25)
(26)
(27)
(22)
(3 3 )
(29)
(28)
(3 2 )
(31) (30)
(15)
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
Caliper body
Air bleeder screw
Guide pin (Green)
Pin boot
Piston seal
Piston
Piston boot
Support
Lock pin (Yellow)
Bushing
Pad clip
Inner pad
Outer pad
Shim
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
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
Primary shoe return spring
Adjusting spring
BR-6
(29)
(30)
(31)
(32)
(33)
(34)
(35)
BR-00374
Adjuster
Shoe hold-down cup
Shoe hold-down spring
Disc rotor (Solid type)
Disc rotor (Ventilated type)
Bolt (For solid disc brake)
Bolt (For ventilated disc brake)

T1: 8 (0.8, 5.8)
T2: 27 (2.8, 19.9)
T3: 37 (3.8, 27.5)
T4: 53 (5.4, 39.1)
General Description
BRAKE
3. MASTER CYLINDER
LHD model
(1)
(2)
(10)
(3)
(9)
(8)
(11)
(4)
(5)
(6)
(7)
BR-00371
(1)
(2)
(3)
(4)
(5)
Cap
Filter
Reservoir tank
C-ring
Primary piston
(6)
(7)
(8)
(9)
(10)
Secondary piston
Cylinder body
Cylinder pin
Seal
Pin
BR-7
(11)
O-ring

T: 13 (1.3, 9.6)
General Description
BRAKE
RHD model
(1)
(2)
(10)
(3)
(9)
(8)
(11)
(4)
(5)
(6)
(7)
BR-00334
(1)
(2)
(3)
(4)
(5)
Cap
Filter
Reservoir tank
C-ring
Primary piston
(6)
(7)
(8)
(9)
(10)
Secondary piston
Cylinder body
Cylinder pin
Seal
Pin
BR-8
(11)
O-ring

T: 13 (1.3, 9.6)
General Description
BRAKE
4. FRONT BRAKE PIPES AND HOSE

LHD model
(8)
(B)
(2)
T2
T1
T1
(1)
T3
T2
T1
(5)
(A)
T4
T1
(8)
(9)
T2
(10)
(2)
T2
(3)
(6)
(5)
(4)
T1
T1
T1
(1)
T2
T4
T2
T1
T2
(6)
(7)
T1
(5)
(9)
T4
T1
(5)
(3)
(4)
(6)
T1
T2
T4
T2
(6)
BR-00442
(A)
(B)
Model with ABS

Model with Vehicle dynamics control (VDC)
(5)
(6)
(7)
Clamp
Gasket
(1)
(2)
(3)
(4)
Front brake pipe ASSY

Two-way connector
Front brake hose RH
Front brake hose LH
(8)
(9)
(10)
Bracket
Master cylinder
VDC control module & hydraulic
BR-9

T1: 15 (1.5, 10.8)
T2: 18 (1.8, 13.0)
T3: 19 (1.9, 14.0)
T4: 33 (3.4, 24.3)
General Description
BRAKE
RHD model
(8)
(B)
(2)
T2
T3
(1)
T1
T1
T2
T3
(5)
T1
(A)
T4
T1
(8)
(5)
(10)
(2)
T2
T1
(9)
(3)
(6)
(4)
T1
(1)
T1
T2
T4
T2
T1
T2
(6)
(7)
T1
(5)
T1
(9)
(5)
T4
(3)
(4)
T1
(6)
T2
T4
T2
(6)
BR-00464
(A)
(B)
Model with ABS

Model with VDC
(6)
(7)
Gasket
(1)
(2)
(3)
(4)
(5)
Front brake pipe ASSY

Two-way connector
Front brake hose RH
Front brake hose LH
Clamp
(8)
(9)
(10)
Bracket
Master cylinder
VDC control module & hydraulic
BR-10

T1: 15 (1.5, 10.8)
T2: 18 (1.8, 13.0)
T3: 19 (1.9, 14.0)
T4: 33 (3.4, 24.3)
General Description
BRAKE
5. CENTER AND REAR BRAKE PIPES AND HOSE

T3
(11) (8)
(11)
(6)
(10)
(10)
T1
(12)
T2
(10)
T2
(4)
(3)
T3
T1
T2
T3
(11)
(10)
T1
(2)
(11)
(10)
T2
(9)
(7)
T3
T1
T1
T1
T1
(10)
(5)
(1)
BR-00337
(1)
(2)
(3)
(4)
(5)
(6)
Center brake pipe ASSY

Two-way connector
Rear brake pipe ASSY
Rear brake hose RH
Rear brake hose LH
Rear brake pipe RH
(7)
(8)
(9)
(10)
(11)
(12)
Rear brake pipe LH

Rear brake hose rear RH
Rear brake hose rear LH
Clamp
Gasket
Bracket
BR-11

T1: 15 (1.5, 10.8)
T2: 18 (1.8, 13.0)
T3: 33 (3.4, 24.3)
General Description
BRAKE
6. BRAKE BOOSTER
(1)
BR-00335
(1)
Brake booster
BR-12
General Description
BRAKE
7. BRAKE PEDAL
LHD MT model
T2
T2
T2
(1)
(2)
T2
T1
(6)
T1
(3)
(4)
(5)
BR-00375
(1)
(2)
(3)
Brake pedal ASSY

Stop light switch
Brake pedal pad
(4)
(5)
(6)
Clutch pedal
Clutch pedal pad
Clutch switch
BR-13

T1: 8 (0.8, 5.8)
T2: 18 (1.8, 13.0)
General Description
BRAKE
LHD AT model, RHD model
T2
(1)
(2)
T1
T2
T1
(3)
BR-00338
(1)
(2)
Brake pedal ASSY

Stop light switch
(3)
Brake pedal pad
BR-14

T1: 8 (0.8, 5.8)
T2: 18 (1.8, 13.0)
General Description
BRAKE
C: CAUTION
Use SUBARU genuine grease etc. or equivalent.
Do not mix grease, etc. with that of another grade
or from other manufacturers.
points.
D: PREPARATION TOOL
1. GENERAL TOOL
TOOL NAME
Snap ring pliers
REMARKS
Used for removing and installing snap ring.
BR-15
Front Brake Pad

BRAKE
2. Front Brake Pad
(4) Attach a rod of less than 12 mm (0.47 in) diameter to the shaded area of the brake pad, and
strike the rod with a hammer to drive brake pad
out of place.
A: REMOVAL
1. 15-INCH TYPE
2) Remove the caliper bolt.
BR-00014
2. 16-INCH TYPE
Refer to 15-inch type. <Ref. to BR-16, 15-INCH
TYPE, REMOVAL, Front Brake Pad.>
BR-00339
3) Raise the caliper body and support it.

NOTE:
Do not disconnect the brake hose from caliper
body.
4) Remove the pad.
3. 17-INCH TYPE
TYPE, REMOVAL, Front Brake Pad.>
B: INSTALLATION
1. 15-INCH TYPE
1) Apply a thin coat of Molykote M7439 to the pad
clip.
BR-00012
NOTE:
If the brake pad is difficult to remove, proceed as
follows:
(1) Remove the caliper body from support.
(2) Remove the support.
(3) Place the support in a vise between wooden
blocks.
BR-00340
2) Apply a thin coat of Molykote AS880N (Part No.

K0779YA010) to the frictional portion between pad
and pad inner shim.
(1)
(2)
BR-00013
BR-00238
(1) Support
(2) Wooden block
BR-16
Front Brake Pad

BRAKE

K0779YA010) to the three frictional portions between inner shim and outer shim of outer pads.

BR-00341
BR-00341
4) Install the pad on support.

5) Install the caliper body on support.
NOTE:
Install the pad indicator in proper direction.
Tightening torque:
27 Nm (2.8 kgf-m, 19.9 ft-lb)
2. 16-INCH TYPE
(1)
(6)

TYPE, INSTALLATION, Front Brake Pad.>
3. 17-INCH TYPE
(5)
(2)

clip.
(6)
(3)
(6)
(5)
(4)
BR-00340

and pad inner shim.
(6)
BR-00342
(1)
(2)
(3)
(4)
(5)
(6)
BR-00238
LH IN
LH OUT
RH IN
RH OUT
Pad indicator
Pad return spring
CAUTION:
Be sure to install so that the direction of pad
return spring faces to the input side of brake rotor rotation direction as shown in the figure.
Correctly install the pad return spring to supporting surface of pad clip as shown in the figure.
BR-17
Front Brake Pad

BRAKE
When the pad return spring is deformed or

damaged, replace the brake pad with new one.
3. 17-INCH TYPE
Check the pad thickness A.
(1)
A
(2)
(3)
BR-00483
BR-00360
(1) Pad return spring

(2) Supporting surface of pad clip
(3) Brake rotor rotation direction
Pad thickness
11 (0.43)
1.5 (0.059)
NOTE:
Always replace the pads for both right and left
wheels at the same time.
Replace the pad if there is oil or grease on it.
Tightening torque:
27 Nm (2.8 kgf-m, 19.9 ft-lb)
C: INSPECTION
1. 15-INCH TYPE
BR-00360
Standard value
Pad thickness
mm (in) Wear limit
Standard
value
mm (in)
Wear limit
11 (0.43)
1.5 (0.059)
NOTE:
Also replace the pad clips if they are twisted or
worn.
2. 16-INCH TYPE
TYPE, INSPECTION, Front Brake Pad.>
BR-18
Front Disc Rotor

BRAKE
3. Front Disc Rotor
C: INSPECTION
A: REMOVAL
1) Check front wheel bearing play and axial hub

runout before disc rotor runout limit inspection.
<Ref. to DS-15, INSPECTION, Front Axle.>
2) Secure the disc rotor by tightening five wheel
nuts.
3) Set a dial gauge 10 mm (0.39 in) inward of rotor
outer perimeter. Turn the disc rotor to check runout.
If the disc rotor runout exceeds specified value, replace with a new disc rotor.
1. 15-INCH TYPE
1) Lift-up the vehicle, and remove the front wheels.
2) Remove the caliper body and the support from
housing, and suspend it from strut using a wire.
BR-00017
3) Remove the disc rotor.

NOTE:
If the disc rotor seizes up within hub, drive the disc
rotor out by pushing with an 8 mm bolt in holes B on
the rotor.
BR-00019

0.05 mm (0.0020 in)
4) Set a micrometer 10 mm (0.39 in) inward of the
rotor outer perimeter, and then measure the disc
rotor thickness. If the thickness of disc rotor is outside the service limit, replace with a new disc rotor.
B
A
BR-00018
4) Clean mud and foreign particles from the caliper

body assembly and the support.
A
BR-00018
2. 16-INCH TYPE
TYPE, REMOVAL, Front Disc Rotor.>
3. 17-INCH TYPE
15

TYPE, REMOVAL, Front Disc Rotor.>
B: INSTALLATION
1) Install the disc rotor.
2) Install the caliper body and the support to housing.
Disc rotor
thickness A 16
mm (in)
17
Tightening torque:
80 Nm (8.2 kgf-m, 59 ft-lb)
BR-19
Standard
value
Limit
24 (0.94)
22 (0.87)
24 (0.94)
22 (0.87)
30 (1.18)
28 (1.10)
Disc rotor
outer diameter
277
(10.91)
294
(11.57)
316
(12.44)
Front Disc Brake Assembly

BRAKE
4. Front Disc Brake Assembly

A: REMOVAL
2. 16-INCH TYPE
1. 15-INCH TYPE
CAUTION:
Do not allow brake fluid to come in contact with
vehicle body; wash away with water and wipe
off completely if spilled.
1) Lift-up the vehicle, and remove the front wheels.
2) Remove the union bolt, and disconnect the
brake hose from caliper body assembly.

TYPE, REMOVAL, Front Disc Brake Assembly.>
3. 17-INCH TYPE
TYPE, REMOVAL, Front Disc Brake Assembly.>
B: INSTALLATION
1. 15-INCH TYPE
1) Install the support on housing.
Tightening torque:
80 Nm (8.2 kgf-m, 59 ft-lb)
clip.
BR-00021
3) Remove the bolt securing lock pin to caliper

body.
BR-00340

and inner shim.
BR-00022
4) Raise the caliper body, and then move it toward

vehicle center to separate it from support.
5) Remove the support from housing.
NOTE:
Remove the support only when replacing itself or
rotor. It need not be removed when servicing the
caliper body assembly.
BR-00023
BR-20
BR-00238

BRAKE


and inner shim.
BR-00238
BR-00341

Tightening torque:
27 Nm (2.8 kgf-m, 19.9 ft-lb)
7) Using new brake hose gaskets, connect the
brake hose.

Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
8) Bleed air from brake system.
2. 16-INCH TYPE
TYPE, INSTALLATION, Front Disc Brake Assembly.>
3. 17-INCH TYPE
Tightening torque:
80 Nm (8.2 kgf-m, 59 ft-lb)
clip.
BR-00340
BR-21
BR-00341

BRAKE
When the pad return spring is deformed or

damaged, replace the brake pad with new one.
NOTE:
Install the pad indicator in proper direction.
(1)
(6)
(1)
(5)
(2)
(2)
(3)
(6)
(1) Pad return spring

(2) Supporting surface of pad clip
(3) Brake rotor rotation direction
(3)
(6)

7) Using new brake hose gaskets, connect the
brake hose.
(5)
(4)
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
(6)
C: DISASSEMBLY
BR-00342
(1)
(2)
(3)
(4)
(5)
(6)
BR-00483
1. 15-INCH TYPE
LH IN
LH OUT
RH IN
RH OUT
Pad indicator
Pad return spring

CAUTION:
Be sure to install so that the direction of pad
return spring faces to the input side of brake rotor rotation direction as shown in the figure.
Correctly install the pad return spring to supporting surface of pad clip as shown in the figure.
CAUTION:
inlet (at brake hose connector).
2) Place a wooden block in caliper body as shown
in the figure to prevent piston from jumping out and
avoid being damaged.
3) Gradually supply compressed air via installation
hole of brake hose to force the piston out.
(1)
BR-00026
(1) Place a 30 mm (1.18 in) wide wood block here.
BR-22

BRAKE
5) Insert the piston into cylinder.
4) Remove the piston boot.
CAUTION:
Do not force the piston into cylinder.
(2)
(1)
BR-00240
5) Remove the piston seal from caliper body cylinder.
BR-00242
CAUTION:
Do not damage the cylinder and piston seal
groove.
(1) Piston
(2) Piston boot
6) Position the boot in the grooves on cylinder and

piston.
(1)
(3)
(4)
(2)
(1)
BR-00027
(1) Piston seal
BR-00243
6) Remove the guide pin and boot from caliper

body.
(1)
(2)
(3)
(4)
2. 16-INCH TYPE
TYPE, DISASSEMBLY, Front Disc Brake Assembly.>
3. 17-INCH TYPE
TYPE, DISASSEMBLY, Front Disc Brake Assembly.>
Piston
Piston boot
Caliper body
Piston seal
7) Apply a coat of specified grease to the lock pin

and guide pin outer surface, cylinder inner surface,
and boot grooves.
Grease:
NIGLUBE RX-2 (Part No. K0779GA102)
D: ASSEMBLY
1. 15-INCH TYPE
1) Clean the caliper body interior using brake fluid.
2) Apply a coat of brake fluid to the 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) Apply a coat of specified grease to the boot and
fit in to the groove on ends of cylinder.
Grease:
BR-23

BRAKE
8) Install the lock pin and guide pin boot on support.

: (3)
(1)
(2)
BR-00362
(1) Pin boot

(2) Lock pin or guide pin
(3) Apply grease.
2. 16-INCH TYPE
TYPE, ASSEMBLY, Front Disc Brake Assembly.>
3. 17-INCH TYPE
TYPE, ASSEMBLY, Front Disc Brake Assembly.>
E: INSPECTION
1) Repair or replace the faulty parts.
2) Check the caliper body and piston for uneven
wear, damage or rust.
3) Check the rubber parts for damage and deterioration.
BR-24
Rear Brake Pad

BRAKE
5. Rear Brake Pad
A: REMOVAL
Tightening torque:
Solid disc brake model
27 Nm (2.8 kgf-m, 19.9 ft-lb)
Ventilated disc brake model
37 Nm (3.7 kgf-m, 27.2 ft-lb)

wheels.
2) Remove the caliper bolt.
C: INSPECTION
BR-00344
3) Raise the caliper body and support it.
NOTE:
Do not disconnect the brake hose from caliper
body.
4) Remove the pad.
NOTE:
If the brake pad is difficult to remove, use the same
procedure as for front disc brake pad.
<Ref. to BR-16, REMOVAL, Front Brake Pad.>
BR-00016
Type of disc rotor

Standard
Pad thickness
value
mm (in)
Wear limit
Solid
Ventilated
9.0 (0.35)
9.0 (0.35)
1.5 (0.059)
1.5 (0.059)
NOTE:
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 wear indicator contacts disc rotor, a
squeaking sound is produced as the wheel rotates.
If this sound is heard, replace the pad.
BR-00032
B: INSTALLATION
clip.
BR-00345

and shim.
BR-25
Rear Disc Rotor

BRAKE
6. Rear Disc Rotor
(2) If the disc rotor seizes up within hub, drive

the disc rotor out by pushing with an 8 mm bolt in
holes B on the rotor.
A: REMOVAL
wheels.
3) Remove the two mounting bolts, and remove the
disc brake assembly.
B
A
BR-00036
B: INSTALLATION
BR-00346
4) Suspend the disc brake assembly so that the

hose is not stretched.
NOTE:
If the disc rotor is difficult to remove, try following
two methods in order.
(1) Turn the adjusting screw using a flat tip
screwdriver until the brake shoe gets away
enough from the disc rotor.
(2)

2) Adjust the parking brake. <Ref. to PB-9, ADJUSTMENT, Parking Brake Assembly (Rear Disc
Brake).>
C: INSPECTION
1) Check rear wheel bearing play and axial hub
runout before disc rotor runout limit inspection.
<Ref. to DS-21, INSPECTION, Rear Hub Unit
Bearing.>
2) Secure the disc rotor by tightening five wheel
nuts.
3) Set a dial gauge 10 mm (0.39 in) inward of rotor
outer perimeter. Turn the disc rotor to check runout.
If the disc rotor runout exceeds specified value, replace with a new disc rotor.
(3)
(1)
(4)
BR-00155
(1)
(2)
(3)
(4)
Adjusting screw
Cover
Flat tip screwdriver
Back plate
BR-00037

0.05 mm (0.0020 in)
BR-26
Rear Disc Rotor

BRAKE
4) Set a micrometer 10 mm (0.39 in) inward of the

rotor outer perimeter, and then measure the disc
rotor thickness. If the thickness of disc rotor is outside the service limit, replace with a new disc rotor.
B
A
BR-00036
Solid disc
Disc rotor thickness A
mm (in) Ventilated disc
Standard value
10 (0.39)
18 (0.71)
BR-27
Limit
8.5 (0.335)
16 (0.63)
Disc outer dia.

274 (10.79)
290 (11.42)
Rear Disc Brake Assembly

BRAKE
7. Rear Disc Brake Assembly
B: INSTALLATION
A: REMOVAL
CAUTION:
wheels.
2) Disconnect the brake hose from caliper body assembly.
3) Remove the caliper lower bolts.
Tightening torque:
53 Nm (5.4 kgf-m, 39.1 ft-lb)
clip.
BR-00345

and shim.
BR-00347
4) Raise the caliper body, and then move it toward

vehicle center to separate it from the support.
5) Remove the support from housing.
NOTE:
Remove the support only when replacing itself or
rotor. It need not be removed when servicing the
caliper body assembly.
CAUTION:
inlet (at brake hose connector).
Tightening torque:
Solid disc brake model
27 Nm (2.8 kgf-m, 19.9 ft-lb)
Ventilated disc brake model
37 Nm (3.7 kgf-m, 27.2 ft-lb)
6) Replace the brake hose gaskets with new ones,
and then connect the brake hose.
Tightening torque:
18 Nm (1.8 kgf-m, 13.0 ft-lb)
C: DISASSEMBLY
1) Remove the piston boot.
BR-00041
2) Place a wooden block in caliper body as shown

in the figure to prevent the piston from jumping out
and avoid being damaged.
BR-28
Rear Disc Brake Assembly

BRAKE
3) Gradually supply compressed air via installation

hole of brake hose to force the piston out.
6) Position the boot in grooves on cylinder and piston.

(3)
(4)
(2)
(1)
(1)
BR-00042
BR-00243
(1) Place a 30 mm (1.18 in) wide wooden block

here.
(1)
(2)
(3)
(4)
4) Remove the piston seal from caliper body cylinder.
Piston
Piston boot
Caliper body
Piston seal
7) Apply a coat of specified grease to the guide pin,

outer surface, sleeve outer surface, cylinder inner
surface, and boot grooves.
CAUTION:
Do not damage the cylinder and piston seal
groove.
Grease:
: (3)
(1)
(2)
BR-00043
5) Remove the lock pin sleeve and boot from caliper body.
6) Remove the guide pin boot.
BR-00362
(1) Pin boot

(2) Lock pin or guide pin
(3) Apply grease.
D: ASSEMBLY
1) Clean the caliper body interior using brake fluid.
2) Apply a coat of brake fluid to the 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) Apply a coat of specified grease to the boot and
fit in to the groove on ends of cylinder.
Grease:
5) Insert the piston into cylinder.
CAUTION:
Do not force the piston into cylinder.
8) Install the guide pin boot on support.

9) Install the lock pin boot on support, and then insert the lock pin sleeve into specified point.
E: INSPECTION
1) Repair or replace the faulty parts.
2) Check the caliper body and piston for uneven
wear, damage or rust.
3) Check the rubber parts for damage or deterioration.
BR-29
Master Cylinder
BRAKE
8. Master Cylinder
A: REMOVAL
CAUTION:
1) Thoroughly drain the brake fluid from reservoir
tank.
2) Disconnect the fluid level gauge harness connector.
3) Remove the brake pipes from master cylinder.
4) Remove the master cylinder mounting nuts, and
take out the master cylinder from brake booster.
NOTE:
To avoid damaging master cylinder, use aluminum
plate while holding with vise.
3) Remove the pin which secures the reservoir tank
to master cylinder, and then remove the reservoir
tank and seal.
B: INSTALLATION
1) Replace the O-ring for the master cylinder with a
new one.
CAUTION:
Do not install the O-ring in wrong place.
BR-00364
4) With pushing-in the primary piston, remove the

C-ring using pliers.
(3)
(2)
(1)
BR-00169
5) With pushing-in the primary piston, remove the

straight pin from the port on installation part of reservoir tank using magnet pick-up tool.
BR-00363
(1) Primary piston

(2) O-ring
(3) Do not install the O-ring on this groove.
(1)

Tightening torque:
Master cylinder mounting nut
13 Nm (1.3 kgf-m, 9.6 ft-lb)
Piping flare nut
Model with ABS
15 Nm (1.5 kgf-m, 10.8 ft-lb)
Model with VDC
19 Nm (1.9 kgf-m, 14.0 ft-lb)
BR-00069
(1) Straight pin
CAUTION:
Be sure to use recommended brake fluid.
3) Bleed air from brake system. <Ref. to BR-38,
PROCEDURE, Air Bleeding.>
C: REPLACEMENT
1) Remove mud and dirt from the surface of brake
master cylinder.
2) Secure the master cylinder on a vise.
6) Extract the primary piston assembly and secondary piston assembly straight out, while taking
care not to scratch the inner surface of cylinder.
7) Clean the inside of master cylinder with brake
fluid. Check the inside of cylinder for damage, deform and wear. Replace the master cylinder as assembly if faulty.
8) Apply recommended brake fluid to the inner wall
of master cylinder, and outer surface of piston assembly.
BR-30
Master Cylinder
BRAKE
9) Ensure that the inner wall of master cylinder, and

piston assembly are free of dirt when assembling.
Install the primary piston assembly and secondary
piston assembly, while taking care not to damage
the master cylinder inner wall.
10) With pushing-in the primary piston, install the
cylinder pin.
11) With pushing-in the primary piston, install the
C-ring to groove using pliers.
D: INSPECTION
Inspect for oil leakage from the master cylinder.
NOTE:
After replacing piston kit; when the oil leakage is
found without damaging or scratching the inside of
cylinder, wear of master cylinder inner wall may be
the cause. In this case, replace the master cylinder
as assembly.
BR-00169
CAUTION:
Ensure the secure installation.
12) Install the seal to reservoir tank.
BR-00072
(1)
(1) Seal
13) Install the reservoir tank to master cylinder, and

secure with pin.
14) Replace the O-ring for the master cylinder with
a new one.
(3)
(2)
(1)
BR-00363
(1) Primary piston

(2) O-ring
BR-31
Brake Booster
BRAKE
9. Brake Booster
Use care when placing the brake booster on the

floor.
Do not change the push rod length.
A: REMOVAL
1) Remove or disconnect the following parts at engine compartment.
(1) Disconnect the connector for brake fluid level gauge.
(2) Remove the brake pipes from master cylinder.
(3) Remove the master cylinder installing nuts.
(4) Disconnect the vacuum hose from brake
booster.
2) Remove the following parts from pedal bracket.
(1) Snap pin and clevis pin
(2) Four brake booster installing nuts
CAUTION:
Do not disassemble the brake booster.
If external force is applied from above when
brake booster is placed in this position, the resin portion as indicated by P, may be damaged.
(1)
(1)
BR-00075
(1) Force
B: INSTALLATION
1) Check and adjust the operating rod of brake
booster.
Standard L:
LHD: 136.3 mm (5.38 in)
RHD: 155.2 mm (6.11 in)
If it is not within the specified value, adjust it by adjusting the brake booster operating rod.
(2)
(3)
(4)
BR-00073
(1)
(2)
(3)
(4)
Nut
Clevis pin
Snap pin
Operating rod
BR-00076
3) Remove the brake booster while shunning brake

pipes.
2) Mount the brake booster in position.
NOTE:
Do not apply strong impact to booster shell and
vacuum pipe.
Be careful not to drop the brake booster. The
brake booster should be replaced if it has been
dropped.
Use special care when handling the 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.
BR-32
Brake Booster
BRAKE
3) Connect the operating rod to brake pedal with

clevis pin and snap pin.
8) Measure the clearance between the threaded

end of stop light switch and stopper.
If it is not within specified value, adjust it by adjusting the position of stop light switch. <Ref. to BR-45,
ADJUSTMENT, Stop Light Switch.>
CAUTION:
Be careful not to rotate the stop light switch.
(1)
Stop light switch clearance A:

0.3 mm (0.012 in)
A
(2)
(3)
BR-00079
9) Apply grease to operating rod connecting pin to

prevent it from wearing.
(4)
BR-00073
(1)
(2)
(3)
(4)
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.
Nut
Clevis pin
Snap pin
Operating rod
NOTE:
Apply a thin coat of grease [SUNLIGHT 2 (Part No.
003602010) or equivalent] to clevis pin.
4) Connect the vacuum hose to brake booster.
5) After replacing the O-ring with a new one, install
the master cylinder to brake booster.
(3)
C: INSPECTION
1. OPERATION CHECK (WITHOUT GAUGES)
CAUTION:
When checking operation, be sure to securely
apply the parking 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 failure if checking is conducted in accordance with the following
procedures.
(2)
(1)
BR-00363
(1) Primary piston

(2) O-ring
6) Connect the brake pipes to master cylinder.

7) Connect the connector for brake fluid level
gauge.
BR-33
Brake Booster
BRAKE
AIR TIGHTNESS CHECK

Start the engine, and idle it for 1 to 2 minutes, then
turn it OFF. Depress the 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, the brake booster is faulty.
(1)
(2)
3) As engine starts, the brake pedal should move

slowly toward the floor. If no change occurs in the
pedal height, the brake booster is faulty.
NOTE:
If faulty, check precisely with gauges.
LOADED AIR TIGHTNESS CHECK
Depress the brake pedal while engine is running,
and turn OFF the engine while the pedal is still depressed. Keep the pedal depressed for 30 seconds; if no change occurs in the pedal height, the
brake booster is functioning normally; if the pedal
height increases, it is faulty.
NOTE:
If faulty, check precisely with gauges.
2. OPERATION CHECK (WITH GAUGES)
(5)
(4)
CAUTION:
When checking operation, be sure to securely
apply the parking brake.
CHECKING WITH GAUGES
(3)
BR-00080
(1)
(2)
(3)
(4)
(5)
Normal Operation
Not OK
1st
2nd
3rd
Connect gauges as shown in the figure. After

bleeding air from pressure gauges, proceed to
each check.
(1)
NOTE:
In the event of defective operation, also 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.
OPERATION CHECK
1) With the engine OFF, depress the 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)
(2)
BR-00081
(1) When engine is stopped

(2) When engine is started
2) With the brake pedal depressed, start the engine.
BR-34
(2)
(3)
(4)
(5)
BR-00082
(1)
(2)
(3)
(4)
(5)
Pressure gauge
Vacuum gauge
Adapter hose
Vacuum hose
Pedal force gauge
Brake Booster
BRAKE
AIR TIGHTNESS CHECK

1) Start the 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 the
brake pedal at this moment.
(1)
(2)
2) Stop the 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
the engine, brake booster is functioning properly.
If defective, refer to AIR TIGHTNESS CHECK.
<Ref. to BR-33, INSPECTION, Brake Booster.>
3) If any fault is found on brake booster, replace the
brake booster with a new one.
LACK OF BOOSTING ACTION CHECK
Turn OFF the 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.
N (kgf, lb)
147
(15, 33)
294
(30, 66)
Fluid pressure
kPa (kg/cm2, psi)
545
(6, 79)
1,564
(16, 227)
Brake pedal force

BR-00083
(1) Pressure gauge

(2) Vacuum gauge
BOOSTING ACTION CHECK
2) Stop the 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 the 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 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
LOADED AIR TIGHTNESS 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
15
16 OUTBACK
Fluid pres16
sure
(Except for
kPa (kg/cm2, OUTBACK)
psi)
17
1) Start the engine and depress the brake pedal

with pedal force of 196 N (20 kgf, 44 lb). Keep the
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.
(1)
(2)
B
(3)
(4)
BR-00084
(1)
(2)
(3)
(4)
N (kgf, lb)
Pressure gauge
Vacuum gauge
Pedal force gauge
Depressed
BR-35
147
(15, 33)
6,003
(61, 871)
294
(30, 66)
11,273
(115, 1,635)
5,381
(55, 780)
10,982
(112, 1,593)
4,963
(51, 720)
10,055
(103, 1,458)
Brake Fluid
BRAKE
10.Brake Fluid
5) Install one end of a vinyl tube onto air bleeder

and insert the other end of the tube into a container
to collect brake fluid.
A: INSPECTION
1) Check that the brake fluid level remains between
MIN and MAX. If out of the specified range, refill
or drain fluid. If the fluid level becomes close to
MIN, refill fluid.
2) Check the fluid for discoloration. If the fluid color
has excessively changed, drain the fluid and refill
with new fluid.
B: REPLACEMENT
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.
Fresh Subaru genuine fluid must be used.
Cover the bleeder with cloth, when loosening
it, to prevent brake fluid from being splashed
over surrounding parts.
Do not allow brake fluid to come in contact
with vehicle body; wash away with water and
wipe off completely if spilled.
to prevent degrading the quality of fluid.
the reservoir tank.
NOTE:
The brake pedal operating must be very slow.
do the work.
The amount of brake fluid required is approximately 500 m2 (16.9 US fl oz, 17.6 Imp fl oz) for total brake system.
1) Either lift-up the vehicle to place a rigid rack under it, or lift-up the vehicle.
2) Remove both the front and rear wheels.
3) Draw out the brake fluid from master cylinder.
brake fluid.
Refer to the specification. <Ref. to BR-2,
BR-00087
CAUTION:
Brake fluid replacement sequence; (A) Front
RH (B) Rear LH (C) Front LH (D) Rear RH
(A)
(1)
(D)
(2)
(C)
(3)
(B)
BR-00089
(1) Master cylinder

(2) Hydraulic unit
(3) Proportioning valve
6) Instruct your co-worker to depress the brake

pedal slowly two or three times and then hold it depressed.
7) Loosen the bleeder screws to drain brake fluid.
And then quickly tighten the screw.
8) Release the brake pedal slowly. Repeat steps 6)
through 8) until there are no more air bubbles in the
drained brake fluid.
NOTE:
Add brake fluid as necessary while performing air
bleed operation, in order to prevent the tank from
running short of brake fluid.
9) After completing the bleeding operation, hold the
brake pedal depressed and tighten the 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
8) above.
BR-36
Brake Fluid
BRAKE
11) Depress the brake pedal with a force of approximately 294 N (30 kgf, 66 lb) and hold it there for approximately 20 seconds to check for no entry of air
and if pedal height remain same.
Visually inspect the bleeder screws and brake pipe
joints to make sure that there is no fluid leakage.
12) Install the 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-37
Air Bleeding
BRAKE
11.Air Bleeding
A: PROCEDURE
CAUTION:
Fresh Subaru genuine fluid must be used.
Cover the bleeder with cloth, when loosening
it, to prevent brake fluid from being splashed
over surrounding parts.
Do not allow brake fluid to come in contact
with vehicle body; wash away with water and
wipe off completely if spilled.
to prevent degrading the quality of fluid.
the reservoir tank.
1. MASTER CYLINDER
NOTE:
If the master cylinder is disassembled or reservoir tank is empty, bleed the master cylinder.
do the work.
1) Loosen the wheel nuts, jack-up the vehicle, support it with rigid racks, and remove the wheels.
2) Disconnect the brake line at primary and secondary sides.
3) Put a plastic bag cover on master cylinder.
4) Carefully depress and hold the brake pedal.
6) Repeat the step4) and 5) until brake fluid is completely drained from outlet plug.
7) Remove the plastic bag.
8) Install the brake pipes to master cylinder.
Tightening torque:
15 Nm (1.5 kgf-m, 10.8 ft-lb)
9) Bleed air from the brake line. <Ref. to BR-38,
BRAKE LINE, PROCEDURE, Air Bleeding.>
2. BRAKE LINE
NOTE:
During the bleeding operation, keep the reservoir
tank filled with brake fluid to eliminate entry of air.
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.
BR-00087
CAUTION:
Brake fluid replacement sequence; (A) Front
RH (B) Rear LH (C) Front LH (D) Rear RH
(A)
(1)
(D)
(2)
BR-00090
5) Close the outlet plug with your finger, and then

release the brake pedal.
(C)
(3)
BR-00089
(1) Master cylinder

(2) Hydraulic unit
(3) Proportioning valve
BR-00091
BR-38
(B)
Air Bleeding
BRAKE
3) Slowly depress the brake pedal and keep it depressed. Then, open the air bleeder to discharge
air together with the fluid.
Release the 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 the bleeder with cloth, when loosening it,
to prevent brake fluid from being splashed over
surrounding parts.
NOTE:
4) Tighten the air bleeder securely when no air
bubbles are visible.
7) If the distance is more than specified, there is a

possibility that air is in the brake line. Bleed the
brake line until pedal stroke meets the specification.
8) Operate the hydraulic control unit in the sequence control mode. <Ref. to ABS-10, ABS Sequence Control.>
9) Recheck the pedal stroke.
10) If the distance is more than specified, there is a
possibility that air is in the inside of the hydraulic
unit. Repeat above steps 2) to 9) 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 ensure that brakes provide normal braking action.
Air bleeder tightening torque:

8 Nm (0.8 kgf-m, 5.8 ft-lb)
5) Perform these steps for the brakes connecting to
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.
6) Check the pedal stroke.
While the engine is idling after warming up, depress the brake pedal with a 500 N (51 kgf, 112 lb)
load and measure the distance between brake pedal and steering wheel. With the brake pedal released, measure the distance between pedal and
steering wheel again. The difference between the
two measurements must not be more than specified value.
(1)
1
2
1
(2)
BR-00094
(1) Steering wheel

(2) Toe board
Specified pedal stroke:

95 mm (3.74 in) or less
When depressing brake pedal with a 500 N
(51 kgf, 112 lb) load.
BR-39
Brake Hose
BRAKE
12.Brake Hose
3) Remove the clamp and remove the brake hose.
A: REMOVAL
1. FRONT BRAKE HOSE
1) Separate the brake pipe from brake hose using a
flare nut wrench.
2) Remove the clamp, bolt at strut mount, and
union bolt.
(1)
(2)
(1)
BR-00349
(1) Brake pipe

(2) Brake hose clamp
(2)
(1)
BR-00095
(1) Brake hose

(2) Brake pipe
2. REAR BRAKE HOSE
(2)
(3)
1) Remove the union bolt from rear brake caliper.
BR-00350
(1) Brake pipe

(2) Brake hose
(1)
B: INSTALLATION
1. FRONT BRAKE HOSE
1) Secure the brake hose to strut mount.
BR-00348
(1) Brake hose
2) Separate the brake pipe from brake hose using a

flare nut wrench.
Tightening torque:
33 Nm (3.4 kgf-m, 24.3 ft-lb)
2) Install the brake hose to caliper using a new gasket.
Tightening torque (Union bolt):
18 Nm (1.8 kgf-m, 13.0 ft-lb)
BR-00021
3) Position the disc in straight-forward direction and

route the brake hose through the hole in bracket on
wheel apron side.
BR-40
Brake Hose
BRAKE
CAUTION:
Be sure the brake hose is not twisted.
4) Temporarily tighten the flare nut to connect the
brake pipe and hose.
5) Fix the brake hose with clamp at wheel apron
bracket.
6) Tighten the flare nut to specified torque.
3) Install the brake hose to rear brake caliper using

a new gasket.
Tightening torque (Union bolt):
18 Nm (1.8 kgf-m, 13.0 ft-lb)
(1)
Tightening torque (Brake pipe flare nut):

15 Nm (1.5 kgf-m, 10.8 ft-lb)
2. REAR BRAKE HOSE

1) Pass the brake hose through the hole of bracket,
and lightly tighten the flare nut to connect brake
pipe.
2) Insert the clamp upward to fix brake hose.
BR-00348
(1) Brake hose
4) Tighten the flare nut to specified torque.

Tightening torque (Brake pipe flare nut):
15 Nm (1.5 kgf-m, 10.8 ft-lb)
(1)
C: INSPECTION
(2)
(3)
BR-00350
Ensure there are no cracks, breakage or damage

on hoses. Check joints for fluid leakage. If any
cracks, breakage, damage or fluid leakage is
found, repair or replace the hose.
(1) Brake pipe

(2) Brake hose
(1)
(2)
BR-00349
(1) Brake pipe

BR-41
Brake Pipe
BRAKE
13.Brake Pipe
A: REMOVAL
NOTE:
center brake pipe.
CAUTION:
wiring harness when servicing the center brake
pipe.
When removing the brake pipe, make sure
that it is not bent.
B: INSTALLATION
NOTE:
center brake pipe.
CAUTION:
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 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)
C: INSPECTION
Ensure there are no cracks, breakage or damage
on pipes. Check joints for fluid leakage. If any
cracks, breakage, damage or fluid leakage is
found, repair or replace the pipes.
NOTE:
Use a mirror when inspecting the low-visible part or
backside.
BR-42
Brake Pedal
BRAKE
14.Brake Pedal
4) Remove the bolts and nuts which secure pedal

bracket.
A: REMOVAL
1. LHD MT MODEL
1) Remove the steering shaft.
2) Disconnect the connectors (stop light switch)
from pedal bracket.
3) Remove the clevis pin which secures lever to
push rod.
4) Remove the nuts which secure clutch master
cylinder.
5) Remove the bolts and nuts which secure pedal
bracket.
(1)
(2)
(3)
BR-00351
BR-00128
(1) Clevis pin

(2) Snap pin
(3) Operating rod
2. LHD AT MODEL
1) Remove the steering shaft.
2) Disconnect the connectors (stop light switch)
from pedal bracket.
3) Remove the clevis pin which secures lever to
push rod.
3. RHD MODEL
Refer to LHD AT model. <Ref. to BR-43, LHD AT
MODEL, REMOVAL, Brake Pedal.>
B: INSTALLATION
CAUTION:
Always use new clevis pins.
2) Inspect the brake pedal after installation. <Ref.
to BR-43, INSPECTION, Brake Pedal.>
C: INSPECTION
1) Move the brake pedal pads in the lateral direction with a force of approx. 10 N (1 kgf, 2 lb) to ensure pedal deflection is in specified range.
BR-43
Brake Pedal
BRAKE
CAUTION:
If excessive deflection is noted, replace the
bushing with a new one.
Deflection of brake pedal:
Limit
(1)
BR-00105
(1) Brake pedal
2) Check the position of pedal pad.

Pedal height L:
LHD: 150 160 mm (5.91 6.30 in)
RHD: 162 172 mm (6.38 6.77 in)
Brake pedal free play A:
0.5 2 mm (0.02 0.08 in) [When the brake
pedal is pulled upward with force of less than
10 N (1 kgf, 2 lb).]
(1)
(3)
(4)
A
(2)
L
BR-00106
(1)
(2)
(3)
(4)
Stop light switch

Mat
Toe board
Brake booster operating rod
3) If it is not within the specified value, adjust it by

adjusting the brake booster operating rod length.
BR-44
Stop Light Switch

BRAKE
15.Stop Light Switch
Specified position L:
2 mm (0.079 in)
A: REMOVAL
2) Disconnect the stop light switch connector.
3) Loosen the nuts, and unscrew the stop light
switch to remove.
(1)
BR-00109
2) Measure the clearance between the threaded

end of stop light switch and stopper.
CAUTION:
BR-00107
Stop light switch clearance A:

0.3 mm (0.012 in)
(1) Stop light switch
B: INSTALLATION
1) Screw the stop light switch onto a bracket and
secure it temporarily with a nut.
2) Adjust the stop light switch position, and then
tighten the nut.
<Ref. to BR-45, ADJUSTMENT, Stop Light
Switch.>
(1)
(2)
Tightening torque:
8 Nm (0.8 kgf-m, 5.8 ft-lb)
(3)
BR-00110
(1) Stop light switch

(2) Stopper
(3) Brake pedal
3) If it is not within the specified value, adjust it by

adjusting the position of stop light switch.
CAUTION:
BR-00108
D: ADJUSTMENT
C: INSPECTION
1) If the stop light switch does not operate properly
(or if it does not fix at the specified position), replace with a new one.
Loosen the lock nut, and adjust the stop light switch
position until the clearance between the threaded
end of the stop light switch and stopper (A) becomes 0.3 mm (0.012 in). Then, tighten the lock
nut.
BR-45
Stop Light Switch

BRAKE
Tightening torque:
8 Nm (0.8 kgf-m, 5.8 ft-lb)
(1)
(2)
(3)
A
(4)
(5)
BR-00111
(1)
(2)
(3)
(4)
(5)
Stop light switch

Lock nut A
Lock nut B
Stopper
Brake pedal
NOTE:
Tighten the lock nut B until the clearance between
the threaded end of stop light switch and stopper
becomes 0 mm (0 inch). Hold the stop light switch
to prevent turning, and then loosen the lock nut B
approx. 60. The clearance (A) becomes 0.3 mm
(0.012 in).
BR-46

BRAKE

A: INSPECTION
1. Insufficient braking (1) Fluid leakage from the hydraulic mechanism
2. Unstable or uneven
braking
(2) Entry of air into the hydraulic mechanism

(3) Wear, deteriorated surface material, adhering water or
fluid on the lining
(4) Improper operation of master cylinder, disc caliper,
brake booster or check valve
(1) Fluid on the lining or rotor
(2) Rotor eccentricity
(3) Improper lining contact, deteriorated surface material,
improper inferior material, or wear
(4) Deformed back plate
(5) Improper tire inflation
(6) Disordered wheel alignment
(7) Loosened back plate or the support installing bolts
(8) Faulty wheel bearing
(9) Trouble in hydraulic system
(10) Uneven effect of the parking brake
3. Excessive pedal
stroke
4. Brake dragging or
improper brake
return
5. Brake noise (1)

(creak sound)
6. Brake noise (2)

(hissing sound)
7. Brake noise (3)
(click sound)
(1) Entry of air into the hydraulic mechanism

(2) Excessive play in the master cylinder push rod
(3) Fluid leakage from the hydraulic mechanism
(4) Improper lining contact or worn lining

(1) Insufficient pedal play
(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) Improper disc caliper operation
(7) Faulty wheel bearing
(1) Hardened or deteriorated brake pad
(2) Worn brake pad
(3) Loosened back plate or the support installing bolts
(4) Loose wheel bearing
(5) Dirty rotor
(1) Worn brake pad
(2) Improper installed pad
(3) Loose or bent rotor
Excessively worn pad or the support
BR-47
Corrective action
Correct or replace. (cup, piston seal, piston
boot, master cylinder piston kit, pipe or
hose)
Bleed air.
Replace, grind or clean.
Correct or replace.
Eliminate cause of fluid leakage, and clean
or replace.
Correct or replace the rotor.
Correct by grinding, or replace.
Rectify or replace.
Adjust to correct pressure.
Adjust alignment.
Retighten to specified torque.
Replace.
Replace the cylinder, brake pipe or hose.
Check, adjust, or replace the rear brake
and cable system.
Bleed air.
Adjust.
Correct or replace. (cup, piston seal, piston
boot, master cylinder piston kit, pipe or
hose)
Correct or replace.
Adjust play.
Clean or replace the cylinder.
Replace.
Correct or adjust.
Replace the spring.
Correct or replace.
Replace.
Replace the pad.
Replace the pad.
Clean the rotor, or clean and replace brake
assembly.
Replace the pad.
Correct or replace the pad.
Retighten or replace.
Replace the pad or the support.

BRAKE
BR-48
PARKING BRAKE
PB
1.
2.
3.
4.
5.
Page
Parking Brake Lever....................................................................................5
Parking Brake Cable ...................................................................................6
Parking Brake Assembly (Rear Disc Brake) ...............................................7
General Description
PARKING BRAKE
A: SPECIFICATION
Type
Effective drum
mm (in)
diameter
Lining dimensions
(length width
mm (in)
thickness)
Lever stroke
notches/N (kgf, lb)
Mechanical on rear brakes, drum in disc

170 (6.69)
163.1 30.0 3.2
(6.421 1.181 0.126)
Manual adjustment
5 to 6/200 (20.4, 45)
PB-2
General Description
PARKING BRAKE
B: COMPONENT
1. PARKING BRAKE (REAR DISC BRAKE)
(1)
(17)
(2)
(3)
(4)
(8)
(6)
(7)
(9)
(11)
(13)
(5)
(10)
(12)
(15)
(14)
(16)
PB-00048
(1)
(2)
(3)
(4)
(5)
(6)
Back plate
Retainer
Spring washer
Lever
Parking brake shoe (Primary)
Parking brake shoe (Secondary)
(7)
(8)
(9)
(10)
(11)
(12)
Strut spring
Strut
Shoe guide plate
Primary return spring
Secondary return spring
Adjusting spring
PB-3
(13)
(14)
(15)
(16)
(17)
Adjuster
Shoe hold-down cup
Shoe hold-down spring
Shoe hold-down pin
Adjusting hole cover
General Description
PARKING BRAKE
2. PARKING BRAKE CABLE

(8)
(7)
T2
(8)
T1
T2
T1
(6)
(3)
(1)
(5)
T1
T1
(4)
T1
(9)
T1
(2)
T1
PB-00056
(1)
(2)
Parking brake lever

(6)
(7)
Clamp
Parking brake cable RH
(3)
Adjusting nut (Self-locking nut)
(8)
Clamp
(4)
(5)
Equalizer
Bracket
(9)
Parking brake cable LH

T1: 18 (1.8, 13.0)
T2: 33 (3.4, 24.3)
C: CAUTION
Be careful not to burn your hands, because each
Use SUBARU genuine grease etc. or the equivalent. Do not mix grease etc. with that of another
points.
Keep grease etc. away from parking brake
shoes.
PB-4
Parking Brake Lever

PARKING BRAKE
2. Parking Brake Lever

A: REMOVAL
1) Set the wheel stoppers to tires.
3) Disconnect the parking brake switch connector.
4) Remove the parking cable adjusting nut (selflocking nut).
5) Remove the parking brake lever.
PB-00053
B: INSTALLATION
Tightening torque:
Parking brake lever
18 Nm (1.8 kgf-m, 13.0 ft-lb)
2) Install a new adjusting nut (self-locking nut).
3) Adjust the lever stroke. <Ref. to PB-5, ADJUSTMENT, Parking Brake Lever.>
C: INSPECTION
1) Operate the parking brake lever 3 to 4 times and
return the lever fully.
2) While pulling the parking brake lever upward,
count the notches.
Lever stroke:
5 to 6 notches when pulled with a force of 200
N (20.4 kgf, 45 lb)
If it is not within the specified value, adjust the parking brake. <Ref. to PB-9, ADJUSTMENT, Parking
Brake Assembly (Rear Disc Brake).>
D: ADJUSTMENT
Adjust the parking lever stroke. <Ref. to PB-9, LEVER STROKE, ADJUSTMENT, Parking Brake Assembly (Rear Disc Brake).>
PB-5
Parking Brake Cable

PARKING BRAKE
3. Parking Brake Cable
12) Remove the cable assembly.
A: REMOVAL
B: INSTALLATION
1) Remove the rear seat cushion.

3) Remove the parking cable adjusting nut (selflocking nut).
4) Remove the parking brake lever. <Ref. to PB-5,
REMOVAL, Parking Brake Lever.>
5) Roll up the floor mat and remove the clamps.
NOTE:
Be sure to pass the cable through the cable guide
inside tunnel.
2) Adjust the lever stroke. <Ref. to PB-5, ADJUSTMENT, Parking Brake Lever.>
C: INSPECTION
Check and replace the removed cable if damaged,
rusty or faulty.
1) Check the cable for smooth operation.
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 corrosion.
PB-00043
6) Remove the inner cable end from equalizer.
PB-00008
(1) Equalizer
(2) Inner cable end

wheels.
8) Remove the parking brake cable from rear
brake. <Ref. to PB-7, REMOVAL, Parking Brake
Assembly (Rear Disc Brake).>
9) Remove the clamp from rear brake.
10) Remove the cable clamp from rear arm bracket.
11) Remove the cable clamp from rear floor.
PB-00026
PB-6
Parking Brake Assembly (Rear Disc Brake)

PARKING BRAKE
4. Parking Brake Assembly

(Rear Disc Brake)
(2) If the disc rotor seizes up within hub, drive

out the disc rotor by pushing two 8 mm bolts in
holes B on rotor.
A: REMOVAL
2) Remove the two mounting bolts and remove the
brake caliper assembly.
B
A
BR-00036
5) Remove the shoe return spring from parking

brake assembly.
6) Remove the front shoe hold down spring and
pin.
BR-00346
3) Suspend the brake caliper assembly so that the

hose is not stretched.
NOTE:
If the disc rotor is difficult to remove, try the following two methods in order.
(1) Turn the adjusting screw using a flat tip
screwdriver until the brake shoe gets away
enough from the disc rotor.
PB-00028
7) Remove the strut and strut spring.

8) Remove the adjuster assembly from parking
brake assembly.
9) Remove the brake shoe.
10) Remove the rear shoe hold down spring and
pin with pliers.
11) Remove the parking brake cable from lever.
(2)
(3)
(1)
(4)
BR-00155
(1)
(2)
(3)
(4)
Adjuster
Adjusting hole cover (rubber)
Back plate
PB-00014
(1) Parking brake cable

(2) Lever
12) Using a flat tip screwdriver, raise the retainer.

Remove the parking lever and washer from brake
shoe.
PB-7

PARKING BRAKE
B: INSTALLATION
Install the adjuster assembly with screw on left

side.
CAUTION:
Be sure the lining surface is free from oil and
grease contamination.
1) Apply brake grease to the following places.
Brake grease:
Brake Grease (Part No. 003602002)
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) Insert the primary side brake shoe into anchor
pin groove.
3) Secure the brake shoe with the shoe hold-down
pin and cup.
4) Install the plate to anchor pin, and then assemble the primary return spring to anchor pin.
PB-00016
(1) LH
7) Install the secondary return spring and adjusting

spring.
(1)
(2)
(4)
(3)
(2)
(5)
(1)
(7)
(3)
(8)
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(4)
(5)
PB-00039
(1)
(2)
(3)
(4)
(5)
Primary return spring

Anchor pin
Plate
Primary shoe
Shoe hold-down pin and shoe hold-down cup
5) Install the parking brake cable to parking brake

lever.
6) Assemble the strut and adjuster, and then secure the secondary side brake shoe with shoe holddown pin and cup.
NOTE:
Install the strut spring of both right and left wheel
facing vehicle front.
(6)
PB-00076
Lever
Secondary brake shoe
Strut spring
Strut
Return spring
Adjuster
Shoe hold-down cup
Adjusting spring
8) Adjust the parking brake. <Ref. to PB-9, ADJUSTMENT, Parking Brake Assembly (Rear Disc
Brake).>
9) Drive the vehicle for parking brake lining breakin.
(1) Drive the vehicle at 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 m (0.12 mile)
in this condition.
(4) Wait 5 to 10 minutes for the parking brake to
cool down.
Repeat once more from step (1).
(5) After breaking-in, re-adjust the parking
brakes.
PB-8

PARKING BRAKE
C: INSPECTION
2. LEVER STROKE
1) Measure the brake disc rotor inside diameter. If

the disc is scored or worn, replace the brake disc
rotor.
1) Adjust the shoe clearance before lever stroke

adjustment. <Ref. to PB-9, SHOE CLEARANCE,
ADJUSTMENT, Parking Brake Assembly (Rear
Disc Brake).>
2) Remove the parking lever cover.
3) Operate the parking brake lever 3 to 4 times.
4) Turn the adjusting nut until lever stroke is at the
specification.
Disc rotor 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)
Lever stroke:
5 to 6 notches when pulled with a force of 200
N (20.4 kgf, 45 lb)
NOTE:
Replace the right and left brake shoe as a set.
D: ADJUSTMENT
1. SHOE CLEARANCE
(1)
1) Return the parking brake lever fully.

2) Remove the adjusting hole cover from back
plate.
3) Turn the adjusting screw using a flat tip screwdriver until the brake shoe is in close contact with
disc rotor.
(1) Adjusting nut (Self-locking nut)
5) Check there is no brake drag.

6) Install the parking lever cover.
(2)
(3)
(1)
(4)
PB-00032
(1)
(2)
(3)
(4)
Adjusting screw
Adjusting hole cover (rubber)
Back plate
4) Turn back (downward) the adjusting screw 3 to 4

notches.
CAUTION:
Check there is no brake drag.
5) Install the adjusting hole cover to back plate.
6) Adjust the parking lever stroke. <Ref. to PB-9,
LEVER STROKE, ADJUSTMENT, Parking Brake
Assembly (Rear Disc Brake).>
PB-9
PB-00054

PARKING BRAKE

A: INSPECTION
Symptom
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.
PB-10
Remedy
Adjustment.
Repair or replace.
Adjustment.
Replace.
Replace.
Replace.
POWER ASSISTED SYSTEM

(POWER STEERING)
PS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Page
Steering Wheel..........................................................................................20
Universal Joint...........................................................................................21
Tilt Steering Column..................................................................................23
Steering Gearbox [LHD Model] .................................................................25
Steering Gearbox [RHD Model] ................................................................46
Pipe Assembly [LHD Model] .....................................................................65
Pipe Assembly [RHD Model].....................................................................71
Oil Pump ...................................................................................................77
Reservoir Tank..........................................................................................83
Power Steering Fluid.................................................................................84
General Description
POWER ASSISTED SYSTEM (POWER STEERING)
A: SPECIFICATION
Non-turbo
(Except for 3.0 R)
Model
Turbo
3.0 R
Minimum turning radius

Whole
system
Gearbox
m (ft)
5.4 (17.8)
Inner wheel
2.0 i, 2.5 i: 37.31.5, 2.0 GT, 3.0 R: 37.21.5, OUTBACK: 37.81.5
Steering angle
Outer wheel
2.0 i, 2.5 i: 33.01.5, 2.0 GT, 3.0 R: 32.91.5, OUTBACK: 33.51.5
Steering wheel diameter
mm (in)
375 (14.76)
Overall gear ratio (Turns, lock to lock
3.2
2.8
Gearbox)
Type
Rack and Pinion, Integral
Backlash
0 (Automatically adjustable)
Valve (Power steering system)
Rotary valve
Type
Vane pump
Oil tank
Installed on body
Specific output
Pump
(Power
steering
system)
Relief pressure
Hydraulic fluid control
Hydraulic fluid
Working
fluid
(Power
steering
system)
Range of revolution
Revolving direction
Fluid
cm3 (cu in)/rev.
7.2 (0.439)
8.5 (0.519)
9.6 (0.586)
6,767 7,453
7,350 8,036
8,300 9,000
(69 76,
(75 82,
(85 92,
kPa (kg/cm2, psi)
981 1,081)
1,067 1,165)
1,204 1,305)
Dropping in response to increased engine revolutions
1,000 rpm: 6.5 (6.9, 5.7) 1,000 rpm: 6.15 (6.5, 5.4) 1,000 rpm: 6.5 (6.9, 5.7)
2 (US qt, Imp qt)
3,000 rpm: 5 (5.3, 4.4) 3,000 rpm: 5.5 (5.8, 4.8) 3,000 rpm: 5.5 (5.8, 4.8)
rpm
680 9,800
680 9,600
Clockwise
ATF DEXRON III or equivalent
Oil tank
0.2 (0.2, 0.2)
Capacity
2 (US qt, Imp qt) Whole system
0.7 (0.7, 0.6)
PS-2
General Description
Steering
wheel
Steering
shaft
Free play
mm (in)
17 (0.67)
Clearance between steering wheel and

column cover
mm (in)
2 4 (0.08 0.16)
LHD
Sliding resistance
N (kgf, lbf)
RHD
Steering
gearbox
(Power
steering
system)
Rack shaft play

in radial direction
LHD
Right-turn
steering
mm (in)
Left-turn
steering
mm (in)
RHD
LHD
RHD
In radial direction
Input shaft play
In axial
direction
mm (in)
LHD
mm (in)
RHD
LHD
Resistance to
rotation
N (kgf, lbf)
RHD
Oil pump
(Power
steering
system)
Steering
wheel
effort
(Power
steering
system)
Radial play
Axial play
Ditch deflection
Pulley
Resistance to rotation
Regular pressure (Unloaded)kPa (kg/cm2, psi)
At standstill with engine idling on a concrete road
Pulley shaft
At standstill with engine stalled on a concrete road
Recommended power steering fluid
mm (in)
mm (in)
mm (in)
N (kgf, lb)
400 (41, 90) or less

Difference between right and left sliding resistance:
Less than 20%
314 (32, 71) or less
Less than 20%
0.3 (0.012) or less
Horizontal movement: 0.6 (0.024) or less
Vertical movement: 0.4 (0.016) or less
Horizontal movement: 0.6 (0.024) or less
Vertical movement: 0.4 (0.016) or less
0.4 (0.016) or less
0.18 (0.0071) or less
0.5 (0.020) or less
0.27 (0.0106) or less
Maximum allowable value: 10.5 (1.1, 2.4) or less
Difference between right and left rotating resistance:
Less than 20%
Maximum allowable value: 13 (1.3, 2.9) or less
Difference between right and left rotating resistance:
Less than 20%
0.4 (0.016) or less
0.9 (0.035) or less
1.0 (0.039) or less
9.22 (0.94, 2.07) or less
981 (10, 142) or less
N (kgf, lb)
29.4 (3.0, 6.6) or less
N (kgf, lb)
294.2 (30, 66.2) or less
Manufacturer
B.P.
CALTEX
CASTROL
MOBIL
SHELL
TEXACO
PS-3
General Description
B: COMPONENT
1. STEERING WHEEL AND COLUMN
(1)
(8)
(2)
(3)
T2
(4)
(7)
T3
(5)
T1
(6)
PS-00501
(1)
(2)
(3)
(4)
Bushing
Steering shaft
Steering roll connector
Column cover
(5)
(6)
(7)
(8)
Steering wheel
Airbag module
Steering wheel lower cover
Insulator
PS-4

T1: 1.2 (0.12, 0.9)
T2: 25 (2.5, 18.1)
T3: 45 (4.6, 33.2)
General Description
2. POWER ASSISTED SYSTEM

Hose and tank
(16)
(19)
(19)
T3
(17)
(15)
T3
(18)
(19)
(7)
(19)
T2
(2)
T1
(20)
(8)
(12)
(4)
(4)
T3
(13)
(5)
T5
(1)
(5)
(11)
(6)
(3)
(4)
(10)
(14)
(4)
(9)
T4
PS-00479
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Eye bolt
Hose
Eye bolt gasket
Clip
Clamp E
O-ring
Cap
Reservoir tank
Pulley
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
Oil pump
Suction hose (Non-turbo model)
Suction hose (Turbo model)
Return hose
Oil cooler
Return hose
Hose bracket
PS-5
(19)
(20)
Clip
Clip

T1: 7.4 (0.75, 5.4)
T2: 17.6 (1.79, 13.0)
T3: 12.7 (1.30, 9.4)
T4: 15 (1.5, 10.8)
T5: 39.2 (4.0, 28.9)
General Description
Gearbox (LHD model)

(39)
(20)
(21)
(3)
T6
T1
T2
T10
T7
T7
(16) (17) (18) (19)
T6
T9
T5
(22)
(4)
(2)
(5)
(34)
T8
(3)
(41)
(23)
(33)
(6)
(8)
(12)
(25)
T4
(31)
T3
(32)
(1)
(10)
(11)
T4
(27)
(22)
(29)
(27)
(30)
(40)
(28)
(30)
(23)
T8
T9
(24)
(29)
(25)
(28)
T11
(9)
(13)
(15)
(42)
T11
(39)
(26)
(7)
T5
(14)
(24)
(38)
(37)
T3
(26)
(36)
(35)
PS-00560
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
Pipe C
Pipe D
Clamp plate
Universal joint
Dust seal
Valve housing
Gasket
Oil seal
Bushing
Seal ring
Pinion & valve ASSY
Oil seal
Back-up washer
Ball bearing
Snap ring
Lock nut
Adjusting screw
Spring
Sleeve
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
Adapter
Clamp
Cotter pin
Castle nut
Dust cover
Clip
Tie-rod end
Clip
Boot
Band
Tie-rod
Pipe B
Pipe A
Steering body
Oil seal
Piston ring
Rack
Rack bushing
Holder
PS-6
(39)
(40)
(41)
(42)
O-ring
Bracket
Bushing
Lock washer

T1: 6 (0.6, 4.3)
T2: 7.4 (0.75, 5.4)
T3: 85 (8.6, 62.2)
T4: 13 (1.3, 9.4)
T5: 15 (1.5, 10.8)
T6: 24 (2.4, 17.4)
T7: 25 (2.5, 18.1)
T8: 27 (2.75, 19.9)
T9: 60 (6.1, 44.1)
T10: 39 (4.0, 28.9)
T11: 78 (8.0, 57.9)
General Description
Gearbox (RHD model)

(1)
(35)
(19)
T6
T4
(33)
(9)
(34)
(28)
(32)
(2)
(31)
T5
(3)
(27)
(26)
T3
(4)
(5)
(30)
T8
(25)
T4
T3
(6)
(29)
T4
(24)
(23)
(22)
(36)
(21)
(7)
(20)
T1
(8)
T6
T7
(37)
(10)
T5
T2
(11)
(19)
(13)
(18)
(14)
(17)
T7
(16)
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
Universal joint
Dust cover
Plug
O-ring
Oil seal
Control valve
Seal ring
Oil seal
Adapter
Clamp
Castle nut
Cotter pin
Dust seal
Clip
Tie-rod end
Clip
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
Boot
Band
Tie-rod
Holder (Turbo, 3.0 R model)
Bushing
Oil seal
Oil seal
O-ring
Rack
Oil seal
Back-up washer
Steering body
Pipe A
Pipe B
Lock nut
Adjusting screw
PS-7
(12)
(33)
(34)
(35)
(36)
(37)
(15)
PS-00505
Spring
Sleeve
Bushing
Bracket
Holder (Except for turbo, 3.0 R
model)

T1: 27 (2.75, 19.9)
T2: 85 (8.6, 62.2)
T3: 20 (2.0, 14.5)
T4: 24 (2.4, 17.4)
T5: 64 (6.5, 47.0)
T6: 90 (9.0, 65.1)
T7: 60 (6.1, 44.1)
T8: 39 (4.0, 28.9)
General Description
3. OIL PUMP
T1
T5
(1)
T3
(2)
T2
(3)
T3
(4)
T3
T4
PS-00480
(1)
(2)
(3)
(4)

T1: 8 (0.8, 5.8)
T2: 15.7 (1.6, 11.6)
T3: 22 (2.2, 15.9)
T4: 25 (2.5, 18.1)
T5: 37.3 (3.8, 27.5)
Oil pump
Pulley
Bracket
Belt tension nut
PS-8
General Description
C: CAUTION
Use SUBARU genuine power steering fluid,
grease etc. or the equivalent. Do not mix fluid,
grease etc. with that of another grade or from other
manufacturers.
points.
Before securing a part on a vise, place cushioning material such as wooden blocks, aluminum
plate or cloth between the part and the vise.
PS-9
General Description
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
925711000
DESCRIPTION
PRESSURE
GAUGE
REMARKS
Used for measuring oil pump pressure.
STAND
Used when inspecting characteristic of gearbox assembly and disassembling it.

Used with BOSS D (34199AG000).
34099AC010
ADAPTER HOSE A
Used with PRESSURE GAUGE (925711000).
34099AC020
ADAPTER HOSE B
Used with PRESSURE GAUGE (925711000).
ST-925711000
926200000
ST-926200000
ST34099AC010
ST34099AC020
PS-10
General Description
ILLUSTRATION
TOOL NUMBER
926230000
DESCRIPTION
SPANNER
REMARKS
For the lock nut when adjusting backlash of gearbox.
SPANNER
Used when measuring the rotating resistance of

gearbox assembly.
926420000
PLUG
When fluid leaks from pinion side of gearbox

assembly, remove pipe B from valve housing,
attach this tool and check fluid leaking points.
926250000
GUIDE
Used for installing holder assembly into rack

housing.
Except for turbo and 3.0 R model.
ST-926230000
34099PA100
ST34099PA100
ST-926420000
ST-926250000
PS-11
General Description
ILLUSTRATION
TOOL NUMBER
34099FA060
DESCRIPTION
PUNCH HOLDER
REMARKS
Used for caulking.
ST34099FA060
34099FA080
PUNCH
Used for removing caulking.

For RHD model.
34199AE090
PLUG WRENCH
Used for removing plug.

For RHD model.
34199AE100
OIL SEAL PLUG

REMOVER
Used for removing oil seal plug.

For RHD model.
ST34099FA080
ST34199AE090
ST34199AE100
PS-12
General Description
ILLUSTRATION
TOOL NUMBER
34199AE110
DESCRIPTION
OIL SEAL PLUG
INSTALLER
REMARKS
Used for installing oil seal plug.
For RHD model.
34199AE120
GEARBOX OIL
SEAL REMOVER
Used for removing gearbox oil seal.

For RHD model.
34199AE130
GEARBOX OIL
SEAL INSTALLER
Used for installing gearbox oil seal.

For RHD model.
34199FE040
INSTALLER A, B, C
Used for installing oil seal to rack assembly.

For turbo and 3.0 R model.
ST34199AE110
ST34199AE120
ST34199AE130
ST34199FE040
PS-13
General Description
ILLUSTRATION
TOOL NUMBER
927490000
DESCRIPTION
INSTALLER A, B, C
REMARKS
Used for installing oil seal to rack assembly.
34199FE010
REMOVER
Used for removing backup ring and oil seal.

927580000
REMOVER
Used for removing backup ring and oil seal.

GUIDE
Used for installing rack and seal into housing

assembly.
ST-927490000
ST34199FE010
ST-927580000
34199FE050
ST34199FE050
PS-14
General Description
ILLUSTRATION
TOOL NUMBER
34199AE000
DESCRIPTION
GUIDE
REMARKS
Used for installing rack and seal into housing
assembly.
34199FE000
INSTALLER &
REMOVER
Used for removing and installing rack oil seal

(outer & inner).
34099FA030
INSTALLER &
REMOVER
Used for removing and installing rack oil seal

(outer & inner).
34199FE060
INSTALLER
Used for installing rack oil seal (outer).

For RHD model.
ST34199AE000
ST34199FE000
ST34099FA030
ST34199FE060
PS-15
General Description
ILLUSTRATION
TOOL NUMBER
34199AE010
DESCRIPTION
INSTALLER
REMARKS
Used for installing rack oil seal (outer).
For RHD model.
34199FE020
BASE
Used for support housing assembly.

For RHD model.
34099FA070
BASE
Used for support housing assembly.

For RHD model.
34199AG000
BOSS D
Used for inspecting characteristic of gearbox

assembly and disassembling it.
Used with STAND (926200000).
ST34199AE010
ST34199FE020
ST34099FA070
ST34199AG000
PS-16
General Description
ILLUSTRATION
TOOL NUMBER
34199AG040
DESCRIPTION
GUIDE
REMARKS
Used for installing sealing of rack.
For 3.0 R model.
For LHD model.
34199AG030
GUIDE
Used for installing seal ring of rack.

Except for 3.0 R model.
For LHD model.
34199AG070
FORMER
Used for forming seal ring of pinion.

For LHD model.
34199AG020
GUIDE
Used for installing seal ring of pinion.

For LHD model.
ST34199AG040
ST34199AG030
ST34199AG070
ST34199AG020
PS-17
General Description
ILLUSTRATION
TOOL NUMBER
34199AG060
DESCRIPTION
GUIDE G (26)
REMARKS
Used for forming seal ring of rack.
For 3.0 R model.
For LHD model.
Used with FORMER PISTON (34199AG080).
Used for forming seal ring of rack.

For LHD model.
Used with FORMER PISTON (34199AG080).
ST34199AG060
34199AG050
GUIDE G (24)
34199AE050
OIL SEAL
REMOVER
Used for removing oil seal.

For LHD model.
34099PA010
OIL SEAL
REMOVER
Used for removing oil seal.

For 3.0 R model.
For LHD model.
ST34199AG050
ST34199AE050
ST34099PA010
PS-18
General Description
ILLUSTRATION
TOOL NUMBER
34199AG090
DESCRIPTION
INSTALLER &
REMOVER
REMARKS
Used for installing oil seal of valve housing.
Used with SEAL INSTALLER (34099FA130).
Used for installing ball bearing of valve housing.
Used for removing oil seal and ball bearing
from valve housing.
For LHD model.
34199AG080
FORMER PISTON
Used for forming seal of rack.

For LHD model.
Used with GUIDE G (26) (34199AG060) or
GUIDE G (24) (34199AG050).
34199AG010
INSTALLER
Used for press-fit oil seal of gearbox cylinder.

For LHD model.
ST34199AG090
ST34199AG080
ST34199AG010
PS-19
Steering Wheel
2. Steering Wheel
2) Check the splines on the steering wheel for damage. If the damage is excessive, replace the steering wheel.
A: REMOVAL
WARNING:
Always refer to Airbag System before performing airbag module service. <Ref. to AB-4,
CAUTION, General Description.>
4) Place alignment marks on the steering wheel
and steering shaft.
(1)
PS-00552
(1) Alignment mark
5) Remove the steering wheel nut, and then draw

out the steering wheel from shaft using steering
puller.
B: INSTALLATION
WARNING:
Always refer to Airbag System before performing airbag module service. <Ref. to AB-4,
1) Align the center of roll connector. <Ref. to AB24, ADJUSTMENT, Roll Connector.>
NOTE:
Align the alignment marks on the steering wheel
and steering shaft.
Tightening torque:
45 Nm (4.6 kgf-m, 33.2 ft-lb)
Column cover-to-steering wheel clearance:
2 4 mm (0.08 0.16 in)
CAUTION:
Insert roll connector guide pin into guide hole
on lower end of surface of steering wheel to
prevent damage.
C: INSPECTION
1) Check the steering wheel for deformation. If the
deformation is excessive, replace the steering
wheel.
PS-20
Universal Joint
3. Universal Joint
Tightening torque:
24 Nm (2.4 kgf-m, 17.4 ft-lb)
A: REMOVAL
2) Place alignment marks on universal joint.
3) Remove the universal joint bolts and then remove the universal joint.
CAUTION:
Excessively large tightening torque of universal joint bolts may lead to heavy steering wheel
operation.
Clearance between coupling of universal joint
to turbo cover:
5) Install the steering wheel. <Ref. to PS-20, INSTALLATION, Steering Wheel.>
C: INSPECTION
Check for wear, damage or any other faults. If necessary, replace it.
PS-00443
B: INSTALLATION
1) Align the cutout at serrated section of the column
shaft and yoke, then install the universal joint into
column shaft.
Service limit:
Universal joint play: 0 mm (0 in)
Maximum swing torque: 0.3 N (0.03 kgf, 0.07
lb)
(1)
(2)
PS-00033
(1) Swinging torque

(2) Play
Measure the folding torque of universal joint.

Service limit:
Maximum load: 3.8 N (0.39 kgf, 0.86 lb) or less
PS-00032
(1)
(2)
(3)
(4)
(5)
Cutout
Yoke
Column shaft
Column shaft side
Gearbox side
PS-00034
2) Install the universal joint to the serrations of

gearbox assembly by matching alignment marks.
3) Tighten the bolt.
PS-21
(1) Yoke (Gearbox side)
Universal Joint
Service limit:
PS-00035
(1) Yoke (Gearbox side)
Service limit:
PS-00036
(1) Yoke (Steering column side)
Service limit:
PS-00037
(1) Yoke (Steering column side)
PS-22
Tilt Steering Column

4. Tilt Steering Column

A: REMOVAL
(1)
(2)
PS-00466
(1)
Tilt steering column
(2)
Universal joint

2) Remove the universal joint. <Ref. to PS-21, REMOVAL, Universal Joint.>
3) Remove the instrument panel lower cover under.
4) Remove the instrument panel lower cover upper.
5) Remove all connectors from the steering column.
6) Remove the two bolts under instrument panel
securing steering column.
7) Pull out the steering shaft assembly from the

hole on toe board.
CAUTION:
Be sure to remove the universal joint before
removing steering shaft assembly installing
bolts when removing steering shaft assembly
or when lowering it for servicing of other parts.
Do not loosen the tilt lever when the steering
column is not secured to the vehicle.
PS-00444
PS-23
Tilt Steering Column

B: INSTALLATION
D: ASSEMBLY
1) Install the grommet to toe board.
Insert the combination switch to the upper column

shaft, and install the upper column cover. Then
route the 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:
Do not overtorque the screw.
E: INSPECTION
PS-00041
2) Insert the end of steering shaft into toe board

grommet.
3) With the tilt lever secured, tighten the steering
shaft mounting bolts under instrument panel.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
4) Connect all the connectors under instrument
panel.
5) Connect the airbag system connector at the harness spool.
1. BASIC INSPECTION
Measure the overall length of steering column. If
not as specified, replace it.
Overall length L:
Standard value
Except for OUTBACK model
833.61.5mm (32.820.059 in)
OUTBACK model
825.41.5mm (32.500.059 in)
NOTE:
Make sure to apply double lock.
6) Install the instrument panel lower cover with tilt
lever held in the lowered position.
7) Install the universal joint. <Ref. to PS-21, INSTALLATION, Universal Joint.>
CAUTION:
Insert roll connector guide pin into guide hole
on lower end of steering wheel surface to prevent damage.
C: DISASSEMBLY
Remove the two screws securing upper steering
column covers, and the two screws securing combination switch, and then remove the related parts.
PS-00491
2. AIRBAG SYSTEM INSPECTION

WARNING:
For airbag inspection procedures, refer to Airbag System. <Ref. to AB-4, CAUTION, General
Description.>
PS-24
Steering Gearbox [LHD Model]

5. Steering Gearbox [LHD Model]

A: REMOVAL
3) Loosen the front wheel nuts.
5) Remove the under cover. <Ref. to EI-26, REMOVAL, Front Under Cover.>
6) Remove the front exhaust pipe assembly. (Nonturbo model) <Ref. to EX(H4SO 2.0)-7, REMOVAL,
WARNING:
Be careful, not to burn your hand because the
exhaust pipe is hot.
7) Using a puller, remove the tie-rod end from the
knuckle arm after pulling off cotter pin and removing castle nut.
9) Remove the one pipe joint at the center of gearbox, and connect the vinyl hose to the pipe and the
joint. Discharge the fluid by turning steering wheel
fully clockwise and counterclockwise. Discharge
the fluid similarly from other pipes.
(1)
(2)
PS-00553
(1) Pipe A
(2) Pipe B
10) Remove the universal joint. <Ref. to PS-21,

REMOVAL, Universal Joint.>
11) Disconnect the pipe C from pressure hose first,
and pipe D from return hose second.
PS-00043
(4)
(1) Castle nut

(2) Tie-rod end
(3) Knuckle arm
(3)
(2)
8) Remove the front crossmember support plate,

jack-up plate and front stabilizer. <Ref. to FS-16,
REMOVAL, Front Stabilizer.>
(1)
PS-00538
(2)
(1)
(1)
(2)
(3)
(4)
(1)
FS-00105
(1) Crossmember support plate

(2) Jack-up plate
PS-25
Pipe C
Pipe D
Pressure hose
Return hose

12) Remove the clamp bolts securing gearbox to

crossmember, and remove the clamp.
3) Tighten the gearbox to the crossmember bracket

via clamp with bolt temporarily.
(1)
(1)
PS-00554
PS-00554
(1) Clamp
(1) Clamp
13) Remove the bolts which secure gearbox bracket, and remove the bracket and gearbox.
4) Tighten the bolts which temporary tightening the

clamp and bracket of gearbox to specified torque.
Tightening torque:
60 Nm (6.1 kgf-m, 44.1 ft-lb)
5) Connect the pipe D to return hose first, and the
pipe C to pressure hose second.
(1)
Tightening torque:
15 Nm (1.5 kgf-m, 10.8 ft-lb)
PS-00555
(1) Bracket
B: INSTALLATION
1) Insert the gearbox into crossmember, being
careful not to damage gearbox boot.
2) Install the gearbox and bracket. Tighten the bolt
temporarily.
(4)
(3)
(2)
(1)
(1)
PS-00555
PS-00538
(1) Bracket
(1)
(2)
(3)
(4)
Pipe C
Pipe D
Pressure hose
Return hose

7) Connect the tie-rod end and knuckle arm, and
tighten with castle nut.
PS-26

Castle nut tightening torque:

27 Nm (2.75 kgf-m, 19.9 ft-lb)
CAUTION:
When connecting, do not hit cap at the bottom
8) After tightening the castle nut to specified tightening torque, tighten it further within 60 until cotter
pin hole is aligned with slot in the nut. Fit the cotter
pin into nut, and then bend the pin to lock.
NOTE:
When adjusting toe-in, hold the boot as shown to
prevent it from being rotated or twisted. If twisted,
straighten it.
(A)
(B)
PS-00051
C: DISASSEMBLY
(C)
1. RACK HOUSING ASSEMBLY

1) Disconnect the four pipes from gearbox.
DS-00042
(A) Cotter pin

(B) Castle nut
(C) Tie-rod end
9) Install the front stabilizer. <Ref. to FS-16, INSTALLATION, Front Stabilizer.>

10) Install the front crossmember support plate and
jack-up plate.
11) Install the front exhaust pipe assembly. (Nonturbo model) <Ref. to EX(H4SO 2.0)-8, INSTALLATION, Front Exhaust Pipe.>
12) Install the under cover. <Ref. to EI-26, INSTALLATION, Front Under Cover.>
14) Tighten the wheel nuts to specified torque.
Tightening torque:
90 Nm (9.1 kgf-m, 65.8 ft-lb)
16) Remove the steering wheel. <Ref. to PS-20,
REMOVAL, Steering Wheel.>
20) Pour fluid into the oil tank, and bleed air. <Ref.
to PS-84, Power Steering Fluid.>
21) Check for fluid leaks.
22) Check the fluid level in oil tank.
23) After adjusting toe-in and steering angle, tighten the lock nut on tie-rod end.
NOTE:
Remove the pipes C and D, which are fixed to
clamp plate, as a single unit.
2) Secure the gearbox removed from vehicle in
vice using ST.
ST1 926200000 STAND
ST2 34199AG000 BOSS D
CAUTION:
Secure the gearbox in a vise using ST as
shown. Do not attempt to secure it without this
ST.
(1)
ST1
ST2
PS-00492
(1) Clamp
3) Remove the tie-rod end and lock nut from gearbox.
Tightening torque:
85 Nm (8.7 kgf-m, 62.7 ft-lb)
PS-27

4) Remove the small clip from the boot using pliers,

and then move the boot to tie-rod end side.
7) Tighten the adjusting screw until it no longer

tightens.
(1)
(1)
PS-00495
PS-00508
(1) Clip
(1) Adjusting screw
5) Using a flat-tip screwdriver, remove the band

from boot.
NOTE:
Replace the boot it there is damage, cracks or deterioration.
8) Hold the rack with a wrench [22 mm width across

flats], and then remove the tie-rod using a wrench
[32 mm width across flats] or adjustable wrench.
(1)
PS-00511
PS-00509
(1) Band
9) Loosen the adjusting screw, and then remove

the spring and sleeve.
10) Remove the two bolts securing valve assembly.
6) Using the ST, loosen the lock nut.

ST 926230000
SPANNER
ST
PS-00116
(1)
PS-00494
(1) Lock nut
PS-28

11) Carefully draw out the input shaft, and then remove the valve assembly.
16) Insert the ST from pinion housing side, and

then remove the oil seal using a press.
ST 34099PA010 OIL SEAL REMOVER (3.0 R
model)
ST 34199AE050 OIL SEAL REMOVER (Except
for 3.0 R model)
(1)
PS-00117
ST
12) Using a drill, release the caulking of holder.

CAUTION:
Make a hole approx. 2 mm (0.08 in) depth using
a drill bit of 3 mm (0.12 in) diameter.
(2)
PS-00138
PS-00516
13) Using a spanner [36 mm width across flats] or

adjustable wrench, remove the holder.
(1) Press
(2) Oil seal
17) Using a press, remove the bushing at gearbox

installation portion.
(1)
PS-00512
(1) Holder
14) Remove the rack bushing and rack stopper

from rack assembly.
15) Remove the oil seal from rack.
PS-00517
2. CONTROL VALVE
1) Disconnect the pipes A and B from gearbox.
2) Secure the gearbox removed from the vehicle in
vise using ST.
ST1 926200000 STAND
PS-29

CAUTION:
Secure the gearbox in a vise using ST as
shown. Do not attempt to secure it without this
ST.
6) Remove the two bolts securing valve assembly.
(1)
PS-00116
7) Carefully draw out the input shaft, and then remove the valve assembly.
ST1
ST2
PS-00492
(1) Clamp

ST 926230000
SPANNER
ST
PS-00143
8) Wrap the tape to spline part, and slide the dust

cover out.
(1)
(1)
PS-00494
(1) Lock nut

tightens.
(1)
PS-00144
(1) Dust cover
PS-00495
(1) Adjusting screw
5) Loosen the adjusting screw, and then remove

the spring and sleeve.
PS-30

9) Using a press remove the pinion & valve assembly from valve housing.
11) Using a snap ring pliers, remove the snap ring,

valve, oil seal and backup washer.
CAUTION:
Be careful not to scratch the pinion & valve assembly.
(1)
(2)
(4)
(3)
(3)
(2)
(1)
PS-00149
(1) Pinion & valve ASSY

(2) Valve housing
(3) Cloth
PS-00518
(1)
(2)
(3)
(4)
10) Using the ST and press, remove the bushing

and oil seal from valve housing.
ST 34199AG090 INSTALLER & REMOVER
CAUTION:
Do not apply force to the end surface of valve
housing.
Do not reuse the oil seal after removal.
Snap ring
Valve
Oil seal
Backup ring
D: ASSEMBLY
1. RACK HOUSING ASSEMBLY
1) Using a press, install the bushing to the gearbox
installation portion.
ST
(1)
(2)
PS-00150
(1) Oil seal

(2) Bushing
PS-00519
2) Insert the ST into rack.

ST 34199AG040 GUIDE (3.0 R model)
ST 34199AG030 GUIDE (Except for 3.0 R model)
(1)
(2)
ST
PS-00520
(1) Seal ring

(2) Rack
PS-31

3) Install the seal ring to piston portion of rack.

(1) Using the ST, form the seal ring properly
ST1 34199AG080 FORMER PISTON
ST2 34199AG060 GUIDE G (26) (3.0 R model)
ST2 34199AG050 GUIDE G (24) (Except for 3.0
R model)
(1)
(3) Insert the ST-A with oil seal assembled from

the gear side of rack. Remove the oil seal from
ST-A near piston, and then remove the ST-A
from rack.
(C)
(2)
(B)
ST A
(A)
PS-00076
ST2
ST1
(A) Oil seal

(B) Rack
(C) Piston
PS-00559
(1) Seal ring

(2) Rack
4) Install the backup washer from gear side of rack.
(2) Using ST-B and ST-C, install the oil seal to

ST-A.
ST 34199FE040 INSTALLER A, B, C (3.0 R
model)
ST 927490000
INSTALLER A, B, C (Except
for 3.0 R model)
NOTE:
Face the oil seal in the direction as shown in the figure.
PS-00077
ST B
ST A
ST C
(1) Oil seal

(2) Backup washer
(3) Rack
5) Install the ST on rack, and equally apply a thin

coat of grease to the rack and ST, then install the oil
seal.
ST 926250000
GUIDE
(A)
PS-00075
(A) Oil seal
CAUTION:
Be careful not to scratch the oil seal lips with
the inner ring section of piston.
PS-32

11) Using a press, press-fit until the groove of ST

reaches the end of holder.
NOTE:
Do not use this ST for turbo model.
ST
(1)
(2)
PS-00522
PS-00078
(1) Groove
(2) Holder
(1) Rack piston inner ring

(2) Outer side oil seal
(3) Rack
6) Apply a coat of grease to the grooves in rack,

sliding surface of sleeve and sealing surface of piston. Then insert the rack into steering body from
cylinder side.
7) Check the thread part of holder and end of gearbox cylinder for burrs and scratches. Correct if necessary.
8) Insert the ST into gearbox cylinder, and then
press-fit the oil seal.
ST 34199AG010 INSTALLER
12) Secure the gearbox in a vice using ST.

ST1 926200000 STAND
(1)
ST1
ST2
ST
PS-00492
(1) Clamp
13) Tighten the holder.
PS-00521
9) Temporarily install the holder to gearbox cylinder.

10) Set the ST to the end of rack.
ST 34199FE000 INSTALLER & REMOVER
(3.0 R model)
ST 34099FA030 INSTALLER & REMOVER
(Except for 3.0 R model)
Tightening torque:
3.0 R model
90 Nm (9.18 kgf-m, 66.4 ft-lb)
Except for 3.0 R model
64 Nm (6.5 kgf-m, 47.0 ft-lb)
(1)
PS-00512
(1) Holder
14) Using ST, caulk the gearbox cylinder at 2 mm

(0.08 in) from end to make punch hole 2 to 2.5 mm
(0.08 to 0.10 in) in diameter.
PS-33

ST 34099FA060
17) Install a new gasket on valve assembly. Insert

the valve assembly into place while facing the rack
teeth toward pinion.
PUNCH HOLDER
(1)
(2)
(4)
(3)
PS-00523
(1)
(2)
(3)
(4)
2 mm (0.08 in)
Diameter: 2 2.5 mm (0.08 0.10 in)
End of cylinder
Holder
PS-00117
18) Tighten the bolts alternately to secure valve assembly.
15) Apply vinyl tape to spline portion, and apply

genuine grease to dust cover, and then install the
dust cover to valve assembly.
CAUTION:
Be sure to install the dust cover to groove on
shaft properly.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
CAUTION:
Be sure to alternately tighten the bolts.
19) Temporarily install the rack, and then operate it
from lock to lock two or three times to make it fit in.
Remove the grease blocking air vent hole.
CAUTION:
If operating the rack from lock to lock without
installing tie-rod, it may damage the oil seal. Always install the tie-rods LH and RH.
20) Apply a coat of grease to the sliding surface of
sleeve and seating surface of spring, and then insert sleeve into steering body.
Charge the adjusting screw with grease, and then
insert the spring into adjusting screw and install on
steering body.
(1)
(2)
PS-00534
(1) Dust cover

(2) Groove
16) Apply genuine grease to the pinion gear and

bearing of valve assembly.
(3)
(2)
(1)
PS-00167
(1) Sleeve
(2) Spring
(3) Adjusting screw
PS-00165
21) Tighten the adjusting screw to specified torque.

Tightening torque:
7.4 Nm (0.75 kgf-m, 5.4 ft-lb)
22) After tightening the adjusting screw with the
specified tightening torque, loosen it by 25.
23) Remove the tie-rod.
PS-34

24) Verify that play is within specified value. <Ref.

to PS-43, SERVICE LIMIT, INSPECTION, Steering
Gearbox [LHD Model].>
25) Loosen the adjusting screw, and then apply liquid gasket to at least 1/3 of the entire perimeter of
adjusting screw thread.
Tightening torque:
78 Nm (8.0 kgf-m, 57.9 ft-lb)
(2)
Liquid gasket:
THREE BOND 1141
(1)
PS-00439
(1) Lock washer

(2) Approx. 40 mm (1.57 in)
31) Bend the lock washer.

CAUTION:
Be careful not to scratch the rack when bending
lock washer.
PS-00092

perimeter.

Tightening torque:
7.4 Nm (0.75 kgf-m, 5.4 ft-lb)
specified tightening torque, loosen it by 25.
28) Install the lock nut. While holding the adjusting
screw with a wrench, tighten lock nut using ST.
ST 926230000
SPANNER
Tightening torque (Lock nut):
39 Nm (4.0 kgf-m, 28.9 ft-lb)
NOTE:
from turning while tightening lock nut.
29) Extend the rack approx. 40 mm (1.57 in) beyond side of steering body.
30) Install the tie-rod and a new lock washer into
rack.
PS-00093
(1) Lock washer
32) Apply a coat of grease to the tie-rod groove,

and then install the boot to housing.
PS-35

CAUTION:
Right side boot has groove for identification.
Be sure to install the boots after identifying left
and right boots.
33) Install a new boot band. Using band clamp pliers, caulk the boot band until caulking part clearance is 2 mm (0.079 in) or less.
(1)
(B)
(2)
(A)
PS-00524
(1) Right side boot

(2) Groove for identification
NOTE:
Make sure that the boot is installed without unusual
inflation or deflation.
PS-00499
(A) Boot band

(B) 2 mm (0.079 in) or less
34) Fix the boot end with clip (small).
PS-00194
PS-00053
(1) Clip
35) After installing, check the boot end is positioned into groove on tie-rod.
36) If the tie-rod end has been removed, screw in
the lock nut and tie-rod end to screwed portion of
tie-rod, and then tighten the lock nut temporarily in
a position as shown in the figure.
PS-36

(2) Connect the pipe C and D to gearbox.
Installed tie-rod length L:

31 mm (1.22 in)
Tightening torque:
Pipe C: 15 Nm (1.5 kgf-m, 10.8 ft-lb)
Pipe D: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
L
(2)
PS-00097
37) Inspect the gearbox as follows:

A Holding the tie-rod end, repeat lock to lock two
or three times as quickly as possible.
B Holding the tie-rod end, turn it slowly at a radius
one or two times as large as possible.
After all, make sure that the boot is installed in
specified position without deflation.
(1)
PS-00525
(1) Pipe C
(2) Pipe D
2. CONTROL VALVE ASSEMBLY

Specified steering grease:
VALIANT GREASE M2 (Part No. 003608001)
1) Clean all parts and tools before reassembling.
2) Apply a coat of specified power steering fluid to
the inner wall of valve housing.
PS-00098
38) Remove the gearbox from ST.

ST1 926200000 STAND
39) Install the four pipes on gearbox.
(1) Connect the pipe A and B to four pipe joints
of gearbox.
Tightening torque:
13 Nm (1.3 kgf-m, 9.4 ft-lb)
(1)
PS-00169
(1) Apply fluid.
3) To avoid scratching the oil seal, apply a coat of

grease to the contact surface of installer and oil
seal.
4) Verify the oil seal direction.
Attach the oil seal to installer and position in valve
housing before pressing into place.
PS-37

5) Press the oil seal into place using a press.

8) Install the backup ring and oil seal to pinion, and

then remove the vinyl tape.
(2)
(3)
(1)
PS-00528
(1) Oil seal

(2) Vinyl tape
(3) Backup ring
ST
9) Set the ST to pinion, and install the seal ring.

ST 34199AG020 GUIDE
ST
PS-00526
6) Attach the bearing to ST, and then position in

value housing. Using the ST and press, install the
special bearing in valve housing.
(1)
PS-00529
ST
(1) Seal ring
10) Remove the ST GUIDE, and form the seal ring

properly using ST FORMER.
ST 34199AG070 FORMER
(1)
(2)
PS-00527
(1) Special bearing

(2) Oil seal
ST
(1)
7) Apply vinyl tape to the groove portion of pinion.
PS-00530
(1) Seal ring
11) Put vinyl tape around the pinion shaft splines to

protect oil seal from damage.
PS-38

12) Install the valve to pinion, and install the snap

ring.
16) Install the dust cover on valve assembly.

CAUTION:
Be sure to install the dust cover to groove on
shaft properly.
(1)
(2)
(1)
(2)
PS-00531
(1) Snap ring

(2) Valve
PS-00534
(1) Dust cover

(2) Groove
13) Fit the pinion & valve assembly into valve housing.
17) Apply genuine grease to the pinion gear and

bearing of valve assembly.
(2)
(1)
PS-00532
(1) Valve housing

PS-00165
14) Using a press, press-fit the pinion & valve assembly into housing by pressing the bearing outer
race.
18) Install a new O-ring on valve assembly.
(1)
(1)
(2)
PS-00535
(3)
(1) O-ring
PS-00533

(2) Bearing
(3) Housing
15) Apply the specified grease to dust cover.
PS-39

19) Insert the valve assembly into place while facing rack teeth toward pinion.
Liquid gasket:
THREE BOND 1141
PS-00143
PS-00092
20) Tighten the bolts alternately to secure valve assembly.

Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
CAUTION:
Be sure to alternately tighten the bolts.
sleeve and seating surface of spring, and then insert the sleeve into steering body.
steering body.
Tightening torque:
7.4 Nm (0.75 kgf-m, 5.4 ft-lb)
27) After tightening to the specified tightening
torque, loosen it by 25.
28) Install the lock nut. While holding the adjusting
ST 926230000
SPANNER
39 Nm (4.0 kgf-m, 28.9 ft-lb)
NOTE:
29) Remove the gearbox from ST.
ST1 926200000 STAND
30) Install the four pipes on gearbox.
(1) Connect the pipe A and B to the gearbox.
(3)
(2)
(1)

perimeter.
PS-00167
Tightening torque:
13 Nm (1.3 kgf-m, 9.4 ft-lb)
(1) Sleeve
(2) Spring
(3) Adjusting screw
22) Tighten the adjusting screw with specified

torque.
Tightening torque:
7.4 Nm (0.75 kgf-m, 5.4 ft-lb)
23) After tightening to the specified tightening
torque, loosen it by 25.
to PS-43, SERVICE LIMIT, INSPECTION, Steering
Gearbox [LHD Model].>
PS-40

(2) Connect the pipe C and D to gearbox.

Tightening torque:
Pipe C: 15 Nm (1.5 kgf-m, 10.8 ft-lb)
Pipe D: 25 Nm (2.5 kgf-m, 18.1 ft-lb)
(2)
(1)
PS-00525
(1) Pipe C
(2) Pipe D
PS-41

E: INSPECTION
1. BASIC INSPECTION
1) Clean all disassembled parts, and check for wear, damage or any other faults, then repair or replace as
necessary.
2) When disassembling, check the inside of gearbox for water. If any water is found, carefully check the boot
for damage, input shaft dust seal, adjusting screw and boot clips for poor sealing. If faulty, replace with new
parts.
No.
Parts
Input shaft
Dust seal
Rack & pinion
Gearbox unit
Inspection
(1) Bend of input shaft
(2) Damage on serration
(1) Crack or damage
(2) Wear
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) Wear or damage on rack bush
(5) Wear on input shaft bearing
Boot
Tie-rod
Tie-rod end
9
10
Adjusting screw
spring
Boot clip
Sleeve
11
Pipes
Crack, damage or deterioration

(1) Looseness of ball joint
(2) Bend of tie-rod
Damage or deterioration on dust
seal
Corrective action
If the bend or damage is excessive, replace the entire
gearbox.
If the outer wall slips, the lip is worn out or damage is
found, replace it with a new one.
(1) Adjust the backlash properly.
By measuring the turning torque of gearbox and sliding
resistance of rack, check if rack & pinion engage uniformly and smoothly with each other. (Refer to Service
limit.)
(2) Keeping the rack pulled out all the way so that all teeth
emerge, check teeth for damage.
Even if abnormality is found in either (1) or (2), replace
the entire gearbox.
Replace the gearbox with a new one.
If the free play of rack shaft in radial direction is out of the
specified range, replace the gearbox with a new one.
(Refer to Service limit.)
If the free plays of input shaft in radial and axial directions
are out of the specified ranges, replace the gearbox with
a new one. (Refer to Service limit.)
Replace.
Replace.
Replace.
Deterioration
Replace.
Deterioration
Damage
(1) Damage to flared surface
(2) Damage to flare nut
(3) Damage to pipe
Replace.
Replace.
PS-42
Replace.

2. SERVICE LIMIT
Make a measurement as follows. If it exceeds the
specified service limit, adjust or replace.
On condition
L: 5 mm (0.20 in)
P: 122.6 N (12.5 kgf, 27.6 lb)
NOTE:
When making a measurement, vise the gearbox
using ST. Never vise the gearbox by inserting aluminum plates, etc. between vise and gearbox.
ST1 926200000 STAND
Sliding resistance of rack shaft:
Service limit
400 N (41 kgf, 90 lb) or less
PS-00101
Left-turn steering:
Service limit
Direction
Direction
0.15 mm (0.0059 in) or less
5 mm(0.20 in)
PS-00099
98N
(10 kgf, 22 lb)
PS-00102
4. INPUT SHAFT PLAY

In radial direction:
PS-00100
3. RACK SHAFT PLAY IN RADIAL DIRECTION

Right-turn steering:
Service limit
0.18 mm (0.0071 in) or less
On condition
P: 98 N (10 kgf, 22 lb)
Service limit
0.19 mm (0.0075 in) or less
PS-00103
In axial direction:
Service limit
PS-43

5. TURNING RESISTANCE OF GEARBOX
On condition
P: 20 49 N (2 5 kgf, 4 11 lb)
Using the ST, measure the gearbox turning resistance.

ST 34099PA100 SPANNER
Service limit:
Maximum allowable resistance:
10.5 N (1.1 kgf, 2.4 lb) or less
Difference between right and left turning resistance:
20% or less
PS-00104
PS-00105
6. OIL LEAKING
b
a
(5)
d
(1)
(4) (3) (2)
(6)
d
f
e
d
PS-00272
(1)
(2)
Power cylinder
Cylinder
(3)
(4)
Rack piston
Rack axle
PS-44
(5)
(6)
Input shaft
Valve housing


2) Even if the location of leak can be easily found
by observing the leaking condition, it is necessary
to thoroughly remove the fluid from the suspected
portion and turn the steering wheel from lock to lock
about thirty to forty times with engine running, then
make comparison of the suspected portion between immediately after and several hours after
this operation.
3) Cause and measure for oil leakage from a
The oil seal is damaged. Replace the valve assembly with a new one.
4) Cause and measure for oil leakage from b
The torsion bar O-ring is damaged. Replace the
valve assembly with a new one.
5) Cause and measure for oil leakage from c
The oil seal is damaged. Replace the valve assembly or oil seal with a new one.
6) Cause and measure for oil leakage from d
The pipe is damaged. Replace the faulty pipe or Oring.
7) Cause and measure for oil leakage from g
The hose is damaged. Replace the hose with a
new one.
8) If leak is other than a, b, c, d, or g, 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 fluid
from the surrounding portions. Then, turn the steering wheel from lock to lock thirty to forty times with
the engine running, and make comparison of the
leaked portion immediately after and several hours
after this operation.
(1) Leakage from e
The cylinder seal is damaged. Replace the rack
bush with a new one.
(2) Leakage from f
There are two possible causes. Take the following step first. Remove the pipe assembly B from
the valve housing, and close the circuit with ST.
ST 926420000
PLUG
Turn the steering wheel from lock to lock thirty to
forty times with the engine running, then make
comparison of the leaked portion between immediately after and several hours after this operation.
If leakage from f is noted again:
The oil seal of pinion & valve assembly is damaged. Replace the pinion & valve assembly with a
new one. Or replace the oil seal and 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.
F: ADJUSTMENT
1) Adjust the front toe. <Ref. to FS-12, FRONT
WHEEL TOE-IN, INSPECTION, Wheel Alignment.>
Standard of front toe:
IN 3 OUT 3 mm (IN 0.12 OUT 0.12 in)
PS-00107
(1) Lock nut
2) Adjust the steering angle of wheels.

Standard of steering angle:
Model
Inner
wheel
Outer
wheel
2.0 i, 2.5 i
3.0 R
OUTBACK
37.31.5
37.21.5
37.81.5
33.01.5
32.91.5
33.51.5
3) If the 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.
(1)
PS-00513
(1) Within 5

with vehicle set in the straight ahead position after
this adjustment, correct it by turning the right and
left tie-rods in opposite direction by same angle.
PS-45
Steering Gearbox [RHD Model]

6. Steering Gearbox [RHD Model]
Small type
A: REMOVAL
3) Loosen the front wheel nuts.
5) Remove the under cover. <Ref. to EI-26, REMOVAL, Front Under Cover.>
6) Remove the front exhaust pipe assembly. (Nonturbo model) <Ref. to EX(H4SO 2.0)-7, REMOVAL,
WARNING:
Be careful, not to burn your hand because the
exhaust pipe is hot.
7) Using a puller, remove the tie-rod end from the
knuckle arm after pulling off cotter pin and removing castle nut.
(1)
(2)
(1)
FS-00105
(1) Front crossmember support plate

(2) Jack-up plate
9) Remove the one pipe joint at the center of gearbox, and connect the vinyl hose to the pipe and the
joint. Discharge the fluid by turning steering wheel
fully clockwise and counterclockwise. Discharge
the fluid similarly from other pipes.
(1)
(2)
PS-00043
PS-00446
(1) Castle nut

(2) Tie-rod end
(3) Knuckle arm
(1) Pipe A
(2) Pipe B
8) Remove the front crossmember support plate,

jack-up plate and front stabilizer. <Ref. to FS-16,
REMOVAL, Front Stabilizer.>
Large type
10) Remove the universal joint. <Ref. to PS-21,

REMOVAL, Universal Joint.>
(1)
PS-00445
PS-46

11) Disconnect the return hose and pressure hose

from gearbox.
13) Remove the bolts which secure the gearbox

bracket, and remove the bracket and gearbox.
(1)
(2)
PS-00449
(1) Bracket
B: INSTALLATION
1) Insert the gearbox into the crossmember, being
careful not to damage gearbox boot.
2) Install the gearbox and bracket. Tighten the bolt
temporarily.
(1)
PS-00536
(1)
(1) Return hose

(2) Pressure hose
12) Remove the clamp bolts securing gearbox to

crossmember, and remove the clamp.
PS-00449
(1) Bracket
3) Tighten the gearbox to the crossmember bracket

via clamp with bolt temporarily.
(1)
PS-00448
(1) Clamp
(1)
PS-00448
(1) Clamp
4) Tighten the bolts which temporary tightening the

clamp and bracket of gearbox to specified torque.
Tightening torque:
60 Nm (6.1 kgf-m, 44.1 ft-lb)
PS-47

5) Connect the return hose and pressure hose to

gearbox.
Tightening torque:
15 Nm (1.5 kgf-m, 10.8 ft-lb)
8) After tightening the castle nut to specified tightening torque, tighten it further within 60 until cotter
pin hole is aligned with slot in the nut. Fit the cotter
pin into nut, and then bend the pin to lock.
(A)
(B)
(C)
(2)
DS-00042
(A) Cotter pin

(B) Castle nut
(C) Tie-rod end
9) Install the front stabilizer. <Ref. to FS-16, INSTALLATION, Front Stabilizer.>

jack-up plate.
11) Install the front exhaust pipe assembly. (Nonturbo model) <Ref. to EX(H4SO 2.0)-8, INSTALLATION, Front Exhaust Pipe.>
12) Install the under cover. <Ref. to EI-26, INSTALLATION, Front Under Cover.>
14) Tighten the wheel nuts to specified torque.
(1)
PS-00536
(1) Return hose

(2) Pressure hose

7) Connect the tie-rod end and knuckle arm, and
tighten with castle nut.
Castle nut tightening torque:
27 Nm (2.75 kgf-m, 19.9 ft-lb)
CAUTION:
When connecting, do not hit cap at the bottom
Tightening torque:
90 Nm (9.1 kgf-m, 65.8 ft-lb)
16) Remove the steering wheel. <Ref. to PS-20,
REMOVAL, Steering Wheel.>
20) Pour fluid into the oil tank, and bleed air. <Ref.
21) Check for fluid leaks.
22) Check the fluid level in oil tank.
23) After adjusting toe-in and steering angle, tighten the lock nut on tie-rod end.
Tightening torque:
85 Nm (8.7 kgf-m, 62.7 ft-lb)
PS-48

NOTE:
When adjusting toe-in, hold the boot as shown to
prevent it from being rotated or twisted. If twisted,
straighten it.
3) Remove the tie-rod end and lock nut from gearbox.

4) Remove the clip from outside boot using pliers,
and then move the boot to tie-rod end side.
PS-00053
PS-00051
C: DISASSEMBLY
(1) Clip
1) Disconnect the pipes A and B from steering body

and control valve housing.
5) Using a flat tip screwdriver, remove the band

from boot.
NOTE:
Replace the boot if there is damage, cracks or deterioration.
(1)
(2)
(1)
PS-00496
(1) Pipe A
(2) Pipe B
2) Secure the gearbox removed from vehicle in a

vice using ST.
ST1 926200000 STAND
CAUTION:
Secure the gearbox assembly in a vice using
the ST as shown. Do not secure the gearbox
without this ST.
PS-00493
(1) Band

ST 926230000
SPANNER
ST
(1)
(1)
PS-00494
ST1
(1) Lock nuts
ST2
PS-00492
(1) Clamp
PS-49


tightens.
ST 34199AE090
PLUG WRENCH
(1)
PS-00495
(1) Adjusting screw
8) Using a 32 mm spanner or adjustable wrench

with cinching boot, remove the tie-rod.
PS-00061
(1) Plug
12) Remove the valve assembly paying attention

not to scratch seal ring or valve housing inner surface.
PS-00058
(1) Tie-rod
9) Loosen the adjusting screw and remove the

spring and sleeve.
10) Clean the dirt adherent to the input shaft. Remove the dust cover paying attention not to scratch
the housing or input shaft and not to allow foreign
matter to enter the gear box interior.
CAUTION:
Wrap the tape to the spline part of input shaft to
avoid damaging dust cover.
(1)
PS-00497
PS-00062
(1) Dust cover
11) Align the ST pin with the plug hole to install. Rotate the ST counterclockwise to remove the plug.
PS-50
(1) Valve ASSY

(2) Seal ring

13) Remove the holder using a 36 mm spanner or

adjustable wrench.
15) Insert the ST from the valve side and press the
back-up ring and oil seal out.
ST 34199FE010 REMOVER (Turbo and 3.0 R
model)
ST 927580000
REMOVER (Except for turbo
and 3.0 R model)
PS-00498
14) Install the ST on valve side of rack and press

outer side oil seal out taking care not to contact
rack with steering body inner surface.
ST 34199FE010 INSTALLER & REMOVER
(Turbo and 3.0 R model)
ST 34099FA030 INSTALLER & REMOVER
(Except for turbo and 3.0 R
model)
NOTE:
Block the pipe connection of steering body to prevent fluid from flowing out.
PS-00065
PS-00064
(1) Rack piston

PS-51

16) Using ST1 and ST2, repair the caulking portion

of cylinder.
ST1 34099FA080 PUNCH
ST2 34199FE020 BASE (Turbo and 3.0 R model)
ST2 34099FA070 BASE (Except for turbo and
3.0 R model)
NOTE:
Do not apply force on the plug edge surface.
PS-00068
(1) Oil seal

(2) O-ring
19) Set the ST in the dimension as shown in the figure.

ST 34199AE120 GEARBOX OIL SEAL REMOVER
PS-00066
(1) Cylinder
PS-00069
17) If the cylinder edge is deformed in a convex

shape, repair using an oil stone.
PS-00067
18) Remove the oil seal using ST and press from

plug.
ST 34199AE100 OIL SEAL PLUG REMOVER
PS-52
(1) 70 mm (2.76 in)

20) Set the stopper to gearbox, and then insert the

tip of ST to gearbox.
22) While fixing the 2-surface width, pull out the oil
seal by rotating nut.
CAUTION:
Take care not to scratch the gearbox inner surface.
PS-00070
(1) Stopper
(2) Oil seal
PS-00072
21) By fixing the 2-surface width, press-in by rotating the rod and attach to oil seal.
(1) 2-surface width

(2) Nut
D: ASSEMBLY
1) Apply a coat of grease to the inside and outside
of new oil seal.
Steering grease:
VALIANT GREASE M2 (Part No. 003608001)
2) Verify the oil seal direction and installation position. Using the ST and press, press-fit the oil seal to
gearbox.
ST 34199AE130 GEARBOX OIL SEAL INSTALLER
PS-00071
PS-00073
(1) Rod
(2) 2-surface width
(1) Oil seal
PS-53

3) Attach the steering body to ST as shown in the

figure. Apply a coat of grease to needle bearing.
ST1 926200000 STAND
5) Insert the ST-A with oil seal assembled from the

gear side of rack. Remove the oil seal from ST-A
near piston, and then remove the ST-A from rack.
CAUTION:
Ensure the needle bearing is free from defects.
If it is faulty, replace the steering body with a
new one.
(C)
(1)
(B)
ST A
(A)
PS-00076
(A) Oil seal

(B) Rack
(C) Piston
ST1
ST2
6) Install the back-up washer from gear side of

rack.
PS-00492
(1) Clamp
4) Using ST-B and ST-C, install the oil seal to STA.

ST 34199FE040 INSTALLER A, B, C (Turbo
and 3.0 R model)
ST 927490000
INSTALLER A, B, C (Except
for turbo and 3.0 R model)
NOTE:
Face the oil seal in the direction as shown in the figure.
ST B
PS-00077
(1) Oil seal

(2) Back-up washer
(3) Rack
ST A
ST C
7) Install the ST on rack, and equally apply a thin

coat of grease to the rack and ST, then install the oil
seal.
ST 926250000
GUIDE
(A)
PS-00075
CAUTION:
Be careful not to scratch the oil seal lips with
the inner ring section of piston.
(A) Oil seal
PS-54

ST2 34199FE060 INSTALLER (Turbo and 3.0 R

model)
34199AE010 INSTALLER (Except for turbo
and 3.0 R model)
NOTE:
Do not use this ST for turbo model.
ST2
(1)
ST1
(2)
PS-00078
(3)
PS-00431
(1) Rack piston inner ring

(3) Rack
8) Apply a coat of grease to the grooves in rack,

sliding surface of sleeve and sealing surface of piston. Install ST on the end of steering body cylinder.
Then insert the rack into steering body from cylinder side.
ST 34199FE050 GUIDE (Turbo and 3.0 R model)
ST 34199AE000 GUIDE (Except for turbo and
3.0 R model)

(2) Rack piston
(3) Inner side oil seal
10) Install a new holder to the cylinder side of steering body.

Tightening torque:
Turbo and 3.0 R model
90 Nm (9.18 kgf-m, 66.4 ft-lb)
Except for turbo and 3.0 R model
64 Nm (6.5 kgf-m, 47.0 ft-lb)
CAUTION:
Do not allow grease to block the air vent hole on
rack.
PS-00498
11) Using the ST, caulk the steering body at one

point less than 3mm (0.12 in) from holder.
PS-00079
(1)
(2)
(3)
(4)
CAUTION:
Be careful not to deform the holder.
Cylinder side of steering body

Air vent hole
Oil seal
Rack
9) Make the ST2 pass through rack, and then

press-in the rack and ST2 using press.
Press-in the rack until ST1 comes in contact with
ST2 and the edge surface of rack is aligned with
that of ST2.
ST1 34199FE050 GUIDE (Turbo and 3.0 R model)
34199AE000 GUIDE (Except for turbo and
3.0 R model)
PS-55

ST 34099FA060
PUNCH HOLDER
13) Apply a coat of grease on the gear teeth of

valve assembly, and then attach the valve assembly taking care not to scratch oil seal and seal ring.
ST
(A)
(B)
ST
PS-00084
(A) Holder
(B) 3 mm (0.12 in)
PS-00086
(1) Seal ring

(2) Oil seal
12) Roll the vinyl tape on serration part of valve assembly, and then apply grease on the tape surface.
14) Apply grease on the oil seal circumference, and

then press it into the plug using ST and press. Replace the O-rings of plug circumference with new
ones.
ST 34199AE110 OIL SEAL PLUG INSTALLER
CAUTION:
Install the oil seal paying attention to its direction.
PS-00085
(1) Vinyl tape
PS-00087
(1) Plug
(2) O-ring
(3) Oil seal
PS-56

15) Using the ST, install plug.

ST 34199AE090 PLUG WRENCH

steering body.
Tightening torque:
64 Nm (6.5 kgf-m, 47.0 ft-lb)
(3)
(2)
(1)
PS-00167
(1) Sleeve
(2) Spring
(3) Adjusting screw

Tightening torque:
9.8 Nm (1.0 kgf-m, 7.2 ft-lb)
specified tightening torque, loosen it.
Tightening torque:
4.9 Nm (0.50 kgf-m, 3.6 ft-lb)
specified tightening torque, loosen 37 it.
PS-00088
(1) Plug
Tightening torque:
4.9 Nm (0.50 kgf-m, 3.6 ft-lb)
22) Remove the tie-rod.
to PS-61, LIMIT, INSPECTION, Steering Gearbox
[RHD Model].>
16) Install the dust cover. Remove the vinyl tape.
(1)
Liquid gasket:
PS-00497
(1) Dust cover
17) Temporarily install the tie-rod to the rack, and

then operate it from lock to lock two or three times
to make it fit in. Remove the grease blocking air
vent hole.
CAUTION:
If operating the rack from lock to lock without
installing tie-rod, it may damage the oil seal. Always install the tie-rods LH and RH.
sleeve and seating surface of spring, and then insert the sleeve into spring body.
PS-57
PS-00092

perimeter.

25) Install the lock nut. While holding adjusting

ST 926230000
SPANNER
39 Nm (4.0 kgf-m, 28.9 ft-lb)
28) Caulk the boot so the space inside boot band

caulking portion becomes 2 mm (0.08 in) or less.
NOTE:
Use a new boot band.
NOTE:
26) Install the tie-rod into rack.
Tightening torque:
90 Nm (9.0 kgf-m, 65.1 ft-lb)
NOTE:
Check the mating face of rack and tie-rod for foreign material, dirt and etc.
27) Apply a coat of grease to the tie-rod groove,
and then install the boot to housing.
(B)
(A)
NOTE:
Make sure that the boot is installed without unusual
inflation or deflation.
PS-00499
(A) Boot band

(B) 2 mm (0.08 in) or less
29) Fix the boot end with clip (small).

PS-00094
PS-00053
(1) Clip
30) After installing, check that the boot end is positioned into groove on tie-rod.
31) If the tie-rod end has been removed, screw in
lock nut and tie-rod end to the screwed portion of
tie-rod, and tighten the lock nut temporarily in a position as shown in figure.
PS-58

Installed tie-rod length L:

31 mm (1.22 in)
PS-00097
32) Inspect the 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 the boot is installed in the
specified position without deflation.
PS-00098
33) Take off the gearbox from ST.

ST1 926200000 STAND
34) Install the pipe A and B to steering body and
control valve housing.
Tightening torque:
T1: 20 Nm (2.0 kgf-m, 14.5 ft-lb)
T2: 24 Nm (2.4 kgf-m, 17.4 ft-lb)
T1
T1
T2
(2)
T2
(1)
PS-00500
(1) Pipe A
(2) Pipe B
PS-59

E: INSPECTION
1. BASIC INSPECTION
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.
Parts
Input shaft
Dust seal
Rack & Pinion
INSPECTION
(1) Bend of input shaft
(2) Damage on serration
(1) Crack or damage
(2) Wear
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
Boot
Tie-rod
Tie-rod end
9
10
Adjusting screw
spring
Boot clip
Sleeve
11
Pipes
Crack, damage or deterioration

(1) Looseness of ball joint
(2) Bend of tie-rod
Damage or deterioration on dust
seal
Corrective action
If the bend or damage is excessive, replace the entire
gearbox.
If the outer wall slips, the lip is worn out or damage is
found, replace it with a new one.
(1) Adjust the backlash properly.
By measuring turning torque of gearbox and sliding resistance of rack, check if rack & 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
the entire gearbox.
Replace the gearbox with a new one.
If the free play of rack shaft in radial direction is out of the
specified range, replace the gearbox with new one. (Refer
to Service limit.)
If the free play of rack shaft in radial and axial direction is
out of the specified range, replace the gearbox with a new
one. (Refer to Service limit.)
Replace.
Replace.
Replace.
Deterioration
Replace.
Deterioration
Damage
(1) Damage to flared surface
(2) Damage to flare nut
(3) Damage to pipe
Replace.
Replace.
PS-60
Replace.

2. LIMIT
specified service limit, adjust or replace.
On condition
L: 5 mm (0.20 in)
P: 98 N (10 kgf, 22 lb)
NOTE:
When making a measurement, vise the gearbox
using ST. Never vise the gearbox by inserting aluminum plates, etc. between vise and gearbox.
ST1 926200000 STAND
P
Sliding resistance of rack shaft:
(1)
(4)
(2)
Limit
314 N (32 kgf, 71 lb) or less
(3)

20% or less
(1)
(2)
(3)
(4)
PS-00326
Under the step

Right-turn steering
Measure point
Right
Left-turn steering:
(1)
Limit
Direction
PS-00324
(1) Right-turn steering

P
(1)
(2)
(1)
(3)
(4)
L
PS-00327
(1)
(2)
(3)
(4)
PS-00325
(1) Left-turn steering
3. RACK SHAFT PLAY IN RADIAL DIRECTION
Under the step

Left-turn steering
Measure point
Left
4. INPUT SHAFT PLAY

In radial direction:
Limit
0.18 mm (0.0071 in) or less
Right-turn steering:
Limit
Direction
Direction
PS-61

On condition
P: 98 N (10 kgf, 22 lb)
PS-00328
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)
PS-00329
5. TURNING RESISTANCE OF GEARBOX

Using the ST, measure the gearbox turning resistance.
ST 34099PA100 SPANNER
Service limit:
Maximum allowable resistance:
13 N (1.3 kgf, 9.6 lb) or less
Difference between right and left turning resistance:
20% or less
ST
PS-00330
PS-62

6. OIL LEAKING
(5)
a
b
(1)
(6)
(4) (3) (2)
PS-00331
(1)
(2)
Power cylinder
Cylinder
(3)
(4)
Rack piston
Rack axle

2) Even if the location of leak can be easily found
by observing leaking condition, it is necessary to
thoroughly remove the oil from suspected portion
and turn steering wheel from lock to lock about 30
to 40 times with engine running, then reinspect the
suspected portion immediately after and several
hours after this operation.
3) Cause and measure for oil leakage from a
The oil seal is damaged. Replace the valve assembly with a new one.
4) Cause and measure for oil leakage from b
The torsion bar O-ring is damaged. Replace the
valve assembly with a new one.
5) Cause and measure for oil leakage from c
The oil seal is damaged. Replace the oil seal with a
new one.
6) Cause and measure for oil leakage from d
The pipe is damaged. Replace the faulty pipe or Oring.
(5)
(6)
Input shaft
Valve housing
F: ADJUSTMENT
1) Adjust the front toe.
Standard of front toe:
IN 3 OUT 3 mm (IN 0.12 OUT 0.12 in)
PS-00107
(1) Lock nut
2) Adjust the steering angle of wheels.

Standard of steering angle:
Model
Inner
wheel
Outer
wheel
PS-63
2.0 i, 2.5 i
2.0 GT, 3.0 R
OUTBACK
37.31.5
37.21.5
37.81.5
33.01.5
32.91.5
33.51.5


when wheels are set in the straight ahead position,
or error is more than 5 on the periphery of steering
wheel, correctly re-install the steering wheel.
(1)
PS-00513
(1) Within 5

with vehicle set in the straight ahead position after
this adjustment, correct it by turning the right and
left tie-rods in the opposite direction each other by
the same angle.
PS-64
Pipe Assembly [LHD Model]

7. Pipe Assembly [LHD Model]
5) Disconnect the return hose and pipe D, pressure

hose and pipe C.
A: REMOVAL
crossmember support plate and jack-up plate.
(4)
(3)
(2)
(1)
(2)
(1)
FS-00105
(1)

(2) Jack-up plate
3) Remove one pipe joint at the center of gearbox,

and connect the vinyl hose to the pipe and the joint.
Discharge the fluid by turning steering wheel fully
clockwise and counterclockwise. Discharge the fluid similarly from other pipes.
PS-00538
(1)
(2)
(3)
(4)
Pipe C
Pipe D
Pressure hose
Return hose

Duct.>
7) Disconnect the suction hose and pressure hose
from oil pump.
(1)
(2)
PS-00553
(1) Pipe A
(2) Pipe B
(1)
4) Remove the clamp E from return hose and pressure hose.

(2)
(3)
PS-00460
(2)
(1) Suction hose

(2) Pressure hose
(1)
PS-00537
(1) Return hose

(2) Pressure hose
(3) Clamp E
PS-65

8) Disconnect the suction hose and return hose

from reservoir tank. Remove the oil cooler from oil
cooler bracket.
CAUTION:
Align the installation position of the resin clip
with the protector edge of suction hose.
(4)
(2)
(3)
(5)
(1)
(3)
(1)
(4)
(2)
PS-00482
(1)
(2)
(3)
(4)
(5)
PS-00455
Reservoir tank
Suction hose
Return hose
Oil cooler
Oil cooler bracket
(1)
(2)
(3)
(4)
9) Remove the hose bracket and take out the hose

assembly from vehicle.
Resin clip
Protector
Suction hose
Pressure hose
3) Connect the suction hose and return hose to reservoir tank. Install the oil cooler to oil cooler bracket.
CAUTION:
Firmly insert the resin clip of return hose to the
bracket.
(2)
(4)
(3)
(1)
(5)
PS-00451
(1)
(1) Hose ASSY

(2) Hose bracket
(2)
PS-00482
B: INSTALLATION
(1)
(2)
(3)
(4)
(5)
1) Temporarily tighten the bolt of hose bracket.
(2)
Reservoir tank
Suction hose
Return hose
Oil cooler
Oil cooler bracket
4) Connect the suction hose and pressure hose to

the oil pump. Tighten the eye bolt of pressure hose.
(1)
PS-00451
(1) Hose ASSY

(2) Hose bracket
2) Install the resin clip to the pressure hose and

suction hose.
PS-66

Tightening torque:
39 Nm (4.0 kgf-m, 28.9 ft-lb)
NOTE:
Ensure that the letter 8 on each clamp are diagonally opposite each other as shown in the figure.
(1)
(1)
(2)
(3)
(2)
PS-00460
PS-00540
(1) Suction hose

(2) Pressure hose
5) Temporarily connect the pressure hose and pipe

C, the return hose and D. Place the clamp E in the
position shown in the figure, and tighten the bolt
temporarily.
(3)
(1) Clamp E
(2) Pressure hose
(3) Return hose
6) Tighten the clamp E.

Tightening torque:
7.4 Nm (0.75 kgf-m, 5.4 ft-lb)
7) Tighten the pressure hose and pipe C, the return
hose and pipe D.
Tightening torque:
15 Nm (1.5 kgf-m, 10.8 ft-lb)
8) Connect the pipe A and B to the four pipe joints
of gearbox.
(1)
Tightening torque:
13 Nm (1.3 kgf-m, 9.4 ft-lb)
(2)
(6)
(4)
(5)
(1)
(2)
PS-00553
PS-00539
(1)
(2)
(3)
(4)
(5)
(6)
Return hose
Pressure hose
Approx. 18 mm (0.71 in)
Clamp E
Pipe C
Pipe D
(1) Pipe A
(2) Pipe B

jack-up plate.
11) Tighten the bolts which hold the hose bracket.
PS-67

Tightening torque:
13 Nm (1.3 kgf-m, 9.4 ft-lb)
(2)
(1)
PS-00451
(1) Hose ASSY

(2) Hose bracket

<Ref. to IN(H4DOTC)-9, INSTALLATION, Air Intake Duct.> <Ref. to IN(H4SO 2.0)-9, INSTALLATION, Air Intake Duct.>
14) Feed the specified fluid.
CAUTION:
Never start the engine before feeding the fluid;
otherwise vane pump might be seized up.
15) Finally, check clearance between pipes or hoses as shown in the figure indicated in General Diagnostic Table. <Ref. to PS-89, INSPECTION OF
CLEARANCE, INSPECTION, General Diagnostic
Table.>
PS-68

C: INSPECTION
Check all disassembled parts for wear, damage or other abnormalities. Repair or replace defective parts as
necessary.
Parts
Pipe
Clamp
Hose
Maintenance Parts
O-ring fitting surface for damage
Nut for damage
Pipe for damage
Clamps for weak clamping force
Flare surface for damage
Flare nut for damage
Outer surface for cracks
Outer surface for wear
Clip for damage
End coupling or adapter for deformation
Corrective action
Replace with a new one.
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. 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 areas and 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.
Trouble
Pressure hose burst
Forced out return hose
Fluid bleeding out of hose

slightly
Possible cause
Excessive holding time of relief status
Malfunction of relief valve
Poor cold characteristic of fluid
Poor connection
Poor holding of clip
Wrong layout, tensioned
Excessive play of engine due to deterioration of
engine mounting rubber
Improper stop position of pitching stopper
Crack on hose
Excessive tightening torque of return hose clip

Power steering fluid, engine oil, electrolyte adhere
on the hose surface
Too many times use in extremely cold weather
PS-69
Corrective action
Instruct customers.
Replace oil pump.
Replace fluid.
Repair.
Retighten.
Replace fluid.
Replace hose.
Replace the parts if defective.
Replace.
Instruct customers.
Replace.
Replace.
Pay attention on service work.
Replace.
Instruct customers.

NOTE:
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.
(B)
(A)
(7)
(11)
(22)
(15)
(16)
(14)
(18)
(8)
(3)
(19) (2)
(21)
(17)
(12)
(4)
(1)
(5)
(20)
(6)
(9)
(10)
(13)
PS-00541
(A)
3.0 L model
Fluid leaking area
(B)
Crack or damage in hose

Crack or damage in hose hardware
Damaged O-ring
Corrective action
Loosen and retighten. Replace if ineffective.
Retighten or replace the clamp.
Replace O-ring or gasket pipe or hose
with new one, if ineffective, replace the
gearbox also.
Replace the oil pump.
Damaged gasket
Crack in oil tank
Replace the oil tank.
Leakage from filler neck (18)
Damaged cap packing

Crack in root of filler neck
High fluid level
Replace the cap.

Adjust the fluid level.
Leakage from surrounding of power

cylinder of gearbox (19) in figure
Damaged oil seal
Replace the oil seal.
Leakage from control valve of gearbox (20) and (21) in figure
Damaged packing or oil seal

Damage in control valve
Replace the problem parts.

Replace the control valve.
(22) Leakage from connecting portion of cooler pipe and hose.
Insufficient tightening of connecting portion.
Loosen and retighten.
Leakage from connecting portions of

pipes and hoses, numbered with (1)
through (8) in figure
Leakage from hose (9) through (13) in

figure
Leakage from surrounding of cast iron
portion of oil pump (14) and (15) in
figure
Leakage from oil tank (16) and (17) in
figure
Possible cause
Insufficient tightening of flare nut, adhesion of
dirt, damage to flare or flare nut or eye bolt
Poor insertion of hose or clamping
Damaged O-ring or gasket
PS-70
Pipe Assembly [RHD Model]

8. Pipe Assembly [RHD Model]
4) Remove the clamp E from the return hose and

pressure hose.
A: REMOVAL
crossmember support plate and jack-up plate.
Large type
(2)
(1)
(3)
(1)
PS-00445
Small type
PS-00542
(1) Return hose

(2) Pressure hose
(3) Clamp E
5) Disconnect the return hose and pressure hose

from gearbox.
(1)
(2)
(1)
FS-00105

(2) Jack-up plate
3) Remove one pipe joint at the center of gearbox,

and connect the vinyl hose to the pipe and the joint.
Discharge the fluid by turning steering wheel fully
clockwise and counterclockwise. Discharge the fluid similarly from other pipes.
(2)
(1)
(1)
(2)
PS-00446
PS-00543
(1) Pipe A
(2) Pipe B
(1) Return hose

(2) Pressure hose
PS-71


Duct.>
7) Disconnect the suction hose and pressure hose
from the oil pump.
Non-turbo model
9) Remove the hose bracket and take out the hose

assembly from vehicle.
(2)
(1)
(1)
PS-00451
(1) Hose ASSY

(2) Hose bracket
(2)
B: INSTALLATION
PS-00460
1) Temporarily tighten the bolt of hose bracket.
Turbo model
(2)
(1)
(1)
(2)
PS-00451
PS-00452
(1) Hose ASSY

(2) Hose bracket
(1) Suction hose

(2) Pressure hose
8) Disconnect the suction hose and return hose

from reservoir tank. Remove the oil cooler from oil
cooler bracket.
(4)
(3)
2) Install the resin clip to the pressure hose and

suction hose.
CAUTION:
Align the installation position of the resin clip
with the protector edge of suction hose.
Non-turbo model
(5)
(2)
(1)
(1)
(2)
(3)
PS-00482
(4)
(1)
(2)
(3)
(4)
(5)
Reservoir tank
Suction hose
Return hose
Oil cooler
Oil cooler bracket
PS-00455
(1)
(2)
(3)
(4)
PS-72
Resin clip
Protector
Suction hose
Pressure hose

Non-turbo model
Turbo model
(1)
(2)
(1)
(4)
(2)
(3)
PS-00456
(1)
(2)
(3)
(4)
PS-00460
Resin clip
Protector
Suction hose
Pressure hose
(1) Suction hose

(2) Pressure hose
Turbo model
3) Connect the suction hose and return hose to reservoir tank. Install the oil cooler to oil cooler bracket.
CAUTION:
Firmly insert the resin clip of return hose to the
bracket.
(1)
(4)
(3)
(2)
(5)
(1) Suction hose

(2) Pressure hose
(1)
(2)
PS-00482
(1)
(2)
(3)
(4)
(5)
Reservoir tank
Suction hose
Return hose
Oil cooler
Oil cooler bracket
4) Connect the suction hose and pressure hose to

the oil pump. Tighten the eye bolt of pressure hose.
Tightening torque:
39 Nm (4.0 kgf-m, 28.9 ft-lb)
PS-73
PS-00452

5) Temporarily connect the return hose and pressure hose to gearbox. Place the clamp E in the position shown in the figure, and tighten the bolt
temporarily.
7) Tighten the joint nut.

Tightening torque:
15 Nm (1.5 kgf-m, 10.8 ft-lb)
8) Connect the pipe A and B to the four pipe joints
of gearbox.
Tightening torque:
13 Nm (1.3 kgf-m, 9.4 ft-lb)
(4)
(1)
(2)
(2)
PS-00446
(1)
(3)
(1) Pipe A
(2) Pipe B

jack-up plate.
11) Tighten the bolts which hold the hose bracket.
PS-00467
(1)
(2)
(3)
(4)
Return hose
Pressure hose
Approx. 27 mm (1.06 in)
Clamp E
Tightening torque:
13 Nm (1.3 kgf-m, 9.4 ft-lb)
NOTE:
Ensure that the letter 8 on each clamp are diagonally opposite each other as shown in the figure.
(2)
(1)
(1)
PS-00451
(2)
(3)
(1) Hose ASSY

(2) Hose bracket
PS-00540
(1) Clamp E
(2) Pipe C
(3) Return hose
6) Tighten the clamp E.

Tightening torque:
7.4 Nm (0.75 kgf-m, 5.4 ft-lb)

14) Feed the specified fluid.
CAUTION:
PS-74

15) Finally, check clearance between pipes or hoses as shown in the figure indicated in General Diagnostic Table. <Ref. to PS-89, INSPECTION OF
CLEARANCE, INSPECTION, General Diagnostic
Table.>
C: INSPECTION
Check all disassembled parts for wear, damage or other abnormalities. Repair or replace defective parts as
necessary.
Parts
Pipe
Clamp
Hose
Maintenance Parts
O-ring fitting surface for damage
Nut for damage
Pipe for damage
Clamps for weak clamping force
Flare surface for damage
Flare nut for damage
Outer surface for cracks
Outer surface for wear
Clip for damage
End coupling or adapter for deformation
Corrective action
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. 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 areas and 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.
Trouble
Pressure hose burst
Forced out return hose
Fluid bleeding out of hose

slightly
Possible cause
Malfunction of relief valve
Poor connection
Poor holding of clip
Wrong layout, tensioned
Excessive play of engine due to deterioration of
engine mounting rubber
Improper stop position of pitching stopper
Crack on hose
Excessive tightening torque of return hose clip

Power steering fluid, engine oil, electrolyte adhere
on the hose surface
Too many times use in extremely cold weather
PS-75
Corrective action
Instruct customers.
Replace oil pump.
Replace fluid.
Repair.
Retighten.
Replace fluid.
Replace hose.
Replace.
Instruct customers.
Replace.
Replace.
Pay attention on service work.
Replace.
Instruct customers.

NOTE:
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.
(A)
(B)
(10)
(11)
(22)
(15)
(16)
(14)
(18)
(9)
(3)
(17)
(19)
(6)
(5)
(12)
(20)
(4)
(1)
(7)
(2)
(21)
(8)
(13)
PS-00562
(A)
3.0 L model
Fluid leaking area
(B)
Crack or damage in hose

Crack or damage in hose hardware
Damaged O-ring
Corrective action
Loosen and retighten. Replace if ineffective.
Retighten or replace the clamp.
Replace O-ring or gasket pipe or hose
with new one, if ineffective, replace the
gearbox also.
Damaged gasket
Crack in oil tank
Leakage from filler neck (18)
Damaged cap packing

Crack in root of filler neck
High fluid level
Replace the cap.

Adjust the fluid level.
Leakage from surrounding of power

cylinder of gearbox (19) in figure
Damaged oil seal
Replace the oil seal.
Leakage from control valve of gearbox (20) and (21) in figure
Damaged packing or oil seal

Damage in control valve

Replace the control valve.
(22) Leakage from connecting portion of cooler pipe and hose.
Insufficient tightening of connecting portion.
Loosen and retighten.
Leakage from connecting portions of

pipes and hoses, numbered with (1)
through (10) in figure
Leakage from hose (11), (12) and

(13) in figure
Leakage from surrounding of cast iron
portion of oil pump (14) and (15) in
figure
Leakage from oil tank (16) and (17) in
figure
Possible cause
Insufficient tightening of flare nut, adhesion of
dirt, damage to flare or flare nut or eye bolt
Poor insertion of hose or clamping
Damaged O-ring or gasket
PS-76
Oil Pump
9. Oil Pump
Turbo model
A: REMOVAL
Duct.>
3) Remove the pulley belt cover.
4) Loosen the belt tension securing bolt and generator securing bolt, and then remove the power
steering pump V-belt.
(1)
(2)
PS-00459
(1) Suction hose

(2) Pressure hose
7) Remove the bolts which hold the power steering

pump bracket.
PS-00461

pump switch.
6) Disconnect the pressure hose and suction hose
from oil pump.
CAUTION:
Do not allow fluid to come into contact with
pulley belt.
To prevent foreign matter from entering the
hose and pipe, cover the open ends with a
clean cloth.
Non-turbo model
PS-00188
8) Place the oil pump bracket in a vise, and remove

the two bolts from the front side of oil pump.
CAUTION:
When securing the oil pump bracket in a vice,
hold the oil pump bracket with the least possible force between two wood pieces.
(1)
(2)
PS-00460
(1) Suction hose

(2) Pressure hose
PS-00128
9) Remove the bolt from the rear side of oil pump.
PS-77
Oil Pump
10) Disassemble the oil pump and bracket by inserting a flat tip screwdriver as shown in the figure.
Tightening torque:
37.3 Nm (3.8 kgf-m, 27.5 ft-lb)
PS-00137
PS-00129
B: INSTALLATION
1) Install the oil pump to bracket.
(1) Place the oil pump bracket in a vise. Tighten
the bushing using a 12.7 mm (1/2) type 14- and
21-mm box wrench until it contact with oil pump
mounting surface.
2) Tighten the bolts which hold the power steering

pump bracket.
CAUTION:
When securing the oil pump bracket on a vice,
hold the oil pump bracket with the least possible force between two wood pieces.
PS-00188
3) Interconnect the pressure hose and suction

hose.
Tightening torque:
Eye bolt
39 Nm (4.0 kgf-m, 28.9 ft-lb)
CAUTION:
If a hose is twisted at this step, take care the
hose may come into contact with some other
parts.
Non-turbo model
PS-00135
(1)
(2)
(3)
(4)
(5)
Bushing
Nut
21 mm
14 mm
Bolt
(1)
(2) Tighten the bolt which holds the oil pump to

bracket.
Tightening torque:
15.7 Nm (1.6 kgf-m, 11.6 ft-lb)
(2)
PS-00460
(1) Suction hose

(2) Pressure hose
PS-00128
PS-78
Oil Pump
Turbo model
(1)
(2)
PS-00459
(1) Suction hose

(2) Pressure hose

switch.
5) Install the V-belts to oil pump.
6) Check the tension of V-belt.
<Ref. to ME(H4SO 2.0)-39, INSPECTION, V-belt.>
7) Tighten the belt tension bolt.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
8) Install the pulley belt cover.
11) Feed the specified power steering fluid. <Ref.
CAUTION:
PS-79
Oil Pump
C: INSPECTION
1. BASIC INSPECTION
Perform the following inspection procedures and replace defective parts.
No.
Parts
Oil pump (Exterior)
INSPECTION
(1) Crack, damage or oil leakage
(2) Play of pulley shaft
(1) Damage
Pulley
(2) Bend
(1) Defect or burning of vane pump

3
Oil pump (Interior)

(2) Bend in the shaft or damage to
bearing
4
5
O-ring
Bracket
Crack or deterioration
Crack
2. SERVICE LIMIT
service limit, replace with a new one.
Corrective action
Replace the oil pump with a new one.
Measure the radial play and axial play.
If any of these exceeds the service limit, replace the
oil pump with a new one.
Measure the V ditch deflection.
If it exceeds the service limit, replace the pulley with a
new one.
Check the resistance to the rotation of pulley.
If it exceeds the service limit, replace the 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 its pulley which is put around with a
string, replace the oil pump with a new one.
Service limit:
Radial play (Direction
)
CAUTION:
When securing the oil pump on a vice, hold
the oil pump with the least possible force between two wood pieces.
Do not set outside of flow control valve or
pulley on a vice; otherwise outside or pulley
might be deformed. Select properly sized wood
pieces.
1) Play of the pulley shaft
(1)
Condition:
P: When applying the force of 9.8 N (1.0 kgf,
2.2 lb)
PS-00145
(1) Dial gauge
Axial play (Direction

)
(1)
(1) Dial gauge
PS-80
PS-00146
Oil Pump
2) Ditch deflection of pulley

Service limit:
NOTE:
Read the value for one surface of V ditch, and then
the value for another off the dial.
Put cloth at a place where fluid drops before

pressure gauge is installed. Wipe off spilt fluid thoroughly after the measurement.
1) Regular pressure measurement
(1) Connect ST1, ST2 and ST3.
ST1 925711000 PRESSURE GAUGE
ST2 34099AC020 ADAPTER HOSE B
ST3 34099AC010 ADAPTER HOSE A
(2) Remove the air intake duct.
(3) Disconnect the pipe C from pump.
(4) Using the gasket (Part No. 34621AC021)
and bolt (Part No. 34620AC010), install the ST2
to pump instead of pressure hose.
Non-turbo model
(1)
PS-00147
(1) Dial gauge
3) Resistance to rotation of pulley

Service limit:
Maximum load: 9.22 N (0.94 kgf, 2.07 lb) or
less
(2)
PS-00460
NOTE:
A rather higher value may be indicated when pulley starts turning.
Measure the load during rotation to make a judgment.
(1) Suction hose

(2) Pressure hose
Turbo model
(1)
(2)
PS-00148
PS-00459
(1) Suction hose

(2) Pressure hose
(1) Spring balance
3. HYDRAULIC PRESSURE
NOTE:
Be sure to complete all items aforementioned in
INSPECTION, prior to measuring hydraulic pressure. Otherwise, pressure cannot be measured
correctly. <Ref. to PS-85, 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.
PS-81
(5) Install the ST3 to the end of pressure hose

which is removed from pump.
(6) Replenish the power steering fluid up to
specified level.
(7) Open the valve, and start the engine.
Oil Pump
3) Measure working pressure.

(1) Using the STs, measure the working pressure.
(2) Open the valve.
(3) Measure the working pressure of control
valve by turning steering wheel from stop to
stop.
(8) Measure the regular pressure.

PS-00152
(1) Valve
Service limit:
981 kPa (10 kg/cm2, 142 psi) or less
(9) If it is not within the specified value, replace
the troubled part caused by following symptoms.
(Pipe or hose clogged, leaks from fluid line, and
mixture of foreign matters in fluid line)
2) Measure the relief pressure.
(1) Using the STs, measure the relief pressure.
(2) Close the valve.
(3) Measure the relief pressure.
PS-00152
(1) Valve
Service limit:
7,650 8,330 kPa (78 85 kg/cm2, 1,110
1,208 psi)
(4) If it is not within the specified value, measure the steering effort. <Ref. to PS-88, MEASUREMENT
OF
STEERING
EFFORT,
INSPECTION, General Diagnostic Table.> If it is
not within specified value, replace the control
valve itself or control valve and pinion as a single unit with new ones.
PS-00153
(1) Valve
Service limit:
Non-turbo model (Except for 3.0 R model):
6,767 7,453 kPa
(69 76 kg/cm2, 981 1,081 psi)
Turbo model:
7,350 8,036 kPa
(75 82 kg/cm2, 1,067 1,165 psi)
3.0 R model:
8,300 9,000 kPa
(85 92 kg/cm2, 1,204 1,305 psi)
(4) If it is not within the specified value, replace
the oil pump.
PS-82
Reservoir Tank
10.Reservoir Tank
C: INSPECTION
A: REMOVAL
Check the reservoir tank for cracks, breakage and

damage. If a failure is found, replace the reservoir
tank.
1) Drain fluid from the reservoir tank.

2) Disconnect the hose from reservoir tank.
CAUTION:
To prevent foreign matter from entering the
hose and pipe, cover the open ends of them
with a clean cloth.
(4)
(3)
(5)
(1)
(2)
PS-00482
(1)
(2)
(3)
(4)
(5)
Reservoir tank
Suction hose
Return hose
Oil cooler
Oil cooler bracket
3) Remove the reservoir tank from body.
B: INSTALLATION
1) Install the reservoir tank to body.
Tightening torque:
13 Nm (1.3 kgf-m, 9.4 ft-lb)
2) Connect the hose to reservoir tank.
(4)
(3)
(5)
(1)
(2)
PS-00482
(1)
(2)
(3)
(4)
(5)
Reservoir tank
Suction hose
Return hose
Oil cooler
Oil cooler bracket
3) Feed the power steering fluid to specified level.

<Ref. to PS-84, Power Steering Fluid.>
PS-83
Power Steering Fluid

11.Power Steering Fluid

A: SPECIFICATION
Recommended power steering fluid
Manufacturer
B.P.
CALTEX
CASTROL
MOBIL
SHELL
TEXACO
B: INSPECTION
1) Check the power steering fluid for deterioration
and contamination. If the fluid is highly deteriorated
or contaminated, drain it and refill with new fluid.
2) Check the joints and units for oil leakage. If any
oil leaks are found, repair or replace the applicable
part.
3) Inspect the fluid level on flat and level surface
with engine OFF by indicator of reservoir tank.
If the level is at MIN. point or below, add fluid to
keep the level in the specified range of the indicator. If at MAX. point or above, drain fluid by using
a syringe or the like.
(1) Check at power steering fluid temperature
20C (68F); read the fluid level on the COLD
side.
(2) Check at power steering fluid temperature
80C (176F); read the fluid level on the HOT
side.
6) If turning the steering wheel in low fluid level

condition, air will be sucked in pipe. In this case,
leave it about half an hour and then do the step 5)
again.
8) Continue to turn the steering wheel slowly from
lock to lock again until the bubbles stop appearing
on oil surface while keeping the fluid at the level in
Step 4).
Normally bubbles stop appearing after three times
turning of steering wheel from lock to lock.
9) In case bubbles do not stop appearing in the
tank, leave it about half an hour and then do the
step 4) all over again.
10) Lower the vehicle, and then idle the engine.
11) Continue to turn the steering wheel from lock to
lock until the bubbles stop appearing and change of
the fluid level is within 3 mm (0.12 in).
12) In case the following happens, leave it about
half an hour and then do step 8) to 11) 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.
13) Check the fluid leakage after turning steering
wheel from lock to lock with engine running.
HOT MAX
COLD MAX
HOT MIN
COLD MIN
PS-00463
C: REPLACEMENT
2) Remove the crossmember support.
3) Remove the pipe joint in the center of gearbox,
and connect the vinyl hose to the pipe and joint.
Wipe fluid off while turning the steering wheel.
4) Add the specified fluid to reservoir tank at MAX
level.
5) Continue to turn the steering wheel slowly from
lock to lock until the bubbles stop appearing on oil
surface while keeping the fluid at the level in the
Step 4).
PS-84


A: INSPECTION
Trouble
Heavy steering effort in all
ranges
Heavy steering effort at
stand still
Steering wheel surges when
turning.
Vehicle leads to one side or

the other
Poor return of steering wheel
to center
Steering wheel surges when
turning.
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 wheel
Improper tires out of specification*1
Improper wheel out of specification*1
Tires not properly inflated
3. Fluid
Low fluid level
Aeration
Dust mix
Deterioration of fluid
Poor warming-up of fluid *2
4. Idle speed
Lower idle speed
Excessive drop of idle speed at start or at turning steering
wheel *3
5. Measure hydraulic pressure. <Ref. to PS-80, INSPECTION,
Oil Pump.>
6. Measure steering effort. <Ref. to PS-88, MEASUREMENT
OF STEERING EFFORT, INSPECTION, General Diagnostic
Table.>
1. Fluid line
Folded hose
Flattened pipe
2. Tire and wheel
Flat tire
Mix use of different tires
Mix use of different wheels
Abnormal wear of tire
Unbalance of remained grooves
Unbalance of tire pressure
3. Front alignment
Improper or unbalance caster
Improper or unbalance toe-in
Loose connection of suspension
4. Others
Damaged joint assembly
Unbalanced height
Unbalanced weight
5. Measure steering effort. <Ref. to PS-88, MEASUREMENT
OF STEERING EFFORT, INSPECTION, General Diagnostic
Table.>
Corrective action
Adjust or replace.
Replace or reinflate.
Refill, bleed air, replace or

instruct customer.
Adjust or instruct customer.

Adjust or replace.
Correct or replace.
Adjust, fix or replace.
Adjust or retighten.
Replace, adjust or instruct customer.
Adjust or replace.
*1 If the tires or wheels are wider than specifications, the load to power steering system is increased. 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 the 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 the
steering wheel from stop to stop several times to warm-up fluid. Then if steering effort reduces normally, there is no abnormal
thing.
PS-85

*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.
1. NOISE AND VIBRATION

CAUTION:
Do not keep the relief valve operated over five 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 turning the steering wheel with service brake and/or parking brake applied, the noise is generated
by creaking between disc and pads. However this does not indicate abnormal function in 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.
These phenomena do not indicate there are some abnormal functions in the system.
Confirm the vibration by turning the steering wheel repeatedly at various speeds from slow to rapid step by
step with parking brake applied on concrete road and in D range for AT model.
Trouble
Hiss noise (continuous)
While engine is running.
Possible cause
Relief valve emits operating sound when steering wheel is
completely turned in either direction. (Do not keep this
condition over five seconds.)
Relief valve emits operating sound when steering wheel is
not turned. This means that the relief valve is defective.
Interference with adjacent parts
Rattling noise (intermittent)

Knocking
When turning steering wheel in
both directions with small angle
repeatedly at engine ON or OFF.
Normal Operation
Check the clearance.
Correct if necessary.
<Ref. to PS-69, INSPECTION,
Pipe Assembly [LHD Model].>
Loosened installation of oil pump, oil tank, pump bracket,

gearbox or crossmember
Loosened installation of oil pump pulley or other pulley(s)
Loosened linkage or play of steering or suspension Loosened tightening of joint or steering column
Retighten.
Sound generates from the inside of gearbox or oil pump.
Replace the faulty parts of the

gearbox or oil pump.
Excessive backlash
Loosened lock nut for adjusting backlash
Adjust and retighten.
Loosened tightening or play of tie-rod, tie-rod end
Vane pump aeration

Grinding noise (continuous)
Corrective action
Vane pump seizing

Pulley bearing seizing of oil pump
Folded hose, flattened pipe
PS-86
Retighten.
Inspect and retighten the fluid

line connection.
Refill the fluid and vent air.
Replace.

Trouble
Squeal, squeak (intermittent or
continuous)
Sizzling noise (continuous)

Whistle (continuous)
Whine or growl (intermittent or
continuous)
While engine is running with/
without steering turned.
Grinding noise (continuous)

While engine is running with the
steering turned.
Vibration
While engine is running with/
without steering turned.
Possible cause
Corrective action
Maladjustment of pulley belt
Adjust or replace.
Damaged or charged pulley belt
(Replace two belts as a set.)
Unequal length of pulley belts
Runout or defacement of V-groove surface of oil pump pulClean or replace.
ley
Fix the wrong part causing aeraFluid aeration
tion.
Replace the fluid and vent air.
Damaged pipe of gearbox
Replace the pipe.
Abnormal inside of hose or pipe
Rectify or replace.
Flattened hose or pipe
Abnormal inside of oil tank
Replace.
Removed oil tank cap
Install cap.
Replace the faulty parts of the
Abnormal pipe of gearbox or abnormal inside of hose
gearbox or hose.
Loosened installation of oil pump, oil pump bracket
Retighten.
Replace the oil pump or hose, if
Abnormal inside of oil pump, hose
the noise can be heard when
running as well as stand still.
Remove the power steering pulTorque converter growl, air conditioner compression growl
ley belt and confirm.
Replace the faulty parts of gearAbnormal inside of gearbox
box.
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
Adjust and instruct customers.
Fix the wrong part.
Vane pump aeration
Vent air.
Replace the oil pump, faulty parts
Damaged valve in oil pump, gearbox
of gearbox.
Looseness of play of steering, suspension parts
Retighten.
PS-87

2. MEASUREMENT OF STEERING EFFORT
10
Step
Check
CHECK STEERING EFFORT.
Is the steering effort less than
1) Stop the vehicle on a concrete road.
29.4 N (3.0 kgf, 6.6 lb)?
4) Install a spring scale on the steering wheel.
5) Pull the spring scale at a right angle to the
steering wheel, and measure both right and left
steering wheel efforts.
NOTE:
When turning the 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 defective.
CHECK STEERING EFFORT.
1) Stop the engine.
2) Pull the spring scale at a right angle to the
steering wheel, and measure both right and left
steering wheel efforts.
CHECK STEERING WHEEL EFFORT.
1) Remove the universal joint.
2) Measure steering wheel effort.
CHECK STEERING WHEEL EFFORT.
Measure steering wheel effort.
Is the steering effort less than

294.2 N (30 kgf, 66.2 lb)?
Yes
Go to step 2.
No
Adjust the backlash.
Go to step 3.
Perform adjustment.
Is steering effort less than 2.26 Go to step 4.

N (0.23 kgf, 0.51 lb)?
Is the difference of steering

effort between clockwise and
counterclockwise less than
20%?
CHECK UNIVERSAL JOINT.
Is the folding torque less than
Measure the folding torque of the joint (yoke of 7.3 N (0.74 kgf, 1.64 lb)?
steering column side). <Ref. to PS-21,
INSPECTION, Universal Joint.>
CHECK UNIVERSAL JOINT.
Is the folding torque less than
Measure the folding torque of the joint (yoke of 3.8 N (0.39 kgf, 0.86 lb)?
gearbox side). <Ref. to PS-21, INSPECTION,
Universal Joint.>
CHECK FRONT WHEEL.
If the front wheels have
Check the front wheel.
unsteady revolution or rattling
and brake for dragging?
CHECK TIE-ROD ENDS.
If the tie-rod ends of suspenRemove the tie-rod ends.
sion have unsteady revolution
or rattling?
CHECK BALL JOINT.
If the ball joints of suspension
Remove the ball joint.
have unsteady revolution or
rattling?
CHECK GEARBOX.
Is the rotating resistance of
Measure the rotating of gearbox.
steering gearbox less than
<Ref. to PS-44, TURNING RESISTANCE OF LHD model: 10.5 N (1.1 kgf,
GEARBOX, INSPECTION, Steering Gearbox 2.4 lbf) or RHD model: 13 N
[LHD Model].> or <Ref. to PS-62, TURNING
(1.3 kgf, 2.9 lbf)? Is the differRESISTANCE OF GEARBOX, INSPECTION, ence between clockwise and
Steering Gearbox [RHD Model].>
counterclockwise less than
20%?
PS-88
Go to step 5.
Check, adjust and

Check, adjust and
Go to step 6.
Replace with a
new one.
Go to step 7.
Replace with a
new one.
Inspect, readjust
and replace if necessary.
Inspect and
Inspect and
Go to step 11.
Go to step 8.
Go to step 9.
Go to step 10.
Readjust the backlash, and if ineffective, replace the

faulty parts.

11
Step
CHECK GEARBOX.
Measure the sliding of gearbox.
<Ref. to PS-43, SERVICE LIMIT, INSPECTION, Steering Gearbox [LHD Model].> or
<Ref. to PS-61, LIMIT, INSPECTION, Steering
Gearbox [RHD Model].>
Check
Yes
Is the sliding resistance of
Steering effort is
steering gearbox less than
normal.
LHD model: 400 N (41 kgf, 90
lbf) or RHD model: 314 N (32
kgf, 71 lbf)? Is the difference
between right and left sliding
resistances less than 20%?
No
Readjust the backlash, and if ineffective, replace the
faulty parts.
3. INSPECTION OF CLEARANCE
This table lists various clearances that must be correctly adjusted to ensure the normal vehicle driving without interfering noise, or any other faults.
LOCATION
(1) Crossmember-to-Hose ASSY
(2) Front exhaust pipe-to-Hose ASSY (Turbo model)
(3) Front frame side-to-Hose ASSY
(4) Turbo cover-to-Hose ASSY (Turbo model)
(5) Master cylinder-to-Return hose (Turbo model)
(6) Master cylinder-to-Hose clip (Model with vehicle dynamics control (VDC))
(7) VDC H/U-to-Hose ASSY (Model with vehicle dynamics control (VDC))
(8) Air cleaner-to-Hose ASSY (Turbo model)
(9) Air boot-to-Hose ASSY
(10) Protector-to-Hose ASSY (Turbo model, DOHC non-turbo model)
(11) Blow-by-to-Hose ASSY (Turbo model)
(12) Over flow hose-to-Hose ASSY (Turbo model)
(13) Brake pipe-to-Return hose (Model with ABS)
(14) Front suspension bracket-to-Return hose
(15) Front wheel apron-to-Return hose
(16) VDC H/U bracket-to-Suction hose (Model with vehicle dynamics control (VDC))
(17) Air cleaner case-to-Suction hose
(18) Air intake duct-to-Suction hose (Turbo model)
(19) Air duct-to-Suction hose (Turbo model)
(20) Front wheel apron-to-Reservoir tank
(21) VDC H/U-to-Reservoir tank (Model with vehicle dynamics control (VDC))
(22) Valve housing-to-DOJ (MT model)
(23) Valve housing-to-Crossmember (Hole)
(24) Bracket-to-Crossmember
(25) Cylinder-to-Crossmember
(26) Elbow-to-Crossmember
(27) Cylinder-to-Exhaust pipe
(28) Universal joint coupling-to-Turbo cover (Turbo model)
(29) Universal joint column side yoke-to-Master cylinder (Closest approach point when universal joint turns by 360) (OUTBACK model)
(30) Cruise control-to-Hose ASSY (Model with cruise control)
(31) Universal joint coupling-to-ATF level gauge (LHD model)
(32) Boot-to-Exhaust pipe (LHD model)
(33) Return hose-to-Pressure hose
PS-89
Minimum allowance mm (in)

3 (0.12)
15 (0.59)
10 (0.39)
10 (0.39)
10 (0.39)
10 (0.39)
5 (0.20)
5 (0.20)
10 (0.39)
10 (0.39)
8 (0.31)
8 (0.31)
10 (0.39)
5 (0.20)
5 (0.20)
5 (0.20)
5 (0.20)
10 (0.39)
10 (0.39)
5 (0.20)
5 (0.20)
12 (0.47)
1 (0.04)
1 (0.04)
5 (0.20)
1 (0.04)
18 (0.71)
15 (0.59)
5 (0.20)
10 (0.39)
10 (0.39)
18 (0.71)
No contact between hoses

LHD model
(19)
(12)
(18)
(17)
(8),(9)
(10),(11),(16)
(27)
(24)
(32)
(1)
(26)
(2)
(7)
(3)
(21)
(6)
(22)
(23)
(20)
(13),(14)
(25)
(15)
(5)
(28),(31)
(33)
(4)
(30)
(29)
PS-00515
RHD model
(12) (19)
(18)
(17)
(8),(9)
(10),(11),(16)
(26)
(24) (27) (1)
(2)
(7)
(3)
(21)
(20)
(13),(14)
(6)
(15)
(25)
(23)
(5)
(22)
(4)
(33)
(28)
(29)
PS-00514
PS-90
BODY SECTION

of SUBARU vehicles.

approval.
HVAC SYSTEM
(HEATER, VENTILATOR AND A/C)
AC
HVAC SYSTEM (AUTO A/C)

(DIAGNOSTICS)
AC(diag)
AIRBAG SYSTEM
AB
AIRBAG SYSTEM (DIAGNOSTICS)
AB(diag)
SEAT BELT SYSTEM
SB
LIGHTING SYSTEM
LI
WIPER AND WASHER SYSTEMS
WW
ENTERTAINMENT
ET
COMMUNICATION SYSTEM
COM
GLASS/WINDOWS/MIRRORS
GW
BODY STRUCTURE
BS
INSTRUMENTATION/DRIVER INFO
IDI
SEATS
SE
SECURITY AND LOCKS
SL
SUNROOF/T-TOP/CONVERTIBLE TOP
(SUNROOF)
SR
EXTERIOR/INTERIOR TRIM
EI
EXTERIOR BODY PANELS
EB
G2320GE7
BODY SECTION
CRUISE CONTROL SYSTEM
CC

(DIAGNOSTICS)
CC(diag)
IMMOBILIZER (DIAGNOSTICS)
IM(diag)
LAN SYSTEM (DIAGNOSTICS)
LAN(diag)
G2320GE7
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.
23.
24.
25.
26.
27.
28.
Page
Refrigerant Pressure with Manifold Gauge Set.........................................19
Refrigerant Recovery Procedure...............................................................20
Refrigerant Charging Procedure ...............................................................21
Refrigerant Leak Check ............................................................................24
Compressor Oil .........................................................................................25
Blower Motor Unit Assembly .....................................................................26
Blower Motor .............................................................................................27
Power Transistor (Auto A/C Model) ..........................................................28
Blower Resistor (Manual A/C Model) ........................................................29
Heater Core...............................................................................................30
Control Unit (Manual A/C Model) ..............................................................31
Control Unit (Auto A/C Model)...................................................................32
Compressor...............................................................................................33
Condenser.................................................................................................35
Heater and Cooling Unit............................................................................36
Evaporator.................................................................................................37
Hose and Tube..........................................................................................38
Relay and Fuse .........................................................................................39
Pressure Switch (Triple Pressure Switch).................................................40
Ambient Sensor (Auto A/C Model) ............................................................41
Sunload Sensor (Auto A/C Model) ............................................................42
In-Vehicle Sensor (Auto A/C Model) .........................................................43
Air Vent Grille ............................................................................................44
Heater Duct ...............................................................................................45
Heater Vent Duct.......................................................................................46
Heater Cock Solenoid Valve .....................................................................47
General Description
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
A: SPECIFICATION
1. HEATER SYSTEM
Item
Specification
On condition
Mode selector switch: HEAT
Temperature control switch: FULL HOT
Temperature difference between hot water
and inlet air: 65C (149F)
Hot water flow rate: 360 2 (95.1 US gal,
79.2 Imp gal)/h
Heating capacity
5.2 kW (4,471 kcal/h,

17,743 BTU/h) or more
Air flow rate
370 m3 (13,066 cu ft)/h
Heat mode (FRESH), FULL HOT at 12.5 V
460 m3 (16,245 cu ft)/h
Temperature control switch: FULL COLD

Blower fan speed:
Auto A/C: 6th position
Manual A/C: 4th position
Mode selector lever: RECIRC
Max air flow rate
264 110 27 mm
(10.4 4.33 1.06 in)
Magnet motor 220 W or less
Sirocco fan type
150 75 mm (5.91 2.95 in)
Heater core size

(height length width)
Type
Blower motor
Fan type and size
(diameter width)
12 V
2. A/C SYSTEM
Auto A/C model
Item
Type of air conditioner
Cooling capacity
Refrigerant
Compressor
Magnet clutch
Type
Discharge
Max. permissible speed
Type
Power consumption
Type of belt
Pulley dia. (effective dia.)
Pulley ratio
Type
Condenser
Core thickness
0.186 m2 (2.002 sq ft)

16 mm (0.63 in)
Radiation area
5.49 m2 (59.09 sq ft)
Core face area
Receiver drier
Effective inner capacity
Expansion valve
Type
Type
Evaporator
Dimensions (W H T)
Blower fan
Specification
Reheat air-mix type
5.3 kW
(4,557 kcal/h, 18,084 BTU/h)
HFC-134a (CH2FCF3)
[0.40.03 kg (0.880.07 lb)]
Scroll, constant volume (SCSA 08C)
74.5 cc (4.55 cu in)/rev
9,000 rpm
Dry, single-disc type
35 W
H4 model: V-belt 4 PK
H6 model: V-belt 6 PK
93 mm (3.7 in)
1.43
Corrugated fin (Sub cool type)
Fan type
Power consumption
AC-2
190 cm3 (11.6 cu in)

Internal equalizing
Single tank
298.6 151 38 mm
(11.76 5.94 1.50 in)
Sirocco fan
150 75 mm (5.91 2.95 in)
220 W
General Description
Motor type
Magnet
H4 model: 90 W
H6 model: 160 W
H4 model: 300 mm (11.8 in)
H6 model: 320 mm (12.6 in)
Magnet
H4 model: 90 W
H6 model: 160 W
H4 model: 300 mm (11.8 in)
H6 model: 320 mm (12.6 in)
800100 rpm
19620 kPa
(2.000.20 kg/cm2, 28.42.9 psi)
Power consumption
Condenser fan (Sub fan)
Fan outer diameter

Motor type
Power consumption
Radiator fan (Main fan)
Fan outer diameter

Idling speed (A/C ON)
MPFI model
ON OFF
Low-pressure switch
operating pressure
Triple switch
High-pressure switch
(Pressure switch) operating pressure
Middle-pressure switch
operating pressure
225+2529 kPa
OFF ON
(2.29+0.250.30 kg/cm2, 32.6+3.64.2 psi)

3,140+50200 kPa
ON OFF
(32.02+0.512.04 kg/cm2, 455.4+7.2529.0 psi)

2,550200 kPa
(26.002.04 kg/cm2, 369.829.0 psi)
1,370120 kPa
(13.971.22 kg/cm2, 198.6517.35 psi)
1,770100 kPa
(18.051.02 kg/cm2, 256.8114.50 psi)
OFF ON
ON OFF
OFF ON
(3)
(1)
Thermo-control amplifier working temperature

(Evaporator outlet air)
(2)
(4)
AC-00601
(1) ON
(2) OFF
(3) 10.5C (33.80.9F)
(4) 4+1.50C (39.2+2.70F)
Manual A/C model

Item
Type of air conditioner
Cooling capacity
Refrigerant
Compressor
Magnet clutch
Type
Discharge
Max. permissible speed
Type
Power consumption
Type of belt
Pulley dia. (effective dia.)
Pulley ratio
AC-3
Specification
Reheat air-mix type
5.3 kW (4,557 kcal/h, 18,084 BTU/h)
HFC-134a (CH2FCF3)
[0.40.03 kg (0.880.07 lb)]
Scroll, constant volume (SCSA 08C)
74.5 cc (4.55 cu in)/rev
9,000 rpm
Dry, single-disc type
35 W
V-belt 4 PK
93 mm (3.7 in)
1.43
General Description
Type
Corrugated fin (Sub cool type)
Core thickness
0.186 m2 (2.002 sq ft)

16 mm (0.63 in)
Radiation area
5.49 m2 (59.09 sq ft)
Core face area
Condenser
Receiver drier
Effective inner capacity
Expansion valve
Type
Type
Evaporator
Dimensions (W H T)
Blower fan
Condenser fan (Sub fan)
Radiator fan (Main fan)

Idling speed (A/C ON)
250 cm3 (15.26 cu in)

Externally equalizing
Single tank
298.6 151 38 mm
(11.7 5.94 1.50 in)
Sirocco fan
150 75 mm (5.91 2.95 in)
220 W
Magnet
90 W
300 mm (11.8 in)
Magnet
90 W
300 mm (11.8 in)
800100 rpm
19620 kPa
(2.000.20 kg/cm2, 28.42.9 psi)
Fan type
Power consumption
Motor type
Power consumption
Fan outer diameter
Motor type
Power consumption
Fan outer diameter
MPFI model
ON OFF
Low-pressure switch
operating pressure
Triple switch
High-pressure switch
(Pressure switch) operating pressure
Middle-pressure switch
operating pressure
225+2529 kPa
OFF ON
(2.29+0.250.30 kg/cm2, 32.6+3.64.2 psi)

3,140+50200 kPa
ON OFF
(32.02+0.51
2.04
kg/cm2, 455.4+7.2529.0 psi)
2,550200 kPa
(26.002.04 kg/cm2, 369.829.0 psi)
1,370120 kPa
(13.971.22 kg/cm2, 198.6517.35 psi)
1,770100 kPa
(18.051.02 kg/cm2, 256.8114.50 psi)
OFF ON
ON OFF
OFF ON
(3)
(1)
Thermo control amplifier working temperature

(Evaporator outlet air)
(2)
(4)
AC-00601
(1) ON
(2) OFF
(3) 10.5C (33.80.9F)
(4) 4+1.50C (39.2+2.70F)
AC-4
General Description
B: COMPONENT
1. HEATER COOLING UNIT
Auto A/C model
(10)
(12)
(11)
(9)
(8)
(13)
T
(14)
(7)
(6)
(5)
T
(4)
(15)
(16)
(3)
(17)
(1)
(2)
AC-00906
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Foot duct (RH)

Evaporator center
Pipe cover
Evaporator cover
Expansion valve
Packing
Evaporator
(8)
(9)
(10)
(11)
(12)
(13)
(14)
Mix actuator
Mode actuator
Heater pipe clamp
Heater core
Heater core cover
Aspirator
Aspirator hose
AC-5
(15)
(16)
(17)
Foot duct (LH)

Unit ASSY
Drain hose

T: 7.5 (0.76, 5.5)
General Description
Manual A/C model
(11)
(13)
(12)
(10)
(9)
(8)
(7)
(6)
(5)
T
(4)
(14)
(15)
(3)
(1)
(16)
(2)
AC-00907
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Foot duct (RH)

Thermo amplifier
Pipe cover
Evaporator cover
Expansion valve
Packing
Evaporator
(8)
(9)
(10)
(11)
(12)
(13)
(14)
Clip
Air mix door linkage
Mode actuator
Heater pipe clamp
Heater core
Heater core cover
Foot duct (LH)
AC-6
(15)
(16)
Unit ASSY
Drain hose

T: 7.5 (0.76, 5.5)
General Description
2. BLOWER MOTOR UNIT
(2)
(3)
(1)
(4)
(5)
(6)
(7)
T
AC-00908
(1)
(2)
(3)
(4)
(5)
Upper case
Intake door actuator
Filter (Auto A/C model)
Filter cover
Blower motor ASSY
(6)
(7)
Control unit (Auto A/C model)

Power transistor (Auto A/C model)
Blower resistor (Manual A/C
model)
AC-7

T: 7.5 (0.76, 5.5)
General Description
3. CONTROL PANEL
Auto A/C model
(A)
(B)
(4)
(3)
(2)
(2)
(1)
(1)
AC-00909
(A)
For integrated audio
(B)
For Mclntosh audio
(1)
(2)
Temperature control dial

Control panel assembly
(3)
Board
(4)
AC-8
Heater control base
General Description
Manual A/C model
(8)
(6)
(4)
(9)
(3)
(7)
(2)
(1)
(10)
(1)
(1)
(5)
AC-00910
(1)
(2)
(3)
(4)
Dial
A/C switch
FRESH/RECIRC switch
Rear window defogger switch
(5)
(6)
(7)
Heater control panel

Heater control base
Temperature control cable
AC-9
(8)
(9)
(10)
Valve
Fan switch ASSY
Switch base
General Description
4. AIR CONDITIONING UNIT
T2
T1
(2)
(6)
(6)
(5)
(4)
(6)
T2
(6)
T3
(1)
T1
(6)
(3)
(8)
T1
(6)
(7)
T3
AC-00911
(1)
(2)
(3)
(4)
Condenser
Hose (High-pressure)
Hose (Low-pressure)
Bracket
(5)
(6)
(7)
(8)
Compressor
O-ring
Clamp
Tube
AC-10

T1: 7.5 (0.76, 5.5)
T2: 10 (1.0, 7.4)
T3: 5 (0.5, 3.7)
General Description
5. COMPRESSOR
H4 model
T3
(4)
(5)
T3
T3
T1
(3)
(2)
T1
(1)
(6)
(7)
T2
AC-00760
(1)
(2)
(3)
(4)
Idler pulley bracket

Idler pulley adjuster
Idler pulley
Compressor upper bracket
(5)
(6)
(7)
Compressor
Compressor lower bracket
V-Belt
AC-11

T1: 23.0 (2.35, 17.0)
T2: 28.9 (2.95, 21.3)
T3: 36 (3.7, 26.6)
General Description
H6 model
T2
(1)
(2)
T2
T2
(3)
T1
AC-00912
(1)
(2)
(3)

T1: 28.9 (2.95, 21.3)
T2: 36 (3.7, 26.6)
Compressor upper bracket

Compressor
Compressor lower bracket
AC-12
General Description
6. HEATER DUCT
(3)
(1)
(4)
(2)
(5)
(6)
AC-00913
(1)
(2)
Front defroster nozzle

Side ventilation duct (LH)
(3)
(4)
Side ventilation duct (RH)

Center ventilation duct
AC-13
(5)
(6)
Rear heater duct (LH)

Rear heater duct (RH)
General Description
C: CAUTION
1. HFC-134a A/C SYSTEM
The cooling system components for the HFC134a system such as the refrigerant and compressor oil are different from the conventional CFC-12
system components and they are incompatible with
each other.
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 to the vehicle.
(A)
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 manifold gauge. The highpressure gas will back-flow resulting in an explosion of the can.
Provide good ventilation and do not work in a
closed area.
In order to prevent global warming, avoid releasing HFC-134a into the atmosphere. Using a refrigerant recovery system, discharge and reuse it.
AC-00762
(A)
2. COMPRESSOR OIL
HFC-134a compressor oil has no compatibility
with that of CFC-12 system.
Use only Denso Oil 8 which is a manufacturerauthorized compressor oil for HFC-134a system.
Do not mix multiple compressor oils.
If CFC-12 compressor oil is used in the 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 CFC-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 atmosphere using a
plug or tape. In order to avoid moisture, store the oil
in a container with its cap tightly closed.
(C)
(B)
(D)
(F)
(E)
AC-00007
3. REFRIGERANT
The CFC-12 refrigerant cannot be used in the
HFC-134a A/C system. The HFC-134a refrigerant,
also, cannot be used in the CFC-12 A/C system.
If an incorrect or no refrigerant is used, it will result in poor lubrication and the compressor itself
may be damaged.
4. HANDLING OF REFRIGERANT
The refrigerant boils at approx. 30C (22F).
When handling it, be sure to wear protective goggles and protective gloves. Direct contact of the refrigerant with skin may cause frostbite.
(A)
(B)
(C)
(D)
(E)
(F)
Goggles
Gloves
Avoid open flame
No direct heat on container
Do not discharge
Loosen
5. O-RING CONNECTIONS
Always use a new O-ring.
In order to keep the O-rings free of lint which will
cause a refrigerant gas leak, perform operations
without gloves and cloth.
AC-14
General Description
Apply compressor oil to O-rings to avoid sticking,

Use a torque wrench to tighten the O-ring fittings.
Over-tightening will result in damage of 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 foreign matter
from entering.
Apply compressor oil to the bead of tube.
AC-00010
(A)
After tightening, use a clean cloth to remove excess compressor 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 further tighten the connections, but disconnect
the connections, remove the O-rings, and check
the O-rings, threads, and connections.
AC-00008
(A) Seal
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 tube beads.
(A)
(B)
(D)
(C)
(C)
AC-00009
(A)
(B)
(C)
(D)
O-ring
OK
NG
Bead
Use compressor oil specified in the service manual to lubricate the O-rings.
Apply oil to the top and sides of O-rings before installation.
AC-15
General Description
D: PREPARATION TOOL
CAUTION:
When working on vehicles with HFC-134a system, only use HFC-134a specified tools and parts. Do
not mix with those of CFC-12. If HFC-134a and CFC-12 refrigerant or compressor oil is mixed, it will
result in poor lubrication and the compressor itself may be destroyed.
In order to prevent the mixture of 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 HFC-134a 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
ILLUSTRATION
Tools and Equipment

Wrench
Various WRENCHES will be required to service any A/C system. 7 to
40 Nm (0.7 to 4.1 kgf-m, 5 to 30 ft-lb) torque wrench and various crowfoot wrenches will be needed. Open end or flare nut wrenches will be
needed to hold the tube and hose fittings.
AC-00213
Applicator bottle
A small APPLICATOR BOTTLE is recommended to apply compressor
oil to the various parts. It can be available at a hardware or drug store.
AC-00012
Manifold gauge set

A MANIFOLD GAUGE SET (with hoses) can be available at either a
refrigerant supplier or an automotive equipment supplier.
AC-00013
AC-16
General Description
ILLUSTRATION
Tools and Equipment

Refrigerant recovery system
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.
AC-00014
Syringe
A graduated plastic SYRINGE will be needed to add oil back into the
system. A syringe can be available at a pharmacy or drug store.
AC-00015
Vacuum pump
A VACUUM PUMP is necessary (for a good working condition), and
may be available at either a refrigerant supplier or an automotive
equipment supplier.
AC-00016
Can tap
A CAN TAP for the 397 g (14 oz.) can is available at an automotive
equipment supplier.
AC-00017
AC-17
General Description
ILLUSTRATION
Tools and Equipment

Temperature gauge
A Pocket THERMOMETER is available at either a industrial hardware
store or a refrigerant suppliers.
AC-00018
Electronic leak detector

An ELECTRONIC LEAK DETECTOR can be available at either a specialty tool supplier or an A/C equipment supplier.
AC-00019
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.
AC-00020
AC-18
Refrigerant Pressure with Manifold Gauge Set

2. Refrigerant Pressure with Manifold Gauge Set

A: PROCEDURE
1) Place the vehicle in the shade and windless condition.
2) Connect the manifold gauge set.
3) Open the front windows and close all doors.
4) Open the front hood.
5) Increase the engine to 1,500 rpm.
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 35C (86 95F)
B: INSPECTION
Symptom
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 fin
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
AC-19
Repair order
Replace the fan motor.
Clean the condenser fin.
Discharge refrigerant.
Replace the receiver dryer.
After evacuating again, charge an
appropriate amount of refrigerant.
Replace the compressor.
Check for leaks.
Replace the expansion valve.
Fully evacuate the expansion valve.
Replace the compressor.

Discharge refrigerant.
Check for leaks.
Replace the receiver dryer.
Refrigerant Recovery Procedure

3. Refrigerant Recovery Procedure
4) Install the low-/high-pressure hoses to the service ports on the low-/high-pressure sides of the
vehicle respectively.
A: PROCEDURE
CAUTION:
During operation, be sure to wear protective
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) Perform the compressor oil return operation.
<Ref. to AC-25, PROCEDURE, Compressor Oil.>
2) Stop the engine.
3) Make sure the valves on low-/high-pressure
sides of manifold gauge set are fully closed.
(A)
(C)
(A)
(C)
(D)
(B)
(C)
(E)
AC-00022
(A) Low-pressure gauge (Compound pressure

gauge)
(B) High-pressure gauge
(C) Close
(D) Low-pressure side service port
(E) High-pressure side service port
5) Connect the center hose to the refrigerant recovery system.

6) Follow the operation manual to activate the refrigerant recovery system.
(B)
(C)
AC-00021

gauge)
(C) Close
AC-20
Refrigerant Charging Procedure

4. Refrigerant Charging Procedure
4) Carefully open the valves on the low-/high-pressure sides to activate the vacuum pump.
A: PROCEDURE
(A)
CAUTION:
During operation, be sure to wear protective
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)
(B)
(C)
(C)
(D)
AC-00024

gauge)
(C) Slowly open
(D) Vacuum pump turn on
5) After the low-pressure gauge reaches 100.0 kPa

(750 mmHg, 29.5 inHg) or higher, evacuate the
system for approx. 15 minutes. (Continue evacuation).
1) Close the valves on low-/high-pressure sides of

the manifold gauge.
AC-00025
(A)
(C)
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.
(B)
(C)
(A)
AC-00023
(C)

gauge)
(C) Close
(B)
(C)
(D)
AC-00026
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.
AC-21

gauge)
(C) Close
(D) Vacuum pump turn off

7) Note the low-pressure gauge reading.
12) Confirm that all the 3 hoses are tightly connected to the manifold gauge set.
(A)
(B)
(C)
(C)
AC-00027
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, it
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.
(A)
(B)
AC-00030

gauge)
(C) Close
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.
15) Carefully open the high-pressure valve with the
engine stopping.
CAUTION:
Do not open the low-pressure valve.
AC-00028
(A)
(A) Tap valve

(B) Center manifold hose
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 weight scale.
(C)
(D)
(E)
AC-00031

gauge)
(C) Close
(D) Ignition switch OFF
(E) Slowly open
(A)
(B)
AC-00029
(A) Refrigerant container (HFC-134a)

(B) Weight scale
(B)
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.
AC-22

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- / 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.
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. The high-pressure gas will backflow resulting in an explosion of the can.
AC-00034
AC-00032
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.
(A)
(C)
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 lowpressure valve.
26) Close the valve on the refrigerant source.
Refrigerant
HFC-134a
Refrigerant amount
Minimum
370 g (0.82 lb)
Maximum
430 g (0.95 lb)
27) Disconnect the hose from the service port, and

install the service port cap.
(B)
(C)
AC-00033

gauge)
(C) Close
20) Confirm that both the low-/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
Window open
AC-23
Refrigerant Leak Check

5. Refrigerant Leak Check

A: INSPECTION
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 high-pressure pipe and evaporator, check the system for
leaks along the high-pressure side through the
compressor. The following items must be checked
thoroughly.
3) Check the joint and seam between pressure
switch (dual switch) and high-pressure pipe.
4) Check the connections between condenser and
pipes, and welded joints on the condenser.
The leak tester may detect the oil on the condenser
fins as a leak.
5) Check the joint between compressor and hoses.
6) Check the machined area of compressor and
other joints on the compressor.
7) 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 3 g (0.1 oz.) per year. This is not a problem.
8) Starting from the connection between low-pressure pipe and evaporator, check the system for
leakage along the low-pressure side through the
compressor. The following items must be checked
thoroughly.
Connection between 2 parts
Connection between pipe and plate
CAUTION:
Carefully check the external surface of hoses
and tubes at approx. 25 mm (0.98 in) per second.
(A)
AC-00036
(A) Flexible hose
10) Disconnect the drain hose from heater case,

and check the hose end for at least 10 seconds.
After the test is finished, reconnect the drain hose.
11) Turn the ignition key to ON position, and run
the blower at high speed for approx. 1 minute. Stop
the blower to check the ventilation grille on the instrument panel. While moving the tester closer to
the grille, run the blower for 1 or 2 seconds, then
stop it. Check the grille at that point for at least 10
seconds.
AC-00037
12) Check the valve in the service port.

13) Visually check the rubber seal in the service
port cap.
AC-00035
9) 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.
AC-00038
AC-24
Compressor Oil
6. Compressor Oil
A: PROCEDURE
NOTE:
Before making repairs, perform the oil return operation to return the compressor oil in circulation with
the refrigerant to the compressor.
1) Increase the engine to 1,500 rpm.
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.
B: REPLACEMENT
NOTE:
If a component has been replaced, add an appropriate amount of compressor oil (same as the
amount of remaining oil in removed component).
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.
AC-25
Blower Motor Unit Assembly

7. Blower Motor Unit Assembly

A: REMOVAL
3) Disconnect the connectors of A/C control module, intake door actuator, blower motor, power transistor and blower resistor.
4) Loosen the bolt and nut to remove blower motor
unit assembly.
AC-00914
B: INSTALLATION
Tightening torque:
Refer to COMPONENT of General Description. <Ref. to AC-5, HEATER COOLING
UNIT, COMPONENT, General Description.>
<Ref. to AC-7, BLOWER MOTOR UNIT, COMPONENT, General Description.>
AC-26
Blower Motor
8. Blower Motor
A: REMOVAL
2) Remove the glove box lower cover. <Ref. to EI51, REMOVAL, Glove Box.>
3) Disconnect the connector of blower motor.
4) Loosen the screw to remove blower motor.
AC-00957
B: INSTALLATION
C: INSPECTION
Connect the battery positive (+) terminal to terminal
No. 2 of blower motor, and negative () terminal to
terminal No. 1. Check the blower motor for smooth
rotation.
2 1
AC-00915
AC-27
Power Transistor (Auto A/C Model)

9. Power Transistor (Auto A/C

Model)
A: REMOVAL
1) Remove the glove box lower cover on passenger side. <Ref. to EI-51, REMOVAL, Glove Box.>
2) Disconnect the power transistor connector.
3) Remove two screws, and then remove the power transistor.
AC-00916
B: INSTALLATION
AC-28
Blower Resistor (Manual A/C Model)

10.Blower Resistor (Manual A/C

Model)
A: REMOVAL
1) Remove the glove box lower cover on passenger side. <Ref. to EI-51, REMOVAL, Glove Box.>
2) Disconnect the blower resistor connector.
3) Remove two screws, and then remove the blower resistor.
AC-00916
B: INSTALLATION
C: INSPECTION
(2)
(4)
(1)
(3)
AC-00766
Measure the blower resistor resistance.

Terminal No.
4 and 2
4 and 3
4 and 1
Standard
Approx. 0.44
Approx. 1.12
Approx. 2.92
If NG, replace the blower resistor.
AC-29
Heater Core
11.Heater Core
A: REMOVAL
1) Remove the heater and cooling unit. <Ref. to
AC-36, REMOVAL, Heater and Cooling Unit.>
2) Remove the screws and remove the heater core
cover and pipe clamp.
AC-00917
3) Remove the heater core.
B: INSTALLATION
AC-30
Control Unit (Manual A/C Model)

12.Control Unit (Manual A/C

Model)
A: REMOVAL
3) Remove the control wires.
AC-00918
4) Remove the integrated panel. <Ref. to ET-5,

REMOVAL, Audio.>
5) Loosen the screw to remove the control unit from
bracket.
B: INSTALLATION
AC-31
Control Unit (Auto A/C Model)

13.Control Unit (Auto A/C Model)

A: REMOVAL
3) Remove the screw, disconnect the connector
and remove the control unit.
AC-00919
B: INSTALLATION
AC-32
Compressor
14.Compressor
7) Remove the bolt and remove the low-pressure

hose and high-pressure hose.
A: INSPECTION
1. MAGNETIC CLUTCH CLEARANCE
Check the clearance of entire circumference
around the drive plate and pulley.
Standard:
0.450.15 mm (0.01770.0059 in)
2. MAGNETIC CLUTCH OPERATION

1) Disconnect the compressor connector.
2) Connect the battery positive (+) terminal to terminal No. 1 of compressor connector, and negative
AC-00772
8) Disconnect the compressor harness from body

harness.
9) Remove the bolts and remove compressor
bracket.
H4 model
AC-00771
3) Check the magnet clutch engagement.

If NG, replace the compressor.
AC-00773
B: REMOVAL
H6 model
1) Perform the compressor oil return operation.

<Ref. to AC-25, PROCEDURE, Compressor Oil.>
2) Turn the A/C switch to OFF and stop the engine.
3) Using the refrigerant recovery system, discharge refrigerant. <Ref. to AC-20, PROCEDURE,
Refrigerant Recovery Procedure.>
REMOVAL, V-belt.> <Ref. to ME(H4DOTC)-39,
REMOVAL, V-belt.> <Ref. to ME(H6DO)-34, REMOVAL, V-belt.>
6) Remove the generator. <Ref. to SC(H4SO 2.0)14, REMOVAL, Generator.> <Ref. to SC(H6DO)14, REMOVAL, Generator.>
AC-00920
10) Remove the bolts, and then remove the bracket

from compressor.
AC-00774
AC-33
Compressor
C: INSTALLATION
2) Replace the O-rings on low-/high-pressure hoses with new ones, then apply compressor oil.
3) When replacing the compressor, adjust amount
of compressor oil. <Ref. to AC-25, PROCEDURE,
Compressor Oil.>
4) Charge refrigerant. <Ref. to AC-21, PROCEDURE, Refrigerant Charging Procedure.>
Tightening torque:
Refer to COMPONENT of General Description. <Ref. to AC-10, AIR CONDITIONING
<Ref. to AC-11, COMPRESSOR, COMPONENT, General Description.>
AC-34
Condenser
15.Condenser
A: REMOVAL
3) Disconnect the pressure hose and pipe from
condenser.
If the condenser is replaced, add an appropriate amount of compressor oil to the compressor.
<Ref.
to
AC-25,
REPLACEMENT,
Compressor Oil.>
B: INSTALLATION
CAUTION:
Replace the O-rings on hoses or pipes with new
ones, and then apply compressor oil. Confirm
that lower guide of condenser (A) has been fitted into holes on radiator panel.
AC-00775
4) Remove the radiator bracket (A) and hood stay

(B).
(A)
AC-00631
(A)
(B)
(A)
Tightening torque:
<Ref. to CO(H4SO 2.0)-5, RADIATOR AND
RADIATOR FAN, COMPONENT, General Description.>
AC-00776
5) Remove the front grille. <Ref. to EI-24, REMOVAL, Front Grille.>

6) Remove two bolts. While lifting condenser, pull it
out through the space between radiator and radiator panel.
C: INSPECTION
1) Check no dust or insects are found on the condenser fins. Air-blow or flush fins with water as
needed.
2) Inspect for oil leakage from condenser. If a failure is found, replace the condenser with a new one.
AC-00777
CAUTION:
Be careful not to damage the condenser fins.
If a damaged fin is found, repair it using a thin
screwdriver.
AC-35
Heater and Cooling Unit

16.Heater and Cooling Unit

A: REMOVAL
3) Drain coolant from the radiator.
4) Remove the bolts securing expansion valve and
pipe in engine compartment. Release the heater
hose clamps in engine compartment to remove the
hoses.
AC-00921
5) Remove the instrument panel. <Ref. to EI-56,

REMOVAL, Instrument Panel Assembly.>
6) Remove the support beam.
7) Remove the blower motor unit assembly. <Ref.
to AC-26, REMOVAL, Blower Motor Unit Assembly.>
8) Disconnect the actuator connector.
9) Remove the bolt and nuts to remove the heater
and cooling unit.
AC-00922
B: INSTALLATION
Tightening torque:
Refer to COMPONENT of General Description. <Ref. to AC-5, HEATER COOLING
AC-36
Evaporator
17.Evaporator
7) Remove the bolt which holds the pipe to evaporator.
A: REMOVAL
3) Remove the blower motor unit assembly. <Ref.
to AC-26, REMOVAL, Blower Motor Unit Assembly.>
4) Disconnect the connector, remove the screw
and then remove the air-mix door actuator and
mode door actuator.
AC-00926
8) Remove the screws and clip to remove the evaporator cover.
AC-00923
5) Disconnect the connector, remove the screw

and remove the pipe cover and evaporator sensor.
AC-00927
9) Pull out the evaporator (A) in the direction of arrow.

(A)
AC-00924
6) Remove the bolts securing expansion valve and

pipe in engine compartment.
AC-00928
CAUTION:
If the evaporator is replaced, add an appropriate amount of compressor oil to evaporator.
<Ref. to AC-25, REPLACEMENT, Compressor
Oil.>
B: INSTALLATION
AC-00925
AC-37
Hose and Tube

18.Hose and Tube
B: INSTALLATION
A: REMOVAL
CAUTION:
When disconnecting or connecting the hoses, do not apply excessive force to them. Confirm that no torsion and excessive tension is
charged after installing.
Seal the disconnected hose with a plug or vinyl tape to prevent foreign matter from entering.
CAUTION:
When disconnecting/connecting hoses, do
not apply an excessive force to them. Confirm
that no torsion and excessive tension is
charged after installing.
Seal the disconnected hose with a plug or vinyl tape to prevent foreign matter from entering.
3) Remove the evaporator unit mounting bolt (A)
and low-pressure hose bracket bolt (B).
4) Remove the low-pressure hose attaching bolts
(C).
5) Disconnect the low-pressure hose from evaporator unit.
6) Disconnect the low-pressure hose from compressor.
7) Remove the low-pressure hose from vehicle.
8) Remove the high-pressure hose attaching bolt
(D).
9) Disconnect the high-pressure hose from compressor.
10) Disconnect the high-pressure hose from condenser.
11) Remove the high-pressure hose from vehicle.
12) Remove the high-pressure attaching bolt (E).
13) Remove the high-pressure tube from vehicle.
Tightening torque:
C: INSPECTION
Check the hoses for cracks, damage and expansion. If any fault is found, replace them with new
ones.
(A)
(B)
(C)
(D)
(D)
(E)
AC-00929
AC-38
Relay and Fuse

19.Relay and Fuse
B: INSPECTION
A: LOCATION
1
2
4
(E)
(1)
(A)
(B)
(D)
(C)
AC-00641
(2)
(1) Joint box

(2) Main fuse box
Main Fan Relay 1
Main Fan Relay 2
Sub Fan Relay
A/C Relay
A/C Fuse
(3) (4): Continuity exists

(1) (2): Continuity does not exist
AC-00787
(A)
(B)
(C)
(D)
(E)
While applying battery voltage to the terminal 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 (Triple Pressure Switch)

20.Pressure Switch (Triple Pressure Switch)

A: INSPECTION
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
pressure switch.
1
3
2
AC-00788
Terminal
No.
Turns OFF.
High and low pressure switch
Middle pressure switch
Increasing to 3,140+50200 (32.02+0.512.04, 455.4+7.2529.0)

Decreasing to 19620 (2.000.20, 28.42.9)
1 and 2
3 and 4
Standard
kPa (kg/cm2, psi)
Operation
Turns ON.
Increasing to 225+2529 (2.29+0.250.30, 32.6+3.64.2)
Turns OFF.
Turns ON.
Decreasing to 2,550200 (26.002.04, 369.829.0)

Decreasing to 1,370120 (141, 19914)
Increasing to 1,770100 (181, 25614)
AC-40
Ambient Sensor (Auto A/C Model)

21.Ambient Sensor (Auto A/C

Model)
A: REMOVAL
3) Disconnect the ambient sensor connector.
4) Remove the ambient sensor from the radiator
lower panel.
AC-00125
B: INSTALLATION
C: INSPECTION
<Ref. to AC(diag)-30, AMBIENT SENSOR, Diagnostic Procedure for Sensors.>
AC-41
Sunload Sensor (Auto A/C Model)

22.Sunload Sensor (Auto A/C

Model)
A: REMOVAL
2) Disconnect the connector and remove the sunload sensor.
AC-00930
CAUTION:
Be careful not to damage the interior trims
when removing the sensor.
B: INSTALLATION
C: INSPECTION
<Ref. to AC(diag)-36, SUNLOAD SENSOR, Diagnostic Procedure for Sensors.>
AC-42
In-Vehicle Sensor (Auto A/C Model)

23.In-Vehicle Sensor (Auto A/C

Model)
A: REMOVAL
2) Remove the instrument panel lower cover. <Ref.
to EI-50, REMOVAL, Instrument Panel Lower Cover.>
3) Disconnect the connector and aspirator hose,
remove the pawl and remove the in-vehicle sensor
(A) from instrument lower cover.
(A)
AC-00790
CAUTION:
Be careful not to damage the sensors and interior trims when removing.
B: INSTALLATION
C: INSPECTION
<Ref. to AC(diag)-32, IN-VEHICLE SENSOR, Diagnostic Procedure for Sensors.>
AC-43
Air Vent Grille

24.Air Vent Grille

A: REMOVAL
1. CENTER GRILLE
2) Remove the three pawls and connector to remove center air vent grill.
AC-00931
2. SIDE GRILLE
Remove the two pawls to remove side air vent grill.
AC-00932
B: INSTALLATION
C: INSPECTION
1) Check the direction and amount of air can be adjusted smoothly.
2) Check the adjustment can be kept in each position.
AC-44
Heater Duct
25.Heater Duct
A: REMOVAL
1. FRONT HEATER DUCT
2) Remove the screws and detach the front heater
duct (A).
(A)
AC-00933
2. REAR HEATER DUCT

1) Remove the heater cooling unit. <Ref. to AC-36,
REMOVAL, Heater and Cooling Unit.>
2) Remove the front seats. <Ref. to SE-7, REMOVAL, Front Seat.>
3) Remove the front side sill cover.
4) Pull off the floor mat to remove the rear center
heater duct (A) and rear heater duct LH, RH (B).
(A)
(B)
AC-00934
B: INSTALLATION
AC-45
Heater Vent Duct

26.Heater Vent Duct

A: REMOVAL
REMOVAL, Instrument Panel Lower Cover.>
2) Remove the screws and detach the center vent
duct (A).
3) Remove the screws and detach the center vent
duct (B).
4) Remove the insulator, remove the screws and
detach the defroster duct.
(B)
(A)
(B)
AC-00935
B: INSTALLATION
AC-46
Heater Cock Solenoid Valve

27.Heater Cock Solenoid Valve

A: REMOVAL
1) Drain the engine coolant. <Ref. to CO(H4SO
2.0)-13, DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>
2) Disconnect the harness connector (A) of the
heater cock solenoid valve.
3) Remove the two bolts to remove the heater cock
solenoid from the bracket.
(A)
AC-00936
4) Pull out the heater cock solenoid. Loosen the

hose clamp and disconnect the two heater hoses.
B: INSTALLATION
C: INSPECTION
1) Remove the heater cock solenoid valve. <Ref. to
AC-47, REMOVAL, Heater Cock Solenoid Valve.>
2) Connect the positive terminal of battery to No. 1
terminal of heater cock solenoid valve, and the
ground terminal to No. 2 terminal. Check that the
heater cock solenoid valve opens and closes normally.
2 1
AC-00888
If any failure is found, replace the heater cock solenoid valve.
AC-47


A: INSPECTION
Symptom
Blower motor
Doesnt operate.
Noise
Doesnt operate.
Compressor
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.
Repair order
Fuse
Blower motor relay
Blower motor
Blower motor resistor
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
Heater cock solenoid valve
Engine coolant
Air mix actuator (Auto A/C)
Wire harness (Auto A/C)
Temperature control cable (Manual A/C)
Mode actuator (Auto A/C)
Air flow switch (Auto A/C)
Mode cable (Manual A/C)
Air inlet select switch (Auto A/C)
FRESH/RECIRC actuator (Auto A/C)
Intake cable (Manual A/C)
AC-48
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)
AC(diag)
1.
2.
3.
4.
5.
6.
7.
8.
9.
Page
Auto A/C Control Module I/O Signal............................................................8
Diagnostic Chart for Self-Diagnosis ..........................................................10
Diagnostics for A/C System Malfunction ...................................................15
Diagnostic Procedure for Actuators ..........................................................24
Diagnostic Procedure for Sensors ............................................................30
Diagnostics with Phenomenon..................................................................38


A: PROCEDURE
Step
START INSPECTIONS.
1) Perform the pre-inspection. <Ref. to
AC(diag)-3, INSPECTION, General Description.>
2) Perform the self-diagnosis. <Ref. to
AC(diag)-10, OPERATION, Diagnostic Chart
for Self-Diagnosis.>
Check
Does the self-diagnosis operate?
Yes
Go to step 2.
IDENTIFY MALFUNCTION PART.

Identify the malfunction part with self-diagnosis.
Can the malfunction part be

identified?
CHECK COMPARTMENT TEMPERATURE.

1) Turn ON the A/C switch.
2) Turn the temperature control dial at maximum cool position.
3) Check the compartment temperature
change.
Does the compartment temperature change?
Repair the malfunction part in

accordance with
each diagnostic
chart.
Go to step 4.
No
<Ref. to AC(diag)15, A/C OR SELFDIAGNOSIS SYSTEMS DO NOT
OPERATE, Diagnostics for A/C
System Malfunction.>
Go to step 3.
<Ref. to AC(diag)20, COMPARTMENT TEMPERATURE DOES NOT

CHANGE, OR A/C
SYSTEM DOES
NOT RESPOND
PROMPTLY.,
Diagnostics for A/
C System Malfunction.>
CHECK A/C SYSTEM RESPONSE.
Does the A/C system respond A/C system is nor- <Ref. to AC(diag)Change the temperature setting, and check the quickly?
mal.
20, COMPARTresponse of A/C system.
MENT TEMPERATURE DOES NOT
CHANGE, OR A/C
SYSTEM DOES
NOT RESPOND
PROMPTLY.,
Diagnostics for A/
C System Malfunction.>
AC(diag)-2
General Description
NOTE:
Be careful not to let the paper get sucked into the
port.
A: CAUTION
Auto A/C control module may be destroyed instantly.
engine is running.
electronic parts such as auto A/C control module,
etc.
sensor and the auto A/C control module, be sure to
turn off the ignition switch.
Auto A/C control module may be damaged.
4) Every A/C-related part is a precision part. Do not
drop them.
A/C control panel and junction box.
(A)
AC-00894
6) If the paper does not move at all, remove the instrument panel lower cover <Ref. to EI-50, REMOVAL, Instrument Panel Lower Cover.> and
check for improper connection of the aspirator hose
(A), in-vehicle sensor and heater unit, and repair
them if necessary.
CAUTION:
For airbag system, yellow-colored wiring harness and connectors are all used. Do not use
the electrical test equipment on these circuits.
wiring harness when servicing the A/C control
panel and junction box.
(A)
B: INSPECTION
Before performing the diagnosis, check the following items which might affect A/C system problems.
AC-00810
1. BATTERY
3. A/C LINE
1) Measure the battery voltage and specific gravity

of electrolyte.
Check the connection for A/C line (A) and lower

side high-pressure pipe.
2) Check the condition of the fuses for A/C system
power supply and other fuses.
3) Check the condition of harness and harness
connector connections.
(A)
2. ASPIRATOR HOSE
1) Turn the ignition switch to ON, and press the A/
C switch.
2) Turn the temperature control dial at maximum
hot position.
3) Turn the air flow control dial to DEF position.
4) Turn the fan speed control dial to 4th position.
5) Approach a strip of paper in front of the in-vehicle sensor suction port (A) located in the instrument
lower cover, and check that air is being sucked into
the port by seeing the paper moving towards the
port.
AC-00895
4. CONTROL LINKAGE
1) Check the state of mode door linkage.
2) Check the state of air mix door linkage.
3) Check the state of intake door linkage.
AC(diag)-3
General Description
5. CONTROL SWITCHES
Start and warm-up the engine completely.
1) Inspection using switches
No.
1
Point to check
OFF switch
Switch operation
Press the OFF switch.
1) Press the AUTO switch.

2) Turn the temperature control dial to the left
fully, and set to 18C (maximum cool position).
AUTO switch
3) Turn the temperature control dial to the right

slowly, and change the setting from 18C (maximum cool position) to 32C.
4) Turn the temperature control dial to the right

fully, and set to 32C (maximum hot position).
Defroster switch
Press the defroster switch.
FRESH/RECIRC
switch
Press the FRESH/RECIRC switch.
MODE switch
Press the MODE switch.
FAN switch
Press the FAN (+) switch.
Judgment standard
Setting temperature display goes out.
Blower fan: OFF
Inlet opening: External air
Compressor: OFF
AUTO display illuminates.
Outlet air temperature: COOL
Blower fan: HI (AUTO)
Outlet opening: FACE
Inlet opening: AUTO
Compressor: AUTO
Outlet air temperature: COOL HOT
Blower fan: AUTO
Outlet opening: FACE B/L FOOT
Inlet opening: AUTO
Compressor: AUTO
Outlet air temperature: HOT
Blower fan: HI (AUTO)
Outlet opening: FOOT
Inlet opening: Ambient (AUTO)
Compressor: AUTO
Defroster switch indicator illuminates.
Outlet air temperature: AUTO
Blower fan: AUTO
Outlet opening: DEF
Inlet opening: External air
Compressor: ON
Inlet opening switches RECIRC FRESH or
FRESH RECIRC each time pressing the
switch.
Outlet opening switches FACE B/L
FOOT F/D each time pressing the switch
Inlet opening switches LO M1 M2 M3
M4 HI each time pressing the switch
2) Compressor operation inspection

No.
1
Point to check
Compressor
Switch operation
1) Turn the A/C switch to ON.
2) Set the FAN switch between LO and HI.
Judgment standard
Compressor: ON
3) Inspection of illumination control

No.
1
Point to check
Illumination
Switch operation
Turn the lighting switch to ON.
AC(diag)-4
Judgment standard
Illumination comes on.


A: LOCATION
1. ENGINE COMPARTMENT
(1)
(3)
(2)
(4)
AC-00896
(1)
(2)
A/C compressor
A/C relay
(3)
Pressure switch
AC(diag)-5
(4)
Ambient sensor

(1)
(2)
AC-00813
AC-00815
(4)
(3)
AC-00814
AC-00816
2. PASSENGER COMPARTMENT
(6)
(7)
(5)
(2)
(8)
(3)
(1)
(4)
AC-00897
(1)
(2)
(3)
Evaporator sensor
Air mix door actuator
Auto A/C control module
(4)
(5)
(6)
Blower motor
Sunload sensor
AC(diag)-6
(7)
(8)
Mode door actuator

In-vehicle sensor

(7)
(6)
(3)
(2)
(1)
AC-00898
(5)
AC-00899
AC(diag)-7
(4)
AC-00900
Auto A/C Control Module I/O Signal

4. Auto A/C Control Module I/O Signal

16 15 14 13 12 11 10 9
10 9
20 19 18 17 16 15 14 13 12 11
To A: B282
To B: B283
AC-00735
AC(diag)-8
Auto A/C Control Module I/O Signal

Terminal No.
A1
A2
Remarks
Battery power supply
ACC power supply
A3
Mode door actuator position signal
A4
Air mix door actuator position signal
A5
A6
A8
A9
In-vehicle sensor
Sunload sensor
Sensor power supply
A10
A/C cut signal
A13
A14, A16
A15
B1, B11
B2
B3
B4
B5
B6
B7
B17
B8
B18
B10
B20
B13
B14
B15, B16
Evaporator center
Ground
Sensor ground
Ambient sensor, engine coolant
temperature sensor
Blower motor control
Blower motor control
RAM monitor
RAM monitor
A/C ON signal
Mode door actuator power supply
Air mix door actuator power supply
Blower fan ON signal
RAM monitor
Control panel
Ignition switch: OFF
Ignition switch: ACC
Mode door: FACE position
Mode door: DEF position
Air mix door: Maximum cool position
Air mix door: Maximum hot position
Ignition switch: ON
Ignition switch: ON, With sunload (No sunload: 0 V)
Ignition switch: ON
Ignition switch: ON
Ignition switch: ON
When operating pressure SW
Ignition switch: ON
Continuity to chassis ground
Continuity to chassis ground
Ignition switch : ON, Blower switch : ON

Ignition switch : ON, Blower switch : ON
A/C ON (A/C OFF: 0 V)

When switching mode door from DEF FACE
When switching mode door from FACE DEF
When switching air mix door from HOT COOL
When switching air mix door from COOL HOT
FRESH (RECIRC: Battery voltage)
RECIRC (FRESH: Battery voltage)
When blower fan is rotating (Not rotating: Battery voltage)
*1: Unable to measure the voltage for digital signal.
B: WIRING DIAGRAM
1. AIR CONDITIONER AUTO A/C MODEL
<Ref. to WI-59, WIRING DIAGRAM, Air Conditioning System.>
AC(diag)-9
Standard value
Battery voltage
Battery voltage
4V
1V
4V
1V
Less than 5 V
3V
5V
Battery voltage
Battery voltage
0V
Less than 5 V
0
0
*1
0.45 V
9.05 V
*1
*1
7 14 V
Battery voltage
Battery voltage
Battery voltage
Battery voltage
0V
0V
0V
*1
*1
Diagnostic Chart for Self-Diagnosis

5. Diagnostic Chart for Self-Diagnosis

A: OPERATION
(A)
PUSH AUTO/TEMP
(1)
AUTO
A/C
A/C
OFF
MODE
(2)
(8)
(7)
(6)
(5)
(4)
(3)
(B)
PUSH AUTO/TEMP
(1)
AUTO
A/C
MODE
(2)
A/C
OFF
(8)
(3)
(4)
(5)
(7)
(6)
AC-00901
(A)
LHD model
(B)
RHD model
(1)
(2)
(3)
Defroster switch
Rear window defogger switch
Air flow control switch
(4)
(5)
(6)
A/C switch
Fan switch
FRESH/RECIRC switch
(7)
(8)
OFF switch
Temperature control dial (AUTO
switch)
NOTE:
For A/C system self-diagnosis, there is one that checks the control panel, and the other that checks the whole
control system (sensor, actuator, blower motor, etc.). Perform the self-diagnosis for control panel first, and
then perform the self-diagnosis for control system.
AC(diag)-10

1. A/C CONTROL PANEL SELF-DIAGNOSIS
2
3
Step
Check
SET SELF-DIAGNOSIS MODE BY OPERAT- Does the self-diagnosis mode
ING A/C CONTROL PANEL.
operate?
2) Turn the ignition switch to ON with the
defroster switch and A/C switch pressed.
3) The screen display and indicator illuminate.
CHECK DISPLAY AND INDICATOR.

Check the display and all indicators illuminate.
CHECK SWITCH AND TEMPERATURE CONTROL DIAL INPUT.
According to the switch check table, press
each switch or turn the temperature control
dial, and check the relative screen display and
indicators illuminate. <Ref. to AC(diag)-12,
SWITCH CHECK TABLE, OPERATION, Diagnostic Chart for Self-Diagnosis.>
CHECK A/C CONTROL PANEL COMMUNICATION.
2) Disconnect the auto A/C control module
harness connector.
3) Using a suitable lead wire, short the terminal No. 15 and No. 16 of auto A/C control module harness connector (B283).
4) Turn the ignition switch to ON with the rear
defogger switch and A/C switch pressed.
5) When no malfunction occurs in the control
panel communication, CL is displayed in the
screen; and when malfunction occurs, OP is
displayed.
Yes
Go to step 2.
Do the display and all indica- Go to step 3.

tors illuminate?
Does the screen display
Go to step 4.
related to each switch and dial
input illuminate?
Is CL displayed in the
screen?
AC(diag)-11
No
Replace the A/C
control panel.
Replace the A/C
control panel.
A/C control panel Replace the A/C

is normal. Turn the control panel.
ignition switch to
OFF, and connect
the auto A/C control module harness connector.

2. SWITCH CHECK TABLE
(A)
(4)
(7)
(5)
(6)
(2)
(3)
(1)
PUSH AUTO/TEMP
AUTO
A/C
A/C
OFF
MODE
(9) (11)
(8)
(10)
(12)
(B)
(1)
(2)
(3) (4)
(5)
(6)
(7)
PUSH AUTO/TEMP
AUTO
A/C
MODE
(12)
A/C
OFF
(8)
(11) (10) (9)
AC-00902
(A)
LHD model
(B)
RHD model
Switch
A/C switch
AUTO switch
Display screen
(9)
(7)
Air flow control switch
(10)
FRESH/RECIRC
(8)
Defroster switch
Rear defogger switch
(1) (2)
(12)
Switch
FAN switch (+)
FAN switch ()
Temperature control dial (Right
turn)
Temperature control dial (Left
turn)
OFF switch
AC(diag)-12
Display screen
(6)
(5)
(3)
(11)
(4)

3. A/C CONTROL SYSTEM SELF-DIAGNOSIS
Step
Check
SET SELF-DIAGNOSIS MODE BY OPERAT- Does the self-diagnosis mode
ING A/C CONTROL PANEL.
operate?
2) Start the engine with the auto switch and
FRESH/RECIRC switch pressed.
NOTE:
Self-diagnosis can also be performed with ignition switch ON, but start the engine because
telling the magnet clutch operation is difficult.
3) All the indicator blinks four times.
CHECK EACH SENSOR AND POTENTIOAre other codes except 20
METER
displayed?
1) After the indicators are completed to blink,
automatically change to the inspection mode of
sensor and potentiometer.
NOTE:
Display items can be changed each time the A/
C switch is pressed. (Step Operation)
2) When malfunction occurs in each sensor
and potentiometer, codes are displayed on the
screen. When no malfunction occurs in each
sensor and potentiometer, code 20 is displayed on the screen.
3) Identify the defective sensor according to
the sensor check table. <Ref. to AC(diag)-14,
SENSOR CHECK TABLE, OPERATION,
Diagnostic Chart for Self-Diagnosis.>
CHECK EACH ACTUATOR, BLOWER FAN Do the actuator, blower fan and
magnet clutch operate along
AND MAGNET CLUTCH.
1) After completing each sensor and potenti- the operating mode table?
ometer inspection, change to the inspection
mode of actuator, blower fan and magnet
clutch by pressing the defroster switch.
2) Each mode will change and operate automatically every four seconds.
NOTE:
Operation mode items can be changed each
time the A/C switch is pressed. (Step Operation)
3) Check the operation of actuator, blower fan
and magnet clutch in each mode according to
the operating mode table. <Ref. to AC(diag)14, OPERATING MODE TABLE, OPERATION, Diagnostic Chart for Self-Diagnosis.>
AC(diag)-13
Yes
Go to step 2.
No
Repair the defec- Go to step 3.

tive sensor. <Ref.
to AC(diag)-30,
Diagnostic Procedure for Sensors.>
A/C control system

is normal. Press
the OFF switch
and complete the
self-diagnosis
mode.
Repair the malfunction part in

accordance with
each diagnostic
chart. <Ref. to
AC(diag)-15, Diagnostics for A/C
System Malfunction.> or <Ref. to
AC(diag)-24, Diagnostic Procedure
for Actuators.>

4. SENSOR CHECK TABLE

NOTE:
When the sunload sensor check is conducted indoors or in the shade, open circuit might be indicated. Always
check the sunload sensor at the place where the sun shines directly on it.
Display screen (Malfunction at
present) *1
21/AUTO Blink
21/AUTO Blink
22/AUTO Blink
23/AUTO Blink
23/AUTO Blink
24/AUTO Blink
25 Blink
25/AUTO Blink
26/AUTO Blink
27/AUTO Blink
28/AUTO Blink
29/AUTO Blink
20 Blink
SENSOR
Trouble contents
Broken
Short
Ambient sensor
Sensor trouble or communication malfunction
Broken
Evaporator sensor
Short
Sensor trouble or communication malfunction
Open *2
Sunload sensor
Short
COOL
Air mix door actuator potentiometer
HOT
FACE
Mode door actuator potentiometer
DEF
When all conditions are normal
In-vehicle sensor
*1: AUTO display does not blink when past malfunction occurred. Past malfunction means that abnormal signal had input for a
certain time continuously in the past.
*2: Present malfunction only is displayed for sunload sensor open circuit.
5. OPERATING MODE TABLE

Display screen
31
32
33
34
35
36
37
38
FRESH/RECIRC
door
FRESH
RECIRC
RECIRC
FRESH
FRESH
FRESH
FRESH
FRESH
Mode door
Air mix door
Blower fan
FACE
FACE
FACE
B/L
FOOT
FOOT
F/D
DEF
Maximum cool
Maximum cool
Maximum cool
50%
50%
Maximum hot
Maximum hot
Maximum hot
LO
LO
M1
M1
M1
M3
M3
HI
AC(diag)-14
A/C compressor (Magnet clutch)

OFF
ON
ON
ON
ON
ON
ON
ON
Diagnostics for A/C System Malfunction

6. Diagnostics for A/C System Malfunction

A: A/C OR SELF-DIAGNOSIS SYSTEMS DO NOT OPERATE
TROUBLE SYMPTOM:
Set temperature is not indicated on the display, switch LEDs are faulty and switches do not operate.
Self-diagnosis system does not operate.
WIRING DIAGRAM:
M/B NO. 8
IGNITION
SWITCH
BATTERY
SBF-7
F/B NO. 22
SBF-1
ACC
F/B NO. 31
i88
A/C CONTROL PANEL
*
i97
: LHD MODEL : 4
RHD MODEL : 6
JOINT
CONNECTOR
1
*
1
10
i3
A: B282
B: B283
A16
A14
B15
B16
A2
A9
A1
B38
AUTO A/C CONTROL MODULE
A: B282
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B: B283
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
B38
i97
i88
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
1 2 3 4 5 6
7 8 9 10 11 12
1 2 3 4
5 6 7 8
AC-00903
AC(diag)-15

Step
CHECK FUSE.
2) Remove the fuse No. 8 from main fuse box.
CHECK FUSE.
2) Remove the fuse No. 22 and 31 from fuse &
relay box.
CHECK A/C CONTROL PANEL POWER CIRCUIT.
1) Replace the A/C control panel.
2) Disconnect the A/C control panel harness
connector.
3) Measure the voltage between A/C control
panel harness connector terminal and chassis
ground after turning the ignition switch to ACC
position.
CHECK A/C CONTROL PANEL POWER CIRCUIT.
Measure the voltage between A/C control
panel harness connector terminal and chassis
ground after turning the ignition switch to ON
position.
CHECK A/C CONTROL PANEL GROUND
POWER CIRCUIT.
Measure the resistance in harness between A/C
control panel and chassis ground after turning
the ignition switch to OFF position.
CHECK AUTO A/C CONTROL MODULE
POWER CIRCUIT.
Measure the voltage between auto A/C control
module connector terminal and chassis ground
after turning the ignition switch to OFF position.
POWER CIRCUIT.
after turning the ignition switch to ACC position.
POWER CIRCUIT.
after turning the ignition switch to ON position.
Check
Is the fuse blown-out?
Yes
Replace the fuse.
No
Go to step 2.
Replace the fuse.
Go to step 3.
Check the harness

for open or short
circuit between A/
C control panel
and fuse.
Check the harness

for open or short
circuit between A/
C control panel
and fuse.

?
Repair the harness for ground

line.
Go to step 6.
Check the harness

for open or short
circuit between
auto A/C control
module and fuse.
Check the harness

for open or short
circuit between
auto A/C control
module and fuse.
Check the harness

for open or short
circuit between
auto A/C control
module and fuse.
AC(diag)-16

10
11
Step
GROUND CIRCUIT.
auto A/C control module and chassis ground.
(B282) No. 14, No. 16 Chassis ground:
CHECK COMMUNICATION CIRCUIT.
Measure the resistance in harness between A/C
control panel and auto A/C control module.
(i88) No. 3 (B283) No. 16:
(i88) No. 7 (B283) No. 15:
CHECK POOR CONTACT.
Check poor contact in auto A/C control module
connector.
Check
?
Yes
Go to step 10.
No
Repair the harness for ground
line.
Is the resistance less than1 ? Go to step 11.
Repair the harness.
Is there poor contact in connector?
Replace the auto

A/C control module.
AC(diag)-17

B: BLOWER FAN DOES NOT ROTATE.

TROUBLE SYMPTOM:
Blower motor does not rotate.
Blower motor does not rotate in HI.
WIRING DIAGRAM:
BATTERY
F/B NO. 27
SBF-1
SBF-4
F/B NO. 28
IGNITION
SWITCH
BLOWER MOTOR
RELAY
F/B NO. 22
SBF-7
22
24
23
21
B225
BLOWER MOTOR
2
1
B87
POWER
TRANSISTOR
3
2
4
1
B: B283
B13
B3
B2
B86
B87
B86
1 2
1 2
3 4
B: B283
B225
1
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
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
AC-00824
AC(diag)-18

Step
CHECK FUSE.
1) Remove the fuse No. 22, 27 and 28 from
fuse & relay box.
CHECK POWER SUPPLY FOR BLOWER
MOTOR.
2) Turn the blower switch to ON.
3) Measure the voltage between blower motor
and chassis ground.
CHECK BLOWER MOTOR RELAY.
2) Remove the blower motor relay.
terminal No. 24 of blower motor relay, and negative () terminal to terminal No. 23.
No. 21 and 22.
Terminals
No. 21 No. 22:
CHECK BLOWER MOTOR.
1) Disconnect the connector from blower
motor.
terminal No. 2 of blower motor connector, and
negative () terminal to terminal No. 1.
3) Make sure the blower motor runs.
CHECK POOR CONTACT.
connector.
Check
Is any fuse blown-out?
Yes
Replace the fuse.
No
Go to step 2.
Repair the open

circuit of blower
motor power supply line harness.

?
Go to step 4.
Replace the
blower motor relay.
Does the blower motor run?
Go to step 5.
Replace the
blower motor.
Replace the auto

A/C control module.
AC(diag)-19

C: COMPARTMENT TEMPERATURE DOES NOT CHANGE, OR A/C SYSTEM

DOES NOT RESPOND PROMPTLY.
WIRING DIAGRAM:
IGNITION SWITCH
F/B No.22
BATTERY
SBF-7
SBF-1
B33 B35
F108
PRESSURE
SWITCH
30
28
F109
C30 C8
D17 B20
ND HU
THROUGH JOINT
CONNECTOR
2
THROUGH JOINT
CONNECTOR
B: B135
B361
14
B360
: 2.0 L TURBO MODEL, 3.0 L MODEL

AND 2.5 L EC, K4, EK MODEL
HU
: 2.0 L NA MODEL
AND 2.5 L KS, KA MODEL
ECM
D: B137
ND
B10
A/C RELAY
C: B136
29
31
C3
C7
A4
B13
F27
MAIN FUSE BOX

A:
F37
B: B143
F35
C:
MAGNET
CLUTCH
A13
F24
B:
B143
C:
F35
F24
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
1 2
1 2 3 4
10 11 12 13 14
F108
1 2 3 4
5 6 7 8
9 10 11 12 13 14 15 16 17 18
F37
A:
C:
5 6 7 8 9
15 16 17 18 19 20
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
1 2 3 4
5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
B282
B:
B283
AUTO A/C
CONTROL MODULE
2
3
10 11 12 13
22 23
30 31
4 5 6 7
14 15 16 17 18 19
24 25
26 27
32 33
34 35
B: B143
F35
1 2
3 4 5
6 7 8 9 10 11 12
B361
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
F27
1 2 3
4 5 6
7 8 9 10 11 12 13 14
B: B283
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
B: B135
1
8 9
20 21
28 29
A:
F109
B360
D: B137
B6
F37
B282
A:
A:
A10
C12
B20
MAIN FUSE BOX
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B10
5 6
14 15 16
25 26 27
33 34 35
1
2 4 5
3
11
8 9 10
12
18 19
20 21
22
23
24 25
26
27
29 28
13
14 16 17
15
6
7
30
31
1
4
2
AC-00905
AC(diag)-20

Step
CHECK FUSE.
2) Remove the fuse No. 22 from fuse & relay
box.
CHECK SIGNAL TO A/C RELAY AND A/C
CONTROL MODULE.
1) Disconnect the A/C relay and auto A/C control module harness connector.
3) Measure the voltage between A/C relay
connector terminal and chassis ground.
4) Measure the voltage between auto A/C
control module harness connector terminal
and chassis ground.
CHECK POWER SUPPLY FOR PRESSURE
SWITCH.
2) Disconnect the pressure switch harness
connector.
switch harness connector terminal and chassis
ground.
CHECK HARNESS BETWEEN PRESSURE
SWITCH AND A/C RELAY, AUTO A/C CONTROL MODULE.
between pressure switch connector and A/C
relay connector.
between pressure switch connector and auto
A/C control module connector.
(B10) No. 1 (F27) No. 31:
(B10) No. 1 (B282) No. 10:
CHECK POWER SUPPLY FOR A/C RELAY.
Measure the voltage between A/C relay connector terminal and chassis ground.
CHECK A/C RELAY.
Check the A/C relay. <Ref. to AC-39, INSPECTION, Relay and Fuse.>
Check
Yes
Replace the fuse.
No
Go to step 2.
Go to step 3.
Check the harness

for open or short
circuit between
fuse and pressure
switch.

?
Check the presRepair the harsure switch. <Ref. ness.

to AC-40,
INSPECTION,
Pressure Switch
(Triple Pressure
Switch).>
Check the harness

for open or short
circuit between
fuse and A/C relay.
Is malfunction found in A/C

relay?
Replace the A/C

relay.
AC(diag)-21
Go to step 7.

10
Step
CHECK A/C ON SIGNAL.
2) Connect the A/C relay and all disconnected
connectors.
3) Start the engine and turn the A/C switch to
ON.
control module harness connector terminal
and chassis ground.
CHECK HARNESS BETWEEN AUTO A/C
CONTROL MODULE AND ECM.
2) Disconnect the harness connector of auto
A/C control module and ECM.
between auto A/C control module connector
and ECM connector.
2.0 L turbo model, 3.0 L model and 2.5 L
EC, K4, EK model
(B283) No. 6 (B137) No. 17:
2.0 L non-turbo model and 2.5 L KS, KA
model
(B283) No. 6 (B135) No. 20:
CHECK MAGNET CLUTCH ON SIGNAL.
1) Stop the engine and turn the A/C switch to
OFF.
3) Measure the voltage between ECM connector terminal and chassis ground.
EC, K4, EK model
model
CHECK MAGNET CLUTCH ON SIGNAL.
ON.
3) Measure the voltage between ECM connector terminal and chassis ground.
EC, K4, EK model
model
Check
Yes
No
Go to step 8.

?
Repair the harness.
Replace the auto

A/C control module.
Check the harness

for open or short
circuit between A/
C relay and ECM.
Is the voltage 0 V?
Replace the ECM.
AC(diag)-22
Go to step 11.

11
12
Step
Check
CHECK POWER SUPPLY FOR MAGNET
CLUTCH.
OFF.
2) Disconnect the harness connector of magnet clutch.
ON.
5) Measure the voltage between magnet
clutch harness connector terminal and chassis
ground.
CONTROL MODULE AND ECM.
?
OFF.
2) Measure the resistance between magnet
clutch harness connector terminal and chassis
ground.
AC(diag)-23
Yes
Go to step 12.
No
Check the harness
for open or short
circuit between A/
C relay and magnet clutch.
Check the compressor. <Ref. to

AC-33, INSPECTION, Compressor.>
Repair the harness.
Diagnostic Procedure for Actuators

7. Diagnostic Procedure for Actuators

A: INTAKE DOOR ACTUATOR
TROUBLE SYMPTOM:
FRESH/RECIRC mode is not changed.
WIRING DIAGRAM:
IGNITION
SWITCH
BATTERY
SBF-7
SBF-1
F/B No.22
INTAKE DOOR
ACTUATOR
B: B283
B: B283
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
1
B20
B10
B91
AUTO A/C
CONTROL MODULE
B91
1 2 3 4 5 6 7
AC-00826
AC(diag)-24

Step
CHECK POWER SUPPLY FOR INTAKE
DOOR ACTUATOR.
2) Disconnect the intake door actuator connector.
4) Measure the voltage between intake door
actuator connector and chassis ground.
CONTROL MODULE AND INTAKE DOOR
ACTUATOR.
connector.
3) Measure the resistance between intake
door actuator connector and auto A/C control
module connector.
(B283) No. 10 (B91) No. 3:
(B283) No. 20 (B91) No. 1:
CHECK OPERATION OF INTAKE DOOR ACTUATOR.
1) Connect the intake door actuator connector.
2) Ground the auto A/C control module connector with a suitable wire.
3) Turn the ignition switch to ON, and check
the operation of intake door actuator.
CHECK OPERATION OF INTAKE DOOR ACTUATOR.
2) Ground the auto A/C control module connector with a suitable wire.
3) Turn the ignition switch to ON, and check
the operation of intake door actuator.
Check
Is the voltage 7 V (at normal
temperature)?
Yes
Go to step 2.
No
Check the harness
for open or short
circuit between
intake door actuator and fuse.

?
Go to step 3.
Repair the harness between auto

A/C control module and intake
door actuator.
Does the actuator move to the Go to step 4.

FRESH side?
Replace the intake

door actuator.
Does the actuator move to the Replace the auto

RECIRC side?
A/C control module.
Replace the intake

door actuator.
AC(diag)-25

B: MODE DOOR ACTUATOR

TROUBLE SYMPTOM:
Air flow outlet is not changed.
WIRING DIAGRAM:
B7
A15
A3
AUTO A/C
CONTROL MODULE
B17
B: B283
A8
A: B282
B77
MODE DOOR ACTUATOR
B77
1 2 3 4 5
A: B282
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B: B283
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
AC-00827
AC(diag)-26

Step
CHECK POWER SUPPLY FOR MODE DOOR
ACTUATOR POSITION SENSOR.
2) Disconnect the mode door actuator connector.
3) Turn the ignition switch and AUTO switch to
ON.
control module connector terminals.
(B282) No. 8 (+) (B282) No. 15 ():
ACTUATOR.
module connector and chassis ground after
turning the air flow control switch to FACE position.
ACTUATOR.
turning the air flow control switch to DEF position.
CONTROL MODULE AND MODE DOOR ACTUATOR.
1) Turn the A/C and ignition switch to OFF.
connector.
3) Measure the resistance between auto A/C
control module and mode door actuator connector.
(B77) No. 1 (B282) No. 15:
(B77) No. 2 (B282) No. 8:
(B77) No. 3 (B282) No. 3:
(B77) No. 4 (B283) No. 17:
(B77) No. 5 (B283) No. 7:
CHECK MODE DOOR ACTUATOR POSITION SWITCH SIGNAL.
1) Connect the connector of auto A/C control
module and mode door actuator.
ON.
3) Check the voltage between auto A/C control module connector terminals while changing the mode between DEF and FACE.
(B282) No. 3 (+) (B282) No. 15 ():
CHECK POOR CONTACT.
and connector.
Check
Yes
Go to step 2.
No
Replace the auto
A/C control module.

temperature)?
Go to step 3.
Replace the auto

A/C control module.

temperature)?
Go to step 4.
Replace the auto

A/C control module.

?
Go to step 5.

A/C control module and mode door
actuator.

between 1 (DEF) 4 (FACE)
V?
Go to step 6.
Replace the mode

door actuator.
Repair connector. Replace the auto

A/C control module.
AC(diag)-27

C: AIR MIX DOOR ACTUATOR

TROUBLE SYMPTOM:
Outlet air temperature does not change.
WIRING DIAGRAM:
A15
A4
B8
B18
AUTO A/C
CONTROL MODULE
B: B283
A8
A: B282
B235
AIR MIX DOOR ACTUATOR
B235
1 2 3 4 5 6 7
A: B282
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B: B283
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
AC-00828
AC(diag)-28

Step
CHECK POWER SUPPLY FOR AIR MIX
DOOR ACTUATOR POSITION SWITCH.
2) Disconnect the air mix door actuator connector.
ON.
control module connector terminals.
(B282) No. 8 (+) (B282) No. 15 ():
DOOR ACTUATOR.
turning the temperature control dial to maximum COOL position.
DOOR ACTUATOR.
turning the temperature control dial to maximum HOT position.
CONTROL MODULE AND AIR MIX DOOR
ACTUATOR.
1) Turn the A/C and ignition switch to OFF.
connector.
3) Measure the resistance between auto A/C
control module and air mix door actuator connector.
(B235) No. 1 (B282) No. 8:
(B235) No. 3 (B282) No. 15:
(B235) No. 5 (B282) No. 4:
(B235) No. 6 (B283) No. 8:
(B235) No. 7 (B283) No. 18:
CHECK AIR MIX DOOR ACTUATOR POSITION SWITCH SIGNAL.
1) Connect the connector of auto A/C control
module and air mix door actuator.
ON.
3) Check the voltage between auto A/C control module connector terminals while changing the setting temperature between maximum
COOL and maximum HOT.
(B282) No. 4 (+) (B282) No. 15 ():
CHECK POOR CONTACT.
and connector.
Check
Yes
Go to step 2.
No
Replace the auto
A/C control module.

temperature)?
Go to step 3.
Replace the auto

A/C control module.

temperature)?
Go to step 4.
Replace the auto

A/C control module.

?
Go to step 5.

A/C control module and air mix
door actuator.

between 1 (Max. HOT) 4
(Max. COOL) V?
Go to step 6.
Replace the air

mix door actuator.
Replace the auto

A/C control module.
AC(diag)-29
Diagnostic Procedure for Sensors

8. Diagnostic Procedure for Sensors

A: AMBIENT SENSOR
TROUBLE SYMPTOM:
Fan speed is not switched when the fan speed control dial is in AUTO position.
WIRING DIAGRAM:
AMBIENT SENSOR
13
14
F78
F108
10
11
C3
C10
THROUGH
JOINT CONNECTOR
B361
B: B283
F78
F108
1 2
1 2 3 4
5 6 7 8
9 10 11 12 13 14 15 16 17 18
B: B280
1 2 3
4 5
6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
23 24 25
26 27
28 29 30
21 22
B26
B25
B1
B11

B:
B280
C:
B281
AUTO A/C
CONTROL MODULE
B: B283
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
B361
1 2 3
4 5 6
7 8 9 10 11 12 13 14
C: B281
4 5 6 7
1 2 3
8 9 10 11 12 13 14 15 16 17 18 19
27 28
22 23
24 25 26
20 21
AC-00829
AC(diag)-30

Step
CHECK AMBIENT SENSOR.
2) Disconnect the connector from ambient
sensor.
terminals of ambient sensor.
Terminals
No. 1 No. 2:
CHECK INPUT SIGNAL FOR AMBIENT SENSOR.
2) Measure the voltage between connector
(F78) terminals.
(F78) No. 1 (+) No. 2 ():
CHECK OUTPUT SIGNAL OF BODY INTEGRATED UNIT.
2) Draw out the body integrated unit.
3) Disconnect the connector from ambient
sensor.
terminals of body integrated unit.
(B281) No. 3 (+) No. 10 ():
BODY INTEGRATED UNIT AND AMBIENT
SENSOR.
between body integrated unit and ambient sensor.
(F78) No. 1 (B281) No. 10:
BODY INTEGRATED UNIT AND AMBIENT
SENSOR.
body integrated unit and ambient sensor.
(F78) No. 2 (B281) No. 3:
CHECK COMMUNICATION ERROR DISPLAY.
1) Connect the connectors of body integrated
unit and ambient sensor to original position.
2) Check Er xx is indicated on the Odo/Trip
meter in combination meter after turning the
ignition switch to ON.
CHECK POOR CONTACT.
connector.
Check
Is the resistance approx. 2.2
k at 25C (77F)?
Yes
Go to step 2.
No
Replace the ambient sensor.
Go to step 6.
Go to step 3.
Go to step 4.
Go to step 6.

?
Go to step 5.
Repair the open

circuit in harness
ambient sensor.

?
Go to step 6.
Repair the open

circuit in harness
ambient sensor.
Is the error display Er xx indi- Check the commu- Go to step 7.

cated?
nication circuit.
<Ref. to
LAN(diag)-2, Basic
Diagnostic Procedure.>
AC(diag)-31
Replace the A/C

control module.

B: IN-VEHICLE SENSOR
TROUBLE SYMPTOM:
Blower fan speed, outlet port and inlet port do not change after turning the AUTO switch to ON.
WIRING DIAGRAM:
i55
IN-VEHICLE
SENSOR
12
11
i3
A: B282
i55
1 2
A: B282
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
A5
A15
B38
AUTO A/C
CONTROL MODULE
B38
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
AC-00830
AC(diag)-32

Step
CHECK IN-VEHICLE SENSOR.
2) Remove the drivers side lower cover.
3) Disconnect the connector from in-vehicle
sensor.
terminals of in-vehicle sensor.
Terminals
No. 1 No. 2:
CHECK INPUT SIGNAL FOR IN-VEHICLE
SENSOR.
2) Measure the voltage between in-vehicle
sensor harness connector terminal and chassis ground.
(i55) No. 2 (+) No. 1 ():
OUTPUT SIGNAL.
2) Remove the auto A/C control module.
terminals of auto A/C control module.
(B282) No. 5 (+) (B282) No. 15 ():
CONTROL MODULE AND IN-VEHICLE SENSOR.
2) Disconnect the connector from auto A/C
control module.
between auto A/C control module and in-vehicle sensor.
(i55) No. 2 (B282) No. 5:
CONTROL MODULE AND IN-VEHICLE SENSOR.
auto A/C control module and in-vehicle sensor.
(i55) No. 1 (B282) No. 15:
CHECK POOR CONTACT.
connector.
Check
k at 20C (68F)?
Yes
Go to step 2.
No
Replace the invehicle sensor.
Go to step 6.
Go to step 3.
Go to step 4.
Go to step 6.

?
Go to step 5.

A/C control module and in-vehicle
sensor.

?
Go to step 6.

A/C control module and in-vehicle
sensor.
Replace the auto

A/C control module.
AC(diag)-33

C: EVAPORATOR SENSOR
WIRING DIAGRAM:
EVAPORATOR
SENSOR
A: B282
B88
1
2
A13
A15
B88
AUTO A/C
CONTROL MODULE
A: B282
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
AC-00831
AC(diag)-34

Step
CHECK EVAPORATOR SENSOR
2) Remove the glove box.
3) Disconnect the connector from evaporator
sensor.
terminals of evaporator sensor.
Terminals
No. 1 No. 2:
CHECK INPUT SIGNAL FOR EVAPORATOR
SENSOR.
(B88) terminal and chassis ground.
(B88) No. 1 (+) No. 2 ():
OUTPUT SIGNAL.
2) Remove the auto A/C control module.
(B282) No. 13 (+) No. 15 ():
AUTO A/C CONTROL MODULE AND EVAPORATOR SENSOR.
control module.
between auto A/C control module and evaporator sensor.
(B88) No. 2 (B282) No. 15:
AUTO A/C CONTROL MODULE AND EVAPORATOR SENSOR.
auto A/C control module and evaporator sensor.
(B88) No. 1 (B282) No. 13:
CHECK POOR CONTACT.
connector.
Check
k at 20C (68F)?
Yes
Go to step 2.
No
Replace the evaporator sensor.
Go to step 6.
Go to step 3.
Go to step 4.
Go to step 6.

?
Go to step 5.
Repair the open

circuit in harness
between auto A/C
control module
and evaporator
sensor.

?
Go to step 6.
Repair the open

circuit in harness
between auto A/C
control module
and evaporator
sensor.
Replace the auto

A/C control module.
AC(diag)-35

D: SUNLOAD SENSOR
TROUBLE SYMPTOM:
Sensor identifies that sunlight is at maximum. Then, A/C system is controlled to COOL side.
Sensor identifies that sunlight is at minimum. Then, A/C system is controlled to HOT side.
NOTE:
When the sunload sensor check is conducted indoors or in the shade, open circuit might be indicated. Always
check the sunload sensor at the place where the sun shines directly on it.
WIRING DIAGRAM:
i51
SUNLOAD
SENSOR
i3
A: B282
i51
1 2
A: B282
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
A6
A8
B38
AUTO A/C
CONTROL MODULE
B38
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
AC-00832
AC(diag)-36

Step
CHECK POWER SUPPLY VOLTAGE FOR
SUNLOAD SENSOR.
2) Disconnect the connector from sunload
sensor.
4) Measure the power supply voltage for sunload sensor.
(i51) No. 1 (+) No. 2 ():
AUTO A/C CONTROL MODULE AND SUNLOAD SENSOR.
control module.
between auto A/C control module and sunload
sensor.
(i51) No. 2 (B282) No. 6:
AUTO A/C CONTROL MODULE AND SUNLOAD SENSOR.
auto A/C control module and sunload sensor.
(i51) No. 1 (B282) No. 8:
CHECK INPUT VOLTAGE FOR AUTO A/C
CONTROL MODULE.
1) Connect the connectors of sunload sensor
and auto A/C control module.
(B282) No. 8 (+) (B282) No. 6 ():
CHECK POOR CONTACT.
connector.
Check
Yes
Go to step 4.
No
Go to step 2.

?
Go to step 3.

A/C control module and sunload
sensor.

?
Go to step 4.

A/C control module and sunload
sensor.
Is the voltage approx. 2.5 V?
Go to step 5.
Replace the sunload sensor.
Replace the auto

A/C control module.
AC(diag)-37

9. Diagnostics with Phenomenon

A: INSPECTION
Symptom
Problem parts
Fuse (M/B No. 8, F/B No. 22, 31)
Connector (Poor contact)
Ground
A/C system fails to operate.
Blower fan motor
Blower fan relay
A/C Relay
Compressor (Magnet clutch)
Evaporator sensor
Fuse (M/B No. 8, F/B No. 22, 31)
Fuse is blown out.
Fuse (M/B No. 8, F/B No. 22, 31)
Illumination cannot dim.
Fuse (M/B No. 8, F/B No. 22, 31)
Ground
Blower fan does not rotate or fan speed cannot be controlled.
Blower fan motor
Blower fan relay
Unable to switch suction vents.
Unable to switch blow vents.
Mode door actuator
Compartment temperature does not increase. (No hot air is dis- Air mix door actuator
charged.)
In-vehicle sensor, ambient sensor, evaporator sensor and
sunload sensor
In-vehicle sensor aspirator hose
A/C Relay
Compartment temperature does not decrease. (No cool air is
Compressor (Magnet clutch)
discharged.)
Radiator fan motor
Radiator fan relay
In-vehicle sensor, ambient sensor, evaporator sensor and
sunload sensor
Compartment temperature is higher or lower than setting tem In-vehicle sensor, ambient sensor, evaporator sensor and
perature.
sunload sensor
Compartment temperature does not quickly respond to setting In-vehicle sensor, ambient sensor, evaporator sensor and
temperature.
sunload sensor
Radiator fan motor
Radiator fan does not rotate during A/C operation.
Radiator fan relay
AC(diag)-38
AIRBAG SYSTEM
AB
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Page
Airbag Connector ......................................................................................10
Inspection Locations After a Collision .......................................................13
Drivers Airbag Module..............................................................................15
Passengers Airbag Module ......................................................................16
Side Airbag Module...................................................................................17
Curtain Airbag Module ..............................................................................19
Airbag Control Module ..............................................................................21
Side Airbag Sensor ...................................................................................22
Curtain Airbag Sensor...............................................................................23
Roll Connector ..........................................................................................24
Front Sub Sensor ......................................................................................25
Airbag Module Disposal (Deployment Processing On Vehicle) ................26
Airbag Module Disposal (Deployment Processing After Removal from Vehicle)...31
General Description
AIRBAG SYSTEM
4. CURTAIN AIRBAG MODULE
A: COMPONENT
Sedan model
1. DRIVERS AIRBAG MODULE

(B)
(A)
(A)
(A)
(B)
(A)
(A)
(A)
(A)
AB-00625
T
T
(A) Bolt
(B) Clip
AB-00752
Tightening torque:
10 Nm (1.0 kgf-m, 7.2 ft-lb)
Wagon model
2. PASSENGERS AIRBAG MODULE

(B)
(A)
(A)
(B)
(A)
(A)
(A)
(A)
(A)
(A)
(A)
AB-00626
T
(A) Bolt
(B) Clip
AB-00753
Tightening torque:
7.4 Nm (0.75 kgf-m, 5.5 ft-lb)
Tightening torque:
7.5 Nm (0.77 kgf-m, 5.5 ft-lb)
3. SIDE AIRBAG MODULE
5. AIRBAG CONTROL MODULE

T
(A)
AB-00754
AB-01193
Tightening torque:
6 Nm (0.61 kgf-m, 4.4 ft-lb)
(A) Bolt
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
CAUTION:
Do not reuse the bolts and nuts.
AB-2
General Description
AIRBAG SYSTEM
6. FRONT SUB SENSOR
CAUTION:
9. STEERING ROLL CONNECTOR

T
(A)
T
(A)
AB-01189
(A) Bolt
AB-00756
Tightening torque:
13 Nm (1.32 kgf-m, 9.6 ft-lb)
CAUTION:
7. SIDE AIRBAG SENSOR
(A)
T
AB-01190
(A) Nut
Tightening torque:
7.4 Nm (0.75 kgf-m, 5.5 ft-lb)
CAUTION:
8. CURTAIN AIRBAG SENSOR
(A)
AB-01191
(A) Nut
Tightening torque:
7.4 Nm (0.75 kgf-m, 5.5 ft-lb)
AB-3
General Description
AIRBAG SYSTEM
10.AIRBAG HARNESS
(1)
(2)
AB-00757
(1)
Airbag main harness
(2)
Airbag rear harness
B: CAUTION
When servicing a vehicle, be sure to turn the ignition switch to OFF, disconnect the ground cable
from 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.
If sensors, airbag module, airbag control module,

pretensioner and harness are deformed or damaged, replace them with new parts.
AB-00120
IN-00203
If the airbag warning light illuminates, repair the

vehicle immediately. Airbag or pretensioner may inflate incorrectly, or not inflate in collision.
AB-4
General Description
AIRBAG SYSTEM
When checking the airbag system, be sure to

use a digital circuit tester. Use of an analog circuit
tester may cause the airbag to activate erroneously.
Do not drop the airbag modules, subject them to

high temperature over 93C (199F), or let water,
oil or grease get on them; the internal parts may be
damaged and reliability greatly lowered.
AB-00121
When checking, use a test harness (1). Since

damage to the connector terminal may cause the
airbag to activate erroneously, do not directly apply
the tester probe to any connector terminal of the
airbag.
AB-00123
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.
(1)
AB-00124
AB-00122
Do not check continuity of the airbag modules for

driver, passenger, side or curtain, or pretensioner.
Install the wire harness securely with the specified clips to avoid interference or tangled up with
other parts.
AB-00125
AB-00006
AB-5
General Description
AIRBAG SYSTEM
Do not allow water or oil to come in contact with

the connector terminals. Do not touch the connector terminals.
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 airbag system.
AB-00126
Either of the airbag modules for driver, passenger, side or curtain, or pretensioner must not be
disassembled.
AB-00129
After removal of each parts for airbag system,

keep them with the pad facing upward on a dry,
clean and flat surface without heat, light sources,
moisture and dust.
AB-00779
The removed front seat with airbag module must

be kept at least 200 mm (8 in) away from walls and
other objects.
AB-00056
When airbag control module, front sub sensor,

side airbag sensor and curtain airbag sensor are
removed, do not reuse the bolts and nuts of them.
Always use new bolts and nuts for them.
(1)
AB-00128
(1) 200 mm (8 in) or more
Do not use the airbag or pretensioner parts from

other vehicles. Always replace the defective parts
with new parts.
Never reuse a deployed airbag and pretensioner.
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 airbag system.
Do not discard a undeployed airbag module or
pretensioner.
AB-6
General Description
AIRBAG SYSTEM
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.
(1)
(2)
AB-00130
(1)
Drivers airbag module
(2)
Passengers airbag module
AB-7
General Description
AIRBAG SYSTEM
C: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
98299FC030
DESCRIPTION
DEPLOYMENT
ADAPTER A
REMARKS
Used for deploying side airbag module.
Used for deploying curtain airbag module.
Used with DEPLOYMENT TOOL
(98299PA030).
98299SA030
DEPLOYMENT
ADAPTER E
Used for deploying drivers airbag module.

Used for deploying passengers airbag module.
(98299PA030).
98299AG030
DEPLOYMENT
ADAPTER X
Used for deploying drivers airbag module.

(98299PA030).
Can not reuse.
98299PA030
DEPLOYMENT
TOOL
Used for deploying airbag module.

Used with each deployment adapter.
ST98299FC030
ST98299SA030
ST98299AG030
ST98299PA030
AB-8
General Description
AIRBAG SYSTEM
2. GENERAL TOOL
TOOL NAME
TORX T30
REMARKS
Used for removing and installing drivers airbag module.
AB-9
Airbag Connector
AIRBAG SYSTEM
2. Airbag Connector
2. DRIVERS AIRBAG MODULE AND PRETENSIONER
A: PROCEDURE
1. POWER SUPPLY
1) How to disconnect:
(1) Move the slide lock (A) in the direction of arrow.
(2) With the slide lock (A) moved, separate the
connector.
(1) Using a flat tip screwdriver, pry the push
lock upward to unlock.
(A)
AB-00478
(2) Pull the connector to disconnect from the

drivers airbag module assembly or retractor assembly.
AB-00721
CAUTION:
When pulling the slide lock or disconnecting
the connector, be sure to hold onto the connector and not the wire.
2) How to connect:
Holding the connector (A), and push it in carefully
until a connecting sound is heard.
AB-00479
2) How to connect:
Connect the connector in the reverse order of disconnecting. At this time, be sure to insert the push
lock until a connecting sound is heard.
AB-00016
CAUTION:
Be sure to insert the connector in until it is
locked. Then pull on it gently to make sure that
it is locked.
CAUTION:
it is locked.
Be sure to push the push lock in securely.
AB-00480
NOTE:
Connector can not be connected when the push
lock is in lock position. To connect the connector,
set the push lock to unlock position.
AB-10
Airbag Connector
AIRBAG SYSTEM
3. DRIVERS AIRBAG (BETWEEN AIRBAG

MAIN HARNESS AND ROLL CONNECTOR),
PASSENGERS AIRBAG
(1) Push the slide lock (A) into the direction of
arrow.
4. SIDE AIRBAG AND CURTAIN AIRBAG

(1) Push the lock arm (A).
(2) With the lock arm (A) pushed in, move the
slide lock (B) in the direction of arrow.
(B)
(A)
(A)
AB-00017
AB-00722
(3) With the slide lock moved, release the lock

arm (back to its original position), and disconnect the connector.
(2) With the slide lock pushed, disconnect the

connector.
CAUTION:
When pulling the side lock or disconnecting the
connector, be sure to hold onto the connector
and not the wire.
AB-00022
CAUTION:
and not the wire.
2) How to connect:
Holding the connector, and push it in carefully until
a connecting sound is heard.
CAUTION:
it is locked.
AB-00018
5. FRONT SUB-SENSOR, SIDE AIRBAG

SENSOR AND CURTAIN AIRBAG SENSOR
Holding the outer part (A), pull it in the direction of
arrow.
CAUTION:
and not the wire.
AB-00023
AB-00024
AB-11
Airbag Connector
AIRBAG SYSTEM
2) How to connect:
CAUTION:
The outer side (A) moves back, and so do not
put your hand on the outer part.
it is locked.
AB-00025
AB-12
Inspection Locations After a Collision

AIRBAG SYSTEM
3. Inspection Locations After a

Collision
A: REPLACEMENT
Replace the following parts when the airbag is deployed.
1. FRONT COLLISION
1) Drivers airbag module
2) Passengers airbag module
3) Drivers seat belt (Pretensioner)
4) Passengers seat belt (Pretensioner)
5) Airbag control module
6) Front sub sensor
7) Roll connector
8) Instrument panel (for integrating with passengers airbag module)
2) When installing a new drivers airbag module,

check for the following, and replace the damaged
parts with new parts.
The steering wheel is in the way, making it difficult to install the airbag module.
The clearance between the drivers airbag module and steering wheel is not constant.
When steering wheel deformation in axial, upward and downward directions exceed limits.
Standard value:
Height deflection A
O.D. deflection L
L
A
2. SIDE COLLISION
1) Airbag control module
2) Side airbag module (operating side seat backrest)
3) Side airbag sensor (operating side)
4) Curtain airbag module (operating side)
5) Curtain airbag sensor (operating side)
AB-00028
3. INSPECTION OF OTHER PARTS
Check for the following, and replace the damaged

1) Check the steering shaft for mounting conditions
and deflection of front and rear, upward and downward directions, and deflection of front and rear direction with tilt lever released. (After collision,
absorbing part of steering shaft may work.)
2) Check the direct type connector of drivers airbag module, pretensioner, etc. for damage, and
also check each harness for pinch and connector
damage. Replace the harness as a unit if damage
is found.
3) Check the installing condition and play of the
seat cushion, backrest, seat rail and headrest.

Airbag module and instrument panel are cracked
or deformed.
Harness and/or connector is cracked, deformed
or open. Harness wire is exposed.
Mounting bracket is cracked or deformed.
B: INSPECTION
If the vehicle is involved in a collision on any side,
even if it is a slight collision, be sure to check the
following systems.

1) Check for the following, and replace the damaged parts with new parts.
Airbag module is cracked or deformed.
The module surface is fouled with grease, oil,
water or cleaning solvent.

Front seat, airbag module and mounting bracket
are damaged or deformed.

Airbag cover is scratched or broken.
Mounting bracket and securing clip are cracked
or deformed.
5. AIRBAG CONTROL MODULE

Control module is cracked or deformed.
AB-13

AIRBAG SYSTEM
9. STEERING SHAFT

Connector is scratched, cracked or deformed.
Airbag is deployed.
Side airbag is deployed.
Curtain airbag is deployed.

Overall length of steering column should be within specifications.
6. FRONT SUB SENSOR
Standard value:
If the section of vehicle as shown in the figure is

damaged, check for the following and replace the
damaged parts with new parts.
Overall length L
Except for OUTBACK model
833.6 +1.30.3 mm (32.82 +0.0510.012 in)
OUTBACK model
825.4 +1.30.3 mm (32.50 +0.0510.012 in)
L
AB-00029
Front sub sensor is cracked or deformed.

Airbag is deployed.
AB-00728
7. SIDE AIRBAG SENSOR AND CURTAIN

AIRBAG SENSOR
If the section of vehicle as shown in the figure is
damaged, check for the following and replace the
damaged parts with new parts.
AB-00030
Side airbag sensor and curtain airbag sensor are

cracked or deformed.
Side airbag sensor or curtain airbag is deployed.
(operating side)
8. ROLL CONNECTOR
Combination switch or steering roll connector is
AB-14
Drivers Airbag Module

AIRBAG SYSTEM
4. Drivers Airbag Module
B: INSTALLATION
A: REMOVAL
CAUTION:
Refer to CAUTION of General Description
before handling the airbag module. <Ref. to AB4, CAUTION, General Description.>
Do not allow harness and connectors to interfere or get tangled up with other parts.
To prevent the misconnection, the connector
is colored. Connect the harness side connector
to the same color of module side connector.
CAUTION:
Refer to CAUTION of General Description before handling the airbag module. <Ref. to AB-4,
1) Position the front wheels straight ahead. (After
moving a vehicle more than 5 m (16 ft) with front
wheels positioned straight ahead, make sure the
vehicle moves straight ahead.)
wait for at least 20 seconds before starting work.
4) Using TORX BIT T30 (1), remove the two
TORX bolts on the side of steering wheel.
(1)
Tightening torque:
10 Nm (1.0 kgf-m, 7.2 ft-lb)
C: INSPECTION
CAUTION:
Check for the following, and replace damaged
Airbag module, harness, connector and mounting bracket are damaged. <Ref. to AB-13, DRIVERS
AIRBAG
MODULE,
INSPECTION,
Inspection Locations After a Collision.>
CC-00018
5) Disconnect the horn harness.

6) Disconnect the airbag connector on the back of
airbag module, and then remove the airbag module. <Ref. to AB-10, PROCEDURE, Airbag Connector.>
AB-00622
7) Refer to CAUTION for handling of a removed

airbag module. <Ref. to AB-4, CAUTION, General
Description.>
AB-15
Passengers Airbag Module

AIRBAG SYSTEM
5. Passengers Airbag Module

A: REMOVAL
CAUTION:
INSTRUMENT PANEL (EXCLUDING STEERING
SUPPORT BEAM), REMOVAL, Instrument Panel
Assembly.>
4) Remove the pawl and remove the passengers
airbag module.
EI-00615
5) Refer to CAUTION for handling of a removed

airbag module. <Ref. to AB-4, CAUTION, General
Description.>
B: INSTALLATION
CAUTION:
Tightening torque:
7.4 Nm (0.75 kgf-m, 5.5 ft-lb)
C: INSPECTION
CAUTION:
Check for the following, and replace damaged
Airbag module, harness, connector, and mounting bracket are damaged. <Ref. to AB-13, PASSENGERS AIRBAG MODULE, INSPECTION,
AB-16
Side Airbag Module

AIRBAG SYSTEM
6. Side Airbag Module
7) Remove the side airbag harness from backrest

frame assembly.
A: REMOVAL
CAUTION:
NOTE:
Remove the passengers side by referring to drivers side.
4) Remove the clip from reverse side of seat cushion assembly and slide rail IN (A), and then remove
the side airbag harness. (Manual seat model)
AB-00450
8) Remove the side airbag module (A) from backrest frame assembly.
(A)
AB-00472
5) Remove the side airbag harness from back side

of seat cushion assembly. (Power seat model)
6) Remove the backrest cover. <Ref. to SE-7, DISASSEMBLY, Front Seat.>
(A)
AB-00451
AB-17
Side Airbag Module

AIRBAG SYSTEM
B: INSTALLATION
CAUTION:
1) Ensure that there are no foreign articles on side
airbag module.
2) Install the side airbag module (A) to backrest
frame assembly.
back side of seat cushion assembly. (Manual seat

model)
Tightening torque:
6.0 Nm (0.61 kgf-m, 4.4 ft-lb)
(A)
AB-00472
6) Draw the side airbag harness around the back

side of seat cushion assembly. (Power seat model)
7) Recline the seat or slide it backward and forward, and check there is no contact between the
seat backrest assembly, cushion cover assembly
and side airbag harness.
(A)
C: INSPECTION
AB-00452
3) Install the side airbag harness to backrest frame

assembly.
NOTE:
Secure the harness to its original position of seat.
AB-00450
4) Install the backrest cover. <Ref. to SE-12, ASSEMBLY, Front Seat.>

5) Install the side airbag harness to slide rail IN (A),
and then secure the connector to the bracket on
CAUTION:
Perform the inspection of following items, and replace the damaged parts with new ones. <Ref. to
AB-13, SIDE AIRBAG MODULE, INSPECTION,
1) With side collision (when side airbag is deployed)
Side airbag module assembly
Backrest pad assembly
Backrest frame assembly
Backrest cover assembly
2) Other replacement parts, which found to be
damaged by visual check
Headrest assembly
Bushing
Slide rail OUT
Slide rail IN
Seat hinge cover
Seat lifter lever
Reclining lever
Side airbag harness and connector on body side.
3) With side collision (when side airbag is not deployed)
Check the seat and airbag module visually, and
then replace them with new ones if damaged or
cracked.
Specially inspect the damage of airbag module
body, mounting bracket, and harness connector.
4) Without side collision (dirt and damage of cover)
Replace the corresponding part with a new one.
AB-18
Curtain Airbag Module

AIRBAG SYSTEM
7. Curtain Airbag Module
Sedan model
A: REMOVAL
CAUTION:
3) Remove the rear quarter trim. (Sedan model)
<Ref. to EI-63, SEDAN MODEL (MODEL WITH
CURTAIN AIRBAG), REMOVAL, Rear Quarter
Trim.>
4) Remove the quarter rear pillar trim. (Wagon
model) <Ref. to EI-63, WAGON MODEL, REMOVAL, Rear Quarter Trim.>
5) Disconnect the curtain airbag module connector.
Sedan model
(B)
(A)
(A)
(A)
(B)
(A)
(A)
(A)
(A)
AB-00625
Wagon model
(A)
(B)
(A)
(B)
(A)
(A)
(A)
(A)
(A)
(A)
(A)
AB-00626
NOTE:
Remove the rear center seat belt retractor on the
RH side before servicing.
8) Remove the airbag guide A from front pillar.
AB-00623
Wagon model
AB-00628
9) Remove the airbag guide B from center pillar.

Sedan model
AB-00624
6) Remove the roof trim. <Ref. to EI-67, REMOVAL, Roof Trim.>

7) Remove the bolts (A) and clips (B), and then remove the curtain airbag module.
CAUTION:
Be careful not to damage the curtain airbag
module during removal.
Never open the curtain airbag module before
deploying it. Never reuse the opened curtain
airbag module.
AB-19
AB-00629
Curtain Airbag Module

AIRBAG SYSTEM
C: INSPECTION
Wagon model
AB-00630
10) Remove the airbag guide C from quarter pillar.

Sedan model
AB-00631
Wagon model
CAUTION:
Perform the inspection of following items, and replace the damaged parts with new ones. <Ref. to
AB-13, CURTAIN AIRBAG MODULE, INSPECTION, Inspection Locations After a Collision.>
1) With side collision (when curtain airbag is deployed)
Curtain airbag module assembly
Roof trim
Front pillar upper trim
Center pillar upper trim
Rear quarter pillar trim
Airbag guide A, B, C
2) Other replacement parts, which found to be
damaged by visual check
Assist grip
Assist grip bracket
Curtain airbag harness and connector on body
side.
3) With side collision (when curtain airbag is not deployed)
Check the roof trim, pillar trim and airbag module
visually, and then replace them with new ones if
damaged or cracked.
Specially inspect the damage of airbag module
body, mounting bracket, harness connector.
4) Without side collision (dirt and damage of cover)
Replace the corresponding part with a new one.
AB-00632
B: INSTALLATION
CAUTION:
When installing the curtain airbag module, install a specified part at specified place.
Be careful not to damage the curtain airbag
module during removal.
Never open the curtain airbag module before
deploying it. Never reuse the deployed curtain
airbag module.
Ensure that there are no foreign articles on
airbag module.
Tightening torque:
7.5 Nm (0.77 kgf-m, 5.5 ft-lb)
AB-20
Airbag Control Module

AIRBAG SYSTEM
8. Airbag Control Module
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
A: REMOVAL
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 one.
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.
3) Remove the console front panel and console
side garnish. <Ref. to EI-54, REMOVAL, Center
Console.>
4) Remove the screws and pull out the audio unit
assembly to disconnect the connector for removal.
C: INSPECTION
Control module, connector, and mounting bracket are damaged.
Airbag is deployed.
EI-00794
5) Disconnect the connector from airbag control

module.
6) Remove the bolts and remove airbag control
module.
AB-00759
B: INSTALLATION
CAUTION:
Be sure to cover with connector water protection cover.
AB-21
Side Airbag Sensor

AIRBAG SYSTEM
9. Side Airbag Sensor

A: REMOVAL
3) Remove the center pillar lower trim. <Ref. to EI60, REMOVAL, Lower Inner Trim.>
4) Remove the center pillar inner protector lower.
SB-00144
5) Remove the front outer seat belt retractor. <Ref.

to SB-12, OUTER SEAT BELT ASSEMBLY, REMOVAL, Front Seat Belt.>
6) Remove the nut and disconnect the airbag connector to remove side airbag sensor.
AB-00634
B: INSTALLATION
CAUTION:
Tightening torque:
7.4 Nm (0.75 kgf-m, 5.5 ft-lb)
C: INSPECTION
Mounting bracket of airbag sensor or connector
is damaged.
AB-22
Curtain Airbag Sensor

AIRBAG SYSTEM
10.Curtain Airbag Sensor

A: REMOVAL
3) Remove the rear seat. <Ref. to SE-14, REMOVAL, Rear Seat.>
4) Detach the nuts and disconnect the airbag connector to remove the curtain airbag sensor.
AB-00727
B: INSTALLATION
CAUTION:
Tightening torque:
7.4 Nm (0.75 kgf-m, 5.5 ft-lb)
C: INSPECTION
Mounting bracket of curtain airbag sensor or connector is damaged.
AB-23
Roll Connector
AIRBAG SYSTEM
11.Roll Connector
A: REMOVAL
3) Remove the drivers airbag module. <Ref. to AB15, REMOVAL, Drivers Airbag Module.>
5) Remove the steering column cover.
6) Remove the screws, and then remove the roll
connector.
AB-00760
B: INSTALLATION
2) Before installing steering wheel, be sure to adjust the direction of roll connector with steering.
<Ref. to AB-24, ADJUSTMENT, Roll Connector.>
C: INSPECTION
Combination switch and roll connector are
D: ADJUSTMENT
1) Check that front wheels are positioned in straight
ahead direction.
2) Turn the roll connector pins (A) clockwise until it
stops.
3) Turn the roll connector pins (A) approx. 3.25
turns until marks are aligned.
(A)
AB-00594
AB-24
Front Sub Sensor

AIRBAG SYSTEM
12.Front Sub Sensor

A: REMOVAL
3) Remove the front bumper face. <Ref. to EI-30,
FRONT BUMPER FACE, REMOVAL, Front
Bumper.>
4) Remove the bolts, and then detach the front sub
sensor.
AB-00636
5) Disconnect the connector from front sub sensor.
B: INSTALLATION
CAUTION:
Tightening torque:
13 Nm (1.32 kgf-m, 9.6 ft-lb)
C: INSPECTION
Front sub sensor, mounting bracket and connector are damaged.
Airbag is deployed.
AB-25
Airbag Module Disposal (Deployment Processing On Vehicle)

AIRBAG SYSTEM
13.Airbag Module Disposal (Deployment Processing On Vehicle)
4) Disconnect the airbag connector.
A: PROCEDURE
CAUTION:
Do not discard an undeployed airbag modules because it may cause a serious personal
injury when accidentally deployed.
As a rule, airbag modules should be deployed while still installed in the vehicle. Do not
remove airbag modules unless necessary.
Deployment of airbag modules should be
done on a flat place free from any possible danger. Avoid deploying outdoors during rainy or
windy weather.
Deploying an 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 smoke
detector nearby.
Wear protective gloves, safety 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 the airbag
module deployment, contact the SUBARU dealer.
AB-00761
5) Short the terminal to the alligator clip furnished

as deployment tool (A).
6) Connect the deployment tool and deployment
adapter E (B).
CAUTION:
The deployment tool should be kept shorted
terminals until just before deployment of airbag
module.
SB-00016
(A) Deployment tool:

(Tool number 98299PA030)
(B) Deployment adapter E:
(Tool number 98299SA030)
7) Connect the deployment adapter E (1) to airbag

connector (AB7).

<Ref. to EI-50, REMOVAL, Instrument Panel Lower Cover.>
(AB7)
(1)
AB-00762
(1) Deployment adapter E:

AB-26

AIRBAG SYSTEM
8) Extend the wiring of deployment tool to the limit,

and make sure the vehicle is empty. Close all the
windows, sunroof and rear gate completely.

3) Remove the instrument panel side cover of passengers side and disconnect the airbag connector.
SB-00017
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 negative ()
terminal.
10) Connect the other cable of deployment tool to
the battery positive (+) terminal, and deploy the airbag module.
AB-00763

5) Connect the deployment tool (A) and deployment adapter E (B).
CAUTION:
module.
SB-00018
CAUTION:
module.
11) Remove the airbag module. <Ref. to AB-15,
Drivers Airbag Module.>
12) Wrap the deployed airbag module in airtight vinyl bag, and discard it.
SB-00016

6) Connect the deployment adapter E to airbag

connector (AB10).
(AB10)
AB-00764
AB-00591

AB-27

AIRBAG SYSTEM

SB-00017

terminal.

3) Disconnect the side airbag module connector
(yellow) under the front seat cushion.
NOTE:
For power seat type, seat need to be removed.
When deploying in vehicle, reinstall the seat after
disconnecting the airbag connector. When deploying after removal from vehicle, refer to Disposal of
Airbag Module (Deploying After Removal from Vehicle). <Ref. to AB-34, SIDE AIRBAG MODULE,
PROCEDURE, Airbag Module Disposal (Deployment Processing After Removal from Vehicle).>
4) Set the backrest at most standing position, and
then set the seat position at the center of slide rail.
adapter A (B).
CAUTION:
module.
SB-00018
CAUTION:
module.
10) Remove the instrument panel upper. <Ref. to
EI-56, REMOVAL, Instrument Panel Assembly.>
11) Remove the passenger airbag module from instrument panel upper.
12) Wrap the airbag module, which were removed
from instrument panel upper, in airtight vinyl bag,
and discard it.
SB-00016

(B) Deployment adapter A:
(Tool number 98299FC030)
7) Connect the deployment adapter A (1) to the

side airbag module connector (yellow).
CAUTION:
Do not place any object on front seat.
AB-00592
AB-28

AIRBAG SYSTEM
Deploy the side airbag one by one to discard.
(1)
AB-00652

AB-00043

4) Disconnect the curtain airbag harness.
Sedan model
SB-00017

terminal.
AB-00623
Wagon model
SB-00018
AB-00624
CAUTION:
module.
11) Remove the side airbag module. <Ref. to AB17, REMOVAL, Side Airbag Module.>

adapter A (B).
AB-29

AIRBAG SYSTEM
CAUTION:
module.

SB-00017
SB-00016

7) Connect the deployment adapter A (1) to the

curtain airbag module connector (yellow).
Sedan model

terminal.
SB-00018
(1)
AB-00653
Wagon model
(1)
CAUTION:
module.
11) Remove the curtain airbag module. <Ref. to
AB-19, REMOVAL, Curtain Airbag Module.>
AB-00654
AB-00655
NOTE:
Fold the airbag cloth three or four times as required
and fasten it with string and seal it with vinyl bag.
AB-30
Airbag Module Disposal (Deployment Processing After Removal from Vehicle)

AIRBAG SYSTEM
14.Airbag Module Disposal (Deployment Processing After

Removal from Vehicle)
4) Install the removed bolts to airbag module.
A: PROCEDURE
CAUTION:
Do not discard an undeployed airbag module
because it may cause serious personal injury
when accidentally deployed.
As a rule, airbag modules should be deployed while still installed in the vehicle. Do not
remove the airbag modules unless necessary.
Deployment of airbag modules 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.
Deploying an 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 smoke
detector nearby.
Wear protective gloves, safety goggles and
earplugs during this operation. Wash your
hands afterwards.
module.
Wrap the deployed airbag module in an airtight vinyl bag, and discard it.
If circumstances do not permit the airbag
module deployment, contact the SUBARU dealer.
AB-00047
5) Bundle three automotive wire harnesses [each

with a sectional area of 1.25 mm2 (0.00194 sq in) or
more], and bind them twofold around airbag module stay.
AB-00048

adapter X (B).
CAUTION:
module.
(A)

3) Remove the drivers airbag module. <Ref. to AB15, Drivers Airbag Module.>
(B)
AB-00715

(B) Deployment adapter X:
(Tool number 98299AG030)
8) Connect the deployment adapter X connector to

airbag module.
AB-31

AIRBAG SYSTEM
9) Install the airbag module with pad side facing upward on a wheel with tire.

AB-00050
10) Put three tires without wheels on the tire installed with the airbag module. Put on an additional
tire with a wheel, and then fasten them tight with a
rope.
SB-00018
CAUTION:
module.
SB-00025
11) Move the battery at least 5 m (16 ft) from tires,

terminal.
AB-00591

3) Remove the instrument panel assembly. <Ref.
to EI-56, REMOVAL, Instrument Panel Assembly.>
4) Remove the passenger airbag module. <Ref. to
AB-16, Passengers Airbag Module.>
(1 )
SB-00065
(1) 5 m (16 ft) or more
AB-32

AIRBAG SYSTEM

more], route them through airbag module bracket
(A). Then, twist them to add strength.
10) Put three tires without wheels on the tire installed with the airbag module. Put on an additional
tire with a wheel on top, and then fasten them tight
with a rope.
(A)
AB-00723
SB-00025

adapter E (B).

terminal.
CAUTION:
module.
(1 )
SB-00065
(1) 5 m (16 ft) or more

SB-00016

8) Connect the deployment adapter E connector to

the airbag module.
9) Install the airbag module with opening side facing upward on a 14-inch or greater size wheel with
tire.
SB-00018
CAUTION:
module.
AB-00052
AB-33

AIRBAG SYSTEM
CAUTION:
module.
AB-00592

4) Remove the side airbag module. <Ref. to AB-17,
REMOVAL, Side Airbag Module.>
5) Install the nuts (A) to airbag module, and then
bind them with bundled three automotive wire harnesses [each with a sectional area of 1.25 mm2
(0.00194 sq in) or more].
SB-00016

8) Connect the deployment adapter A connector to

airbag module.
9) Install the airbag module on a 14-inch or greater
size tire without wheel.
(A)
AB-00725
AB-00724

adapter A (B).
10) Put two tires without wheels (A) under the tire
installed with the side airbag module (B). Put on an
additional tire without a wheel (C), and then put a
tire with a wheel (D) on top. Fasten them tight with
a rope.
(D)
(C)
(B)
(A)
AB-00146
AB-34

AIRBAG SYSTEM

terminal.

4) Remove the curtain airbag module. <Ref. to AB19, REMOVAL, Curtain Airbag Module.>
5) Extend the airbag cloth and cut off the airbag at
the position of 750 mm (29.5 in) (A) from inflator
end.
A
(1 )
SB-00065
(1) 5 m (16 ft) or more

AB-00656

more], and then bind them through the holes in airbag module bracket.
SB-00018
CAUTION:
especially hot, leave it unattended for 40 minutes, and discard it.
module.
AB-00657

adapter A (B).
AB-00043

AB-35

AIRBAG SYSTEM
CAUTION:
module.

terminal.
(1 )
SB-00065
SB-00016
(1) 5 m (16 ft) or more


9) Connect the deployment adapter A connector to

airbag module.
10) Install the airbag module on a 14-inch or greater size tire without wheel.
SB-00018
AB-00658
11) Put a tire without a wheel (A) under the tire installed with the curtain airbag module (B). Put on
two additional tires without a wheels (C), and then
put a tire with a wheel (D) on top. Fasten them tight
with a rope.
CAUTION:
especially hot, leave it unattended for 40 minutes, and discard it.
module.
(D)
(C)
(B)
(A)
AB-00655
AB-00659
AB-36
AB(diag)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Page
Airbag Control Module I/O Signal..............................................................22
Airbag Connector ......................................................................................26
Airbag Warning Light Illumination Pattern.................................................29
Inspection Mode........................................................................................31
Airbag Warning Light Failure.....................................................................33
Diagnostic Chart with Trouble Code .........................................................41


A: PROCEDURE
1
Step
Check
READ DTC.
Is the normal code detected?
<Ref. to AB(diag)-30, Read Diagnostic Trouble
Code (DTC).>
READ DTC.
Is DTC displayed?
<Ref. to AB(diag)-30, Read Diagnostic Trouble
Code (DTC).>
PERFORM DIAGNOSIS.
1) Judge the possible cause from List of
Diagnostic Trouble Code <Ref. to AB(diag)37, List of Diagnostic Trouble Code (DTC).>.
2) Inspect the DTC using List of Diagnostic
Trouble Code (DTC).
AB(diag)-32, Clear Memory Mode.>
AB(diag)-31, Inspection Mode.>
6) Read any DTC again.
Is DTC displayed?
AB(diag)-2
Yes
No
Finish the diagno- Go to step 2.
sis.
Go to step 3.
Go to Airbag
Warning Light Failure. <Ref. to
AB(diag)-33, Airbag Warning Light
Failure.>
Perform the proce- Finish the diagnodure 1) to 5) in
sis.
step 3.


A: CHECK
Customers Name
Date Vehicle Brought In
Inspectors Name
Registration No.
km
V.I.N.
miles
Odometer Reading
Date Problem Occurred
Weather
Registration Year
Fine
Cloudy
Rainy
Vehicle Operation
Snowy
Other:
C (F)
Temperature
Road Condition
Level road
Uphill
Downhill
Rough road
Starting
Idling
Driving ( Constant speed
Acceleration
Steering wheel turn
Others:
Others:
Deceleration
)
Details of Problem
Check Airbag Warning Light
DTC output
Normal (After turning the ignition switch to ON, lit for 6 seconds and goes off.)
Remains ON
Remains OFF
Normal Code
AB(diag)-3
DTC: (Code:
General Description
When checking, use a test harness (1). Do not

directly apply the tester probe to any connector terminal of the airbag.
A: CAUTION
When servicing a vehicle, be sure to turn the ignition switch to OFF, disconnect the ground cable
from battery, and wait for more than 20 seconds
before starting work.
The airbag system is equipped with a backup
power source. If the airbag system is serviced within 20 seconds from the ground cable is disconnected, it may inflate.
If sensors, airbag module, airbag control module,
pretensioner and harness are deformed or damaged, replace them with new parts.
(1)
AB-00120
AB-00122
Do not use the airbag system and pretensioners

on other vehicles. When replacing parts, be sure to
replace them with new ones.
When checking the airbag system, be sure to
use a digital circuit tester. Use of an analog circuit
tester may cause the airbag to activate erroneously.
Do not drop the airbag module, subject them to

high temperature over 93C (199F), or let water,
oil or grease get on them; the internal parts may be
damaged and reliability is greatly lowered.
AB-00121
AB-00123
AB(diag)-4
General Description
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.
The airbag module cannot be used again if once

deployed.
AB-00127
AB-00124
Install the wire harness securely with the specified clips to avoid interference or tangled up with
other parts.
After removal, keep the airbag module with the

pad facing upward on a dry, clean and flat surface
away from heat, light sources, moisture and dust.
AB-00056
AB-00125
Do not allow water or oil to come in contact with

the connector terminals. Do not touch the connector terminals.
Do not check continuity of either of the airbag

modules for driver, passenger, side or curtain, or
pretensioner.
AB-00006
AB-00126
Either of the airbag modules for driver, passenger, side or curtain, or pretensioner must not be
disassembled.
AB(diag)-5
General Description
The removed front seat with an airbag module

must be kept at least 200 mm (8 in) away from walls
and other objects.
(1)
AB-00128
(1) 200 mm (8 in) or more

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.
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.
AB-00129
Do not discard undeployed airbag modules.

They could easily cause a serious accident if accidentally deployed.
AB(diag)-6
General Description
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.
(1)
(2)
AB-00130
(1)
Drivers airbag module
(2)
Passengers airbag module
AB(diag)-7
General Description
B: INSPECTION
Measure the battery voltage and check electrolyte.
C: PREPARATION TOOL
CAUTION:
To check the voltage and resistance of airbag system component, be sure to use the specified test
harness.
1. SPECIAL TOOL
TEST HARNESS F
ILLUSTRATION
3F
TOOL NUMBER
98299FC010
DESCRIPTION
TEST HARNESS F
REMARKS
Used when measuring voltage and resistance of
airbag module harnesses.
2F
1F
ST98299FC010
3F
2F
1
1F
3F
2F
1
2
3 4 5 6
1 2
1F
2 1
AB-00927
AB(diag)-8
General Description
TEST HARNESS H
ILLUSTRATION
TOOL NUMBER
98299FA030
DESCRIPTION
TEST HARNESS H
REMARKS
front sub-sensor.
2H
1H
3H
ST98299FA030
3H
2H
1
1H
3H
2H
1H
1
2
3 4 5 6
1 2
2 1
AB-00720
AB(diag)-9
General Description
TEST HARNESS R
ILLUSTRATION
TOOL NUMBER
98299FE030
DESCRIPTION
TEST HARNESS R
REMARKS
airbag control module.
5R
6R
3R
4R
2R
1R
ST98299FE030
1R
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
52
50
49
47
12
10
9
7
51
8
48
11
16
35
34
36
30
24
43
4
44
3
37
27
21
38
32
46
42
45
41
33
14
31
5
1
6
2
13
19
29
39
40
20
28
15
17
23
25
22
26
18
4R
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
1 2 3 4 5 6 7 8 9 10 11 12 13 14
1
5R
3R
2R
6R
1R
3R
4R
18 17 16
15 14 13
46 45 44 43 42 41 29 28 27 26 25 24 23 22 21 20 19 6 5 4 3 2 1
52 51 50 49 48 47 40 39 38 37 36 35 34 33 32 31 30 12 11 10 9 8 7
1 2 3 4
5 6 7 8
9 10 11 12 13 14 15 16 17 18
1 2 3 4 5
6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
2R
1 2 3
4 5 6
7 8 9 10 11 12 13 14
5R
6R
AB-00606
AB(diag)-10
General Description
TEST HARNESS N
ILLUSTRATION
TOOL NUMBER
98299SA000
DESCRIPTION
TEST HARNESS N
REMARKS
drivers airbag module and seat belt pretensioner.
2N
1N
ST98299SA000
2N
1N
1N
2N
2
1
AB-00928
AB(diag)-11
General Description
TEST HARNESS P
ILLUSTRATION
TOOL NUMBER
98299SA020
DESCRIPTION
TEST HARNESS P
REMARKS
drivers airbag module harness and passenger
airbag module harness.
2P
1P
3P
ST98299SA020
1
1P
2P
3P
4
4
3
2
1
4
AB-00679
AB(diag)-12
General Description
TEST HARNESS Q
ILLUSTRATION
TOOL NUMBER
98299SA040
DESCRIPTION
TEST HARNESS Q
REMARKS
drivers airbag module.
2Q
1Q
ST98299SA040
2Q
1Q
1Q
2Q
2
1
AB-00929
AB(diag)-13
General Description
TEST HARNESS U
ILLUSTRATION
7U
TOOL NUMBER
98299AG000
DESCRIPTION
TEST HARNESS U
6U
8U
9U
5U
4U
3U
2U
1U
ST98299AG000
AB(diag)-14
REMARKS
airbag control module.
General Description
1U
26 34 30 33 31 25 23 36 28 48 47 37 27 21 4 18 20 19 62 61 63 49 6 10 5 9 56 60 55 59 8 12 7 11 39 22 41 53 57 54 58 40 46 29 35 45 2 51 1 52 32 38 44 42 43 24 3 50 14 67 13 16 15 17 64 66 65 68
6U
4U
1
6
7
8U
8
1
10
11
12
13
14
15
7U
16
1
17
18
3
4
3U
5
6
1
2
4
5
9U
6
1
10
11
12
13
14
15
10
16
11
17
12
18
13
19
14
20
2U
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
5U
1U
52 51
50 49
60 59 58 57 56 55 54 53
68 67 66 65 64 63 62 61
2U
2 1
26 25 24
23 22 21 4 3
37 36 35 34 33 32 31 30 29 28 27 12 11 10 9 8 7 6 5
48 47 46 45 44 43 42 41 40 39 38 20 19 18 17 16 15 14 13
1 2 3
4 5 6
7 8 9 10 11 12 13 14
3U
1 2 3 4 5
6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
4U
5U
6U
7U
8U
9U
1 2 3 4
5 6 7 8
9 10 11 12 13 14 15 16 17 18
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
2
1
6 5 4 3
1
2
3 4 5 6
2
1
6 5 4 3
1 2
AB-00930
AB(diag)-15
General Description
TEST HARNESS V
ILLUSTRATION
1V
TOOL NUMBER
98299AG010
DESCRIPTION
TEST HARNESS V
REMARKS
side airbag sensor and curtain airbag sensor.
3V
2V
ST98299AG010
3V
2V
4
1V
3V
2V
1V
1 2
3
4 5 6 7 8
4 3 2 1
1 2 3 4
AB-00677
AB(diag)-16
General Description
AIRBAG RESISTOR
ILLUSTRATION
TOOL NUMBER
98299PA040
DESCRIPTION
REMARKS
AIRBAG RESISTOR Used in replacement of airbag module for which
resistance value is same as airbag module.
ST98299PA040
3
3
2
1
6 5 4 3
1
2
AB-00433
AB(diag)-17


A: LOCATION
1. LHD MODEL
(8)
AB23
(9)
(11)
AB21
AB16
AB32
(13)
(15)
(1)
AB9
AB39
AB19
(6)
AB10
AB1
B31
AB17
(4)
(17)
AB20
AB31
(3)
AB6
AB18
AB7
(5)
AB38
AB25
(18)
AB33
AB2
AB40
AB24
(2)
(16)
AB37
AB13
(7)
AB26
AB23
(10)
(12)
AB34
(14)
AB-01450
(1)
(2)
(3)
Front sub-sensor (RH)

Front sub-sensor (LH)
Airbag control module with built-in
safing and electric sensor
(4)
(5)
(6)
Airbag main harness

Roll connector
Passengers airbag inflator
(7)
(8)
(9)
(10)
(11)
(12)
Drivers airbag inflator

Airbag rear harness
Side airbag sensor (RH)
Side airbag sensor (LH)
Seat belt pretensioner (RH)
Seat belt pretensioner (LH)
AB(diag)-18
(13)
(14)
(15)
(16)
(17)
(18)
Curtain airbag sensor (RH)

Curtain airbag sensor (LH)
Side airbag inflator (RH)
Side airbag inflator (LH)
Curtain airbag inflator (RH)
Curtain airbag inflator (LH)

Connector
No.
(AB1)
(AB2)
(AB6)
(AB7)
(AB9)
(AB10)
(AB13)
(AB16)
(AB17)
(AB17)
(AB18)
(AB18)
Pin
28
12*1
20*2
12*1
20*2
Yellow
Yellow
Yellow
Yellow
Yellow
Yellow
Yellow
Yellow
Yellow
Male
Female
Male
Connector
Yellow Yellow Yellow
color
Male/Female Female Female Female
Connector
(AB19)
No.
Pin
2
Connector
Yellow
color
Male/Female Female
Female Female Female Female Female Female
(AB20)
(AB21)
(AB23)
(AB24)
(AB25)
(AB26)
(AB28)
(AB31)
(AB32)
(AB33)
(AB34)
Yellow
Black
Yellow
Yellow
Yellow
Black
Yellow
Yellow
Yellow
Yellow
Yellow
Male
Connector
(AB37) (AB38)
No.
Pin
2
2
Connector
Orange Black
color
Male/Female Female Female
Female Female Female
(AB39)
(AB40)
Yellow
Yellow
Male
Male
Male
*1: Model without curtain airbag

*2: Model with curtain airbag
AB(diag)-19

2. RHD MODEL
(10) (12)
AB28
(7)
AB16
AB26
AB37
(2)
AB34
(14)
(16)
AB24
AB40
AB2
(5)
AB7
AB33
(18)
AB25
AB38
AB18
AB6
(3)
B31
AB1
(4)
AB17
AB20
(17)
AB10
(6)
(1)
AB19
AB9
AB31
AB39
(15)
AB13
(8)
AB23
AB21
(9)
(11)
AB32
(13)
AB-00680
(1)
(2)
(3)
Front sub-sensor (LH)

Front sub-sensor (RH)
Airbag control module with built-in
safing and electric sensor
(4)
(5)
(6)
Airbag main harness

Roll connector
Passengers airbag inflator
(7)
(8)
(9)
(10)
(11)
(12)
Drivers airbag inflator

Airbag rear harness
Side airbag sensor (LH)
Side airbag sensor (RH)
Seat belt pretensioner (LH)
Seat belt pretensioner (RH)
AB(diag)-20
(13)
(14)
(15)
(16)
(17)
(18)
Curtain airbag sensor (LH)

Curtain airbag sensor (RH)
Side airbag inflator (LH)
Side airbag inflator (RH)
Curtain airbag inflator (LH)
Curtain airbag inflator (RH)

Connector
No.
(AB1)
(AB2)
(AB6)
(AB7)
(AB9)
(AB10)
(AB13)
(AB16)
(AB17)
(AB17)
(AB18)
(AB18)
Pin
28
12*1
20*2
12*1
20*2
Yellow
Yellow
Yellow
Yellow
Yellow
Yellow
Yellow
Yellow
Yellow
Male
Female
Male
Connector
Yellow Yellow Yellow
color
Male/Female Female Female Female
Connector
(AB19)
No.
Pin
2
Connector
Yellow
color
Male/Female Female
(AB20)
(AB21)
(AB23)
(AB24)
(AB25)
(AB26)
(AB28)
(AB31)
(AB32)
(AB33)
(AB34)
Yellow
Black
Yellow
Yellow
Yellow
Black
Yellow
Yellow
Yellow
Yellow
Yellow
Male
Connector
(AB37) (AB38)
No.
Pin
2
2
Connector
Orange Black
color
Male/Female Female Female
Female Female Female
(AB39)
(AB40)
Yellow
Yellow
Male
Male
Male
*1: Model without curtain airbag

*2: Model with curtain airbag
AB(diag)-21
Airbag Control Module I/O Signal

5. Airbag Control Module I/O Signal

A: WIRING DIAGRAM
FB-39
F/B FUSE NO.12
(IG)
FB-32
F/B FUSE NO.4
(IG)
GY
GY
COMBINATION
METER
i10
A3 BrW
A4 BrW
AIRBAG
WARNING LIGHT
CHECK
CONNECTOR
GY
NOT
CIRCUIT
14
A13 Lg
i1
Lg
Lg
RB
B36
B79
DIAGNOSIS
CONNECTOR
RB
LHD
RHD
B82
GROUND
TERMINAL
BY
B81
R
RB
Lg
GY
BY
B31
LHD
AB1
RHD
RB
19
Lg
3
RHD: B
GY
LHD: BY
A:
FB-41
F/B FUSE NO.25
(IG)
BrW
TO POWER SUPPLY ROUTING

FB-36
F/B FUSE NO.5
(IG)
E
AB6
AB1 (YELLOW)
2
1
3 4 5 6
AB6
(YELLOW)
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16 17
B79
1
8
2 3
9 10
4 5
11 12
(GRAY)
6 7
13 14
18 19 20 21 22 23 24 25 26 27 28
B82
1
4
A:
AIRBAG CONTROL MODULE
i10
(GREEN)
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
i1
1 2
3 4
5 6 7 8 9 10
11 12 13
14 15 16
17 18 19 20 21 22
26
27 28
23 24 25
2
3
5 6 7 8
AB-00769
AB(diag)-22

1
2
FRONT SUB SENSOR RH
1
2
FRONT SUB SENSOR LH
AB16
20
9
26
15
L
Br
W
G
W
G
L
Br
AB13
27
B
YL
YB
YG
YW
BW 28
10
11
8
7
YW 17
YG 16
YB
YL
13
14
AB6
1
2
L
YL
YB
Y
3
4
AB2
AB7
4
3
2
1
1
2
AB9
AB38
1
2
AB37
BW
YL
YB
YG
YW
L
YL
YB
Y
STEERING
ROLL
CONNECTOR
GAB-2
GAB-1
AB10
INFLATOR
(PASSENGER SIDE)
INFLATOR
(DRIVER SIDE)
AB2
AB13 (YELLOW)
AB9
AB16 (YELLOW)
1 2 3 4
AB6
(YELLOW)
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16 17
AB38
AB37
1 2
1 2
1 2
18 19 20 21 22 23 24 25 26 27 28
AB-00770
AB(diag)-23

RB
RG
B
G
L
W
YB
YG
RB
RG
RL
RW
2
1
5
6
20
4
18
19
8
7
15
13
16
17
10
7
9
12
11
12
OC
YR
YL
WC
5
6
AB18
WC : WITH CURTAIN AIRBAG
AB25
PRETENSIONER RH
AB26 (YELLOW)
1 2
SIDE AIRBAG
SENSOR RH
AB28 (YELLOW)
AB24 (YELLOW)
AB34 (YELLOW)
AB33 (YELLOW)
1
2
AB33
AB40
INFLATOR
(SIDE RH)
OC
CURTAIN
AIRBAG
SENSOR RH
AB18 (YELLOW)
1 2 3 4 5 6
1 2
1 2 3 4
RB
RG
RB
RG
RL
RW
AB34
1
2
AB24
1
2
3
4
YB
YG
B
G
L
W
AB28
1
2
3
4
AB26
1
2
YR
YL
OC : WITHOUT CURTAIN AIRBAG
INFLATOR
(CURTAIN RH)
WC
AB18 (YELLOW)
1 2
3 4
5 6 7 8 9 10 11 12
7 8 9 10 11 12
13 14 15 16 17 18 19 20
AB-01513
AB(diag)-24

12
11
RB
RG
B
G
L
W
YB
YG
RB
RG
RL
RW
5
6
13
1
15
14
9
10
18
20
17
16
9
12
10
7
6
5
OC
YR
YL
WC
2
1
AB17
AB20
SIDE AIRBAG
SENSOR LH
PRETENSIONER LH
AB21 (YELLOW)
1 2
AB23 (YELLOW)
AB19 (YELLOW)
AB32 (YELLOW)
AB31 (YELLOW)
CURTAIN
AIRBAG
SENSOR LH
AB17 (YELLOW)
1 2 3 4 5 6
1 2
1 2 3 4
1
2
AB31
AB39
INFLATOR
(SIDE LH)
OC
RB
RG
RB
RG
RL
RW
AB32
1
2
3
4
YB
YG
AB19
1
2
B
G
L
W
AB23
1
2
3
4
AB21
1
2
YR
YL
INFLATOR
(CURTAIN LH)
WC
AB17 (YELLOW)
1 2
3 4
5 6 7 8 9 10 11 12
7 8 9 10 11 12
13 14 15 16 17 18 19 20
AB-01514
AB(diag)-25
Airbag Connector
6. Airbag Connector
2. DRIVERS AIRBAG MODULE AND PRETENSIONER
A: PROCEDURE
1. POWER SUPPLY
(1) Move the slide lock (A) in the direction of arrow.
(2) With the slide lock (A) moved, separate the
connector.
(1) Using a flat tip screwdriver, pry the push
lock upward to unlock.
(A)
AB-00478
(2) Pull the connector to disconnect from drivers side airbag module assembly or retractor
assembly.
AB-00721
CAUTION:
When pulling the slide lock or disconnecting
the connector, be sure to hold onto the connector and not the wire.
2) How to connect:
Holding the connector (A), and push it in carefully
until a connecting sound is heard.
AB-00479
2) How to connect:
Connect the connector in the reverse order of disconnecting. At this time, be sure to insert the push
AB-00016
CAUTION:
Be sure to insert the connector in until it locks.
Then pull on it gently to make sure that it is
locked.
CAUTION:
Be sure to insert the connector in until it
locks. Then pull it gently to make sure that it is
locked.
AB-00480
NOTE:
Connector can not be connected when the push
lock is in lock position. To connect the connector,
set the push lock to unlock.
AB(diag)-26
Airbag Connector
3. DRIVERS AIRBAG (BETWEEN AIRBAG

MAIN HARNESS AND ROLL CONNECTOR),
PASSENGERS AIRBAG
(1) Push the slide lock (A) into the direction of
arrow.
4. SIDE AIRBAG AND CURTAIN AIRBAG

(1) Push the lock arm (A).
(2) With the lock arm (A) pushed in, move the
slide lock (B) in the direction of arrow.
(B)
(A)
(A)
AB-00017
AB-00722
(2) With the slide lock pushed, separate the

connector.
(3) With the slide lock moved, release the lock

arm (back to its original position), and disconnect the connector.
CAUTION:
Be sure to hold onto the connector and not wire
when pulling the slide lock or disconnecting
the connector.
AB-00022
CAUTION:
the connector.
2) How to connect:
Holding the connector, push it in carefully until a
connecting sound is heard.
CAUTION:
Be sure to insert the connector in until it locks.
Then pull it gently to make sure that it is locked.
AB-00018
5. FRONT SUB-SENSOR, SIDE AIRBAG

SENSOR AND CURTAIN AIRBAG SENSOR
Holding outer part (A), pull it in the direction of arrow.
CAUTION:
the connector.
AB-00023
AB-00024
AB(diag)-27
Airbag Connector
2) How to connect:
CAUTION:
Outer side (A) move back, and so do not put
your hand on the outer part.
Be sure to insert the connector in until it
locks. Then pull it gently to make sure that it is
locked.
AB-00025
AB(diag)-28
Airbag Warning Light Illumination Pattern

7. Airbag Warning Light Illumination Pattern

A: INSPECTION
Keep the ignition switch ON, and confirm that the
airbag warning light remains off approx. 6 seconds
after being turned on.
(2)
(1)
ON
OFF
(3)
AB-00135
(1) Airbag warning light

(2) Approx. 6 sec.
(3) Ignition switch (ON)
AB(diag)-29


Code (DTC)
NOTE:
The harness (yellow/black) of ground terminal is
wrapped by tapes with the harness (red, red/black)
of diagnosis connector.
4) Read the DTC by identifying the way airbag
warning light blinks.
The airbag warning light blinks a DTC 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.
A: OPERATION
3) Connect one of the ground terminals to the diagnosis connector terminal No. 2 in the instrument
panel lower cover area.
NOTE:
List of Diagnostic Trouble Code (DTC) <Ref. to
AB(diag)-37, List of Diagnostic Trouble Code
(DTC).>
Airbag Warning Light Failure <Ref. to AB(diag)33, Airbag Warning Light Failure.>.
B82
1 2
3
4 5 6 7 8
AB-00778
(1)
ON
(2)
OFF
10
1.2
1
0.3
0.3
0.3
10
1.2
0.3
(5)
ON
(3)
OFF
10
10
1.2
0.3
0.6
0.6
1.2
1
0.3
0.3
10
1.2
10
(5)
ON
(4)
OFF
(5)
AB-00137
(1)
(2)
For example
Blinking code 12:
(3)
(4)
Blinking code 21:

Blinking normal code:
5) Turn the ignition switch to OFF, and disconnect

the ground terminal from diagnosis connector terminal No. 2.
6) Wind the tape around the ground terminal and
return it to its original position.
AB(diag)-30
(5)
Sec.
Inspection Mode
9. Inspection Mode
A: PROCEDURE
Recreate the circumstance by referring to the conditions described in the checklist.
AB(diag)-31
Clear Memory Mode


A: OPERATION
3) Connect one of the ground terminals to the diagnosis connector terminal No. 2 in the instrument
panel lower cover area.
B82
1 2
3
4 5 6 7 8
AB-00778
4) While the warning light blinks, connect another

diagnosis terminal to the diagnosis connector terminal No. 3.
5) Once the memory is erased, the warning light returns the normal blink pattern (0.6 sec. on). Failure
to recover to the normal blink rate indicates that
trouble parts still remain. Having repaired such
parts, erase the memory again and confirm that the
blink rate has returned to normal.
6) When the memory has been cleared, disconnect
the diagnosis terminal from the diagnosis connector.
7) Wind the tape around the ground terminal and
return it to its original position.
AB(diag)-32
Airbag Warning Light Failure

11.Airbag Warning Light Failure

A: AIRBAG WARNING LIGHT REMAINS ON
Airbag warning light failure
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 terminal from the battery, and wait more than 20 seconds before starting to work.
Before replacing the airbag module, seat belt pretensioner, roll connector, control module and
sensor, reconnect each part and confirm that the warning light operates properly.
When inspecting the airbag main harness, disconnect the airbag module connector of the drivers
and passengers seats for safety reasons.
WIRING DIAGRAM:
IGNITION
SWITCH
No.5
A3
A4
AIRBAG
CIRCUIT
A13
14
i1
i10
BATTERY
B36
AIRBAG
INDICATOR
LIGHT
B31
AB1
AB6
AB1
1
2
3 4 5 6
i1
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
AB6
i10
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16 17
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
18 19 20 21 22 23 24 25 26 27 28
AB-00661
AB(diag)-33

Step
CHECK POOR CONTACT.
1) Turn the ignition switch OFF, disconnect the
battery ground terminal, and wait more than 20
seconds.
2) Confirm that the firm contact is secured
between the airbag control module and connector (AB6). <Ref. to AB-21, Airbag Control
Module.>
CHECK AIRBAG MAIN HARNESS.
1) Remove the instrument panel lower cover
and disconnect the connector (AB7) and
(AB2).
2) Remove the instrument panel side cover of
passenger side and disconnect the connector
(AB10) and (AB9).
3) Disconnect the connector (AB6) from airbag control module, and connect the connector
(1U) in the test harness U. <Ref. to AB-21, Airbag Control Module.>
4) Connect the battery ground terminal and
turn the ignition switch ON.
5) Connect the connectors (7U) and (8U) in
the test harness U.
NOTE:
After problem has been eliminated, disconnect
the connectors (7U) and (8U).
CHECK GROUND CIRCUIT.
seconds.
2) Disconnect the connector (AB6) from airbag control module.
3) Connect the connector (1U) in the test harness U to body harness connector (AB6).
(2U) in the test harness U and chassis ground.
(2U) No. 10 Chassis ground:
CHECK AIRBAG MAIN HARNESS AND
BODY HARNESS.
1) Disconnect the connector (7U) and (8U).
2) Remove the combination meter.
(i10) and connector (2U) in the test harness U.
(2U) No. 7 (i10) No. 13:
CHECK POOR CONTACT IN CONNECTORS
(AB1) AND (B31).
seconds.
2) Confirm that firm contact is secured
between connectors (AB1) and (B31).
Check the airbag main harness for abnormalities.
Check
Is there poor contact in connector (AB6)?
Does the airbag warning light

go off?
Yes
No
Replace the airbag Go to step 2.
main harness with
body harness or
replace the airbag
control module.
<Ref. to AB-21,
Airbag Control
Module.>
Go to step 3.
Go to step 4.

?
Replace the airbag Repair the chascontrol module.

sis ground circuit.
<Ref. to AB-21,
Airbag Control
Module.>

?
Replace the com- Go to step 5.

bination meter
printed circuit.
<Ref. to IDI-16,
Combination
Meter.>
Is there poor contact in connectors (AB1) and (B31)?
Go to step 6.
Repair the body
harness or replace
the airbag main
harness with body
harness.
Is anything unusual to airbag

main harness?
Replace the airbag Repair the body

main harness with harness.
body harness.
AB(diag)-34

B: AIRBAG WARNING LIGHT REMAINS OFF

Fuse No. 5 (in fuse box) is blown.
Body harness circuit is open.
Airbag warning light is faulty.
Airbag main harness is faulty.
CAUTION:
ground terminal from battery, and wait more than 20 seconds before starting to work.
WIRING DIAGRAM:
IGNITION
SWITCH
No.5
A3
A4
AIRBAG
CIRCUIT
A13
14
i1
i10
BATTERY
B36
AIRBAG
INDICATOR
LIGHT
B31
AB1
AB6
AB1
1
2
3 4 5 6
i1
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
AB6
i10
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16 17
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
18 19 20 21 22 23 24 25 26 27 28
AB-00661
AB(diag)-35

Step
Check
Do warning lights other than
Turn the ignition switch to ON, and confirm that the airbag turn on?
warning lights equipped in the combination
meter are turned on.
CHECK FUSE NO. 5 (IN MAIN FUSE BOX).

Remove the fuse No. 5 and perform visual
inspection.
Yes
Go to step 2.
Is the fuse No. 5 (in main fuse Replace the fuse

box) blown out?
No. 5. If the fuse
No. 5 is blown
again, go to step
3.
CHECK AIRBAG WARNING LIGHT CIRCUIT Does the airbag warning light Go to step 4.
(IN COMBINATION METER).
turn on?
seconds.
2) Disconnect the connector (AB1) from
(B31).
Does the airbag warning light Replace the airbag
1) Turn the ignition switch OFF, disconnect the turn on?
control module.
<Ref. to AB-21,
seconds.
Airbag Control
2) Connect the connector (AB1) to (B31).
Module.>
3) Disconnect the connector (AB6) from airbag control module. <Ref. to AB-21, Airbag
Control Module.>
AB(diag)-36
No
Repair the combination meter
power supply.
<Ref. to IDI-3,
Combination
Meter System.>
Go to step 3.
Replace the airbag

warning light bulb
or combination
meter printed circuit. <Ref. to IDI16, Combination
Meter.>
Replace the airbag

main harness with
body harness.


A: LIST
DTC
11
12
15
16
21
22
23
Memory function
Experienced
Experienced
Experienced
Experienced
Airbag main harness circuit is open, shorted or
shorted to ground.
Airbag module harness (Drivers side) circuit is
open, shorted or shorted to ground.
Roll connector circuit is open, shorted or shorted
to ground.
Drivers airbag module is faulty.
shorted to ground.
Airbag module harness (Passengers side) circuit
is open, shorted or shorted to ground.
Passengers airbag module is faulty.
Airbag main harness circuit (Drivers side) is
shorted to power supply.
Airbag module harness circuit (Drivers side) is
Roll connector is shorted to the power supply.
Airbag main harness circuit (Passengers side) is
Airbag module harness circuit (Passengers side)
is shorted to power supply.
Experienced
Experienced
None
24
None
25
Experienced
31
Experienced
Front airbag module and seat belt pretensioner (LH/

RH) are deployed.
(AB6), (AB17) and (AB18) are not connected properly to airbag control module.

Airbag main harness circuit is open.
Fuse No. 25 (in joint box) is blown.
Airbag rear harness circuit is open.
Airbag rear 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.
AB(diag)-37
Reference
<Ref. to AB(diag)-41,
DTC 11, Diagnostic
Chart with Trouble
Code.>
DTC 12, Diagnostic
Chart with Trouble
Code.>
DTC 15, Diagnostic
Chart with Trouble
Code.>
DTC 16, Diagnostic
Chart with Trouble
Code.>
DTC 21, Diagnostic
Chart with Trouble
Code.>
DTC 22, Diagnostic
Chart with Trouble
Code.>
DTC 23, Diagnostic
Chart with Trouble
Code.>
DTC 24, Diagnostic
Chart with Trouble
Code.>
DTC 25, Diagnostic
Chart with Trouble
Code.>
DTC 31, Diagnostic
Chart with Trouble
Code.>

DTC
Memory function
32
Experienced
33
Experienced
Front sub-sensor harness (LH) circuit is shorted.
Front sub-sensor harness (LH) circuit is open.
Front sub-sensor (LH) is faulty.

34
41
42
45
46
51
52
Experienced
Experienced
Experienced
Experienced
Experienced
Experienced
Experienced
Side airbag harness (RH) is faulty.

Side airbag module (RH) is faulty.
Side airbag harness (LH) is faulty.
Side airbag module (LH) is faulty.
Side airbag harness (RH) is shorted to power supply.
Side airbag harness (LH) is shorted to power supply.
Side airbag sensor (RH) is faulty.
Side airbag sensor (LH) is faulty.
53
Experienced
54
55
56
57
Experienced
Experienced
Experienced
Experienced
Side airbag module is deployed.

Curtain airbag module is deployed.
Curtain airbag sensor (RH) is faulty.

Curtain airbag harness (RH) is faulty.
Curtain airbag sensor (LH) is faulty.
Curtain airbag harness (LH) is faulty.
AB(diag)-38
Reference
DTC 32, Diagnostic
Chart with Trouble
Code.>
DTC 33, Diagnostic
Chart with Trouble
Code.>
DTC 34, Diagnostic
Chart with Trouble
Code.>
DTC 41, Diagnostic
Chart with Trouble
Code.>
DTC 42, Diagnostic
Chart with Trouble
Code.>
DTC 45, Diagnostic
Chart with Trouble
Code.>
DTC 46, Diagnostic
Chart with Trouble
Code.>
DTC 51, Diagnostic
Chart with Trouble
Code.>
DTC 52, Diagnostic
Chart with Trouble
Code.>
DTC 53, Diagnostic
Chart with Trouble
Code.>
DTC 54, Diagnostic
Chart with Trouble
Code.>
DTC 55, Diagnostic
Chart with Trouble
Code.>
DTC 56, Diagnostic
Chart with Trouble
Code.>
DTC 57, Diagnostic
Chart with Trouble
Code.>

DTC
Memory function
58
Experienced
59
61
62
65
66
71
72
75
76
Experienced
Experienced
Experienced
Experienced
Experienced
Experienced
Experienced
Experienced
Experienced
Seat belt pretensioner (RH) circuit is open, shorted

or shorted to ground.
Pretensioner is faulty.
Pretensioner harness is faulty.
Seat belt pretensioner (LH) circuit is open, shorted
or shorted to ground.
Seat belt pretensioner (RH) circuit is shorted to
power supply.
Seat belt pretensioner (LH) circuit is shorted to
power supply.
shorted to ground.
Airbag module harness (Drivers side) circuit is
open, shorted or shorted to ground.
Roll connector circuit is open, shorted or shorted
to ground.
shorted to ground.
Airbag module harness (Passengers side) circuit
is open, shorted or shorted to ground.
Airbag main harness circuit (Drivers side) is
Airbag module harness circuit (Drivers side) is
Roll connector is shorted to power supply.
Airbag main harness circuit (Passengers side) is
Airbag module harness circuit (Passengers side)
is shorted to power supply.
AB(diag)-39
Reference
DTC 58, Diagnostic
Chart with Trouble
Code.>
DTC 59, Diagnostic
Chart with Trouble
Code.>
DTC 61, Diagnostic
Chart with Trouble
Code.>
DTC 62, Diagnostic
Chart with Trouble
Code.>
DTC 65, Diagnostic
Chart with Trouble
Code.>
DTC 66, Diagnostic
Chart with Trouble
Code.>
DTC 71, Diagnostic
Chart with Trouble
Code.>
DTC 72, Diagnostic
Chart with Trouble
Code.>
DTC 75, Diagnostic
Chart with Trouble
Code.>
DTC 76, Diagnostic
Chart with Trouble
Code.>

DTC
91
92
95
96
Memory function
Experienced
Experienced
Experienced
Experienced
Curtain airbag harness (RH) circuit is faulty.
Curtain airbag module (RH) is faulty.
Curtain airbag harness (LH) circuit is faulty.
Curtain airbag module (LH) is faulty.
Curtain airbag harness (RH) circuit is shorted to
power supply.
Curtain airbag harness (LH) circuit is shorted to
power supply.
AB(diag)-40
Reference
DTC 91, Diagnostic
Chart with Trouble
Code.>
DTC 92, Diagnostic
Chart with Trouble
Code.>
DTC 95, Diagnostic
Chart with Trouble
Code.>
DTC 96, Diagnostic
Chart with Trouble
Code.>
Diagnostic Chart with Trouble Code

13.Diagnostic Chart with Trouble Code

A: DTC 11
Airbag main harness circuit is open, shorted or shorted to ground.
Airbag module harness (Drivers side) circuit is open, shorted or shorted to ground.
Roll connector circuit is open, shorted or shorted to ground.
CAUTION:
WIRING DIAGRAM:
17
16
13
14
AB6
1
2
3
4
AB2
AB7
STEERING
ROLL CONNECTOR
AB38
1
2
1
2
AB37
INFLATOR
(DRIVER SIDE)
AB2
1 2 3 4
(YELLOW)
AB6
(YELLOW)
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16 17
AB38 (BLACK)
1 2
AB37 (ORANGE)
1 2
18 19 20 21 22 23 24 25 26 27 28
AB-00662
AB(diag)-41

Step
CHECK DRIVERS AIRBAG MODULE.
seconds.
2) Remove the drivers airbag module. <Ref.
to AB-15, Drivers Airbag Module.>
3) Connect the connector (1N) in the test harness N to connector (AB38).
4) Connect the airbag resistor to connector
(2N) in the test harness N.
5) Connect the connectors (1Q) in the test
harness Q to connector (AB37).
(2Q) in the test harness Q.
CHECK ROLL CONNECTOR.
seconds.
2) Disconnect the test harness N from connector (AB38).
3) Disconnect the test harness Q from connector (AB37).
4) Remove the instrument panel lower cover,
disconnect the connector (AB7) from (AB2).
5) Connect the connector (1P) in the test harness P to connector (AB2).
(2P) and (3P) in the test harness P.
CHECK AIRBAG MAIN HARNESS (DRIVERS AIRBAG HARNESS).
seconds.
2) Disconnect the airbag resistor from connector (2P) and (3P) in the test harness P.
passengers side and disconnect the connector
(AB10) and (AB9). <Ref. to AB-16, Passengers Airbag Module.>
(2U) in the test harness U and connector (2P)
and (3P) in the test harness P.
(2U) No. 2 (2P) No. 1:
(2U) No. 4 (2P) No. 2:
(2U) No. 8 (3P) No. 3:
(2U) No. 12 (3P) No. 4:
Check
Yes
Does the airbag warning light Replace the
illuminate for 6 seconds and go drivers airbag
off?
module. <Ref. to
AB-15, Drivers
Airbag Module.>
No
Go to step 2.
Does the airbag warning light Replace the roll

Go to step 3.
illuminate for 6 seconds and go connector. <Ref. to
off?
AB-24, Roll Connector.>

?
AB(diag)-42
Go to step 4.
Replace the airbag

main harness with
body harness.

Step
Measure the resistance between connector
(2U) terminals in the test harness U.
(2U) No. 2 (2U) No. 4:
(2U) No. 8 (2U) No. 12:
Check
M?
AB(diag)-43
Yes
No
Replace the airbag Replace the airbag
control module.
main harness with
<Ref. to AB-21,
body harness.
Airbag Control
Module.>

B: DTC 12
Airbag module harness (Passengers side) circuit is open, shorted or shorted to ground.
CAUTION:
WIRING DIAGRAM:
7
8
11
10
AB6
1
2
3
4
AB9
AB10
INFLATOR
(PASSENGER SIDE)
AB6
AB9
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16 17
1 2 3 4
18 19 20 21 22 23 24 25 26 27 28
AB-00663
AB(diag)-44

Step
CHECK PASSENGERS AIRBAG MODULE.
seconds.
2) Remove the instrument panel side cover on
the passengers side.
(AB9).
CHECK AIRBAG MAIN HARNESS (PASSENGERS AIRBAG HARNESS).
seconds.
(2U) No. 3 (2P) No. 1:
(2U) No. 5 (2P) No. 2:
(2U) No. 9 (3P) No. 3:
(2U) No. 13 (3P) No. 4:
(2U) terminals in the test harness U and
between the connector (2U) and chassis
ground.
(2U) No. 3 (2U) No. 5:
(2U) No. 9 (2U) No. 13:
Check
Yes
No
Does the airbag warning light Replace the pas- Go to step 2.
illuminate for 6 seconds and go sengers airbag
off?
module. <Ref. to

?
Go to step 3.

M?

control module.
main harness with
<Ref. to AB-21,
body harness.
Airbag Control
Module.>
AB(diag)-45
Replace the airbag

main harness with
body harness.

C: DTC 15
Airbag main harness circuit (Drivers side) is shorted to power supply.
Airbag module harness circuit (Drivers side) is shorted to power supply.
CAUTION:
WIRING DIAGRAM:
17
16
13
14
AB6
1
2
3
4
AB2
AB7
STEERING
ROLL CONNECTOR
AB38
1
2
1
2
AB37
INFLATOR
(DRIVER SIDE)
AB2
1 2 3 4
(YELLOW)
AB6
(YELLOW)
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16 17
AB38 (BLACK)
1 2
AB37 (ORANGE)
1 2
18 19 20 21 22 23 24 25 26 27 28
AB-00662
AB(diag)-46

Step
seconds.
3) Connect the connector (AB38) to connector
seconds.
seconds.
(AB10) and (AB9).
turn the ignition switch ON. (engine OFF)
(2U) No. 4 (+) Chassis ground ():
Check
Yes
off?
module. <Ref. to
AB-15, Drivers
Airbag Module.>
No
Go to step 2.
Does the airbag warning light Replace the roll

Go to step 3.
illuminate for 6 seconds and go connector. <Ref. to
off?
AB(diag)-47

control module.
main harness with
<Ref. to AB-21,
body harness.
Airbag Control
Module.>

D: DTC 16
Airbag main harness circuit (Passengers side) is shorted to power supply.
Airbag module harness circuit (Passengers side) is shorted to power supply.
CAUTION:
WIRING DIAGRAM:
7
8
11
10
AB6
1
2
3
4
AB9
AB10
INFLATOR
(PASSENGER SIDE)
AB6
AB9
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16 17
1 2 3 4
18 19 20 21 22 23 24 25 26 27 28
AB-00663
AB(diag)-48

Step
seconds.
(AB9).
seconds.
Check
Yes
No
illuminate for 6 seconds and go sengers airbag
off?
module. <Ref. to

control module.
main harness with
<Ref. to AB-21,
body harness.
Airbag Control
Module.>
E: DTC 21
CAUTION:
Step
CHECK IF DTC 21 IS INDICATED.
Read the DTC. <Ref. to AB(diag)-30, Read
Check
Yes
Is DTC 21 indicated for airbag Replace the airbag
warning light?
control module.
<Ref. to AB-21,
Airbag Control
Module.>
AB(diag)-49
No
Perform the clear
memory mode.
<Ref. to AB(diag)32, Clear Memory
Mode.>

F: DTC 22
WIRING DIAGRAM:
* 43
*
7
8
11
10
17
16
13
14
* 12
*
AB18
AB6
AB17
WITH
CURTAIN AIRBAG
:6
AB2
1
2
:5
3
4
*1
*2
*3
*4
: 11
AB7
: 12
WITHOUT
CURTAIN AIRBAG
STEERING
ROLL
CONNECTOR
:2
:1
:5
:6
AB37
AB38
AB9
1
2
AB26
1
2
3
4
1
2
1
2
AB21
1
2
*1
*2
*3
*4
AB10
AB17
AB17
AB18
1 2
3 4
5 6 7 8 9 10 11 12
1 2 3 4 5 6
1 2
3 4
5 6 7 8 9 10 11 12
AB2
AB9
INFLATOR
(PASSENGER SIDE)
INFLATOR
(DRIVER SIDE)
PRETENSIONER LH
1 2 3 4
7 8 9 10 11 12
13 14 15 16 17 18 19 20
(WITH CURTAIN AIRBAG)
13 14 15 16 17 18 19 20
(WITHOUT CURTAIN AIRBAG)
PRETENSIONER RH
AB18
1 2 3 4 5 6
7 8 9 10 11 12
AB38
AB6
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
AB21
AB37
AB26
1 2
1 2
AB-00729
This DTC is indicated when the front airbag module and the pretensioner are deployed.
Once this DTC is displayed, the memory cannot be cleared. Replace the following parts.
Airbag control module. <Ref. to AB-21, Airbag Control Module.>
Drivers airbag module. <Ref. to AB-15, Drivers Airbag Module.>
Passengers airbag module. <Ref. to AB-16, Passengers Airbag Module.>
Front sub-sensor of both sides. <Ref. to AB-25, Front Sub Sensor.>
Front seat belt outer with pretensioner of both sides. <Ref. to SB-12, Front Seat Belt.>
AB(diag)-50

G: DTC 23
(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
terminal from battery, and wait more than 20 seconds before starting to work.
Step
Check
CHECK POOR CONTACT IN CONNECTORS Is there rust or damage on the
(AB6), (AB17) AND (AB18).
harness connector and the
1) Turn the ignition switch OFF, disconnect the control module connector?
seconds.
2) Disconnect the connectors (AB6), (AB17)
and (AB18) from airbag control modules. <Ref.
to AB-21, Airbag Control Module.>
Yes
No
control module.
<Ref. to AB-21,
Airbag Control
Module.> Or
replace the body
harness with airbag main harness. Replace the
body harness with
side airbag harness.
CHECK POOR CONTACT IN CONNECTORS Does the airbag warning light Finish the diagno- Replace the airbag
control module.
illuminate for 6 seconds and go sis.
(AB6), (AB17) AND (AB18).
off?
<Ref. to AB-21,
1) Ensure that the connectors are firmly
Airbag Control
reconnected.
Module.>
AB(diag)-51

H: DTC 24
CAUTION:
WIRING DIAGRAM:
IGNITION
SWITCH
BATTERY
No.25
AB6
AB6
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
AB-00666
AB(diag)-52

Step
Check
CHECK AIRBAG CONTROL MODULE.
seconds.
Control Module.>
3) Connect the connector (1U) in the test harness U to connector (AB6).
CHECK FUSE NO. 25 (IN JOINT BOX).
Is the fuse No. 25 blown out?
1) Confirm that the ignition switch is turned
OFF.
2) Remove the fuse No. 25 (in joint box) and
perform visual inspection.
AB(diag)-53
Yes
No
control module.
<Ref. to AB-21,
Airbag Control
Module.>
Replace the fuse Repair the body

No. 25. If the fuse harness.
No. 25 is blown
again, repair the
bulkhead harness.
Or replace the airbag main harness
with body harness.

I:
DTC 25

CAUTION:
WIRING DIAGRAM:
IGNITION
SWITCH
BATTERY
No.12
AB6
AB6
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
AB-00665
AB(diag)-54

Step
Check
CHECK AIRBAG CONTROL MODULE.
seconds.
Control Module.>
CHECK FUSE NO. 12 (IN JOINT BOX).
Is the fuse No. 12 blown out?
1) Confirm that the ignition switch is turned
OFF.
2) Remove the fuse No. 12 (in joint box) and
perform visual inspection.
AB(diag)-55
Yes
No
control module.
<Ref. to AB-21,
Airbag Control
Module.>
Replace the fuse Repair the body

No. 12. If the fuse harness.
No. 12 is blown
again, repair the
bulkhead harness.
Or replace the airbag main harness
with body harness.

J: DTC 31
Front sub-sensor harness (RH) circuit is shorted.
Front sub-sensor harness (RH) circuit is open.
CAUTION:
WIRING DIAGRAM:
20
9
AB6
1
2
AB16
FRONT SUB SENSOR RH
AB16
AB6
1 2
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
AB-00667
AB(diag)-56

Step
CHECK AIRBAG MAIN HARNESS (FRONT
SUB-SENSOR HARNESS RH).
seconds.
(AB2).
(AB10) and (AB9).
Control Module.>
6) Disconnect the front sub-sensor (RH), and
then connect the connector (1H) in the test
harness H to connector (AB16).
(3U) in the test harness U and connector (3H)
in the test harness H.
(3U) No. 7 (3H) No. 5:
(3U) No. 9 (3H) No. 6:
SUB-SENSOR HARNESS RH).
Check
?
Yes
Go to step 2.

M?
Replace the front Replace the airbag

sub-sensor (RH). main harness with
<Ref. to AB-25,
body harness.
Front Sub Sensor.> When the
sensor is not OK,
though the sensor
is replaced,
replace the airbag
control module.
<Ref. to AB-21,
Airbag Control
Module.>
AB(diag)-57
No
Replace the airbag
main harness with
body harness.

K: DTC 32
Front sub-sensor harness (LH) circuit is shorted.
Front sub-sensor harness (LH) circuit is open.
CAUTION:
WIRING DIAGRAM:
15
26
AB6
2
1
AB13
FRONT SUB SENSOR LH
AB13
AB6
1 2
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
AB-00668
AB(diag)-58

Step
SUB-SENSOR HARNESS LH).
seconds.
(AB2).
(AB10) and (AB9).
Control Module.>
6) Disconnect the front sub-sensor (LH), and
then connect the connector (1H) in the test
harness H to connector (AB13).
(3U) in the test harness U and connector (3H)
in the test harness H.
(3U) No. 6 (3H) No. 5:
(3U) No. 8 (3H) No. 6:
SUB-SENSOR HARNESS LH).
Check
?
Yes
Go to step 2.
No
Replace the airbag
main harness with
body harness.

M?
Replace the front Replace the airbag

sub-sensor (LH). main harness with
<Ref. to AB-25,
body harness.
Front Sub Sensor.> When the
sensor is not OK,
though the sensor
is replaced,
replace the airbag
control module.
<Ref. to AB-21,
Airbag Control
Module.>
L: DTC 33
When DTC 33 is displayed, the circuit within the front sub-sensor (RH) is faulty. Replace the front sub-sensor
(RH). <Ref. to AB-25, Front Sub Sensor.>
M: DTC 34
When DTC 34 is displayed, the circuit within the front sub-sensor (LH) is faulty. Replace the front sub-sensor
(LH). <Ref. to AB-25, Front Sub Sensor.>
AB(diag)-59

N: DTC 41
Side airbag module (RH) is faulty.
CAUTION:
When inspecting the airbag rear harness, disconnect the side airbag module connector, curtain
airbag module connector and seat belt pretensioner connector for safety reasons.
WIRING DIAGRAM:
8
7
OC
2
1
WC
15
13
16
17
10
7
9
12
AB18

AB24
1
2
1
2
3
4
AB28
AB25
SIDE AIRBAG
SENSOR RH
AB24
AB28
AB18
1 2 3 4
1 2
3 4
5 6 7 8 9 10 11 12
1 2
INFLATOR
(SIDE RH)
AB18
13 14 15 16 17 18 19 20
2 3 4 5 6
8 9 10 11 12
AB-00773
AB(diag)-60

1. MODEL WITH CURTAIN AIRBAG
Step
CHECK SIDE AIRBAG MODULE.
seconds.
(AB24), and connect the connector (1F) in test
harness F to connector (AB24).
3) Connect the airbag resistor to the connector (3F) in the test harness F.
CHECK AIRBAG REAR HARNESS (SIDE
AIRBAG MODULE HARNESS RH).
seconds.
2) Disconnect the connector (AB26) from seat
belt pretensioner (RH). <Ref. to SB-12, Front
Seat Belt.>
3) Disconnect the connector (AB33) from curtain airbag module (RH).
4) Disconnect the airbag resistor from the test
harness F.
Control Module.>
(3U) in the test harness U and connector (3F)
in the test harness F.
(3U) No. 20 (3F) No. 4:
(3U) No. 18 (3F) No. 3:
(3U) No. 20 (3U) No. 18:
Check
Yes
No
Does the airbag warning light Replace the side Go to step 2.
illuminate for 6 seconds and go airbag module
off?
(RH). <Ref. to AB17, REMOVAL,
Side Airbag Module.>

?
Go to step 3.
Replace the airbag

rear harness with
body harness.

M?
Go to step 4.
Replace the airbag

rear harness with
body harness.

M?

control module.
rear harness with
<Ref. to AB-21,
body harness.
Airbag Control
Module.>
AB(diag)-61

2. MODEL WITHOUT CURTAIN AIRBAG
Step
seconds.
3) Connect the airbag resistor to the connector (3F) in the test harness F.
seconds.
Seat Belt.>
harness F.
Control Module.>
6) Connect the connector (1R) in the test harness R to connector (AB18).
(3R) in the test harness R and connector (3F)
(3R) No. 20 (3F) No. 4:
(3R) No. 18 (3F) No. 3:
(3R) terminals in the test harness R.
(3R) No. 20 (3R) No. 18:
(3R) in the test harness R and chassis ground.
(3R) No. 20 Chassis ground:
Check
Yes
No
off?

?
Go to step 3.
Replace the airbag

rear harness with
body harness.

M?
Go to step 4.
Replace the airbag

rear harness with
body harness.

M?

control module.
rear harness with
<Ref. to AB-21,
body harness.
Airbag Control
Module.>
AB(diag)-62

O: DTC 42
Side airbag module (LH) is faulty.
CAUTION:
WIRING DIAGRAM:
18
20
17
16
9
10
OC
9
12
10
7
WC
5
6
AB17 AIRBAG CONTROL MODULE

AB23
1
2
3
4
1
2
AB19
AB20
INFLATOR
(SIDE LH)
AB19
AB23
AB17
1 2 3 4
1 2
3 4
5 6 7 8 9 10 11 12
1 2
SIDE AIRBAG
SENSOR LH
AB17
13 14 15 16 17 18 19 20
1 2 3 4 5 6
7 8 9 10 11 12
AB-00774
AB(diag)-63

Step
seconds.
(3F) in the test harness F.
AIRBAG MODULE HARNESS LH).
seconds.
belt pretensioner (LH). <Ref. to SB-12, Front
Seat Belt.>
3) Disconnect the connector (AB31) from curtain airbag module (LH).
4) Disconnect the airbag resistor from test
harness.
Control Module.>
(3U) No. 12 (3F) No. 4:
(3U) No. 10 (3F) No. 3:
(3U) No. 12 (3U) No. 10:
Check
Yes
No
off?
(LH). <Ref. to AB17, REMOVAL,

?
Go to step 3.
Replace the airbag

rear harness with
body harness.

M?
Go to step 4.
Replace the airbag

rear harness with
body harness.

M?

control module.
rear harness with
<Ref. to AB-21,
body harness.
Airbag Control
Module.>
AB(diag)-64

Step
seconds.
seconds.
Seat Belt.>
harness.
Control Module.>
(3R) in the test harness R and connector (3F)
(3R) No. 12 (3F) No. 4:
(3R) No. 10 (3F) No. 3:
(3R) No. 12 (3R) No. 10:
Check
Yes
No
off?

?
Go to step 3.
Replace the airbag

rear harness with
body harness.

M?
Go to step 4.
Replace the airbag

rear harness with
body harness.

M?

control module.
rear harness with
<Ref. to AB-21,
body harness.
Airbag Control
Module.>
AB(diag)-65

P: DTC 45
Side airbag harness (RH) is shorted to power supply.
CAUTION:
WIRING DIAGRAM:
8
7
OC
2
1
WC
15
13
16
17
10
7
9
12
AB18

AB24
1
2
1
2
3
4
AB28
AB25
SIDE AIRBAG
SENSOR RH
AB24
AB28
AB18
1 2 3 4
1 2
3 4
5 6 7 8 9 10 11 12
1 2
INFLATOR
(SIDE RH)
AB18
13 14 15 16 17 18 19 20
2 3 4 5 6
8 9 10 11 12
AB-00773
AB(diag)-66

Step
seconds.
seconds.
Seat Belt.>
harness.
Control Module.>
Check
Yes
No
off?
AB(diag)-67

control module.
rear harness with
<Ref. to AB-21,
body harness.
Airbag Control
Module.>

Step
seconds.
seconds.
Seat Belt.>
harness.
Control Module.>
(3R) No. 20 (+) Chassis ground ():
Check
Yes
No
off?
AB(diag)-68

control module.
rear harness with
<Ref. to AB-21,
body harness.
Airbag Control
Module.>

Q: DTC 46
Side airbag harness (LH) is shorted to power supply.
CAUTION:
WIRING DIAGRAM:
18
20
17
16
9
10
OC
9
12
10
7
WC
5
6

AB23
1
2
3
4
1
2
AB19
AB20
INFLATOR
(SIDE LH)
AB19
SIDE AIRBAG
SENSOR LH
AB23
AB17
AB17
1 2 3 4
1 2
3 4
5 6 7 8 9 10 11 12
1 2 3 4 5 6
1 2
13 14 15 16 17 18 19 20
7 8 9 10 11 12
AB-00774
AB(diag)-69

Step
seconds.
seconds.
Seat Belt.>
harness.
Control Module.>
Check
Yes
No
off?
AB(diag)-70

control module.
rear harness with
<Ref. to AB-21,
body harness.
Airbag Control
Module.>

Step
seconds.
seconds.
Seat Belt.>
harness.
Control Module.>
Check
Yes
No
off?
AB(diag)-71

control module.
rear harness with
<Ref. to AB-21,
body harness.
Airbag Control
Module.>

R: DTC 51
CAUTION:
WIRING DIAGRAM:
8
7
OC
2
1
WC
15
13
16
17
10
7
9
12
AB18

AB24
1
2
1
2
3
4
AB28
AB25
SIDE AIRBAG
SENSOR RH
AB24
AB28
AB18
1 2 3 4
1 2
3 4
5 6 7 8 9 10 11 12
1 2
INFLATOR
(SIDE RH)
AB18
13 14 15 16 17 18 19 20
2 3 4 5 6
8 9 10 11 12
AB-00773
AB(diag)-72

Step
AIRBAG SENSOR HARNESS RH).
seconds.
Seat Belt.>
(AB24).
Control Module.>
7) Disconnect the connector (AB28) from side
airbag sensor (RH), and connect the connector
(2V) in the test harness V to connector (AB28).
(4U) in the test harness U and connector (3V)
in the test harness V.
(4U) No. 5 (3V) No. 2:
(4U) No. 7 (3V) No. 1:
(4U) No. 8 (3V) No. 5:
(4U) No. 6 (3V) No. 4:
Check
?
Yes
Go to step 2.

M?
Replace the side Replace the airbag

airbag sensor
rear harness with
(RH). <Ref. to AB- body harness.
22, Side Airbag
Sensor.> When
the sensor is not
OK, though the
sensor is replaced,
replace the airbag
control module.
<Ref. to AB-21,
Airbag Control
Module.>
AB(diag)-73
No
Replace the airbag
rear harness with
body harness.

Step
seconds.
Seat Belt.>
(AB24).
Control Module.>
airbag sensor (RH), and connect the connector
(4R) in the test harness R and connector (3V)
(4R) No. 5 (3V) No. 2:
(4R) No. 7 (3V) No. 1:
(4R) No. 8 (3V) No. 5:
(4R) No. 6 (3V) No. 4:
Check
?
Yes
Go to step 2.

M?

airbag sensor
rear harness with
22, Side Airbag
Sensor.> When
the sensor is not
OK, though the
sensor is replaced,
replace the airbag
control module.
<Ref. to AB-21,
Airbag Control
Module.>
AB(diag)-74
No
Replace the airbag
rear harness with
body harness.

S: DTC 52
CAUTION:
WIRING DIAGRAM:
18
20
17
16
9
10
OC
9
12
10
7
WC
5
6

AB23
1
2
3
4
1
2
AB19
AB20
INFLATOR
(SIDE LH)
AB19
AB23
AB17
1 2 3 4
1 2
3 4
5 6 7 8 9 10 11 12
1 2
SIDE AIRBAG
SENSOR LH
AB17
13 14 15 16 17 18 19 20
1 2 3 4 5 6
7 8 9 10 11 12
AB-00774
AB(diag)-75

Step
AIRBAG SENSOR HARNESS LH).
seconds.
Seat Belt.>
(AB19).
Control Module.>
airbag sensor (LH), and connect the connector
(4U) No. 3 (3V) No. 4:
(4U) No. 1 (3V) No. 5:
(4U) No. 2 (3V) No. 1:
(4U) No. 4 (3V) No. 2:
Check
?
Yes
Go to step 2.

M?

airbag sensor
rear harness with
(LH). <Ref. to AB- body harness.
22, Side Airbag
Sensor.> When
the sensor is not
OK, though the
sensor is replaced,
replace the airbag
control module.
<Ref. to AB-21,
Airbag Control
Module.>
AB(diag)-76
No
Replace the airbag
rear harness with
body harness.

Step
seconds.
Seat Belt.>
(AB19).
Control Module.>
airbag sensor (LH), and connect the connector
(4R) in the test harness R and connector (3V)
(4R) No. 3 (3V) No. 4:
(4R) No. 1 (3V) No. 5:
(4R) No. 2 (3V) No. 1:
(4R) No. 4 (3V) No. 2:
Check
?
Yes
Go to step 2.

M?

airbag sensor
rear harness with
22, Side Airbag
Sensor.> When
the sensor is not
OK, though the
sensor is replaced,
replace the airbag
control module.
<Ref. to AB-21,
Airbag Control
Module.>
AB(diag)-77
No
Replace the airbag
rear harness with
body harness.

T: DTC 53
When DTC 53 is displayed, the circuit within the side airbag sensor (RH) is faulty. Replace the side airbag
sensor (RH). <Ref. to AB-22, Side Airbag Sensor.>
U: DTC 54
When DTC 54 is displayed, the circuit within the side airbag sensor (LH) is faulty. Replace the side airbag
sensor (LH). <Ref. to AB-22, Side Airbag Sensor.>
V: DTC 55
This code is displayed when the side airbag module and curtain airbag module are deployed.
Once this code is displayed, the memory cannot be erased. Replace the following parts.
Airbag control module. <Ref. to AB-21, Airbag Control Module.>
Front seat with side airbag module. (Operating side) <Ref. to SE-7, Front Seat.>
Side airbag sensor. (Operating side) <Ref. to AB-22, Side Airbag Sensor.>
Curtain airbag module. (Operating side) <Ref. to AB-19, Curtain Airbag Module.>
Curtain airbag sensor. (Operating side) <Ref. to AB-23, Curtain Airbag Sensor.>
AB(diag)-78

W: DTC 56
CAUTION:
WIRING DIAGRAM:
5
6
20
4
18
19
AB33
1
2
1
2
3
4
AB34
AB40
CURTAIN AIRBAG
SENSOR RH
AB33
AB34
AB18
1 2 3 4
1 2
3 4
5 6 7 8 9 10 11 12
1 2
INFLATOR
(CURTAIN RH)
13 14 15 16 17 18 19 20
AB-00671
AB(diag)-79

Step
CHECK AIRBAG REAR HARNESS (CURTAIN AIRBAG SENSOR HARNESS RH).
seconds.
Seat Belt.>
airbag module (RH).
(AB40).
Control Module.>
7) Disconnect the connector (AB34) from curtain airbag sensor (RH), and connect the connector (2V) in the test harness V to connector
(AB34).
(5U) No. 14 (3V) No. 4:
(5U) No. 16 (3V) No. 5:
(5U) No. 15 (3V) No. 1:
(5U) No. 13 (3V) No. 2:
CHECK AIRBAG REAR HARNESS (CURTAIN AIRBAG SENSOR HARNESS RH).
Check
?
Yes
Go to step 2.

M?
Replace the cur- Replace the airbag

tain airbag sensor rear harness with
23, Curtain Airbag
Sensor.> When
the sensor is not
OK, though the
sensor is replaced,
replace the airbag
control module.
<Ref. to AB-21,
Airbag Control
Module.>
AB(diag)-80
No
Replace the airbag
rear harness with
body harness.

X: DTC 57
CAUTION:
WIRING DIAGRAM:
13
1
15
14
12
11
AB32
1
2
3
4
1
2
AB31
AB39
INFLATOR
(CURTAIN LH)
AB31
AB32
AB17
1 2 3 4
1 2
3 4
5 6 7 8 9 10 11 12
1 2
CURTAIN AIRBAG
SENSOR LH
13 14 15 16 17 18 19 20
AB-00672
AB(diag)-81

Step
CHECK AIRBAG REAR HARNESS (CURTAIN AIRBAG SENSOR HARNESS LH).
seconds.
Seat Belt.>
airbag module (LH).
(AB39).
Control Module.>
7) Disconnect the connector (AB32) from curtain airbag sensor (LH), and connect the connector (2V) in the test harness V to connector
(AB32).
(5U) No. 11 (3V) No. 4:
(5U) No. 9 (3V) No. 5:
(5U) No. 10 (3V) No. 1:
(5U) No. 12 (3V) No. 2:
CHECK AIRBAG REAR HARNESS (CURTAIN AIRBAG SENSOR HARNESS LH).
Check
?
Yes
Go to step 2.
No
Replace the airbag
rear harness with
body harness.

M?
Replace the cur- Replace the airbag

tain airbag sensor rear harness with
23, Curtain Airbag
Sensor.> When
the sensor is not
OK, though the
sensor is replaced,
replace the airbag
control module.
<Ref. to AB-21,
Airbag Control
Module.>
Y: DTC 58
When DTC 58 is displayed, the circuit within the curtain airbag sensor (RH) is faulty. Replace the curtain airbag sensor (RH). <Ref. to AB-23, Curtain Airbag Sensor.>
Z: DTC 59
When DTC 59 is displayed, the circuit within the curtain airbag sensor (LH) is faulty. Replace the curtain airbag sensor (LH). <Ref. to AB-23, Curtain Airbag Sensor.>
AB(diag)-82

AA:DTC 61
Seat belt pretensioner (RH) circuit is open, shorted or shorted to ground.
CAUTION:
WIRING DIAGRAM:
*1
*2
WITH CURTAIN AIRBAG
*1
*2
: 11
: 12
WITHOUT CURTAIN AIRBAG

:5
:6
AB26
1
*1
*2
PRETENSIONER RH
AB26
AB18
AB18
1 2
1 2
3 4
5 6 7 8 9 10 11 12
1 2 3 4 5 6
13 14 15 16 17 18 19 20
7 8 9 10 11 12
AB-00775
AB(diag)-83

Step
CHECK SEAT BELT PRETENSIONER.
seconds.
Seat Belt.>
CHECK AIRBAG REAR HARNESS (PRETENSIONER HARNESS RH).
seconds.
harness.
airbag module (RH).
5) Disconnect the connectors (AB17) and
(AB18) from airbag control modules. <Ref. to
AB-21, Airbag Control Module.>
(3U) in the test harness U and connector (2N)
in the test harness N.
(3U) No. 17 (2N) No. 2:
(3U) No. 19 (2N) No. 1:
(3U) No. 19 (3U) No. 17:
Check
Yes
No
Does the airbag warning light Replace the seat Go to step 2.
illuminate for 6 seconds and go belt pretensioner
off?
(RH). <Ref. to SB12, Front Seat
Belt.>

?
Go to step 3.
Replace the airbag

rear harness with
body harness.

M?
Go to step 4.
Replace the airbag

rear harness with
body harness.

M?

control module.
rear harness with
<Ref. to AB-21,
body harness.
Airbag Control
Module.>
AB(diag)-84

Step
seconds.
Seat Belt.>
seconds.
harness.
(3R) in the test harness R and connector (2N)
(3R) No. 17 (3N) No. 2:
(3R) No. 19 (3N) No. 1:
(3R) No. 19 (3R) No. 17:
Check
Yes
No
off?
Belt.>

?
Go to step 3.
Replace the airbag

rear harness with
body harness.

M?
Go to step 4.
Replace the airbag

rear harness with
body harness.

M?

control module.
rear harness with
<Ref. to AB-21,
body harness.
Airbag Control
Module.>
AB(diag)-85

AB:DTC 62
Seat belt pretensioner (LH) circuit is open, shorted or shorted to ground.
CAUTION:
WIRING DIAGRAM:
*1
*2
WITH CURTAIN AIRBAG
*1
*2
:6
:5

:2
:1
AB21
1
*1
*2
PRETENSIONER LH
AB21
AB17
AB17
1 2
1 2
3 4
5 6 7 8 9 10 11 12
1 2 3 4 5 6
13 14 15 16 17 18 19 20
7 8 9 10 11 12
AB-00776
AB(diag)-86

Step
seconds.
Seat Belt.>
CHECK AIRBAG REAR HARNESS (PRETENSIONER HARNESS LH).
seconds.
harness.
airbag module (LH).
(3U) in the test harness U and connector (2N)
(3U) No. 13 (2N) No. 1:
(3U) No. 11 (2N) No. 2:
(3U) No. 11 (3U) No. 13:
Check
Yes
No
off?
(LH). <Ref. to SB12, Front Seat
Belt.>

?
Go to step 3.
Replace the airbag

rear harness with
body harness.

M?
Go to step 4.
Replace the airbag

rear harness with
body harness.

M?

control module.
rear harness with
<Ref. to AB-21,
body harness.
Airbag Control
Module.>
AB(diag)-87

Step
seconds.
Seat Belt.>
3) Connect the connector (1N) in the test harness N to the connector (AB21).
seconds.
harness.
(3R) in the test harness R and connector (2N)
(3R) No. 13 (2N) No. 1:
(3R) No. 11 (2N) No. 2:
(3R) No. 11 (3R) No. 13:
Check
Yes
No
off?
Belt.>

?
Go to step 3.
Replace the airbag

rear harness with
body harness.

M?
Go to step 4.
Replace the airbag

rear harness with
body harness.

M?

control module.
rear harness with
<Ref. to AB-21,
body harness.
Airbag Control
Module.>
AB(diag)-88

AC:DTC 65
Seat belt pretensioner (RH) circuit is shorted to power supply.
CAUTION:
WIRING DIAGRAM:
*1
*2
WITH CURTAIN AIRBAG
*1
*2
: 11
: 12

:5
:6
AB26
1
*1
*2
PRETENSIONER RH
AB26
AB18
AB18
1 2
1 2
3 4
5 6 7 8 9 10 11 12
1 2 3 4 5 6
13 14 15 16 17 18 19 20
7 8 9 10 11 12
AB-00775
AB(diag)-89

Step
seconds.
Seat Belt.>
seconds.
harness.
airbag module (RH).
Check
Yes
No
off?
Belt.>
AB(diag)-90

control module.
rear harness with
<Ref. to AB-21,
body harness.
Airbag Control
Module.>

Step
seconds.
Seat Belt.>
seconds.
harness.
(AB18) from the airbag control modules. <Ref.
to AB-21, Airbag Control Module.>
Check
Yes
No
off?
Belt.>
AB(diag)-91

control module.
rear harness with
<Ref. to AB-21,
body harness.
Airbag Control
Module.>

AD:DTC 66
Seat belt pretensioner (LH) circuit is shorted to power supply.
CAUTION:
WIRING DIAGRAM:
*1
*2
WITH CURTAIN AIRBAG
*1
*2
:6
:5

:2
:1
AB21
1
*1
*2
PRETENSIONER LH
AB21
AB17
AB17
1 2
1 2
3 4
5 6 7 8 9 10 11 12
1 2 3 4 5 6
13 14 15 16 17 18 19 20
7 8 9 10 11 12
AB-00776
AB(diag)-92

Step
seconds.
Seat Belt.>
3) Connect the connector (1N) in the test harness N to the connector (AB21).
seconds.
harness.
airbag module (LH).
Check
Yes
No
off?
Belt.>
AB(diag)-93

control module.
rear harness with
<Ref. to AB-21,
body harness.
Airbag Control
Module.>

Step
seconds.
Seat Belt.>
seconds.
harness.
Check
Yes
No
off?
Belt.>
AB(diag)-94

control module.
rear harness with
<Ref. to AB-21,
body harness.
Airbag Control
Module.>

AE:DTC 71
Airbag module harness (Drivers side) circuit is open, shorted or shorted to ground.
Roll connector circuit is open, shorted or shorted to ground.
CAUTION:
WIRING DIAGRAM:
17
16
13
14
AB6
1
2
3
4
AB2
AB7
STEERING
ROLL CONNECTOR
AB38
1
2
1
2
AB37
INFLATOR
(DRIVER SIDE)
AB2
1 2 3 4
(YELLOW)
AB6
(YELLOW)
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16 17
AB38 (BLACK)
1 2
AB37 (ORANGE)
1 2
18 19 20 21 22 23 24 25 26 27 28
AB-00662
AB(diag)-95

Step
seconds.
seconds.
seconds.
(AB10) and (AB9). <Ref. to AB-16, Passengers Airbag Module.>
(2U) No. 2 (2P) No. 1:
(2U) No. 4 (2P) No. 2:
(2U) No. 8 (3P) No. 3:
(2U) No. 12 (3P) No. 4:
Check
Yes
off?
module. <Ref. to
AB-15, Drivers
Airbag Module.>
No
Go to step 2.

operate properly?
Replace the roll

Go to step 3.
connector. <Ref. to

?
Go to step 4.
AB(diag)-96
Replace the airbag

main harness with
body harness.

Step
ground.
(2U) No. 2 (2U) No. 4:
(2U) No. 8 (2U) No. 12:
Check
M?
AB(diag)-97
Yes
No
control module.
main harness with
<Ref. to AB-21,
body harness.
Airbag Control
Module.>

AF:DTC 72
Airbag module harness (Passengers side) circuit is open, shorted or shorted to ground.
CAUTION:
WIRING DIAGRAM:
7
8
11
10
AB6
1
2
3
4
AB9
AB10
INFLATOR
(PASSENGER SIDE)
AB6
AB9
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16 17
1 2 3 4
18 19 20 21 22 23 24 25 26 27 28
AB-00663
AB(diag)-98

Step
seconds.
(AB9).
seconds.
(2U) No. 3 (2P) No. 1:
(2U) No. 5 (2P) No. 2:
(2U) No. 9 (3P) No. 3:
(2U) No. 13 (3P) No. 4:
ground.
(2U) No. 3 (2U) No. 5:
(2U) No. 9 (2U) No. 13:
Check
Yes
No
illuminate for 6 seconds and go senger airbag
off?
module. <Ref. to

?
Go to step 3.

M?

control module.
main harness with
<Ref. to AB-21,
body harness.
Airbag Control
Module.>
AB(diag)-99
Replace the airbag

main harness with
body harness.

AG:DTC 75
Airbag main harness circuit (Drivers side) is shorted to power supply.
Airbag module harness circuit (Drivers side) is shorted to power supply.
CAUTION:
WIRING DIAGRAM:
17
16
13
14
AB6
1
2
3
4
AB2
AB7
STEERING
ROLL CONNECTOR
AB38
1
2
1
2
AB37
INFLATOR
(DRIVER SIDE)
AB2
1 2 3 4
(YELLOW)
AB6
(YELLOW)
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16 17
AB38 (BLACK)
1 2
AB37 (ORANGE)
1 2
18 19 20 21 22 23 24 25 26 27 28
AB-00662
AB(diag)-100

Step
seconds.
3) Connect the connector (AB38) to connector
harness Q to the connector (AB37).
seconds.
seconds.
(AB10) and (AB9).
turn the ignition switch ON. (engine OFF)
Check
Yes
off?
module. <Ref. to
AB-15, Drivers
Airbag Module.>
No
Go to step 2.

operate properly?
Replace the roll

Go to step 3.
connector. <Ref. to

control module.
main harness with
<Ref. to AB-21,
body harness.
Airbag Control
Module.>
AB(diag)-101

AH:DTC 76
Airbag main harness circuit (Passengers side) is shorted to power supply.
Airbag module harness circuit (Passengers side) is shorted to power supply.
CAUTION:
WIRING DIAGRAM:
7
8
11
10
AB6
1
2
3
4
AB9
AB10
INFLATOR
(PASSENGER SIDE)
AB6
AB9
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16 17
1 2 3 4
18 19 20 21 22 23 24 25 26 27 28
AB-00663
AB(diag)-102

Step
seconds.
(AB9).
seconds.
Check
Yes
No
illuminate for 6 seconds and go senger airbag
off?
module. <Ref. to
AB(diag)-103

control module.
main harness with
<Ref. to AB-21,
body harness.
Airbag Control
Module.>

AI: DTC 91
Curtain airbag module (RH) is faulty.
CAUTION:
WIRING DIAGRAM:
5
6
20
4
18
19
AB33
1
2
1
2
3
4
AB34
AB40
CURTAIN AIRBAG
SENSOR RH
AB33
AB34
AB18
1 2 3 4
1 2
3 4
5 6 7 8 9 10 11 12
1 2
INFLATOR
(CURTAIN RH)
13 14 15 16 17 18 19 20
AB-00671
AB(diag)-104

Step
CHECK CURTAIN AIRBAG MODULE.
seconds.
CHECK AIRBAG REAR HARNESS (CURTAIN AIRBAG MODULE HARNESS RH).
seconds.
Seat Belt.>
airbag module (RH).
harness F.
Control Module.>
(5U) No. 6 (3F) No. 4:
(5U) No. 8 (3F) No. 3:
(5U) No. 6 (5U) No. 8:
Measure the resistance between the terminals
of connector (3F) in the test harness F.
(3F) No. 3 (3F) No. 4:
Check
Yes
No
Does the airbag warning light Replace the cur- Go to step 2.
illuminate for 6 seconds and go tain airbag modoff?
ule (RH). <Ref. to
AB-19, Curtain Airbag Module.>

?
Go to step 3.
Replace the airbag

rear harness with
body harness.

M?
Go to step 4.
Replace the airbag

rear harness with
body harness.

M?

control module.
rear harness with
<Ref. to AB-21,
body harness.
Airbag Control
Module.>
AB(diag)-105

AJ:DTC 92
Curtain airbag module (LH) is faulty.
CAUTION:
WIRING DIAGRAM:
13
1
15
14
12
11
AB32
1
2
3
4
1
2
AB31
AB39
INFLATOR
(CURTAIN LH)
AB31
AB32
AB17
1 2 3 4
1 2
3 4
5 6 7 8 9 10 11 12
1 2
CURTAIN AIRBAG
SENSOR LH
13 14 15 16 17 18 19 20
AB-00672
AB(diag)-106

Step
seconds.
CHECK AIRBAG REAR HARNESS (CURTAIN AIRBAG MODULE HARNESS LH).
seconds.
Seat Belt.>
airbag module (LH).
harness F.
Control Module.>
(5U) No. 1 (3F) No. 3:
(5U) No. 3 (3F) No. 4:
(5U) No. 1 (5U) No. 3:
Measure the resistance between the terminals
of connector (3F) in the test harness F.
(3F) No. 3 (3F) No. 4:
Check
Yes
No
ule (LH). <Ref. to

?
Go to step 3.
Replace the airbag

rear harness with
body harness.

M?
Go to step 4.
Replace the airbag

rear harness with
body harness.

M?

control module.
rear harness with
<Ref. to AB-21,
body harness.
Airbag Control
Module.>
AB(diag)-107

AK:DTC 95
Curtain airbag harness (RH) is shorted to power supply.
CAUTION:
WIRING DIAGRAM:
5
6
20
4
18
19
AB33
1
2
1
2
3
4
AB34
AB40
CURTAIN AIRBAG
SENSOR RH
AB33
AB34
AB18
1 2 3 4
1 2
3 4
5 6 7 8 9 10 11 12
1 2
INFLATOR
(CURTAIN RH)
13 14 15 16 17 18 19 20
AB-00671
AB(diag)-108

Step
seconds.
seconds.
Seat Belt.>
airbag module (RH).
harness F.
Control Module.>
Check
Yes
No
ule (RH). <Ref. to
AB(diag)-109

control module.
rear harness with
<Ref. to AB-21,
body harness.
Airbag Control
Module.>

AL:DTC 96
Curtain airbag harness (LH) is shorted to power supply.
CAUTION:
WIRING DIAGRAM:
13
1
15
14
12
11
AB32
1
2
3
4
1
2
AB31
AB39
INFLATOR
(CURTAIN LH)
AB31
AB32
AB17
1 2 3 4
1 2
3 4
5 6 7 8 9 10 11 12
1 2
CURTAIN AIRBAG
SENSOR LH
13 14 15 16 17 18 19 20
AB-00672
AB(diag)-110

Step
seconds.
harness F to the connector (AB31).
seconds.
Seat Belt.>
airbag module (LH).
harness F.
Control Module.>
Check
Yes
No
ule (LH). <Ref. to
AB(diag)-111

control module.
rear harness with
<Ref. to AB-21,
body harness.
Airbag Control
Module.>

AB(diag)-112
SEAT BELT SYSTEM
SB
1.
2.
3.
4.
5.
6.
7.
Page
Pretensioner Connector ..............................................................................6
Inspection Locations After a Collision .........................................................7
Seat Belt Warning System ..........................................................................8
Front Seat Belt ..........................................................................................12
Rear Seat Belt...........................................................................................14
Disposal of Pretensioner ...........................................................................17
General Description
SEAT BELT SYSTEM
A: COMPONENT
1. FRONT SEAT BELT
T3
(1)
(2)
T1
T3
(5)
T1
(3)
(4)
T1
(6)
T2
SB-00178
(1)
(2)
(3)
Adjustable anchor ASSY

Shoulder anchor
Outer seat belt ASSY
(4)
(5)
(6)
Seat belt retractor

Inner seat belt ASSY
SB-2

T1: 30 (3.1, 22)
T2: 38 (3.9, 28)
T3: 53 (5.4, 39)
General Description
SEAT BELT SYSTEM
2. REAR SEAT BELT (SEDAN MODEL)
(1)
(2)
(4)
(3)
SB-00147
(1)
(2)
Outer seat belt RH ASSY

Shoulder seat belt CTR ASSY
(3)
(4)
Outer seat belt LH ASSY

Center seat belt LH ASSY
SB-3

T: 30 (3.1, 22)
General Description
SEAT BELT SYSTEM
3. REAR SEAT BELT (WAGON MODEL)
T2
(6)
(2)
T1
(1)
(7)
T1
T1
(3)
(4)
T1
T1
(5)
SB-00148
(1)
(2)
(3)
(4)
Outer seat belt RH ASSY

Shoulder seat belt CTR ASSY
Outer seat belt LH ASSY
Center seat belt RH ASSY
(5)
(6)
(7)
Center seat belt LH ASSY

Outer belt guide RH
Outer belt guide LH
SB-4

T1: 30 (3.1, 22)
T2: 53 (5.4, 39.1)
General Description
SEAT BELT SYSTEM
B: CAUTION
Before starting service, turn the ignition switch to
OFF, disconnect the battery ground cable and wait
for 20 seconds or more.
The pretensioner system has a backup power
source. The pretensioner might deploy if you do not
wait for 20 seconds or more before starting work.
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 allow current to flow through or voltage to
reach the pretensioner. Do not use a circuit tester
to check resistance of the pretensioner.
Do not disassemble or attempt to repair the pretensioner. If it is dented, cracked or deformed, replace it with a new one.
Do not use the airbag or pretensioner parts from
other vehicles. Always replace the parts with new
ones.
When handling a seat belt with deployed pretensioner, wear gloves and goggles. Wash your hands
afterwards.
Do not reuse a seat belt with deployed 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.
C: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
98299SA010
DESCRIPTION
DEPLOYMENT
ADAPTER D
REMARKS
Used for deploying the pretensioner.
(98299PA030).
DEPLOYMENT
TOOL
Used for deploying the pretensioner.

Used with DEPLOYMENT ADAPTER D
(98299SA010).
ST98299SA010
98299PA030
ST98299PA030
2. GENERAL TOOL
TOOL NAME
TORX T50
REMARKS
Used for removing and installing the inner seat belt assembly.
SB-5
Pretensioner Connector
SEAT BELT SYSTEM
2. Pretensioner Connector
A: REMOVAL
1) Using a flat tip screwdriver, pry the push lock upward to unlock.
AB-00478
2) Pull out the connector to disconnect it from retractor assembly.
AB-00479
B: INSTALLATION
Connect the connector in the reverse order of disconnection. At this time, be sure to insert the push
CAUTION:
it is locked.
AB-00480
SB-6

SEAT BELT SYSTEM
3. Inspection Locations After a

Collision
A: INSPECTION
Check for the following, and replace with new parts
if necessary.
Center pillar lower garnish is discolored or
cracked.
Wire harness and connector are damaged.
SB-7
Seat Belt Warning System

SEAT BELT SYSTEM
4. Seat Belt Warning System

A: WIRING DIAGRAM
1. LHD MODEL
<Ref. to WI-308, LHD MODEL, WIRING DIAGRAM, Seat Belt Warning System.>
2. RHD MODEL
<Ref. to WI-309, RHD MODEL, WIRING DIAGRAM, Seat Belt Warning System.>
B: INSPECTION
TROUBLE SYMPTOM:
Seat belt warning light does not come on or go off.
Buzzer does not beep.
1. DRIVERS SEAT
Step
CHECK BODY INTEGRATED UNIT SYSTEM.
Check DTC of body integrated unit using Subaru Select Monitor. <Ref. to LAN(diag)-14,
CHECK VEHICLE SPEED SIGNAL.
Check DTC of ABS or vehicle dynamics control
(VDC) using Subaru Select Monitor. <Ref. to
ABS(diag)-15, OPERATION, Subaru Select
Monitor.> <Ref. to VDC(diag)-16, OPERATION, Subaru Select Monitor.>
link connector.
OFF).
ON.
4) Read the data of Drivers Seat SW input
Monitor.>
CHECK SEAT BELT WARNING LIGHT.
Read the data of D-belt warning light O/P
Monitor.>
1) Insert the tang plate into the drivers seat
belt buckle.
2) Read the data of Drivers Seat SW input
Monitor.>
Read the data of D-belt warning light O/P
Monitor.>
Check
Is DTC displayed?
Yes
No
nosis according to
DTC.
Is DTC displayed?

nosis according to
DTC
Is the data of Drivers Seat

SW input OFF?
Go to step 4.
Check the harness

chassis ground.
Is the data of D-belt warning Go to step 5.

light O/P ON?
Or does the seat belt warning
Is the data of Drivers Seat
Go to step 6.
SW input ON?
Check the harness

between ignition
switch and body
integrated unit.
Is the data of D-belt warning Go to step 7.

light O/P OFF?
Or is the seat belt warning light
on combination meter off?
Check the harness

between ignition
switch and body
integrated unit.
SB-8
Check the body

integrated unit.

SEAT BELT SYSTEM
Step
CHECK VEHICLE MODEL.
Check
Is the vehicle EC, EK or KA
model?
Yes
Go to step 8.
CHECK SEAT BELT WARNING SYSTEM.

1) Hold the tang plate disconnected from seat
belt buckle.
Does the seat belt warning

light illuminate?
Go to step 9.

light blink and the buzzer
beep?
Go to step 10.
Replace the body

integrated unit.
Does the buzzer stop beeping

and the seat belt warning light
change from blinking to illuminating?
Go to step 11.
Replace the body

integrated unit.
NOTE:
2) Hold the tang plate disconnected from seat
belt buckle.
3) Start the engine, and set the vehicle speed
to more than 24 km/h (15MPH).
10
11
NOTE:
wheels may light the ABS or VDC warning light,
but this indicates no malfunction. When diagnosis is finished, perform the ABS or VDC memory clearance procedure. <Ref. to ABS(diag)-15,
OPERATION, Subaru Select Monitor.> <Ref. to
VDC(diag)-16, OPERATION, Subaru Select
Monitor.>
While the seat belt warning light is blinking and
the buzzer is beeping, decelerate the vehicle
speed to less than 21 km/h (13 MPH).
to more than 24 km/h (15 MPH).
2) Wait for approx. 108 seconds while the seat
belt warning light is blinking and the buzzer is
beeping.
NOTE:
Monitor.>
No
The seat belt
warning light system is normal at
of harness connector may be the
cause. Check the
poor contact.
Replace the body
integrated unit.
The seat belt

Replace the body
warning system is integrated unit.
normal. A temporary poor contact
cause. Check the
poor contact.
2. PASSENGERS SEAT
Step
Check
CHECK BODY INTEGRATED UNIT SYSTEM. Is DTC displayed?
Check DTC of body integrated unit using Subaru Select Monitor. <Ref. to LAN(diag)-14,
SB-9
Yes
No
nosis according to
DTC.

SEAT BELT SYSTEM
Step
Check DTC of ABS or VDC using Subaru
Select Monitor. <Ref. to ABS(diag)-15, OPERATION, Subaru Select Monitor.> <Ref. to
Monitor.>
link connector.
OFF).
ON.
4) Read the data of P seatbelt SW input
Monitor.>
Read the data of P-belt warning light O/P
Monitor.>
1) Insert the tang plate into the passengers
seat belt buckle.
2) Read the data of P seatbelt SW input
Monitor.>
Read the data of P-belt warning light O/P
Monitor.>
CHECK VEHICLE MODEL.
Check
Is DTC displayed?
Yes
No
nosis according to
DTC.
Is the data of P seatbelt SW

input OFF?
Go to step 4.
Check the harness

chassis ground.
Is the data of P-belt warning

light O/P ON?
Or does the passengers seat
belt warning light illuminate?
Go to step 5.
Check the harness

between ignition
switch and body
integrated unit.
Is the data of P seatbelt SW

input ON?
Go to step 6.
Check the body

integrated unit.
Is the data of P-belt warning Go to step 7.

light O/P OFF?
Or is the passengers seat belt
warning light off?
Check the harness

between ignition
switch and body
integrated unit.
Is the vehicle EC, EK or KA

model?
Go to step 8.

1) Hold the tang plate disconnected from seat light illuminate?
belt buckle.
Go to step 9.
The seat belt

warning system is
normal at this time.
A temporary poor
contact of harness connector
may be the cause.
Check the poor
contact.
Replace the body
integrated unit.
SB-10

SEAT BELT SYSTEM
Step
NOTE:
2) Insert the tang plate of drivers seat belt into
seat belt buckle.
3) Hold the tang plate of passengers seat belt
disconnected from seat belt buckle.
10
11
NOTE:
Monitor.>
While the seat belt warning light is blinking and
the buzzer is beeping, decelerate the vehicle
speed to less than 21 km/h (13 MPH).
2) Wait for approx. 108 seconds while the seat
belt warning light is blinking and the buzzer is
beeping.
Check
light blink and the buzzer
beep?
Yes
Go to step 10.
No
Replace the body
integrated unit.

Go to step 11.
Replace the body

integrated unit.
NOTE:
Monitor.>
SB-11
The seat belt

Replace the body
warning system is integrated unit.
normal. A temporary poor contact
cause. Check the
poor contact.
Front Seat Belt

SEAT BELT SYSTEM
5. Front Seat Belt
8) Disconnect the pretensioner connector (A), and

remove the bolt, and then remove the seat belt retractor.
A: REMOVAL
1. OUTER SEAT BELT ASSEMBLY
1) Turn the ignition switch to OFF, disconnect the
battery ground cable from battery, and wait for
more than 20 seconds before starting work.
2) Fold the backrest all the way forward, and then
move the front seat all the way forward.
4) Remove the center pillar upper trim. <Ref. to EI62, REMOVAL, Upper Inner Trim.>
5) Remove the bolt, and remove the center pillar inner protector lower.
(B)
(A)
SB-00154
NOTE:
Disconnect the tension reducer connector (B) for
the seat belt retractor with tension reducer function.
CAUTION:
Do not drop or apply any impact to the pretensioner.
Since the pretensioner and bracket are integrated as a unit, do not disassemble them.
2. INNER SEAT BELT ASSEMBLY

SB-00144
6) Remove the bolt, and then remove the shoulder

anchor.

battery ground cable from battery, and wait for
3) Disconnect the seat belt warning light connector
under the seat.
4) Remove the harness clips from slide rail.
5) Remove the TORX bolt, and then remove the
inner seat belt assembly.
SB-00152
7) Remove the bolt, and then remove the adjustable anchor assembly.
SE-00332
SB-00153
SB-12
Front Seat Belt

SEAT BELT SYSTEM
B: INSTALLATION
CAUTION:
The parts of driver and passenger sides are
not identical. Before installation, make sure
that the correct part is used.
Be careful not to twist the seat belts during
installation.
Tightening torque:
<Ref. to SB-2, FRONT SEAT BELT, COMPONENT, General Description.>

Tightening torque:
<Ref. to SB-2, FRONT SEAT BELT, COMPONENT, General Description.>
C: INSPECTION
if necessary.
Pretensioner is cracked or deformed.
Seat belt is slackened, bent or worn. Seat belt is
abnormally wound or extended.

if necessary.
Inner seat belt assembly is deformed or damaged.
Seat belt buckle cannot be engaged properly.
SB-13
Rear Seat Belt

SEAT BELT SYSTEM
6. Rear Seat Belt

A: REMOVAL
1. OUTER SEAT BELT RH ASSEMBLY AND
LH ASSEMBLY (SEDAN MODEL)

4) Remove the rear shelf trim. <Ref. to EI-70, REMOVAL, Rear Shelf Trim.>
5) Remove the bolt to remove shoulder seat belt
assembly.

2) Remove the seat belt lower anchor bolt.
SB-00089
3. CENTER SEAT BELT LH ASSEMBLY

(SEDAN MODEL)
SB-00084

SEDAN MODEL (MODEL WITH CURTAIN AIRBAG), REMOVAL, Rear Quarter Trim.>
4) Remove the bolt to remove outer seat belt assembly.
1) Remove the rear seat cushion. <Ref. to SE-14,

REMOVAL, Rear Seat.>
2) Remove the bolt to remove center seat belt LH
assembly.
SB-00150
SB-00089
NOTE:
For the model with rear seat belt warning light, disconnect the connector of seat belt warning light.
2. SHOULDER SEAT BELT CTR ASSEMBLY (SEDAN MODEL)

1) Remove the rear cushion seat. <Ref. to SE-14,
2) Remove the seat belt lower anchor bolt.
SB-00149
NOTE:
SB-14
Rear Seat Belt

SEAT BELT SYSTEM

LH ASSEMBLY (WAGON MODEL)
3) Remove the clips, and then lower the roof trim

end.
1) Remove the luggage floor box. <Ref. to EI-74,

REMOVAL, Luggage Floor Box.>
2) Remove the rear seat cushion and backrest
shoulder. <Ref. to SE-14, SEDAN MODEL, REMOVAL, Rear Seat.>
3) Remove the rear quarter lower trim. <Ref. to EI63, WAGON MODEL, REMOVAL, Rear Quarter
Trim.>
4) Remove the bolt to remove outer seat belt retractor.
SB-00155
CAUTION:
When removing the roof trim clip, do not pull
the roof trim end backward with excessive
force, otherwise roof trim may be damaged.
4) Remove the bolt to remove seat belt retractor.
SB-00151
5) Remove the bolts to remove outer seat belt

guide.
SB-00160
6. CENTER SEAT BELT RH ASSEMBLY

AND LH ASSEMBLY (WAGON MODEL)
SEDAN MODEL, REMOVAL, Rear Seat.>
2) Remove the bolts, and then detach the center
seat belt assembly.
SB-00158
5. SHOULDER SEAT BELT CTR ASSEMBLY (WAGON MODEL)

1) Remove the quarter rear pillar trim. <Ref. to EI63, WAGON MODEL, REMOVAL, Rear Quarter
Trim.>
2) Remove the cover (A) from roof trim, and then
inset the seat belt to the inside of roof trim.
SB-00156
(A)
NOTE:
SB-00236
SB-15
Rear Seat Belt

SEAT BELT SYSTEM
B: INSTALLATION
CAUTION:
During installation, make sure that the seat
belts are not twisted.
After installation, make sure that the seat
belts are smoothly extended and wound.

6. CENTER SEAT BELT RH ASSEMBLY

AND LH ASSEMBLY (WAGON MODEL)
CAUTION:
C: INSPECTION

CAUTION:

if necessary.
Seat belt is slackened, bent or wore. Seat belt is

(SEDAN MODEL)

CAUTION:

if necessary.


(SEDAN MODEL)

if necessary.
Inner belt is deformed or damaged.
CAUTION:


if necessary.
CAUTION:
After seat belt guide installation, make sure
that the seat belts are wound.

if necessary.
6. CENTER SEAT BELT RH ASSEMBLY AND

SB-00157

if necessary.
Inner belt is deformed or damaged.
SB-16
Disposal of Pretensioner
SEAT BELT SYSTEM
7. Disposal of Pretensioner
A: CAUTION
Discard deployed pretensioners because it 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.
Wear protective gloves, safety goggles and earplugs during this operation. Wash your hands afterwards.
Do not drop or damage the pretensioner.
Because deploying of pretensioners cause 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 after deployment of
the pretensioner. Therefore, it must be deployed in
a well-ventilated place with no fire alarms nearby.
After deployment, the pretensioner is especially
hot, leave it unattended for 40 minutes or longer,
and then discard it.
Do not let water get on the deployed pretensioner.
Wrap the deployed pretensioner in an airtight vinyl bag, and then discard it.
If circumstances do not permit the pretensioner
deployment, contact the SUBARU dealer.
CAUTION:
The terminals of deployment tool should be
kept shorted until just before deployment of the
pretensioner.
(A)
(B)
SB-00021

(B) Deployment adapter D:
7) Connect the deployment adapter D connector

and pretensioner connector.
and make sure that the vehicle is empty. Close all
B: PROCEDURE
1. DEPLOYING OF PRETENSIONER WHILE
INSTALLED IN VEHICLE
seconds.
4) Disconnect the pretensioner connector (A).
SB-00017

and secure to the nearby area. Connect the deployment tool alligator clip to the battery negative ()
terminal.
the battery positive (+) terminal, and deploy the
pretensioner.
(A)
SB-00129
5) Short the terminal to alligator clip of deployment

tool (A).
adapter D (B).
SB-17
SB-00018
SEAT BELT SYSTEM
CAUTION:
After deployment, the pretensioner is especially hot, leave it unattended for 40 minutes or
longer, and then discard it.
11) Remove the front outer belt. <Ref. to SB-12,
REMOVAL, Front Seat Belt.>
12) Cut off the seat belt as close to retractor as possible.
4) Cut off the seat belt as close to retractor as possible.
SB-00130
5) Short the terminal to alligator clip of deployment

tool.
6) Connect the deployment tool (A) and deployment adapter D (B).
CAUTION:
The terminals of deployment tool should be
kept shorted until just before deployment of the
pretensioner.
SB-00130
13) Wrap the deployed pretensioner in airtight vinyl

bag, and discard it.
(A)
(B)
SB-00021

(B) Deployment adapter D:
SB-00131
2. DEPLOYING OF PRETENSIONER AFTER REMOVAL FROM VEHICLE

seconds.
3) Remove the front outer belt. <Ref. to SB-12, REMOVAL, Front Seat Belt.>
7) Connect the deployment adapter D connector

and pretensioner connector.
8) Install the pretensioner on a wheel with tire.
Then, bundle three automotive wire harness [each
more], and bind them twofold around the pretensioner bracket and wheel.
SB-00024
SB-18
SEAT BELT SYSTEM
9) Put three tires without wheels on the tire installed with pretensioner. Put on an additional tire
with a wheel on top, and then fasten them tight with
a rope.
12) Wrap the deployed pretensioner in airtight vinyl

bag, and discard it.
SB-00131
SB-00025

terminal.
(1 )
SB-00065
(1) 5 m (16 ft) or more

the battery positive (+) terminal, and deploy the
pretensioner.
SB-00018
CAUTION:
After deployment, the pretensioner is especially hot, leave it unattended for 40 minutes or
longer, and then discard it.
SB-19
SEAT BELT SYSTEM
SB-20
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.
32.
33.
34.
35.
Page
Headlight and Tail Light System .................................................................3
Front Fog Light System...............................................................................4
Rear Fog Light System ...............................................................................5
Turn Signal Light and Hazard Light System................................................6
Back-up Light System .................................................................................7
Stop Light System .......................................................................................8
Room Light System.....................................................................................9
Combination Switch (Light) .......................................................................10
Headlight Beam Leveler System...............................................................12
Combination Base Switch Assembly.........................................................13
Headlight Assembly ..................................................................................14
Headlight Bulb...........................................................................................18
Front Turn Signal Light Bulb .....................................................................19
Clearance/Parking Light Bulb....................................................................20
Front Fog Light Assembly .........................................................................21
Front Fog Light Bulb..................................................................................22
Rear Fog Light ..........................................................................................23
Side Turn Signal Light Assembly ..............................................................24
Rear Combination Light Assembly............................................................25
Tail/Stop Light Bulb ...................................................................................26
Rear Turn Signal Light Bulb ......................................................................27
Back-up Light Assembly............................................................................28
Back-up Light Bulb ....................................................................................29
Rear Fog Light Bulb ..................................................................................30
License Plate Light Assembly ...................................................................31
License Plate Light....................................................................................32
High-mounted Stop Light ..........................................................................33
Spot Map Light ..........................................................................................34
Room Light................................................................................................35
Luggage Room Light.................................................................................36
Trunk Room Light......................................................................................37
Glove Box Light.........................................................................................38
Door Step Light .........................................................................................39
Ignition Switch Illumination........................................................................40
General Description
LIGHTING SYSTEM
A: SPECIFICATION
Halogen type low beam
Halogen type high beam
Headlight
12 V 55 W
12 V 60 W
12 V 21 W
12 V 5 W
12 V 55 W
12 V 2.7 W (LED)
Front turn signal light

Clearance/parking light
Front fog light
Side turn signal light
Tail/stop light (Model with
rear fog light)
Tail light (Model without rear
Sedan
fog light)
Stop light (Model without
rear fog light)
Wagon Tail/stop light
Turn signal light
Sedan
Wagon
Rear combination light
Back-up light
License plate light
Sedan
Wagon
Sedan
Wagon
Rear fog light

High-mounted stop light
Interior light
Spot map light
Luggage room light
Trunk room light
Glove box light
Door step light
B: CAUTION
12 V 5/21 W
12 V 5/21 W
12 V 21 W
12 V 5/21 W
12 V 21 W
12 V 16 W
12 V 21 W
12 V 5 W
12 V 21 W
12 V 2 W (LED)
12 V 21 W
12 V 1.3 W (LED)
12 V 8 W
12 V 8 W
12 V 13 W
12 V 5 W
12 V 1.4 W
12 V 3.5 W
After reassembly, make sure functional parts operate smoothly.
Before removing or installing parts, always disconnect the battery ground cable from battery.
When replacing the audio, control module and other parts provided with memory functions, record the
memory contents before disconnecting the battery
ground cable. Otherwise, the memory will be
erased.
Reassemble the parts in the reverse order of disassembly procedure unless otherwise indicated.
Adjust parts to the given specifications.
Connect the connectors securely during reassembly.
WARNING:
The 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 the electrical 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 TOOL
TOOL NAME
Circuit tester
REMARKS
LI-2
Headlight and Tail Light System

LIGHTING SYSTEM
2. Headlight and Tail Light System
3. TAIL AND ILLUMINATION RELAY

Measure the resistance between tail and illumination relay terminals when connecting terminal No. 4
to battery positive terminal and terminal No. 3 to
battery ground terminal.
A: WIRING DIAGRAM
1. HALOGEN TYPE HEADLIGHT
<Ref. to WI-269, WIRING DIAGRAM, Headlight
System.>
(1)
2. CLEARANCE LIGHT AND ILLUMINATION LIGHT
(2)
<Ref. to WI-259, WIRING DIAGRAM, Clearance

Light and Illumination Light System.>
(3)
B: INSPECTION
(2)
(1)
(3)
(4)
(4)
LI-00001
1. HEADLIGHT SWITCH
<Ref. to LI-10, INSPECTION, Combination Switch
(Light).>
Current
Flow
No flow
2. HEADLIGHT RELAY
Measure the resistance between headlight relay
terminals when connecting terminal No. 4 to battery
positive terminal and terminal No. 3 to battery
ground terminal.
(1)
(2)
(1)
(3)
(4)
(2)
(3)
(4)
LI-00001
Current
Flow
No flow
Terminal No.
1 and 2
Standard
Less than 1
More than 1 M
LI-3
Terminal No.
1 and 2
Standard
Less than 1
More than 1 M
Front Fog Light System

LIGHTING SYSTEM
3. Front Fog Light System

A: WIRING DIAGRAM
1. FRONT FOG LIGHT
<Ref. to WI-267, WIRING DIAGRAM, Front Fog
Light System.>
B: INSPECTION
1. FRONT FOG LIGHT SWITCH
Measure the resistance between front fog light
switch terminals.
(Light).>
2. FRONT FOG LIGHT RELAY

Measure the resistance between front fog light relay terminals when connecting terminal No. 4 to
battery positive terminal and terminal No. 3 to battery ground terminal.
(1)
(2)
(1)
(3)
(4)
(2)
(3)
(4)
LI-00001
Current
Flow
No flow
Terminal No.
1 and 2
Standard
Less than 1
More than 1 M
LI-4
Rear Fog Light System

LIGHTING SYSTEM
4. Rear Fog Light System

A: WIRING DIAGRAM
1. REAR FOG LIGHT
<Ref. to WI-279, WIRING DIAGRAM, Rear Fog
Light System.>
B: INSPECTION
1. REAR FOG LIGHT SWITCH
Measure the rear fog light switch resistance between terminals. <Ref. to LI-10, INSPECTION,
Combination Switch (Light).>
2. REAR FOG LIGHT RELAY

Measure the resistance between rear fog light relay
terminals while connecting terminal No. 4 to battery
positive terminal and No. 3 to battery ground terminal.
(1)
(2)
(1)
(3)
(4)
(2)
(3)
(4)
LI-00001
Current
Flow
No flow
Terminal No.
1 and 2
Standard
Less than 1
More than 1 M
LI-5
Turn Signal Light and Hazard Light System

LIGHTING SYSTEM
5. Turn Signal Light and Hazard

Light System
A: WIRING DIAGRAM
1. TURN SIGNAL LIGHT AND HAZARD
LIGHT SYSTEM
<Ref. to WI-282, WIRING DIAGRAM, Turn Signal
Light and Hazard Light System.>
B: INSPECTION
1. TURN SIGNAL SWITCH
(Light).>
2. HAZARD SWITCH
Measure the resistance between hazard switch terminals.
3 2
1
LI-00261
Switch position
OFF
ON
Terminal No.
2 and 3
Standard
More than 1 M
Less than 1
3. TURN SIGNAL LIGHT AND HAZARD

LIGHT MODULE
Connect the battery and turn signal light bulb to the
module. The module is properly functioning if it
blinks when power is supplied to the circuit.
3
2 1
8 7 6 5 4
LI-00262
LI-6
Back-up Light System

LIGHTING SYSTEM
6. Back-up Light System
battery positive terminal and terminal No. 3 to battery ground terminal.
A: WIRING DIAGRAM
1. BACK-UP LIGHT
(1)
<Ref. to WI-257, WIRING DIAGRAM, Back-up

Light System.>
(2)
(1)
(3)
(4)
(2)
B: INSPECTION
1. BACK-UP LIGHT SWITCH (MT MODEL)
(3)
(4)
Measure the resistance between back-up light

switch terminals.
LI-00001
Current
Flow
No flow
2 1
Terminal No.
1 and 2
Standard
Less than 1
More than 1 M
NOTE:
Check other than back-up light relay. <Ref. to 4AT52, INSPECTION, Inhibitor Switch.>
LI-00263
Switch position
When shift lever is
set in reverse
position
Other positions
Terminal No.
1 and 2
Standard
Less than 1
More than 1 M
2. INHIBITOR SWITCH (4AT MODEL)

Measure the resistance between inhibitor switch
terminals.
6 5 4 3 2 1
12 11 10 9 8 7
LI-00005
Switch position
When the selector lever is in R
range
Other positions
Terminal No.
1 and 2
Standard
Less than 1
More than 1 M
3. BACK-UP LIGHT RELAY (5AT MODEL)

Measure the resistance between back-up light relay terminals when connecting terminal No. 4 to
LI-7
Stop Light System

LIGHTING SYSTEM
7. Stop Light System

A: WIRING DIAGRAM
1. STOP LIGHT
<Ref. to WI-281, WIRING DIAGRAM, Stop Light
System.>
B: INSPECTION
1. STOP LIGHT SWITCH
Measure the resistance between stop light switch
terminals.
(1)
2 1
(2)
2 1
4 3
LI-00265
(1) Model without cruise control

(2) Model with cruise control
Switch position
When brake pedal
is depressed
When brake pedal
is released
Terminal No.
Model without
cruise control: 1
and 2
Model with cruise
control: 2 and 3
Standard
Less than 1
More than 1 M
LI-8
Room Light System

LIGHTING SYSTEM
8. Room Light System
3. TRUNK ROOM LIGHT SWITCH
A: WIRING DIAGRAM
Measure the resistance between trunk room light

switch terminals.
1. INTERIOR LIGHT
<Ref. to WI-271, WIRING DIAGRAM, Interior Light
System.>
3 2 1
B: INSPECTION
1. DOOR SWITCH
Measure the resistance between door switch terminals.
LI-00277
Switch position
When trunk lid is
opened
When trunk lid is
closed
1
2
3
LI-00007
Switch position
When door is
opened
When door is
closed
Terminal No.
Standard
Less than 1
1 and 3
More than 1 M
2. REAR GATE LATCH SWITCH

Measure the resistance between rear gate latch
switch terminals.
1
2
LI-00276
Switch position
When rear gate is
opened
When rear gate is
closed
Terminal No.
Standard
Less than 1
1 and 2
More than 1 M
LI-9
Terminal No.
Standard
Less than 1
1 and 3
More than 1 M
Combination Switch (Light)

LIGHTING SYSTEM
9. Combination Switch (Light)
5) Remove the screws which secure switch, then

remove the combination switch.
A: REMOVAL
2) Remove the screws and remove the steering
column cover (upper and lower).
OFF
OFF
LI-00331
B: INSTALLATION
C: INSPECTION
SL-00258
3) Disconnect the connector from combination

switch.
4) Remove three screws, and pull the combination
base switch assembly toward you. (Only for KA
model)
Measure the resistance between combination

switch terminals.
(A)
8
17
7 6 5 4 3
2
16 1514131211 10
1
9
8
17
7
6 5 4 3 2
16 1514131211 10
1
9
(B)
LI-00184
(A) LHD and EK model

(B) KA model
LI -00332
1. LIGHTING SWITCH
LHD model
Switch position
OFF
Tail
Head
LI-10
Terminal No.
14 and 16
13, 14 and 16
Standard
More than 1 M
Less than 1
Less than 1
Combination Switch (Light)

LIGHTING SYSTEM
4. FRONT FOG LIGHT
EK model
Switch position
OFF
Tail
Head
Terminal No.
14 and 16
13, 14 and 10
Standard
More than 1 M
Less than 1
Less than 1
KA model
Switch position
OFF
Tail
Head
Switch position
OFF
ON
Terminal No.
15 and 9
14, 15 and 9
Standard
More than 1 M
Less than 1
Less than 1
LHD model
Terminal No.
7, 8 and 16
17 and 16
7 and 16
Standard
Less than 1
Less than 1
Less than 1
Switch position
OFF
ON
Switch position
OFF
ON
Switch position
OFF
ON
Terminal No.
8, 7 and 10
17 and 10
7 and 10
Standard
Less than 1
Less than 1
Less than 1
Terminal No.
1, 2 and 9
10 and 9
2 and 9
Standard
Less than 1
Less than 1
Less than 1
LHD model/EK model

Terminal No.
1 and 2
2 and 3
Standard
Less than 1
More than 1 M
Less than 1
Terminal No.
6 and 7
7 and 8
Standard
Less than 1
More than 1 M
Less than 1
KA model
Switch position
Left
Neutral
Right
Standard
More than 1 M
Less than 1
12 and 16
Terminal No.
12 and 10
Standard
More than 1 M
Less than 1
Terminal No.
Standard
More than 1 M
Less than 1
KA model
3. TURN SIGNAL SWITCH

Switch position
Left
Neutral
Right
Terminal No.
LHD model/EK model
KA model
Switch position
Passing
Low beam
High beam
Standard
More than 1 M
Less than 1
5. REAR FOG LIGHT
EK model
Switch position
Passing
Low beam
High beam
Terminal No.
10 and 11
KA model
2. DIMMER & PASSING SWITCH

Switch position
Passing
Low beam
High beam
LHD model/EK model
LI-11
16 and 13
Headlight Beam Leveler System

LIGHTING SYSTEM
10.Headlight Beam Leveler System

A: WIRING DIAGRAM
1. HEADLIGHT BEAM LEVELER SYSTEM
<Ref. to WI-243, WIRING DIAGRAM, Headlight
Beam Leveler System.>
B: INSPECTION
1. HEADLIGHT BEAM LEVELER ACTUATOR
1) Turn on the headlights.
2) Confirm the headlight beam level is lowered by
changing the switch position to 0 1 2 3
4 5.
2. HEADLIGHT BEAM LEVELER SWITCH

Connect the battery and headlight beam leveler
switch connector to the circuit tester. Measure the
voltage at each switch position.
3
2 1
8 7 6 5 4
LI-00270
Switch position
Terminal No.
0
1
2
3
4
5
6, 7 (+) and battery ()
Standard
84 89% of the
battery voltage
67 73% of the
battery voltage
51 57% of the
battery voltage
36 41% of the
battery voltage
21 26% of the
battery voltage
7 10% of the
battery voltage
LI-12
Combination Base Switch Assembly

LIGHTING SYSTEM
11.Combination Base Switch

Assembly
2. PARKING SWITCH
Measure the resistance between parking switch
terminals.
A: REMOVAL
3) Remove the screws and remove the steering
column lower cover.
2 1
4 3
LI-00183
Switch position
OFF
ON
SL-00258
4) Remove the combination switch. <Ref. to LI-10,

REMOVAL, Combination Switch (Light).> <Ref. to
WW-7, REMOVAL, Combination Switch (Wiper).>
5) Remove the four screws and remove the roll
connector.
6) Remove the three screws.
LI-00271
7) Disconnect the connector and remove the combination base switch assembly.
B: INSTALLATION
2) Before installing steering wheel, be sure the direction of roll connector is adjusted with steering.
<Ref. to AB-24, ADJUSTMENT, Roll Connector.>
C: INSPECTION
1. COMBINATION BASE SWITCH ASSEMBLY
Inspect the combination base switch assembly and
roll connector for crack or deformation. If any damage is found, replace with a new one.
LI-13
Terminal No.
2 and 4
1 and 4
Standard
Less than 1
Less than 1
Headlight Assembly
LIGHTING SYSTEM
12.Headlight Assembly
1) Remove the headlight assembly. <Ref. to LI-14,

REMOVAL, Headlight Assembly.>
2) Remove the eight screws.
A: REMOVAL
2) Remove the air intake duct. (When removing the
headlight RH)
LI-00327
3) Remove headlight side bracket.

LI-00273
(A)

4) Remove the front bumper. <Ref. to EI-30, REMOVAL, Front Bumper.>
5) Disconnect each harness connector.
6) Remove the 4 bolts and disengage clips, and
then detach the headlight assembly.
LI-00328
(A) Headlight side bracket
4) Heat the sealing portion between headlight assembly and lens using heating gun.
LI-00274
B: INSTALLATION
C: DISASSEMBLY
CAUTION:
Do not touch the bulb glass portion.
Do not touch inside the lens (extension portion) or reflector portion.
Replace the packing with a new one.
LI-14
Headlight Assembly
LIGHTING SYSTEM
CAUTION:
Avoid heating one specific point of the seal portion and heating the headlight assembly to
100C (212F) or more.
CAUTION:
Completely remove the packing not to leave
any chips behind.
(A)
(A)
LI-00060
(C)
(A) Packing
(B)
D: ASSEMBLY
1) Cut the tip of packing (A) at an angle of 45.
2) With the cut end facing upward, insert packing
(A) into the groove around the seal.
(C)
CAUTION:
If the packing protrudes, slowly take it off the
groove.
Do not stretch the packing. If the packing is
stretched, seal fails.
LI-00329
(A) Headlight ASSY upper

(B) Headlight ASSY lower
(C) Heated portion
(A)
5) Unhook the hook, and then take the lens off the
headlight assembly.
LI-00061
(A) Packing
LI-00330
6) Remove the packing (A) from seal groove.
3) After making a round of the seal, cut its tip at an

angle of 45, with its length 10 mm (0.39 in) longer
than the circumference of seal so that the tip overlaps the other. Then, press it onto the seal, using a
screwdriver.
10mm
LI-00062
LI-15
Headlight Assembly
LIGHTING SYSTEM
4) Match the positions of the lens and headlight assembly, and then insert the lens into the headlight
assembly.
CAUTION:
Remove the turn signal light bulb and clearance/parking light bulb before removing the
lens.
5) Secure the hook, and then install the clip and
screw.
6) Put the seal portion of headlight assembly into
the water and check that water does not enter inside the headlight.
CAUTION:
Be sure that water does not enter inside the
headlight through the bulb socket and ventilation hole.
E: ADJUSTMENT
1. HEADLIGHT AIMING
CAUTION:
Turn off the light before adjusting headlight
beam level. If the light is necessary to check
aiming, do not turn on for more than two minutes.
NOTE:
Before checking the headlight beam level, be sure
of the following:
The area around the headlight has not sustained
any accident, damage or other type of deformation.
Vehicle is parked on a level surface.
The inflation pressure of tires is correct.
Vehicles fuel tank is fully filled.
1) Bounce the vehicle several times to normalize
the suspension.
2) Make certain that someone is seated in the drivers seat.
3) Turn the headlights on and then adjust the low
beam pattern.
NOTE:
Position the headlight beam leveler switch to 0.
Adjust the vertical aim (A) first, then horizontal
aim (B).
(B)
(A)
LI-00275
LI-16
Headlight Assembly
LIGHTING SYSTEM
(A)
W1
W2
W2
W
W1
(A)
(B)
h
H
(C)
LI-00324
(A)
Vehicle center
(B)
Bulb center marking
(C)
3 m (10 ft)
Illustration above shows the illumination pattern for LHD model. Illumination pattern for RHD model is symmetrically opposite.
H mm (in)
W mm (in)
1,180 (46.46)
Sedan
640 (25.20)
Wagon
Except for OUTBACK
635 (25.00)
LI-17
OUTBACK
705 (27.76)
h mm (in)
at 3 m (10 ft)
30 (1.18)
Headlight Bulb
LIGHTING SYSTEM
13.Headlight Bulb
7) Remove the light bulb retaining spring (A) to remove bulb.
A: REMOVAL
1. HIGH BEAM AND LOW BEAM
(A)
CAUTION:
Because the 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 performance.
headlight bulb RH).
LI-00279
B: INSTALLATION
C: INSPECTION
1. HALOGEN TYPE
1) Visually check the bulb for blow out.
2) Check the bulb specification.
<Ref. to LI-2, SPECIFICATION, General Description.>
3) If NG, replace the bulb with a new one.
LI-00273
3) Remove the battery cover. (When removing the

headlight bulb LH).
4) Tilt the washer tank filler neck. (When removing
the headlight bulb LH).
5) Disconnect the harness connector.
6) Remove the bulb assembly (A) to remove high
beam. To remove the low beam, remove the back
cover (B), and then go to Step 7.
(B)
(A)
LI-00278
LI-18
Front Turn Signal Light Bulb

LIGHTING SYSTEM
14.Front Turn Signal Light Bulb

A: REMOVAL
1) When removing the turn signal light bulb, fully
turn the steering wheels to opposite direction from
desired turn signal light bulb.
(3)
(2)
(1)
LI-00311
(1) Turn the steering wheel fully.

(2) Mud guard
(3) Front turn signal light
2) Turn the mud guard inward.

3) Turn the socket (A) from wheel arch part, and
then remove the front turn signal light bulb.
(A)
LI-00283
CAUTION:
For 5AT model, remove the turn signal light
bulb LH from engine compartment with removing battery, because it can not be removed from
wheel arch part.
B: INSTALLATION
C: INSPECTION
LI-19
Clearance/Parking Light Bulb

LIGHTING SYSTEM
15.Clearance/Parking Light Bulb

A: REMOVAL
clearance light/parking light bulb RH).
LI-00273
2) Remove the battery cover. (When removing the

clearance light/parking light bulb LH)
3) Tilt the washer tank filler neck. (When removing
the clearance/parking light bulb)
4) Remove the headlight low beam back cover (B).
5) Turn the socket (A) and remove the bulb.
(B)
(A)
LI-00285
B: INSTALLATION
C: INSPECTION
2) Check the bulb specification. <Ref. to LI-2,
LI-20
Front Fog Light Assembly

LIGHTING SYSTEM
16.Front Fog Light Assembly
2. OUTBACK MODEL
A: REMOVAL

2) Remove the two clips, and then turn over the
lower mud guard.
1. EXCEPT FOR OUTBACK MODEL

2) Remove the front fog light cover (A).
(A)
LI-00288
LI-00287
3) Disengage the two clips, and then turn over the

lower mud guard.

4) Remove the mounting bolts, and then detach the
fog light assembly by pulling it.
LI-00325
B: INSTALLATION
LI-00288

5) Remove the mounting bolts, and then detach the
fog light assembly by pulling it.

CAUTION:
When installing the fog light assembly, be sure
to secure the upper hock.
LI-00289
LI-00326
LI-21
Front Fog Light Bulb

LIGHTING SYSTEM
17.Front Fog Light Bulb

A: REMOVAL
2) Disengage the two clips, and then turn over the
lower mud guard.
LI-00288

4) Remove the back cover.
LI-00291
5) Remove the spring retainer then detach the fog

light bulb.
B: INSTALLATION
C: INSPECTION
LI-22
Rear Fog Light

LIGHTING SYSTEM
18.Rear Fog Light

A: REMOVAL
NOTE:
Rear fog light is installed to rear combination light
of drivers side for sedan and rear gate garnish of
drivers side for wagon.
1. SEDAN MODEL
Remove the rear combination light. <Ref. to LI-25,
REMOVAL, Rear Combination Light Assembly.>
2. WAGON MODEL
1) Remove the rear gate trim. <Ref. to EI-69, REMOVAL, Rear Gate Trim.>
2) Disconnect the harness connectors and remove
the rear gate garnish. <Ref. to EI-76, REMOVAL,
Rear Gate Garnish.>
3) Remove the mounting nuts and detach the rear
fog light assembly.
LI-00292
B: INSTALLATION
LI-23
Side Turn Signal Light Assembly

LIGHTING SYSTEM
19.Side Turn Signal Light Assembly

A: REMOVAL
2) Remove the scalp caps. <Ref. to GW-18, REPLACEMENT, Scalp Cap.>
3) Remove the mirror. <Ref. to GW-20, REPLACEMENT, Outer Mirror.>
4) Disconnect the harness connector, remove the 3
mounting screws and then remove the side turn
signal light assembly.
LI-00293
B: INSTALLATION
C: INSPECTION
1) Install the side turn signal light assembly and
check that it blinks normally.
2) If it does not blink normally, replace the side turn
signal light assembly with a new one.
NOTE:
Since LED (Light Emitting Diode) is used for side
turn signal light, replace the side turn signal light
assembly when the LED is powered off.
LI-24
Rear Combination Light Assembly

LIGHTING SYSTEM
20.Rear Combination Light Assembly
4) Remove the two bolts, and then detach the rear

combination light by pulling it to the rear side of vehicle.
A: REMOVAL
1. SEDAN MODEL
2) Remove the trunk room side trim. <Ref. to EI-71,
REMOVAL, Trunk Room Trim.>
3) Remove the four nuts, and then detach the rear
combination light after disconnecting the connector.
LI-00296
5) Remove the rear combination light after turning

the socket of tail/stop light bulb and rear turn signal
light bulb to remove the bulbs.
B: INSTALLATION
LI-00294
2. WAGON MODEL
2) Remove the clips.
LI-00295
3) While pressing the portion (A), insert your finger

or flat-tip screwdriver wrapped with tape into the
clearance (B) to remove pawls in the order of (C),
(D), (E), and remove the rear combination cover.
(E)
(C)
(A)
(D)
(B)
LI-00284
LI-25
Tail/Stop Light Bulb

LIGHTING SYSTEM
21.Tail/Stop Light Bulb

A: REMOVAL
1. SEDAN MODEL
1) Remove the trunk side trim cover.
2) Turn the socket and remove the bulb.
(A)
(B)
LI-00297
Model without rear fog light

(A) Tail light
(B) Stop light
Model with rear fog light
(A) Tail/stop light
(B) Rear fog light (Drivers side only)
2. WAGON MODEL
1) Remove the rear combination light assembly.
<Ref. to LI-25, WAGON MODEL, REMOVAL, Rear
Combination Light Assembly.>
LI-00298
B: INSTALLATION
C: INSPECTION
LI-26
Rear Turn Signal Light Bulb

LIGHTING SYSTEM
22.Rear Turn Signal Light Bulb

A: REMOVAL
1. SEDAN MODEL
1) Remove the trunk side trim cover.
LI-00299
2. WAGON MODEL
<Ref. to LI-25, WAGON MODEL, REMOVAL, Rear
Combination Light Assembly.>
LI-00300
B: INSTALLATION
C: INSPECTION
LI-27
Back-up Light Assembly

LIGHTING SYSTEM
23.Back-up Light Assembly

A: REMOVAL
NOTE:
In case of model with rear fog light, back-up light is
installed to only passengers side.
1. SEDAN MODEL
Remove the rear combination light. <Ref. to LI-25,
REMOVAL, Rear Combination Light Assembly.>
2. WAGON MODEL
the rear gate garnish. <Ref. to EI-76, REMOVAL,
Rear Gate Garnish.>
3) Remove the mounting nuts and detach the backup light assembly.
LI-00301
B: INSTALLATION
LI-28
Back-up Light Bulb

LIGHTING SYSTEM
24.Back-up Light Bulb

A: REMOVAL
1. SEDAN MODEL
1) Remove the bulb inspection cover of trunk side
trim.
LI-00304
2. WAGON MODEL
1) Remove the bulb inspection cover of rear gate
trim.
LI-00305
B: INSTALLATION
C: INSPECTION
LI-29
Rear Fog Light Bulb

LIGHTING SYSTEM
25.Rear Fog Light Bulb

A: REMOVAL
1. SEDAN MODEL
1) Remove the bulb inspection cover of trunk side
trim.
LI-00302
2. WAGON MODEL
1) Remove the rear fog light assembly. <Ref. to LI23, REMOVAL, Rear Fog Light.>
2) Remove the mounting screws, and then remove
the rear fog light assembly.
LI-00292
B: INSTALLATION
C: INSPECTION
1. SEDAN MODEL
2. WAGON MODEL
1) Install the rear fog light assembly to check that it
illuminate normally.
2) If it does not illuminate, replace the rear fog light
assembly with a new one.
NOTE:
Since LED (Light Emitting Diode) is used for the
rear fog light, replace the rear fog light assembly
when the LED is powered off.
LI-30
License Plate Light Assembly

LIGHTING SYSTEM
26.License Plate Light Assembly

A: REMOVAL
1. SEDAN MODEL
1) Remove the trunk lid garnish. <Ref. to EI-75,
REMOVAL, Trunk Lid Garnish.>
2) Remove the trunk lid trim. <Ref. to EI-71,
TRUNK LID TRIM, REMOVAL, Trunk Room Trim.>
3) Turn and remove the bulb socket (A). Disengage
the clip (B) and remove the license plate light assembly.
(B)
(B)
(A)
LI-00306
B: INSTALLATION
LI-31
License Plate Light

LIGHTING SYSTEM
27.License Plate Light

A: REMOVAL
1. SEDAN MODEL
1) Remove the trunk lid trim. <Ref. to EI-71,
TRUNK LID TRIM, REMOVAL, Trunk Room Trim.>
2) Turn and remove the bulb socket (A).
(A)
LI-00307
3) Remove the bulb.
2. WAGON MODEL
1) Remove the license plate light mounting screw
(A) and then remove the lens (B).
(B)
(A)
(B)
(A)
LI-00308
2) Remove the bulb.
B: INSTALLATION
C: INSPECTION
LI-32
High-mounted Stop Light

LIGHTING SYSTEM
28.High-mounted Stop Light
5) Disengage three claws and remove the lens (A).
A: REMOVAL
1. SEDAN MODEL
2) Push the high-mounted stop light backward of
the vehicle (1), raise the rear portion of it (2) and remove the clips to remove it.
(2)
(A)
LI-00310
6) Remove the bulb.
2. WAGON MODEL
(1)

2) Detach the roof spoiler. <Ref. to EI-40, REMOVAL, Roof Spoiler.>
3) Remove the nuts (A), then detach the highmounted stop light.
LI-00333
3) Remove the harness from clamp.

(A)
(A)
(2)
LI-00312
(1)
LI-00334
B: INSTALLATION
(1) Harness
(2) Clamp
C: INSPECTION
4) Disengage two claws (A), pull out the highmounted stop light from the cover and remove the
claw (B).
(A)
1. SEDAN (STANDARD TYPE)

2. SEDAN (REAR SPOILER BUILT-IN

TYPE) AND WAGON
(B)
1) Install the high-mounted stop light to test if it illuminates normally.

2) If the high-mounted stop light does not illuminate, replace it with a new one.
LI-00309
NOTE:
Since LED (Light Emitting Diode) is used for the
high-mounted stop light of wagon model, replace
the high-mounted stop light assembly when the
LED is powered off.
LI-33
Spot Map Light

LIGHTING SYSTEM
29.Spot Map Light
2. SPOT MAP LIGHT SWITCH
A: REMOVAL
Measure the resistance between spot map light

switch terminals.

2) Remove the lens (A) and spot map light mounting screws (B).
(A)
LI-00313
Model with sunroof
(B)
LI-00314
Model without sunroof

(B)
(B)
LI-00320

the spot map light.
B: INSTALLATION
C: INSPECTION
1. SPOT MAP LIGHT BULB
LI-34
Switch position
OFF
ON
Terminal No.
1 and 2
Standard
More than 1 M
185.4
Room Light
LIGHTING SYSTEM
30.Room Light
2. ROOM LIGHT SWITCH
A: REMOVAL
Measure the resistance between room light switch

terminals.

2) Remove the lens (A) and mounting screws (B).
3 2 1
(A)
LI-00257
LI-00315
(B)
Switch position
OFF
ON
DOOR
LI-00316
3) Disconnect the harness connector and remove

the room light.
B: INSTALLATION
C: INSPECTION
1. ROOM LIGHT BULB
LI-35
Terminal No.
1 and 3
2 and 3
Standard
More than 1 M
1.50.5
1.50.5
Luggage Room Light

LIGHTING SYSTEM
31.Luggage Room Light

A: REMOVAL
2) Remove luggage room light body (A).
(A)
LI-00258

the lens.
B: INSTALLATION
C: INSPECTION
1. LUGGAGE ROOM LIGHT BULB
2. LUGGAGE ROOM LIGHT SWITCH

Measure the resistance between luggage room
light switch terminals.
LI-00259
Switch position
OFF
ON
DOOR
Terminal No.
1 and 2
2 and 3
Standard
More than 1 M
1.50.5
1.50.5
LI-36
Trunk Room Light

LIGHTING SYSTEM
32.Trunk Room Light

A: REMOVAL
2) Turn the trunk room light counterclockwise to
60 to remove it and disconnect the harness connector.
LI-00321
3) Remove the bulb (A).
(A)
LI-00286
B: INSTALLATION
C: INSPECTION
1. TRUNK ROOM LIGHT BULB
2. TRUNK LID SWITCH (TRUNK ROOM

LIGHT SWITCH)
Measure the resistance between trunk lid switch
terminals.
1
LI-00290
LI-37
Trunk lid position

Close
Open
Terminal No.
1 and 3
Standard
More than 1 M
1.50.5
Glove Box Light

LIGHTING SYSTEM
33.Glove Box Light

A: REMOVAL
4) Remove the glove box light.
LI-00323
B: INSTALLATION
C: INSPECTION
LI-38
Door Step Light

LIGHTING SYSTEM
34.Door Step Light

A: REMOVAL
2) Remove the lens (A), and then remove the door
step light bulb.
(A)
LI-00266
3) Remove the front door trim. <Ref. to EI-48, REMOVAL, Door Trim.>
5) Remove the mounting screw from rear side of
trim and remove the door step light.
LI-00267
B: INSTALLATION
C: INSPECTION
LI-39
Ignition Switch Illumination

LIGHTING SYSTEM
35.Ignition Switch Illumination

A: REMOVAL
2) Remove the screws and detach the upper column cover and lower column cover.
4) Disconnect the ignition switch illumination connector (A).

5) Turn the ignition switch illumination connector to
left and remove it.
(B)
(A)
(C)
(A) Ignition switch illumination connector

(B) Ignition switch illumination
(C) Immobilizer antenna connector
SL-00258

LI-00343
B: INSTALLATION
C: INSPECTION
1
Step
CHECK IGNITION SWITCH ILLUMINATION.
Make sure the ignition switch illumination illuminates when drivers side door is open.
CHECK IGNITION SWITCH ILLUMINATION.
Make sure the ignition switch illumination
blinks when ignition switch is turned to ON.
Check
Yes
No
Does the ignition switch illumi- Ignition switch illu- Go to step 2.
nation illuminate?
mination is normal.
Does the ignition switch illumi- Check the funcnation blink?
tion setting of body
integrated unit.
<Ref. to
LAN(diag)-2, Basic
LI-40
Check the ignition

switch illumination
circuit. <Ref. to
SL-26, CHECK
IGNITION
SWITCH ILLUMINATION, INSPECTION, Keyless
Entry System.>
WW
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Page
Wiper and Washer System .........................................................................6
Combination Switch (Wiper)........................................................................7
Wiper Blade...............................................................................................12
Washer Tank and Motor............................................................................15
Front Wiper Arm........................................................................................16
Front Wiper Motor and Link.......................................................................17
Front Washer Nozzle ................................................................................19
Rear Wiper Arm ........................................................................................20
Rear Wiper Motor......................................................................................21
Rear Washer .............................................................................................22
General Description
A: SPECIFICATION
Front wiper motor
Rear wiper motor
Input
Input
Pump type
Input
Pump type
Input
Front washer motor

Rear washer motor
12 V 72 W or less
12 V 42 W or less
Centrifugal
12 V 36 W or less
Centrifugal
12 V 36 W or less
B: COMPONENT
1. FRONT WIPER
LHD model
T1
T1
(5)
(4)
T1
T1
T2
T2
(3)
(1)
(1)
(3)
(2)
(2)
WW-00215
(1)
(2)
(3)
Wiper rubber
Wiper blade ASSY
Wiper arm
(4)
(5)
Wiper link ASSY

Wiper motor ASSY
WW-2

T1: 6.0 (0.61, 4.4)
T2: 20 (2.0, 14.5)
General Description
RHD model
T1
T1
(5)
(4)
T1
T1
T2
T2
(3)
(1)
(1)
(3)
(2)
(2)
WW-00222
(1)
(2)
(3)
Wiper rubber
Wiper blade ASSY
Wiper arm
(4)
(5)
Wiper link ASSY

Wiper motor ASSY
WW-3

T1: 6.0 (0.61, 4.4)
T2: 20 (2.0, 14.5)
General Description
2. REAR WIPER (WAGON MODEL)
(5)
(6)
T2
T1
(4)
(1)
(3)
(2)
WW-00167
(1)
(2)
(3)
Wiper rubber
Wiper blade ASSY
Wiper arm
(4)
(5)
(6)
Wiper arm cover

Cap
Wiper motor ASSY
WW-4

T1: 7.5 (0.77, 6.0)
T2: 8.0 (0.82, 5.9)
General Description
3. WASHER TANK
(1)
(1)
(2)
(2)
(1)
(4)
(3)
(7)
(6)
T
(8)
(7)
(5)
(2)
WW-00331
(1)
(2)
(3)
(4)
Washer nozzle
Washer hose
Washer tank
Washer tank cap
(5)
(6)
(7)
(8)
Front washer motor

Rear washer motor
Grommet
Washer motor cover

T: 6.0 (0.61, 4.3)
C: CAUTION
Connect the connectors and hoses securely during reassembly.
Be careful that wiring harnesses of airbag system pass near electrical parts and switches.
Wiring harnesses and connectors of all airbag system are yellow color. Do not use a tester equipment on
these circuits.
Care must be taken when connecting 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 is easily
formed on the glass, causing the wiper to chatter and judder, therefore, be careful not to let this happen.
WW-5
Wiper and Washer System

2. Wiper and Washer System

A: WIRING DIAGRAM
1. WIPER AND WASHER (FRONT) LHD MODEL
<Ref. to WI-324, LHD MODEL, WIRING DIAGRAM, Front Wiper and Washer System.>
2. WIPER AND WASHER (FRONT) RHD MODEL

<Ref. to WI-325, RHD MODEL, WIRING DIAGRAM, Front Wiper and Washer System.>
3. WIPER AND WASHER (REAR) LHD MODEL

<Ref. to WI-326, LHD MODEL, WIRING DIAGRAM, Rear Wiper and Washer System.>
4. WIPER AND WASHER (REAR) RHD MODEL

<Ref. to WI-327, RHD MODEL, WIRING DIAGRAM, Rear Wiper and Washer System.>
B: INSPECTION
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 properly.
Repair order
(1) Wiper fuse (Front: F/B No. 30, Rear: F/B No. 23)
(2) Combination switch
(3) Wiper motor assembly
(4) Wiring harness
(5) Body integrated unit (rear wiper only)
(3) Wiring harness
(3) Wiring harness
(4) Body integrated unit (rear wiper only)
(1) Washer switch
(2) Washer motor
(3) Wiring harness
(2) Wiring harness
(1) Washer motor
(2) Washer hose and nozzle
WW-6
Combination Switch (Wiper)

3. Combination Switch (Wiper)
C: INSPECTION
A: REMOVAL
1. COMBINATION SWITCH

3) Remove the screw to remove steering column
cover (upper and lower).
1) Inspect the continuity between each connector

terminal.
SL-00258
4) Disconnect the connector from combination

switch.
5) Remove the three screws, and pull out the combination base switch assembly toward you. (EC,
EK, KS and K4 model)
9 8
18 17
7 6 5 4 3
16 15 14 13 12
2 1
11 10
WW-00046
EC, EK, KS and K4 model
Front
Rear
(Wagon
model)
LI -00332
6) Remove the switch securing screw to remove

combination switch.
B: INSTALLATION
WW-7
Switch position Terminal No.

OFF
7 and 16
INT
7 and 16
LO
7 and 17
HI
8 and 17
Washer ON
2 and 11
2 and 11
Washer ON
12 and 10
2 and 10
OFF
INT
2 and 13
ON
2 and 10
2 and 12
Washer ON
12 and 10
2 and 10
Standard
Less than 1
Less than 1
Less than 1
Less than 1
Less than 1
Less than 1
More than 1 M
Less than 1
Less than 1
Less than 1

KA model
Front
Rear
(Wagon
model)
Switch position Terminal No.

OFF
3 and 12
INT
3 and 12
LO
3 and 11
HI
2 and 11
Washer ON
8 and 17
8 and 16
Washer ON
16 and 18
8 and 18
OFF
INT
8 and 15
ON
8 and 18
8 and 16
Washer ON
16 and 18
8 and 18
Standard
Less than 1
Less than 1
Less than 1
Less than 1
Less than 1
Less than 1
More than 1 M
Less than 1
Less than 1
Less than 1
2) If continuity is not as specified, replace the

switch.
WW-8

2. FRONT WIPER
1) Check with Subaru Select Monitor
Step
Check
CHECK INPUT SIGNAL TO BODY INTEIs the input signal normal?
GRATED UNIT.
When the front wiper switch is operated, check
the input signal using Subaru Select Monitor.
link connector.
3) Select {Body Integrated Unit} from the main
menu.
5) When the front wiper switch is set to LO or
HI, check the input signal.
Yes
End.
No
Replace the body
integrated unit.
<Ref. to SL-45,
Body Integrated
Module.>
2) Intermittent operation inspection

(1) Turn the wiper switch to INT.
(2) Adjust the intermittent control switch to MAX.
(3) Apply the battery voltage to switch terminal No. 16 and 2 (EC, EK, KS and K4 model) or terminal No.
12 and 8 (KA model).
(4) Measure the voltage between combination switch terminals.
Terminals
No. 7 No. 2: EC, EK, KS and K4 model
No. 3 No. 8: KA model
(A)
(B)
(F)
(C)
(G)
(H)
(F)
(D)
(G)
(I)
(F)
(E)
(G)
(J)
WW-00053
(A)
(B)
(C)
(D)
Switch position
Voltage
MIN.
MAX.
(E)
(F)
(G)
Non-intermittent type
12 V
0V
3) If operation is not as specified, replace the switch.
WW-9
(H)
(I)
(J)
Approx. 2 sec.
166 sec.
31 sec.

3. REAR WIPER
1) Check with Subaru Select Monitor
Step
CHECK INPUT OF REAR WIPER.
Check the input from body integrated unit
link connector.
3) Select {Body Integrated Unit} from the main
menu.
5) Check the input of rear wiper switch.
CHECK OUTPUT OF BODY INTEGRATED
UNIT.
When the rear wiper switch is operated, check
the output using Subaru Select Monitor.
2) Operate the rear wiper switch to set to each
position of ON and INT.
3) At this time, check the output of body integrated unit.
Check
Is the input normal?
Yes
Go to step 2.
No
Check the rear
wiper switch. <Ref.
to WW-7,
INSPECTION,
Combination
Switch (Wiper).>
When it is set to ON, is ON output continuously? When it is

set to INT, is ON/OFF output
repeatedly? (INT OFF time
(when vehicle parked): 12 seconds for Wagon)
Check the rear

wiper motor. <Ref.
to WW-21,
INSPECTION,
Rear Wiper
Motor.>
Replace the body

integrated unit.
<Ref. to SL-45,
Body Integrated
Module.>
2) Rear wiper motor circuit check
Step
Check
Yes
CHECK POWER SUPPLY CIRCUIT OF REAR Is the voltage more than 10 V? Go to step 2.
WIPER MOTOR.
1) Disconnect the harness connector of rear
wiper motor.
2) Turn the ignition switch to ACC.
3) Measure the voltage between the rear
wiper motor harness connector terminal and
chassis ground.
Wagon model
(D43) No. 1 (+) Chassis ground ():
CHECK GROUND CIRCUIT OF REAR WIPER Is the resistance less than 10 Go to step 3.
MOTOR.
?
2) Measure the resistance between the rear
wiper motor harness connector terminal and
chassis ground.
Wagon model
(D43) No. 3 Chassis ground:
WW-10
No
Check the fuse
(No. 23 in fuse &
relay box).
Check the fusible link (No. 7 in
main fuse box).
Repair the open

circuit of rear wiper
motor ground
cable.

Step
CHECK HARNESS BETWEEN BODY INTEGRATED UNIT AND REAR WIPER MOTOR.
2) Disconnect the harness connector of body
integrated unit.
3) Disconnect the harness connector of rear
wiper motor.
4) Measure the resistance between the harness connector terminals of body integrated
unit and rear wiper motor.
Wagon model
(B280) No. 1 (D43) No. 2:
(B280) No. 8 (D43) No. 4:
CHECK OPERATION OF REAR WIPER MOTOR.
1) Remove the rear wiper motor.
2) Check the rear wiper motor. <Ref. to WW21, INSPECTION, Rear Wiper Motor.>
Check
?
Yes
Go to step 4.
No
Repair the open
circuit of harness
rear wiper motor.
Does the rear wiper motor

rotate normally?
End.
Replace the rear

wiper motor.
NOTE:
Rear wiper intermittent time (AT model only)
(AT model only)
Rev
Except for reverse mode
Vehicle speed (km/h (MPH))
80 (50 )
50 80 (31 50)
20 50 (12 31)
0 20 (0 12)
Intermittent stopping time

(sec.)
Wagon
Continuous operation
3
6
9
12
WW-11
Wiper Blade
4. Wiper Blade
C: DISASSEMBLY
A: REMOVAL
1. METAL TYPE
CAUTION:
When replacing wiper blades or etc., be sure to
stand up the driver side wiper arm first, then
passenger side wiper arm next. Also, when putting the wiper arms back, be sure to start with
passenger side first, then driver side next. Doing this in the reverse order may result in damage of passenger side wiper arm by hitting with
driver side wiper blade.
Pull side (A) of the wiper rubber stopper and remove the rubber from blade assembly.
1. FRONT
While pushing the locking clip (A) up, pull out the
blade from arm to the arrow direction.
WW-00009
2. RESIN TYPE
3
Pull the wiper rubber top slightly from the stopper

(A) and pull out fully.
(A)
(A)
3
1
WW-00064
2. REAR
Turn the blade in the direction of arrow (A) and remove it from arm.
(1)
(2)
(3)
(A)
(1)
(2)
(3)
(A)
WW-00207
Turn the wiper blade.

Wiper arm
Wiper blade
Installing part of wiper blade
B: INSTALLATION
2) Confirm that the clip is locked securely.
WW-12
WW-00143
Wiper Blade
D: ASSEMBLY
2) Make sure the wiper rubber is securely fastened

to the pull stopper (A).
1. METAL TYPE
1) Insert the wiper rubber onto blade so that the
stopper is in the position shown in the figure.
WW-00037
WW-00230
2. RESIN TYPE
WW-00193
1) Insert the wiper rubber through the claw (B).
2) Insert the wiper rubber until its top end protrudes

approx. 20 mm (0.79 in) from stopper (D).
20 mm ( 0.79 in. )
A
B
WW-00145
WW-00146
WW-13
Wiper Blade
3) Insert the wiper rubber into the claw (A).
WW-00147
E: INSPECTION
1) When the wiper does not perform well, inspect
the followings:
Make sure the movable part of the wiper blade
assembly moves smoothly.
Make sure the wiper rubber is not deformed or
damaged.
2) If damaged, replace with new one.
WW-14
Washer Tank and Motor

5. Washer Tank and Motor
D: ASSEMBLY
A: REMOVAL

2) Confirm that water does not leak from installation area of motor.
1) Open the hood.

3) Remove the front bumper. <Ref. to EI-30, REMOVAL, Front Bumper.>
4) Remove the clip holding washer water supply
tap.
E: INSPECTION
Apply battery voltage to the connector terminal of
the washer motor and make sure the motor operates.
2 1
WW-00173
WW-00170
5) Remove the two bolts and one nut, hose, connector and washer motor cover, and then remove
the washer tank.
WW-00171
B: INSTALLATION
Tightening torque:
6.0 Nm (0.61 kgf-m, 4.4 ft-lb)
C: DISASSEMBLY
Pull out the washer motor from tank.
WW-00172
WW-15
Front Wiper Arm

6. Front Wiper Arm
C: ADJUSTMENT
A: REMOVAL
Operate the wiper once. Align the wiper blade to

ceramic print point mark (A) of front window panel.
CAUTION:
When replacing wiper blades or etc., be sure to
stand up the driver side wiper arm first, then
passenger side wiper arm next. Also, when putting the wiper arms back, be sure to start with
passenger side first, then driver side next. Doing this in the reverse order may result in damage of passenger side wiper arm by hitting with
driver side wiper blade.
1) Open the hood.
2) Remove the cap.
3) Remove the nut to remove wiper arm.
WW-00232
B: INSTALLATION
2) Operate the wiper once.
3) Align the wiper blade to ceramic print point mark
(A) of front window panel.
(A)
WW-00048
Tightening torque:
Refer to COMPONENT of General Description.
<Ref. to WW-2, FRONT WIPER, COMPONENT, General Description.>
WW-16
(A)
WW-00048
Front Wiper Motor and Link

7. Front Wiper Motor and Link
RHD model
A: REMOVAL
2) Remove the cowl panel. <Ref. to EI-39, REMOVAL, Cowl Panel.>
3) Disconnect the connector of wiper motor assembly.
4) Remove the bolt to remove wiper assembly.
3 2 1
5 4
WW-00208
2) When the battery is connected to the terminal of

connectors, confirm that the wiper motor operates
at high speed.
LHD model
3 2 1
5 4
WW-00217
NOTE:
Wiper motor and wiper link can not be disassembled, because those are assembly part.
B: INSTALLATION
Tightening torque:
<Ref. to WW-2, FRONT WIPER, COMPONENT, General Description.>
WW-00219
RHD model
3 2 1
5 4
C: INSPECTION
1) When the battery is connected to the terminal of
connectors, confirm that the wiper motor operates
at low speed.
LHD model
WW-00209
3 2 1
5 4
3) Connect the battery to terminals of connector,

and remove the terminal connection with wiper motor rotated at low speed, and stop the wiper motor
through operation.
LHD model
WW-00218
3 2 1
5 4
WW-00220
WW-17
Front Wiper Motor and Link

RHD model
3 2 1
5 4
WW-00210
4) Connect the battery and confirm that the wiper

motor stops at automatic stop position after the
wiper motor operates at low speed again.
LHD model
3 2 1
5 4
WW-00221
RHD model
3 2 1
5 4
WW-00211
WW-18
Front Washer Nozzle

8. Front Washer Nozzle

A: REMOVAL
1) Remove the front hood insulator. <Ref. to EB13, FRONT HOOD INSULATOR, REMOVAL,
Front Hood.>
2) Hold the pawl of washer nozzle (A) toward the
arrow direction, and remove the washer nozzle.
Injection angle should be adjusted with 0.5 mm

(0.020 in) thickness steel scale. Use maximum
thickness of 0.5 mm steel scale, because the injection slit width of washer nozzle is 0.6 mm (0.024 in).
Adjusting with a flat tip driver may damage the injection slit and cause the faulty injection.
(1)
(3)
(A)
(2)
(4)
WW-00212
WW-00177
3) Remove the washer hose from washer nozzle.
B: INSTALLATION
2) Adjust the washer nozzle position. <Ref. to WW19, ADJUSTMENT, Front Washer Nozzle.>
C: INSPECTION
Make sure the nozzle and hose are not clogged.
Make sure the hose is not bent.
D: ADJUSTMENT
1) Turn the wiper switch to OFF position.
2) While the vehicle is at standstill, adjust the washer injection position as shown in the figure.
Injection position:
A: 250 mm (9.84 in)
B: 435 mm (17.13 in)
A
(1)
WW-00161
(1) Nozzle
WW-19
(1)
(2)
(3)
(4)
Inside of washer nozzle injection

0.6 mm (0.024 in)
Steel scale
Max. 0.5 mm (0.020 in)
Rear Wiper Arm

9. Rear Wiper Arm

A: REMOVAL
1. WAGON MODEL
1) Detach the wiper arm cover (A).
2) Remove the nut (B) to remove wiper arm.
(A)
(B)
WW-00179
B: INSTALLATION
2) Operate the rear wiper once.
3) Align the blade with the marking (A) of glass.
(A)
WW-00229
Tightening torque:
<Ref. to WW-4, REAR WIPER (WAGON MODEL), COMPONENT, General Description.>
C: ADJUSTMENT
1) Operate the rear wiper once.
2) Align the blade with the marking (A) of glass.
(A)
WW-00229
WW-20
Rear Wiper Motor

10.Rear Wiper Motor
C: INSPECTION
A: REMOVAL
1) Connect the battery to wiper motor connector

and confirm that wiper motor operates.
1. WAGON MODEL
2) Remove the rear wiper arm. <Ref. to WW-20,
WAGON MODEL, REMOVAL, Rear Wiper Arm.>
3) Remove the rear gate lower trim. <Ref. to EI-69,
REMOVAL, Rear Gate Trim.>
4) Disconnect the harness connector of wiper motor assembly.
5) Remove the bolts to remove wiper motor assembly (A).
2 1
4 3
WW-00186
2) Connect the battery to terminals of connector,

and remove the terminal connection with wiper motor rotated, and stop the wiper motor through operation.
(A)
2 1
4 3
WW-00183
B: INSTALLATION
1. WAGON MODEL
2) Be sure that the pivot cap with the arrow mark
facing up, as shown in the figure.
WW-00187
3) Connect the battery and confirm that the wiper

motor stops at automatic stop position after the
wiper motor operates at low speed again.
2 1
4 3
WW-00185
Tightening torque:
<Ref. to WW-4, REAR WIPER (WAGON MODEL), COMPONENT, General Description.>
WW-21
WW-00032
Rear Washer
11.Rear Washer
A: REMOVAL
1. WAGON MODEL
2) Remove the washer hose from washer nozzle.
3) Push the pawl of nozzle from the reverse side of
roof spoiler with a flat tip screwdriver or equivalent,
and remove the washer nozzle.
WW-00214
B: INSTALLATION
C: INSPECTION
Make sure the nozzle and hose are not clogged.
Make sure the hose is not bent.
WW-22
ENTERTAINMENT
ET
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
Page
Audio System ..............................................................................................3
Front Accessory Power Supply Socket System ..........................................4
Audio ...........................................................................................................5
Front Speaker .............................................................................................6
Tweeter .......................................................................................................7
Squawker ....................................................................................................8
Rear Speaker ..............................................................................................9
Woofer.......................................................................................................10
Power Amplifier .........................................................................................11
Antenna.....................................................................................................12
Antenna Amplifier......................................................................................13
Noise Suppressor......................................................................................14
Navigation Display ....................................................................................15
GPS Antenna ............................................................................................16
Navigation Body ........................................................................................17
Front Accessory Power Supply Socket .....................................................18
Steering Satellite Switch ...........................................................................19
General Description
ENTERTAINMENT
A: CAUTION
Before disassembling or reassembling parts, always disconnect the battery ground cable. When
replacing the audio, control unit, and other parts
provided with memory functions, record the memory contents before disconnecting the battery
erased.
Reassemble the parts in the reverse order of disassembly unless otherwise indicated.
After reassembly, make sure the functional parts
operate smoothly.
B: PREPARATION TOOL
1. GENERAL TOOL
TOOL NAME
Circuit tester
Conductive silver composition
(DUPONT No. 4817 or
equivalent)
REMARKS
Used for repairing antenna
wire.
ET-2
Audio System
ENTERTAINMENT
2. Audio System
A: WIRING DIAGRAM
<Ref. to WI-116, WIRING DIAGRAM, Audio System.>
B: INSPECTION
Symptom
No power coming in. (No display and no sound from speakers)
A specific speaker does not operate.

Audio generates noise with engine running.
AM (MW, LW: Europe only) and FM modes are weak or noisy.
Repair order
(1) Check the fuse and power supply for audio.
(2) Check the audio ground.
(3) Remove the audio and repair it.
(1) Check the speaker.
(2) Check the output circuit between audio and speaker.
(2) Check the generator.
(3) Check the ignition coil.
(1) Check the antenna.
(2) Check the antenna amplifier.
(3) Check the noise suppressor.
ET-3
Front Accessory Power Supply Socket System

ENTERTAINMENT
3. Front Accessory Power Supply Socket System

A: WIRING DIAGRAM
<Ref. to WI-242, WIRING DIAGRAM, Front Accessory Power Supply Socket System.>
ET-4
Audio
ENTERTAINMENT
4. Audio
A: REMOVAL
3) Remove the console front panel (A). <Ref. to EI54, REMOVAL, Center Console.>
4) Remove the console side garnish (B). <Ref. to
EI-54, REMOVAL, Center Console.>
(A)
(B)
(B)
ET-00113
5) Remove the screws, and slightly pull the audio

out from center console.
ET-00114
6) Disconnect the harness connector and antenna

feeder cord, and then remove the audio.
B: INSTALLATION
ET-5
Front Speaker
ENTERTAINMENT
5. Front Speaker
A: REMOVAL
3) Remove the front speaker mounting screws.
ET-00080

front speaker.
B: INSTALLATION
ET-6
Tweeter
ENTERTAINMENT
6. Tweeter
A: REMOVAL
1. MODEL WITH TWEETER
3) Remove the tweeter mounting screws.
ET-00081

tweeter.
2. MODEL WITH MCINTOSH AUDIO SYSTEM

3) Remove the gusset cover. <Ref. to GW-19, REMOVAL, Outer Mirror Assembly.>
tweeter.
ET-00082
B: INSTALLATION
ET-7
Squawker
ENTERTAINMENT
7. Squawker
A: REMOVAL
NOTE:
Model with McIntosh audio system only.
3) Remove the squawker mounting screws.
ET-00083

squawker.
B: INSTALLATION
ET-8
Rear Speaker
ENTERTAINMENT
8. Rear Speaker
A: REMOVAL
2) Remove the rear door trim. <Ref. to EI-48, REMOVAL, Door Trim.>
3) Remove the rear speaker mounting screws.
ET-00084

the rear speaker.
B: INSTALLATION
ET-9
Woofer
ENTERTAINMENT
9. Woofer
4) Remove the woofer bracket mounting clips (A)

and screws, and then remove the woofer bracket.
A: REMOVAL
1. SEDAN MODEL
(A)
NOTE:
3) Remove the woofer mounting screws.
ET-00106
5) Disconnect the harness connector and detach

woofer.
B: INSTALLATION
ET-00085
4) Disconnect the harness connector and detach

woofer.
2. WAGON MODEL
NOTE:
2) Remove the hooks (A) and detach woofer cover.
<Ref. to EI-63, REMOVAL, Rear Quarter Trim.>
(A)
(A)
ET-00086
3) Remove the quarter lower trim. <Ref. to EI-63,

ET-10
Power Amplifier
ENTERTAINMENT
10.Power Amplifier
A: REMOVAL
1) Move the passengers seat to the foremost position.
3) Disconnect the harness connector of power amplifier.
4) Remove the nuts to remove power amplifier.
ET-00029
B: INSTALLATION
ET-11
Antenna
ENTERTAINMENT
11.Antenna
3) Apply conductive silver composition (DUPONT

No. 4817) on the broken portion with a drawing
pen.
A: INSPECTION
Measure the resistance between antenna terminal
and each antenna wire.
If an antenna wire is OK, resistance will be less
than 1 . If an antenna wire is broken, resistance
will be more than 1 M.
(A)
NOTE:
When checking the continuity, wind a piece of aluminum foil around the tip of tester probe and press
the foil against wire with your finger.
(B)
(C)
ET-00009
(A)
(A) Broken portion

(B) Masking film
(C) Conductive silver composition
4) Dry out the deposited portion.

5) After repair has been completed, measure the
resistance in repaired wire.
(C)
(B)
ET-00007
(A) Tester probe

(B) Aluminum foil
(C) Antenna wire
To locate the broken point, move the probe along

antenna wire.
ET-00008
B: REPAIR
1) Clean the antenna wire and surrounding area
with a cloth dampened by alcohol.
2) Paste a thin masking film on the glass along broken wire.
ET-12
Antenna Amplifier
ENTERTAINMENT
12.Antenna Amplifier
C: INSPECTION
A: REMOVAL
Measure the resistance of antenna amplifier.

Sedan model
1. SEDAN MODEL
(1)-a

3) Disconnect the harness connectors and terminals.
5) Remove the screw and detach antenna amplifier.
(1)-b
(2)
(1)-a
(1)-b
(2)-b
(3)
(3)-a
ET-00090
Wagon model
(1)
(1)-b (1)-a
(3)-a
(2)-b
(2),(3)
ET-00088
ET-00091
2. WAGON MODEL
3) Disconnect the harness connectors and terminals.
4) Remove the screw and detach antenna amplifier.
ET-00089
B: INSTALLATION
ET-13
Terminal No.
1-a and Amplifier body
1-b and Amplifier body
Standard
More than 10 k
More than 10 k
More than 10 k
More than 10 k
Noise Suppressor
ENTERTAINMENT
13.Noise Suppressor
A: REMOVAL
1. SEDAN MODEL
4) Disconnect the harness connector from noise
suppressor.
5) Remove the harness clip.
6) Remove the screw and detach noise suppressor.
ET-00092
2. WAGON MODEL
3) Disconnect the harness connector from noise
suppressor.
4) Remove the screws and detach noise suppressor.
ET-00093
B: INSTALLATION
ET-14
Navigation Display
ENTERTAINMENT
14.Navigation Display
A: REMOVAL
2) Remove the clips, and then remove the center
upper panel.
ET-00097
3) Remove the display mounting screws.
ET-00098
4) Disconnect the harness connector, and then remove the navigation display.
B: INSTALLATION
ET-15
GPS Antenna
ENTERTAINMENT
15.GPS Antenna
A: REMOVAL
2) Remove the combination meter. <Ref. to IDI-16,
REMOVAL, Combination Meter.>
3) Remove the GPS antenna mounting screw, and
then remove the GPS antenna.
ET-00099
ET-00100
4) Remove the audio. <Ref. to ET-5, REMOVAL,

Audio.>
5) Remove the GPS antenna cord connector from
steering support beam stay (on the drivers side).
B: INSTALLATION
ET-16
Navigation Body
ENTERTAINMENT
16.Navigation Body
A: REMOVAL
3) Remove the navigation body mounting screws in
numerical order and pull it out.
NOTE:
To remove the screw (4) easier, move the navigation body after removing the screw (3).
(3)
(2)
(4)
(1)
ET-00107
4) Remove the harness connector and antenna cable, and then remove the navigation body.
B: INSTALLATION
ET-17
Front Accessory Power Supply Socket

ENTERTAINMENT
17.Front Accessory Power Supply Socket

A: REMOVAL
1. FRONT
2) Remove the console front panel. <Ref. to EI-54,
REMOVAL, Center Console.>
3) Disconnect the harness connector, and remove
the accessory power supply socket.
ET-00094
2. REAR
3) Disconnect the harness connector, and remove
the accessory power supply socket.
ET-00095
B: INSTALLATION
ET-18
Steering Satellite Switch

ENTERTAINMENT
18.Steering Satellite Switch

A: REMOVAL
WARNING:
With the airbag module equipped, always refer
to Airbag System when performing the airbag
module repair service. <Ref. to AB-15, INSPECTION, Drivers Airbag Module.>
5) Remove the cover from steering wheel.
6) Remove each one of satellite switch mounting
screw from the LH and RH side.
CS-00331
7) Remove the satellite switch.
B: INSTALLATION
ET-19
Steering Satellite Switch

ENTERTAINMENT
C: INSPECTION
1 2 3 4 5
CS-00387
Step
MUTE SWITCH CONTINUITY CHECK.
1) Press the mute switch.
2) Measure the resistance between satellite
Terminals
No. 1 No. 2:
VOLUME SWITCH CONTINUITY CHECK.
1) Press the volume switch.
Terminals
No. 1 No. 2: Volume up
No. 1 No. 2: Volume down
MODE SWITCH CONTINUITY CHECK.
1) Press the mode switch.
Terminals
No. 1 No. 2:
SEEK SWITCH CONTINUITY CHECK.
1) Press the seek switch.
Terminals
No. 1 No. 2: Seek up
No. 1 No. 2: Seek down
CHECK SATELLITE SWITCH INSULATION.
1) Not to operate the satellite switch.
Terminals
No. 1 No. 2:
Check
Yes
Is the resistance approx. 22 ? Go to step 2.
No
Replace the satellite switch.
Is the resistance approx. 90 ? Go to step 3.

(Volume up)
Is the resistance approx. 200
? (Volume down)

?
Go to step 4.

? (Seek up)
k? (Seek down)
Go to step 5.

k?
Satellite switch is
normal.
ET-20
COM
1.
2.
3.
4.
Page
Horn System ...............................................................................................3
Horn ............................................................................................................4
Horn Switch.................................................................................................5
General Description
A: CAUTION
Before disassembling or reassembling parts, always disconnect the battery ground cable from battery. When replacing audio, control module, and
other parts provided with memory functions, record
memory contents before disconnecting the battery
erased.
Reassemble in reverse order of disassembly, unless otherwise indicated.
B: PREPARATION TOOL
1. GENERAL TOOLS
TOOL
NAME
Circuit
tester
TORX BIT
T30
REMARKS
Used for removing and installing drivers airbag module.
COM-2
Horn System
2. Horn System
A: WIRING DIAGRAM
1. HORN
<Ref. to WI-245, WIRING DIAGRAM, Horn System.>
B: INSPECTION
1. HORN RELAY
Measure the horn relay resistance between terminals (indicated in table below) when connecting the
terminal No. 4 to battery positive terminal and terminal No. 3 to battery ground cable.
(1)
(2)
(1)
(3)
(4)
(2)
(3)
(4)
COM00001
Current
Flow
No Flow
Terminal No.
1 and 2
Standard
Less than 1
More than 1 M
COM-3
Horn
3. Horn
A: REMOVAL
2) Remove the two clips and turn up the lower mud
guard RH.
LI-00288
3) Remove the horn bracket mounting bolt (A).

the horn assembly (B).
(A)
(B)
COM00016
B: INSTALLATION
C: INSPECTION
With 12 V direct current supplied between horn terminals, check that the horn sounds properly.
COM00020
COM-4
Horn Switch
4. Horn Switch
A: REMOVAL
WARNING:
Before servicing, be sure to read the notes in
AB section for proper handling of drivers airbag module. <Ref. to AB-4, CAUTION, General
Description.>
NOTE:
Horn switch is a unit with the drivers airbag module.
B: INSTALLATION
C: INSPECTION
Measure the resistance between horn switch terminal and airbag module bracket.
(1)
(2)
COM00037
(1) Horn switch terminal

(2) Airbag module bracket
Switch position
When horn switch
is pushed.
When horn switch
is not pushed.
Terminal No.
Resistance
Horn switch terminal and airbag

module bracket
Less than 1
More than 1 M
COM-5
Horn Switch
COM-6
GW
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Page
Power Window System ...............................................................................8
Power Window Control Switch ....................................................................9
Front Door Glass.......................................................................................11
Front Regulator and Motor Assembly .......................................................16
Remote Control Mirror System..................................................................17
Scalp Cap..................................................................................................18
Outer Mirror Assembly ..............................................................................19
Outer Mirror...............................................................................................20
Remote Control Mirror Switch ...................................................................21
Rear Door Glass .......................................................................................23
Rear Regulator and Motor Assembly ........................................................25
Windshield Glass ......................................................................................26
Rear Gate Glass .......................................................................................29
Rear Window Glass ..................................................................................30
Rear Window Defogger System................................................................31
Rear Window Defogger.............................................................................32
Rear Quarter Glass ...................................................................................34
Sun Roof Glass .........................................................................................35
Rearview Mirror.........................................................................................36
Wiper Deicer System ................................................................................37
Wiper Deicer Switch..................................................................................38
General Description
A: COMPONENT
1. FIXED GLASS (SEDAN MODEL)
(2)
(4)
(3)
(1)
(5)
(2)
(6)
(8)
(10)
(3)
(2)
(5)
(9)
(3)
(9)
(7)
(2)
(8)
GW-00449
(1)
(2)
(3)
(4)
Windshield glass
Dam rubber
Molding
Rearview mirror mount
(5)
(6)
(7)
(8)
Locating pin
Rear window glass
Six light glass
Bracket
GW-2
(9)
(10)
Clip
Holder
General Description
2. FIXED GLASS (WAGON MODEL)

(2)
(4)
(1)
(3)
(5)
(8)
(9)
(8)
(6)
(7)
(6)
(2)
GW-00314
(1)
(2)
(3)
Windshield glass
Dam rubber
Molding
(4)
(5)
(6)
Rearview mirror mount

Locating pin
Fastener
GW-3
(7)
(8)
(9)
Rear quarter glass

Locating pin
Glass
General Description
3. FRONT DOOR GLASS
T3
(9)
(4)
(1)
T1
T3
(6)
T3
(5)
(10)
T1
T1
(7)
(3)
T2
(2)
T1
T2
(8)
T2
T2
GW-00256
(1)
(2)
(3)
(4)
(5)
Glass
Door sash (Front)
Door sash (Rear)
Weather strip
Stabilizer (Outer)
(6)
(7)
(8)
(9)
(10)
Stabilizer (Inner)
Regulator ASSY
Motor ASSY
Mirror gusset
Guide ASSY
GW-4

T1: 7.4 (0.75, 5.5)
T2: 13.7 (1.4, 10.1)
T3: 5.9 (0.60, 4.4)
General Description
4. REAR DOOR GLASS
(4)
(5)
T1
(6)
(1)
T1
(7)
(3)
T1
T2
(8)
(2)
T2
GW-00257
(1)
(2)
(3)
(4)
Glass
Door sash (Front)
Door sash (Rear)
Weather strip
(5)
(6)
(7)
(8)
Stabilizer (Outer)
Stabilizer (Inner)
Regulator ASSY
Motor ASSY
GW-5

T1: 7.4 (0.75, 5.5)
T2: 13.7 (1.4, 10.1)
General Description
5. MIRROR
(3)
(6)
(2)
(5)
(1)
(4)
GW-00447
(1)
(2)
Outer mirror
Mirror
(3)
(4)
Scalp cap
Side turn signal light
(5)
(6)
Rearview mirror
Mount
B: CAUTION
When electrical connectors are disconnected, always conduct an operational check after connecting them
again.
Avoid impact and damage to the glass.
GW-6
General Description
C: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
61299AE000
DESCRIPTION
SPACER
REMARKS
Used for adjusting the upper end position of front
door glass. (Glass thickness: 5 mm (0.197 in))
SPACER
Used for adjusting the upper end position of rear

door glass. (Glass thickness: 4 mm (0.157 in))
ST61299AE000
61299AE010
ST61299AE010
2. GENERAL TOOL
TOOL NAME
Circuit tester
Piano wire
Windshield glass knife
REMARKS
Used for checking voltage and continuity.
Used for removing the window glass.
Used for removing the window glass.
GW-7
Power Window System

2. Power Window System

A: WIRING DIAGRAM
<Ref. to WI-294, Power Window System.>
B: INSPECTION
Symptom
All power windows do not operate.
One window does not operate.

Window Lock does not operate.
Repair order
(1) Fuse (SBF-5)
(1) Power window circuit breaker
(2) Power window relay
(3) Wiring harness
(4) Body integrated unit
(1) Power window main switch
(2) Power window sub switch
(3) Power window motor
(4) Wiring harness
Power window main switch
GW-8
Power Window Control Switch

3. Power Window Control

Switch
A: REMOVAL
1. MAIN SWITCH
4) Remove the screws from the reverse side of
front door trim to remove the power window main
switch.
GW-00259
2. SUB SWITCH
2) Remove the door trim. <Ref. to EI-48, REMOVAL, Door Trim.>
4) Remove the screws from the reverse side of
door trim to remove the power window sub switch.
GW-00260
B: INSTALLATION
1. MAIN SWITCH
2. SUB SWITCH
GW-9
Power Window Control Switch

C: INSPECTION
1. MAIN SWITCH
Measure switch resistance.
6 5 4
3 2 1
14 13 12 11 10 9 8 7
GW-00406
LHD model
Drivers seat
Switch position
AUTO UP
UP
DOWN
AUTO DOWN
Terminal No.
10 and 2, 7 and 1
10 and 2, 7 and 1
10 and 1, 7 and 2
10 and 1, 7 and 2
Standard
Less than 1
Less than 1
Less than 1
Less than 1
Switch position
AUTO UP
UP
DOWN
AUTO DOWN
Terminal No.
11 and 1, 14 and 2
11 and 1, 14 and 2
11 and 2, 14 and 1
11 and 2, 14 and 1
Standard
Less than 1
Less than 1
Less than 1
Less than 1
Terminal No.
2 and 3, 4 and 5
1 and 2, 4 and 5
1 and 2, 3 and 4
Standard
Less than 1
Less than 1
Less than 1
RHD model
Drivers seat
Replace the main switch if faulty.
2. SUB SWITCH
Measure switch resistance.
5 4 3 2 1
GW-00407
Passengers seat and

rear
Switch position
UP
OFF
DOWN
Replace the sub switch if faulty.
GW-10
Front Door Glass

4. Front Door Glass
6) Remove the stabilizer.
A: REMOVAL
2) Remove the sealing cover. <Ref. to EB-20, REMOVAL, Front Sealing Cover.>
3) Remove the outer mirror assembly. <Ref. to
GW-19, REMOVAL, Outer Mirror Assembly.>
4) Remove the clip (A), and remove the front end of
weather strip.
GW-00263
7) Remove the clips (A), and remove the rear end

of weather strip.
(A)
(A)
GW-00261
5) Remove the gusset.

GW-00264
8) Remove the screw (A) from the rear end of

weather strip outer to remove weather strip outer.
(A)
GW-00265
9) Remove the screws to remove guide assembly.

10) Operate the power window switch to move
glass to position shown in the figure, and then remove the two nuts through service holes.
GW-00262
GW-00266
GW-11
Front Door Glass

11) Remove the door glass.
sure of 255 N (2.50.5 kgf, 5.51.1 lb) to the

glass, then secure it.
(1)
F
(3)
A
(2)
(2)
A = A
GW-00267
GW-00063
CAUTION:
Since the gear may be disengaged, do not
turn regulator in the closing direction after removal of the glass.
B: INSTALLATION
CAUTION:
Make sure that glass stay is placed securely in
sash.
2) Adjust the front door glass. <Ref. to GW-12, ADJUSTMENT, Front Door Glass.>
(1) Fully closed position

(2) Stabilizer
(3) 10 15 mm (0.39 0.59 in)
4) For adjustment of clearance between front glass

and center pillar cover, loosen the nuts (A), and
move the glass sash back and forward until clearance becomes the value shown.
Tightening torque:
Refer to COMPONENT of General Description. <Ref. to GW-4, FRONT DOOR GLASS,
COMPONENT, General Description.>
C: ADJUSTMENT
(A)
(2)
(1)
(3)
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
weather strip.
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 the regulator B-channel in a
position at the top of slotted hole.
3) Lower the door glass 10 15 mm (0.39 0.59
in) from fully closed position. While applying outward pressure of 45.0 5.0 N (4.50.5 kgf, 9.91.1
lb) (F) to upper edge of glass above midpoint of two
outer stabilizers, press the inner stabilizer at pres-
GW-00319
(1) Adjust a line parallel

(2) Sash
(3) Inner panel
(1)
(1)
A A
A-A
GW-00064
BO0388
(1) 11 mm (0.433 in)
GW-12
Front Door Glass

5) To adjust the upper end and lower end of center

pillar, loosen the stopper bolt (A) or nut (B) securing
door sash, move the stopper position until the
clearance between center pillar cover is equal.
6) Adjust so that the upper and lower ends of center pillar are the same size.
(A)
(1)
(2)
(3)
(3)
(A)
GW-00320
(B)
(2)
(1)
(3)
(B)
(3)
GW-00440
GW-00321
CAUTION:
Measure the clearance from center pillar at
more than 50 mm (1.969 in) apart from the upper end of window glass.
(1)
(2)
(4)
(5)
(3)
GW-00322
(1)
(2)
(3)
(4)
(5)
Glass
Center pillar cover
Check point
50 mm (1.969 in)
11 mm (0.433 in)
GW-13
(A)
(B)
(1)
(2)
(3)
Glass tilts too far rearward

Glass tilts too far forward
Narrow
Wide
Stopper adjusting direction
Front Door Glass

7) After adjusting the clearance between center pillar, up and down the glass several times to check
glass contact to stopper when glass is fully closed.
Adjust it to contact the front and rear stopper simultaneously.
(1)
(3)
8) For glass stroke adjustment, install the ST to

glass, close the door, and raise the glass with regulator until positional relationship between glass
and weather strip becomes as shown. And secure
the glass so that the upper stopper correctly touches the glass holder.
ST 61299AE000 SPACER
(Glass thickness: 5 mm (0.197
in) for front door glass)
(2)
(1)
A
(2)
(5)
A
(3)
(2)
A-A
GW-00430
(4)
(1)
(1) 3.2 4.8 mm (0.126 0.189 in)

(2) When reusing weather strip: 5.5 mm (0.217 in)
With new weather strip: 3 mm (0.118 in)
(3) ST
(6)
For preventing wind noise, adjust the glass at the

position where tip of gusset is raised up a little.
GW-00324
(1) Narrow
(2) Wide
(3) When the stopper of door sash (front) contacts
first
(4) When the stopper of door sash (rear) contacts
first
(5) Raise B channel
(6) Lower B channel
(A)
GW-00325
(A) 0 1.5 mm (0 0.059 in)
9) After stabilizer adjustment, carry out the glass

cohesion adjustment. First, visually ensure the positional relationship between retainer & molding
and glass of the roof side, and then begin with rear
sash adjustment. Install the ST to glass and 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, the sash
moves back and forth. Therefore, when one nut is
adjusted, secure the other.
GW-14
Front Door Glass

10) Make the same adjustment of two adjusting

bolts of rear sash.
in) for front door glass)
13) After adjustment of the glass, close the door. 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.
14) During adjustment, loosen the other three
clamping bolts.
(1)
A
(2)
A
(3)
A-A
GW-00430
(1) 3.2 4.8 mm (0.126 0.189 in)

(3) ST
NOTE:
Do not tilt the sash bracket to inner panel during adjustment. Otherwise smooth regulator operation
cannot be achieved.
(A)
(1)
(4)
15) After adjustment, tighten the bolts and nuts.
(3)
(2)
(5)
GW-00270
(1)
(2)
(3)
(4)
(5)
GW-00271
Sash bracket
Rear sash
Adjust a line parallel
Sash
Inner panel
11) Make adjustment of front sash in the same

manner as that of rear sash.
NOTE:
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.
12) After adjustments, tighten the nuts.
GW-15
Front Regulator and Motor Assembly

5. Front Regulator and Motor

Assembly
A: REMOVAL
1) Remove the door glass. <Ref. to GW-11, REMOVAL, Front Door Glass.>
2) Disconnect the motor connector.
3) Remove the four bolts and two nuts to remove
regulator assembly.
GW-00273
4) Remove the screws to remove motor assembly.
GW-00274
NOTE:
When removing the motor assembly, secure the
arm correctly, because the regulator arm moves in
the force of balancing spring.
B: INSTALLATION
2) Adjust the front door glass. <Ref. to GW-12, ADJUSTMENT, Front Door Glass.>
Tightening torque:
Refer to COMPONENT of General Description. <Ref. to GW-4, FRONT DOOR GLASS,
C: INSPECTION
1) Make sure that the power window motor rotates
properly when the battery voltage is applied to the
terminals of motor connector.
2) Change polarity of battery connection to terminals to ensure that the motor rotates in reverse direction.
GW-16
Remote Control Mirror System

6. Remote Control Mirror System

A: WIRING DIAGRAM
<Ref. to WI-306, Remote Control Mirror System.>
B: INSPECTION
Symptom
All function does not operate.
One side of the mirror motor does not operate.
Mirror heater does not operate.
Repair order
(1) Fuse (F/B No. 6)
(1) Mirror switch
(2) Wiring harness
(1) Mirror switch
(2) Mirror motor
(3) Wiring harness
(1) Mirror switch
(2) Mirror heater
(3) Wiring harness
GW-17
Scalp Cap
7. Scalp Cap
A: REPLACEMENT
1) Remove the outer mirror. <Ref. to GW-20, REPLACEMENT, Outer Mirror.>
2) Press-in the upper side clips (A) from inside of
door mirror.
(A)
(A)
GW-00312
3) Pull the scalp cap frontward of door mirror, remove the upper side clips (A) and lower side hooks
(B), and then remove the scalp cap.
(A)
(B)
GW-00275
4) Insert the lower hooks (B) of scalp cap to door

mirror and push the upper clips (A) in.
(A)
(B)
GW-00276
5) Install the scalp cap securely.

CAUTION:
Do not remove the scalp cap forcibly. The lower
hooks may be damaged.
GW-18
Outer Mirror Assembly

8. Outer Mirror Assembly

A: REMOVAL
1) Remove the mirror gusset cover.

3) Disconnect the mirror connector.
4) Remove the screws to remove mirror assembly.
: (1)
GW-00277
(1) Hook
GW-00278
B: INSTALLATION
C: INSPECTION
Check that the rearview mirror moves properly when the battery voltage is applied to terminals.
Model without mirror heater
Switch position
OFF
UP
DOWN
LEFT
RIGHT
Terminal No.
6 (+) and 3 () or 8 ()
3 (+) or 8 (+) and 6 ()
7 (+) and 3 () or 8 ()
3 (+) or 8 (+) and 7 ()
Model with mirror heater

Switch position
OFF
UP
DOWN
LEFT
RIGHT
Terminal No.
7 (+) and 3 () or 9 ()
3 (+) or 9 (+) and 7 ()
8 (+) and 3 () or 9 ()
3 (+) or 9 (+) and 8 ()
Replace the outer mirror assembly if defective.
GW-19
Outer Mirror
9. Outer Mirror
A: REPLACEMENT
1) Face the mirror upward.
2) Use a flat tip screwdriver to remove clip (A).
3) Lift the lower mirror up to remove hooks (B).
(A)
(B)
GW-00279
4) Disconnect the mirror heater connector from the

end of mirror. (Model with mirror heater)
GW-00280
5) Catch the hooks (B) and install clips (A).
(B)
(A)
GW-00450
CAUTION:
When removing the mirror, be careful not to
damage the back side of mirror with a flat tip
screwdriver.
When installing the mirror, insert the hook
and clip securely.
GW-20
Remote Control Mirror Switch

10.Remote Control Mirror Switch

A: REMOVAL
1) Remove the instrument panel lower cover. <Ref. to EI-50, REMOVAL, Instrument Panel Lower Cover.>
R
0
1
GW-00282
3) Remove the remote control mirror switch from instrument panel lower cover.
B: INSTALLATION
GW-21
Remote Control Mirror Switch

C: INSPECTION
1. REMOTE CONTROL MIRROR SWITCH
Move the remote control mirror switch to each position and check continuity between terminals.
7 6 5 4
3 2 1
16 15 14 13 12 11 10 9 8
GW-00283
Change over switch R

Switch position
OFF
UP
DOWN
LEFT
RIGHT
Terminal No.
10 and 12, 15 and 14

10 and 15, 12 and 14
10 and 11, 15 and 14
10 and 15, 11 and 14
Standard
More than 1 M
Less than 1
Less than 1
Less than 1
Less than 1
Terminal No.
10 and 8, 15 and 14
10 and 15, 8 and 14
10 and 9, 15 and 14
10 and 15, 9 and 14
Standard
More than 1 M
Less than 1
Less than 1
Less than 1
Less than 1
Change over switch L

Switch position
OFF
UP
DOWN
LEFT
RIGHT
Replace the remote control mirror switch if defective.
GW-22
Rear Door Glass

11.Rear Door Glass
6) Operate the power window switch to move the

glass to position shown in the figure, and then remove the two nuts through service holes.
A: REMOVAL
2) Remove the sealing cover. <Ref. to EB-24, REMOVAL, Rear Sealing Cover.>
3) Remove the stabilizer.
GW-00287
7) Remove the rear sash retaining nuts (A) and

move rear sash (B) backward.
(A)
GW-00284
4) Remove the clips (A), and remove the front end

and rear end of weather strip.
(B)
GW-00288
8) Remove the door glass.

CAUTION:
Since the gear may be disengaged, do not
turn regulator in the closing direction after removal of the glass.
(A)
(A)
GW-00285
5) Loosen the two screws to remove weather strip

outer.
GW-00286
GW-23
Rear Door Glass

B: INSTALLATION
CAUTION:
Make sure that glass stay is placed securely in
sash.
2) Adjust the rear door glass. <Ref. to GW-24, ADJUSTMENT, Rear Door Glass.>
2) Install the ST to glass and adjust the glass adhesion to the value shown.
in) for rear door glass)
(1)
A
Tightening torque:
Refer to COMPONENT of General Description. <Ref. to GW-5, REAR DOOR GLASS,
C: ADJUSTMENT
(3)
A-A
NOTE:
The rear door glass, as a rule, should be adjusted
in the same manner as front door glass, although
they are different in dimension. <Ref. to GW-12,
ADJUSTMENT, Front Door Glass.>
1) Adjust the glass position using the following dimensions as a guide line.
(1)
(2)
GW-00431
(1) 3.2 4.8 mm (0.126 0.189 in)

(3) ST
NOTE:
If rear glass adhesion is higher than necessary,
glass may get caught in weather strip of center pillar corner, resulting in early wear of weather strip.
Care should be taken for adjustment.
After adjustment, move the glass up and down to
check whether it is caught.
(1)
A-A
GW-00067
(1) 11 mm (0.433 in)
NOTE:
If dimensions are smaller than the given dimensions, glass may get caught in weather strip during
lifting/lowering operation and may not be fully open.
After adjustment, move the glass up and down to
check whether it is caught.
GW-24
Rear Regulator and Motor Assembly

12.Rear Regulator and Motor Assembly

A: REMOVAL
1) Remove the rear door glass. <Ref. to GW-23,
REMOVAL, Rear Door Glass.>
2) Remove the nut (A) to remove front sash.
C: INSPECTION
1) Make sure that the power window motor rotates
properly when the battery voltage is applied to the
terminals of motor connector.
2) Change polarity of battery connection to terminals to ensure that the motor rotates in reverse direction.
(A)
GW-00289
3) Disconnect the motor connector.

4) Remove the four bolts and two nuts to remove
regulator assembly.
GW-00290
5) Remove the screws to remove motor assembly.
GW-00291
B: INSTALLATION
2) Adjust the rear door glass. <Ref. to GW-24, ADJUSTMENT, Rear Door Glass.>
Tightening torque:
Refer to COMPONENT of General Description. <Ref. to GW-5, REAR DOOR GLASS,
GW-25
Windshield Glass
13.Windshield Glass
Because the locating pins are bonded to the corners of glass, use piano wire to cut the pin.
A: REMOVAL
1. USING WINDSHIELD GLASS KNIFE
(2)

2) Remove the glass molding.
3) Tape the body side of the circumference of windshield glass for protection.
4) Apply sufficient amount of soapy water to the adhesive part.
5) Insert the windshield glass knife into adhesive
part.
6) While holding the knife edge and windshield
glass edge at a right angle, move the windshield
glass knife in parallel to the windshield glass edge
along face and edge of windshield glass to cut the
adhesive part.
NOTE:
Do not twist windshield glass knife.
Cutting of adhesive part shall be started with wider gap between windshield glass and body.
(1)
(1)
(1)
(3)
A-A
GW-00070
(1) Locating pin

(2) Body panel
(3) Windshield glass
2. USING PIANO WIRE

2) Remove the molding.
3) Tape the body side of the circumference of windshield glass for protection.
4) Make a hole in the adhesive part using drill or
knife.
5) Pass the piano wire through the hole, and attach
securely both the wire ends to pieces of wood.
(1)
A-A
(2)
A
(1)
GW-00039
(3)
6) Pull the wire ends alternately to cut off the adhesive part.
A
(3)
GW-00410
(1) Windshield glass knife

(2) Tape for protection
(3) Locating pin
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.
GW-26
Windshield Glass
B: INSTALLATION
1) Clean the external circumference of windshield
glass with alcohol or white gasoline.
2) Remove the adhesive layer on the body using
cutter knife to obtain smooth face of 2 mm (0.08 in)
thick.
CAUTION:
Be careful not to damage the body and paint
surface.
(1)
6) Apply two types of primers to the adhesive layer

of glass using sponge.
Glass primer:
Betawipe VP04604
Betaprime 5001
7) Apply primer to the adhesive layer of body.
Painted surface primer:
Betaprime 5402
NOTE:
Primer once attached to the painted surface of
the body and internal trim is hard to wipe off. Mask
the circumference of such area.
Let primer dry for about ten minutes before installing the glass.
Do not touch the surface coated with primer.
(3)
(2)
(4)
(1)
GW-00071
(1)
(2)
(3)
(4)
Adhesive
2 mm (0.08 in)
Dam rubber
Glass
(3)
(2)
3) Clean the body with alcohol or white gasoline to

eliminate cutting power, dust and dirt completely
from body.
4) Install the dam rubber.
5) Fit molding mark (B) to notch (A) of glass side
and install the molding to entire perimeter of glass.
GW-00073
(1) Application of primer

(2) Glass side
(3) Body side
8) Cut off the cartridge nozzle tip as shown and set

it in sealant gun.
(A)
(1)
(2)
GW-00238
(1) 10 mm (0.39 in)

(2) 15 mm (0.59 in)
(B)
GW-00316
GW-27
Windshield Glass
9) Apply adhesive to the glass end surface as

shown.
Adhesive:
Gurit-ESSEX
Betaseal 1502 or equivalent
(1)
GW-00239
(1) 9 12 mm (0.35 0.47 in)
10) Fit the locating pins using suction rubber cup to

install windshield glass.
GW-00045
11) Lightly press the windshield glass for tight fit.

12) Make flush the adhesive surface jutted out using spatula.
13) After completion of all work, allow the vehicle to
stand for about 24 hours.
NOTE:
When door is opened/closed after glass is bonded, always lower the door glass and then open/
close it carefully.
Move the vehicle slowly.
For minimum drying time and vehicle standing
time before driving after bonding, follow instructions or instruction manual from the adhesive manufacturer.
14) After curing of adhesive, pour the water on external surface of vehicle to check that there are no
water leaks.
NOTE:
When a vehicle is returned to the user, tell him or
her that the vehicle should not be subjected to
heavy impact for at least three days.
15) Install the cowl panel. <Ref. to EI-39, INSTALLATION, Cowl Panel.>
GW-28
Rear Gate Glass

14.Rear Gate Glass

A: REMOVAL
1) Remove the rear wiper motor. <Ref. to WW-21,
REMOVAL, Rear Wiper Motor.>
2) Disconnect the electrical connectors from rear
defogger terminal.
3) Remove the glass in the same procedure as for
windshield glass. <Ref. to GW-26, REMOVAL,
Windshield Glass.>
B: INSTALLATION
1) Apply adhesive in the same procedure as for
windshield glass. <Ref. to GW-27, INSTALLATION, Windshield Glass.>
2) Insert the glass clip pin into rear gate hole, and
after pushing on the area around the clip pin to secure it, push lightly all around the area to seal it.
3) About one hour after installation, conduct a leak
test.
NOTE:
close it carefully.
5) Connect the rear defogger terminals.
6) Install the rear wiper. <Ref. to WW-21, INSTALLATION, Rear Wiper Motor.>
(1)
(2)
(3)
(4)
(5)
(6)
(8)
(7)
GW-00240
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Upside
Molding
Glass
Adhesive
Downside
Glass
Molding
Adhesive

GW-29
Rear Window Glass

15.Rear Window Glass

A: REMOVAL
1) Disconnect the electrical connectors from rear
defogger terminal.
2) Remove the glass in the same procedure as for
Windshield Glass.>
B: INSTALLATION
1) Bond the dam rubber.

5) After curing of adhesive, pour the water on external surface of vehicle to check that there are no water leaks.
NOTE:
(3)
(1)
(2)
(5)
(3)
(2)
(6)
(4)
GW-00436
(1)
(2)
(3)
(4)
(5)
(6)
Locating pin (bonded)

Dam rubber
11 mm (0.433 in)
4 mm (0.157 in)
Rear window glass
40 mm (1.575 in)
2) Install the glass in the same procedure as for

3) Connect the connector to the rear defogger and
antenna terminals.
NOTE:
close it carefully.
GW-30
Rear Window Defogger System

16.Rear Window Defogger System

A: WIRING DIAGRAM
<Ref. to WI-304, Rear Defogger System.>
B: INSPECTION
Symptom
Rear window defogger does not operate.
Repair order
(1) Fuse (M/B No. 10) (F/B No. 22)
(1) Rear defogger relay
(2) Defogger switch
(3) Rear defogger condenser
(4) Defogger wire
(5) Wiring harness
NOTE:
Rear window defogger system can be customized on the touch panel in center display or Subaru Select Monitor.
System name
Rear window defogger timer
Initial setting
OFF after 15 min.
GW-31
Customize setting
Repeat 15 min. operation and
2 min. stop.
Rear Window Defogger

17.Rear Window Defogger

A: INSPECTION
CAUTION:
Check that the rear window defogger timer is in initial setting or customize setting before inspection.
Step
When the rear window defogger switch is operated, check the input signal using Subaru
Select Monitor.
link connector.
3) Select {Body Integrated Unit} from Main
Menu.
5) When the rear window defogger switch is
set to ON, check the input signal.
Check
After rear defogger switch is
set to ON, does it turn to OFF
in 15 minutes? Or does it
repeat 15 minutes operation
and 2 minutes stop?
2. HEAT WIRE INSPECTION

CAUTION:
When wiping stain on glass off with cloth, use a
dry and soft cloth and move it along the heat
wire to avoid damage to the heat wire.
2) Turn the defogger switch to ON.
3) Wrap the tips of tester probe with aluminum foil
to avoid damage to heat wire.
Yes
No
Replace the body
integrated unit.
<Ref. to SL-45,
REMOVAL, Body
Integrated Module.>
END.
Standard voltage:
Approx. 6 V
(1)
GW-00077
(4)
(1) Center of heat wire
(1)
(3)
Voltage
Approx. 6 V
Approx. 12 V or 0 V
(2)
GW-00076
(1)
(2)
(3)
(4)
Tester probe
Aluminum foil
Heat wire
Push
4) Measure the voltage at heat wire center with DC

voltmeter.
Criteria
Normal Operation
Broken
NOTE:
If the measured value is 12 volts, heat wire is
open between heat wire center and positive (+) terminal of tester probe.
If zero volt, heat wire is open between wire center and ground.
5) Connect the tester probe of positive lead of voltmeter to positive terminal of heat wire and move
tester probe of negative lead along the heat wire up
to the negative terminal end. If voltage changes
from zero to several volts during movement of
tester probe, heat wire is open at the voltage
change point.
GW-32
Rear Window Defogger

B: REPAIR
1) Clean the broken portion with alcohol or white
gasoline.
2) Mask both side of wire with thin film.
3) Apply the conductive silver composition (DUPONT No. 4817) to the broken portion.
(1)
(3)
(2)
(4)
GW-00078
(1)
(2)
(3)
(4)
Broken portion
Thin film
Broken wire
Conductive silver composition (DUPONT No.
4817)
4) After repair, check the wire.
GW-33
Rear Quarter Glass

18.Rear Quarter Glass
2) Cut out the nozzle head and apply adhesive to

the glass end surface as shown.
A: REMOVAL
(2)
Remove the glass in the same procedure as for

Windshield Glass.>
(7)
(1)
(6)
(3)
(2)
(2)
(3)
(5)
(4)
GW-00412
(1)
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(1)
GW-00332
(1) Locating pin

(2) Dam rubber
B: INSTALLATION
1) Install the dam rubber.
(4)
3) Install the glass in the same procedure as for

(1)
(2)
(3)
GW-00411
(1)
(2)
(3)
(4)
Dam rubber
Molding
10.5 mm (0.413 in) (constant)
Ceramic terminal
Locating pin
Dam rubber
Adhesive
Molding
8 10 mm (0.31 0.39 in)
15 mm (0.59 in)
10 mm (0.39 in)
NOTE:
close it carefully.
5) After curing of adhesive, pour the water on external surface of vehicle to check that there are no water leaks.
NOTE:
GW-34
Sun Roof Glass

19.Sun Roof Glass

A: REMOVAL
<Ref. to SR-6, REMOVAL, Glass Lid.>
B: INSTALLATION
<Ref. to SR-7, INSTALLATION, Glass Lid.>
C: ADJUSTMENT
<Ref. to SR-7, ADJUSTMENT, Glass Lid.>
GW-35
Rearview Mirror
20.Rearview Mirror
A: REMOVAL
1) Pull the mirror 45 downward to remove.
GW-00448
CAUTION:
Be careful not to damage the mirror surface.
2) When the rearview mirror mount is damaged,
use the piano wire or spatula to remove.
CAUTION:
Be careful not to damage the windshield glass.
B: INSTALLATION
1) When the rearview mirror mount is removed,
clean the old adhesive, and mate with the windshield glass mark to install.
Adhesive:
REPAIR KIT IN MR (Part No. 65029FC000) or
equivalent
2) Rotate the mirror base for 90 clockwise to install.
C: INSPECTION
Check that the mirror is not damaged.
Check that the spring is not damaged.
GW-36
Wiper Deicer System

21.Wiper Deicer System

A: WIRING DIAGRAM
<Ref. to WI-328, Wiper Deicer System.>
B: INSPECTION
Symptom
Wiper deicer does not operate.
Repair order
(1) Fuse (F/B No. 4, 9)
(1) Wiper deicer relay
(2) Wiper deicer switch
(3) Wiring harness
Refer to Rear Window Defogger for inspection.

<Ref. to GW-32, INSPECTION, Rear Window Defogger.>
NOTE:
Wiper deicer system can be customized on the touch panel in center display or Subaru Select Monitor.
System name
Initial setting
OFF after 15 min.
Wiper deicer timer
Customize setting
Continuous operation*
*: When one of following items is occurred, finish the continuous operation and goes to OFF after 15 min.
Ambient temperature that is more than 10C (41F) continues for 10 sec.
Malfunction occurs on ambient temperature sensor
Vehicle speed that is below 15 km/h (9 MPH) continues 15 min.
Malfunction occurs on CAN communication
C: REPAIR
Refer to Rear Window Defogger for repair.
<Ref. to GW-33, REPAIR, Rear Window Defogger.>
GW-37
Wiper Deicer Switch

22.Wiper Deicer Switch

A: REMOVAL
1) Remove the instrument panel lower cover. <Ref. to EI-50, REMOVAL, Instrument Panel Lower Cover.>
2) Disconnect the harness connector and remove the wiper deicer switch.
R
0
1
2
GW-00292
B: INSTALLATION
C: INSPECTION
CAUTION:
Check that the wiper deicer timer is in initial setting or customize setting before inspection.
Step
When the wiper deicer switch is operated,
check the input signal using Subaru Select
Monitor.
link connector.
3) Select {Body Integrated Unit} from Main
Menu.
5) When the wiper deicer switch is set to ON,
check the input signal.
Check
Yes
After the wiper deicer switch is END.
set to ON, does it turn to OFF
in 15 minutes? Or does it operates continuously?
2. CHECK SWITCH
Switch position
OFF
ON
Remove the wiper deicer switch and measure the

switch resistance.
Terminal No.
1 and 2
No
Replace the body
integrated unit.
<Ref. to SL-45,
REMOVAL, Body
Integrated Module.>
Standard
More than 1 M
Less than 1
Replace the wiper deicer switch if faulty.

7 6 5
4 3 2 1
15
14 13 12 11 10
9 8
GW-00330
GW-38
BODY STRUCTURE
BS
1.
Page
General Description
BODY STRUCTURE
A: SPECIFICATION
Refer to Body repair manual for body structure,
datum points and datum dimensions. <Ref. to Pub
No. L0879GJ.>
BS-2
IDI
1.
2.
3.
4.
5.
6.
7.
8.
9.
Page
Combination Meter System.........................................................................3
Clock System ............................................................................................13
Combination Meter....................................................................................16
Speedometer.............................................................................................18
Tachometer ...............................................................................................19
Fuel Gauge ...............................................................................................20
Engine Coolant Temperature Gauge ........................................................21
Clock .........................................................................................................22
General Description
A: SPECIFICATION
Speedometer
Tachometer
Water temperature gauge
Fuel gauge
Oil pressure warning light
ABS warning light
Airbag warning light
Seat belt warning light
Door open warning light
Brake fluid and parking brake warning light
Charge warning light
ATF temperature warning light
AWD warning light
Vehicle dynamics control (VDC) warning light
Vehicle dynamics control (VDC) indicator light
Turn signal indicator light
HI-beam indicator light
Immobilizer indicator light
Cruise indicator light
Cruise set indicator light
Front fog light indicator light
Rear fog light indicator light
AWD LO indicator light
SPORT indicator light
AT select lever position indicator light
Light illumination indicator light
Meter illumination light
LCD back light
Odo/Trip indicator
SPORT shift indicator
Combination meter
Stepping motor type
LED
LCD
B: CAUTION
Be careful not to damage the meters and instrument panel.
Be careful not to damage the meter glass.
Make sure the 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 an excessive force on the printed circuit.
Do not drop or otherwise apply impact.
When the combination meter of model with immobilizer has been replaced, be sure to perform the registration procedure of immobilizer.
C: PREPARATION TOOL
1. GENERAL TOOL
TOOL NAME
Circuit tester
REMARKS
IDI-2
Combination Meter System

2. Combination Meter System

A: WIRING DIAGRAM
1. COMBINATION METER
<Ref. to WI-130, WIRING DIAGRAM, Combination
Meter System.>
B: INSPECTION
1. SELF-DIAGNOSIS
The self-diagnosis (checking of each meter, warning light, indicator, illumination, LCD, buzzer
sound) of combination meter can be performed in
the following procedure.
1) Connect the diagnostic connector (A) near the
fuse & relay box.
(A)
IDI00133

3) While meter indicator needle deflecting, press
the odo/trip meter knob twice.
NOTE:
When odo/trip meter knob is pressed only once,
display mode is shifted to DTC display mode. <Ref.
to IDI-12, DTC DISPLAY MODE, INSPECTION,
Combination Meter System.>
When the self-diagnosis function is operated, the
checking of warning light, indicator, and LCD display is performed, hereafter, every pressing the
odo/trip meter knob, the operation check is performed in the order of meter, illumination and buzzer. <Ref. to IDI-4, LIST OF SELF-DIAGNOSIS
MODE OPERATION, INSPECTION, Combination
Meter System.> To cancel the self-diagnosis
mode, set the ignition switch to OFF or disconnect
the diagnosis connector.
NOTE:
When the engine starts during diagnosis, the selfdiagnosis mode is not cancelled, however, once
the vehicle starts driving, the self-diagnosis mode
is cancelled automatically for safety.
IDI-3

2. LIST OF SELF-DIAGNOSIS MODE OPERATION

Speedometer,
Microcomputer
AT select lever
Odo/Trip indica- SPORT shift
Illumination
Buzzer (SPORT
tachometer, fuel running type
position indicator
indicator
(indicator neeshift buzzer,
gauge, water
warning light,
tor light
dle, plate, ring,
speed warning
temperature
indicator light
LCD)
buzzer)
gauge
Step 0. Processing to self-diagnosis mode
Operating initial Initial illuminatNormal
Normal
Initial illuminatInitial illuminatNot beep.
operation
ing
ing
ing
Step 1-1. Check each indication after initial operation
Repeat the
Light ON
With the highPerform the seg- Perform the seg- Light at the
Not beep.
sweep operaest brightness,
ment check. For ment check. For highest brighttion (After holdilluminate the
the illumination
the illumination
ness.
ing on lowest
position sequen- order, refer to
order, refer to
position for one
tially at a cycle
the illumination
the illumination
second, reaches
of 1.5 seconds. order table.
order table.
to highest position within 5
seconds, and
after holding on
highest position
for one second,
reaches to lowest position
within 5 seconds).
Step 1-2. Press the trip knob (trip knob input is not accepted till the meter indicator needle reaches the highest position): sweep
complete, AT select lever position indicator display is set
After completLight ON
Keep the posiUnderbar _ is 1 is displayed. Light at the
Not beep.
ing sweep in
tion indicated
displayed.
highest brightstep 1-1, back to
when the trip
ness.
lowest position.
knob is pressed.
Step 2-1. Press the trip knob, and hold it: Check each meter
All meters are
Light OFF
Keep the posiDisplay the cur- 2 is disLight at the
Not beep.
moved simultation indicated
rent meter
played.
highest brightneously in every
that set in step
directing angle
ness.
0.5 sec. from
1-2.
on odometer.
the lowest posiEx.) Display
tion to highest
135054 when
position.
Speedometer/
Speedometer/
Tachometer:
Tachometer:
135 degree,
Approx. 5
Water temperadegrees at
ture gauge/Fuel
every movegauge: 54
ment.
degree.
Water temperature gauge/Fuel
gauge: Approx.
2 degrees at
every movement.
Step 2-2. Release the trip knob: Specifying the meter directing position
Not beep.
Display the cur- 2 is displayed. Light at the
Light OFF
Keep the posiStop at directhighest brightrent meter
tion indicated
ing position
ness.
that specified at directing angle
when the trip
on odometer.
step 1-2.
knob is
released.
Step 3-1. Press the trip knob, and hold it: Check illumination
IDI-4

Speedometer,
tachometer, fuel
gauge, water
temperature
gauge
Keep the position that specified at step 2-2.
Microcomputer
running type
warning light,
indicator light
AT select lever
position indicator light
Odo/Trip indicator
Light OFF
SPORT shift
indicator
Varying from the Illumination

3 is dishighest brightbrightness is
played.
ness (ILL6) to
displayed. (From
the lowest lumi- ILL6 to ILL1)
nescence (ILL1)
every second.
After reaching at
ILL1, repeat it
from ILL6.
Step 3-2. Release the trip knob: Specifying the illumination brightness
Keep the posiLight OFF
Keep the bright- Display the
3 is displayed.
tion that speciness at the time brightness at the
fied at step 2-2.
when the trip
time when the
knob is
trip knob is
released.
released.
Step 4-1. Press the trip knob: Check the beeping of SPORT shift buzzer (AT model)
Illumination
8 is disAll meter indica- Light OFF
Light at the
brightness is
played. Blinks
tor needle
highest brightwith buzzer.
returns to lowest
ness. Keep the
displayed.
position.
position indicated that set in
step 1-2.
Step 4-2. Press the trip knob: Check the VDC indicator light (Model with VDC)
All meter indica- VDC warning
Light at the
Illumination
4 is displayed.
tor needle
light and VDC
highest brightbrightness is
returns to lowest operation indica- ness. Keep the
displayed.
position.
tor light blink.
position indicated that set in
step 1-2.
Step 4-3. Press the trip knob: Check the speed warning buzzer (KS model)
Speedometer
Light OFF
Light at the
Illumination
4 is displayed.
indicates the
highest brightbrightness is
vehicle speed,
ness. Keep the
displayed.
which was
position indidetected when
cated that set in
the speed warnstep 1-2.
ing started.
Step 5. Press the trip knob: Complete the self-diagnosis 1 cycle
All meter indicator needle returns to lowest position, and go back to step 1 after completion.
IDI-5
Illumination
(indicator needle, plate, ring,
LCD)
Buzzer (SPORT
shift buzzer,
speed warning
buzzer)
Varying from the

highest brightness (ILL6) to
the lowest luminescence (ILL1)
every second.
After reaching at
ILL1, repeat it
from ILL6.
Not beep.
Keep the brightness at the time

when the trip
knob is
released.
Not beep.
Light at the
highest brightness.
SPORT shift
buzzer beeps.
Light at the
highest brightness.
Not beep.
Light at the
highest brightness.
Speed warning
buzzer beeps.

Illuminating order table

Illuminating
order
Trip meter A/B
Odo/trip meter
SPORT shift
indicator
AT select lever
position indicator
Display time
(sec.)
10
11
AB
A
B
A
B
A
B
A
B
A
B
8888.8 00000 1111.1 22222 3333.3 44444 5555.5 66666 7777.7 88888 9999.9
888888 000000 111111 222222 333333 444444 555555 666666 777777 888888 999999
8
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
IDI-6
Go back
to 1 and
repeat

3. SYMPTOM CHART
Symptom
Combination meter assembly does not operate.
Repair order
(1) Power supply
(1) Ground circuit
(2) Combination meter
Speedometer does not operate.
(1) ABSCM or VDCCM

(2) Harness
Tachometer does not operate.
(1) ECM
(2) Harness
Fuel gauge does not operate.
(1) Communication circuit

(2) Fuel level sensor
(3) Harness
Water temperature gauge does not operate.
(1) Communication circuit

(2) Engine coolant temperature sensor
(3) Harness
Error display is shown on the odo/trip meter.
Communication circuit
Reference
<Ref. to IDI-8, CHECK
POWER SUPPLY AND
GROUND CIRCUIT,
ABSCM OR VDCCM,
ENGINE CONTROL
MODULE, INSPECTION, Combination
Meter System.>
FUEL LEVEL SENSOR., INSPECTION,
Combination Meter
System.>
ENGINE COOLANT
TEMPERATURE SENSOR., INSPECTION,
Combination Meter
System.>
<Ref. to IDI-11, COMMUNICATION ERROR
DISPLAY, INSPECTION, Combination
Meter System.>
CAUTION:
When measuring the voltage and resistance of each control module or 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 of more
than 2 mm (0.08 in) in diameter.
IDI-7

4. CHECK POWER SUPPLY AND GROUND CIRCUIT
Step
CHECK POWER SUPPLY FOR COMBINATION METER.
IDI-16, REMOVAL, Combination Meter.>
2) Disconnect the combination meter harness
connector.
(i10) No. 3, No. 4 (+) Chassis ground ():
CHECK POWER SUPPLY FOR COMBINATION METER.
Measure the voltage between combination
CHECK GROUND CIRCUIT OF COMBINATION METER.
between combination meter connector and
chassis ground.
(i10) No. 11, No. 12 Chassis ground:
Check
Yes
No
Check the harness
for open or short
between the ignition switch and
combination
meter.
Check the harness

for open or short
between the fuse
and combination
meter.

?
Replace the meter Repair the wiring

case assembly.
harness.
Check
Is the voltage less than 1 V
5 V or more?
Yes
No
Replace the meter Go to step 2.
case assembly.
5. CHECK ABSCM OR VDCCM
Step
1) Lift up the vehicle and support it with rigid
racks.
2) Drive the vehicle faster than 10 km/h (6
MPH).
Warning:
Be careful not to get caught in the running
wheels.
CHECK HARNESS BETWEEN ABSCM OR Is the resistance less than 10
VDCCM AND COMBINATION METER.
?
2) Disconnect the connector from ABSCM or
VDCCM and combination meter.
or VDCCM harness connector and combination meter harness connector.
Model without VDC
(B301) No. 23 (i10) No. 19:
Model with VDC
(B310) No. 36 (i10) No. 19:
IDI-8
Model without
VDC: Check the
ABSCM. <Ref. to
ABS(diag)-2,
Basic Diagnostic
Procedure.>
Model with VDC:
Check the
VDCCM. <Ref. to
VDC(diag)-2,
Basic Diagnostic
Procedure.>
Repair the wiring

harness.

6. CHECK ENGINE CONTROL MODULE
Step
Check
Yes
CHECK ECM SIGNAL.
Is the voltage more than 0 Go to step 2.
14 V?
model
EC, K4, EK model
CHECK HARNESS BETWEEN COMBINAIs the resistance less than 10

TION METER AND ECM.
?
combination meter.
3) Measure the resistance between ECM harness connector and combination meter harness connector.
model
(B135) No. 27 (i10) No. 20:
EC, K4, EK model
(B134) No. 23 (i10) No. 20:
No
Check the ECM.
<Ref. to EN(H4SO
2.0)(diag)-2, Basic
Diagnostic Procedure.> <Ref. to
EN(H4SO
2.5)(diag)-2, Basic
Diagnostic Procedure.> <Ref. to
EN(H4DOTC)(diag
)-2, Basic Diagnostic Procedure.> <Ref. to
EN(H6DO)(diag)2, Basic Diagnostic Procedure.>
case assembly.
harness.
7. CHECK FUEL LEVEL SENSOR.
Step
1) Set the ignition switch to ON.
2) Check that the error code is displayed in
odo/trip meter.
Check
Is the error code Er xx displayed in odo/trip meter?
CHECK FUEL LEVEL SENSOR.

1) Remove the fuel level sensor. <Ref. to
(FULL) or 31 33
FU(H4SO 2.0)-49, REMOVAL, Fuel Level Sen- (EMPTY)?
sor.> <Ref. to FU(H4SO 2.5)-51, REMOVAL,
Fuel Level Sensor.> <Ref. to FU(H4DOTC)-51,
REMOVAL, Fuel Level Sensor.> <Ref. to
FU(H6DO)-50, REMOVAL, Fuel Level Sensor.>
2) Measure the resistance between fuel level
sensor terminals when the float is in FULL or
EMPTY position.
Terminals
No. 1 No. 4:
IDI-9
Yes
No
Check the commu- Go to step 2.
nication circuit.
<Ref. to IDI-11,
COMMUNICATION ERROR
DISPLAY,
INSPECTION,
Combination
Meter System.>
Go to step 3.
Replace the fuel
level sensor.

Step
CHECK FUEL SUB LEVEL SENSOR.
1) Remove the fuel sub level sensor. <Ref. to
FU(H4SO 2.0)-50, REMOVAL, Fuel Sub Level
Sensor.> <Ref. to FU(H4SO 2.5)-52,
REMOVAL, Fuel Sub Level Sensor.> <Ref. to
FU(H4DOTC)-52, REMOVAL, Fuel Sub Level
Sensor.> <Ref. to FU(H6DO)-51, REMOVAL,
Fuel Sub Level Sensor.>
2) Measure the resistance between fuel sub
level sensor terminals when the float is in
FULL or EMPTY position.
Terminals
No. 1 No. 2:
CHECK HARNESS BETWEEN FUEL SUBLEVEL SENSOR AND BODY INTEGRATED
UNIT.
2) Measure the resistance between fuel sub
level sensor harness connector terminal and
body integrated unit harness connector terminal.
(R59) No. 1 (B281) No. 19:
CHECK HARNESS BETWEEN FUEL LEVEL
SENSOR AND FUEL SUB LEVEL SENSOR.
Measure the resistance between fuel level sensor harness connector terminal and fuel sub
level sensor harness connector terminal.
(R58) No. 1 (R59) No. 2:
CHECK FUEL LEVEL SENSOR GROUND
CIRCUIT.
Measure the resistance between fuel level sensor harness connector terminal and chassis
ground.
Check
(FULL) or 61 63
(EMPTY)?
Yes
Go to step 4.
No
Replace the fuel
sub level sensor.

?
Go to step 5.
Repair the wiring

harness.

?
Go to step 6.
Repair the wiring

harness.

?

case assembly.
harness.
IDI-10

8. CHECK ENGINE COOLANT TEMPERATURE SENSOR.
Step
1) Set the ignition switch to ON.
odo/trip meter.
Check
Yes
No
Check the commu- Go to step 2.
nication circuit.
<Ref. to IDI-11,
COMMUNICATION ERROR
DISPLAY,
INSPECTION,
Combination
Meter System.>
CHECK ENGINE COOLANT TEMPERATURE Is the engine coolant tempera- Replace the meter Replace the
SENSOR.
ture sensor OK?
case assembly.
engine coolant
Check the engine coolant temperature sensor.
temperature sen<Ref. to EN(H4SO 2.0)(diag)-2, Basic Diagsor.
nostic Procedure.> <Ref. to
EN(H4DOTC)(diag)-2, Basic Diagnostic Procedure.> <Ref. to EN(H6DO)(diag)-2, Basic
9. COMMUNICATION ERROR DISPLAY
Error code
When the following error code is displayed in the

odo/trip meter, inspect the communication circuit
since the communication malfunction is generated
between each control module. <Ref. to LAN(diag)2, Basic Diagnostic Procedure.>
Er IU
Er
Er HC
Er LC
Er EG
Er TC
Er Ab
IDI00100
Er SP
Er SS
IDI-11
Remarks
Malfunction in integrated unit
Simultaneous malfunction of
high/low speed CAN communication
Malfunction of high-speed
CAN communication
Malfunction of low-speed
CAN communication
EGI Communication malfunction
TCM Communication malfunction
ABSCM/VDCCM Communication malfunction
ABSCM/VDCCM DTC information, vehicle speed pulse
malfunction
Wheel speed data malfunction

10.DTC DISPLAY MODE

When DTC display mode is operated, {ECM}, {TCM}, {ABSCM/VDCCM} is displayed repeatedly in this order
by pressing the odo/trip meter button. DTC is displayed in the following table according to type of control
module, receiving DTC, DTC detected, No DTC. If CAN communication is broken down, ----- is displayed.
Control module
ECM
TCM
ABSCM/VDCCM
When CAN communication is
broken down.
Condition
Receiving DTC
DTC detected
No DTC
Receiving DTC
DTC detected
No DTC
Receiving DTC
DTC detected
No DTC
Display
Trip A + P (blinking)
Trip A + Pxxxx
Trip A + P----
Trip B + P (blinking)
Trip B + Pxxxx
Trip B + P----
Trip A + C (blinking)
Trip A + Cxxxx
Trip A + C----
-----
IDI-12
Clock System
3. Clock System
A: WIRING DIAGRAM
1. CLOCK
<Ref. to WI-129, WIRING DIAGRAM, Clock System.>
B: INSPECTION
1. SYMPTOM CHART
Symptom
No display is shown.
Repair order
(1) Power supply
(1) Clock body
Illumination does not illuminate.
(1) Illumination power supply

(2) Clock body
Brightness does not change even when bright

switch is pressed.
(1) Bright switch

(2) Clock body
Acc or ign is displayed.
ACC or ignition power supply
Err is displayed in all items.
(1) Communication circuit between combination

meter and clock
(2) Clock body
Err is displayed when a specified item is

selected.
Communication circuit between combination

meter and each control module
IDI-13
Reference
POWER SUPPLY AND
GROUND CIRCUIT,
INSPECTION, Clock
System.>
ILLUMINATION CIRCUIT, INSPECTION,
Clock System.>
BRIGHT CIRCUIT,
INSPECTION, Clock
System.>
ACC OR IGNITION
POWER SUPPLY,
INSPECTION, Clock
System.>
COMMUNICATION
CIRCUIT, INSPECTION, Clock System.>
<Ref. to IDI-11, COMMUNICATION ERROR
DISPLAY, INSPECTION, Combination
Meter System.>
Clock System
Step
Check
Yes
CHECK CLOCK POWER SUPPLY.
1) Disconnect the clock harness connector.
2) Measure the voltage between clock harness connector and chassis ground.
CHECK CLOCK GROUND CIRCUIT.
Is the resistance less than 10 Replace the clock
?
body.
2) Measure the resistance between clock harness connector and chassis ground.
No
Check the harness
for open or short
between fuse and
clock.
Repair the wiring

harness.
3. CHECK ILLUMINATION CIRCUIT
Step
CHECK ILLUMINATION CIRCUIT POWER
SUPPLY.
3) Turn the ignition switch and lighting switch
to ON.
Check
Yes
No
Is the voltage more than 10 V? Replace the clock Check the harness
body.
for open or short
between fuse and
clock.
4. CHECK BRIGHT CIRCUIT
Step
Check
CHECK BRIGHT CIRCUIT POWER SUPPLY. Is the voltage more than 10 V?
CHECK HARNESS BETWEEN CLOCK AND Is the resistance less than 10
BODY INTEGRATED UNIT.
?
3) Measure the resistance between clock harness connector and body integrated unit harness connector.
(i59) No. 2 (i84) No. 30:
IDI-14
Yes
No
Replace the clock Go to step 2.
body.
Replace the body

integrated unit.
Repair the wiring

harness.
Clock System
5. CHECK ACC OR IGNITION POWER SUPPLY
Step
CHECK ACC POWER SUPPLY.
3) Turn the ignition switch to ACC.
CHECK THE IGNITION POWER SUPPLY.
Check
Yes
No
Check the open
circuit in harness
between fuse and
clock.
Is the voltage more than 10 V? Replace the clock Check the open
body.
circuit in harness
between fuse and
clock.
6. CHECK COMMUNICATION CIRCUIT
Step
CHECK THE HARNESS BETWEEN CLOCK
AND COMBINATION METER.
2) Disconnect the harness of clock and combination meter.
connectors of clock and combination meter.
(i59) No. 5 (i10) No. 18:
1) Connect all the disconnected connectors.
odo/trip meter.
Check
?
Yes
Go to step 2.
Check the commu- Replace the clock

nication circuit.
body.
<Ref. to IDI-11,
COMMUNICATION ERROR
DISPLAY,
INSPECTION,
Combination
Meter System.>
IDI-15
No
Repair the wiring
harness.
Combination Meter
4. Combination Meter
A: REMOVAL
2) Set the tilt steering at the lowest position.
3) Remove the instrument panel under cover and
lower cover of drivers seat side. <Ref. to EI-56,
REMOVAL, Instrument Panel Assembly.>
4) Remove the screws of combination meter (one
for upper side, two for lower side) and pull tilting the
meter toward you.
IDI00101
5) Disconnect the connector in the rear side of

combination meter to remove meter.
CAUTION:
Be careful not to damage the meter or instrument panel.
Pay particular attention to avoid damaging
the meter glass.
B: INSTALLATION
CAUTION:
Make sure the electrical connector is connected securely.
Make sure that each meter operates normally.
When the combination meter of model with
immobilizer has been replaced, be sure to perform the registration procedure of immobilizer.
IDI-16
Combination Meter
C: DISASSEMBLY
CAUTION:
Use gloves to avoid damage and getting fingerprints on the glass surface and meter surfaces.
Be careful not to apply excessive force to the trip knob.
Be sure not to touch the meter indicator needle.
Remove the pawl (A), and then detach the meter glass assembly (B) and meter panel assembly (C) from
meter case assembly (D).
(A)
(B)
(C)
(D)
IDI00102
1. BULB REPLACEMENT
LEDs are used for all of warning lights and indicator lights of combination meters, replace the meter case assembly if faulty.
D: ASSEMBLY
IDI-17
Speedometer
5. Speedometer
A: SPECIFICATION
Since the meter case assembly cannot be disassembled, do not remove or inspect the speedometer alone. (Do not remove the cover on the back
side.)
IDI-18
Tachometer
6. Tachometer
A: SPECIFICATION
Since the meter case assembly cannot be disassembled, do not remove or inspect the tachometer
alone. (Do not remove the cover on the back side.)
IDI-19
Fuel Gauge
7. Fuel Gauge
A: SPECIFICATION
Since the meter case assembly cannot be disassembled, do not remove or inspect the fuel gauge
alone. (Do not remove the cover on the back side.)
IDI-20
Engine Coolant Temperature Gauge


Gauge
A: SPECIFICATION
Since the meter case assembly cannot be disassembled, do not remove or inspect the water temperature gauge alone. (Do not remove the cover on
the back side.)
IDI-21
Clock
9. Clock
A: REMOVAL
2) Remove the center air vent grille. <Ref. to AC44, REMOVAL, Air Vent Grille.>
3) Loosen the screws, and then remove the clock
(B) from center air vent grille (A).
(A)
(B)
IDI00103
B: INSTALLATION
IDI-22
SEATS
SE
1.
2.
3.
4.
Page
Front Seat ...................................................................................................7
Rear Seat ..................................................................................................14
Seat Heater System ..................................................................................19
General Description
SEATS
A: COMPONENT
1. FRONT SEAT (STANDARD SEAT)
(4)
(1)
(3)
(25)
(2)
(5)
(7)
(9)
(6)
T1
(8)
T4
(11)
(10)
T5
(12)
(24)
(13)
(19)
(17)
(14)
(23)
T2
(18)
(22)
(16)
(21)
(15)
T6
T3
T6
T2
(20)
SE-00510
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
Backrest cover
Backrest pad
Backrest frame ASSY
Headrest ASSY
Headrest lock bushing
Side airbag module
Cover frame
Backrest back cover
Seat side cover inside
Hinge inner cover RH
Rear bolt cover inside
Seat cushion cover
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
Seat cushion pad

Seat cushion frame ASSY
Rear bolt cover outside
Reclining lever
Seat side cover outside
Lifter lever
Hinge inner cover LH
Outer slide rail
Inner slide rail
Connecting wire
Seat heater unit
SE-2
(25)
Lumber support lever

T1: 6 (0.61, 4.43)
T2: 10 (1.02, 7.38)
T3: 22 (2.24, 16.2)
T4: 30 (3.06, 22.1)
T5: 52 (5.30, 38.4)
T6: 53 (5.40, 39.1)
General Description
SEATS
2. FRONT SEAT (POWER SEAT)
(4)
(1)
(3)
(23)
(2)
(5)
(7)
(9)
(6)
T1
)8(
T3
(11)
(10)
T3
(12)
(22)
(13)
(18)
(14)
T3
(17)
(19)
(21)
(16)
T2
(20)
(15)
T4
T3
T3
SE-00511
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
Backrest cover
Backrest pad
Backrest frame ASSY
Headrest ASSY
Headrest lock bushing
Side airbag module
Cover frame
Backrest back cover
Seat side cover inside
Hinge inner cover RH
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
Rear bolt cover inside

Seat cushion cover
Seat cushion pad
Seat cushion frame ASSY
Rear bolt cover outside
Power seat switch knob
Seat side cover outside
Hinge inner cover LH
Slide rail ASSY
SE-3
(21)
(22)
(23)
Power seat switch unit

Seat heater unit
Lumber support lever

T1: 6 (0.61, 4.43)
T2: 22 (2.24, 16.2)
T3: 52 (5.30, 38.4)
T4: 53 (5.40, 39.1)
General Description
SEATS
3. REAR SEAT (SEDAN MODEL)
(2)
(11)
(6)
T1
(1)
(2)
(4)
(8)
(9)
(10)
(7)
(5)
T2
(3)
SE-00422
(1)
(2)
(3)
(4)
(5)
(6)
Backrest
Headrest
Cushion
Armrest
Center through frame
Hook
(7)
(8)
(9)
(10)
(11)
Backrest pad ASSY

Backrest cover ASSY
Rear pad & cushion frame ASSY
Rear cushion cover
Headrest bushing
SE-4

T1: 10 (1.02, 7.38)
T2: 24.5 (2.5, 18.1)
General Description
SEATS
4. REAR SEAT (WAGON MODEL)
(1)
T3
(17)
(18)
(2)
(16)
(2)
(3)
T1
(12)
(13)
T3
(15)
(14)
(11)
(6)
(5)
T2
T3
(4)
(10)
T3
(8)
(19)
(9)
T3
(7)
T1
SE-00513
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Headrest
Headrest bushing
Backrest cover RH
Backrest pad RH
Backrest frame RH
Hinge ASSY RH
Seat cushion pad
Seat cushion cover
Hinge ASSY center
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
Hinge ASSY LH
Backrest pad LH
Backrest cover LH
Backrest frame LH
Seat back latch
Seat back latch cover
Holder & button
Striker
Backrest shoulder RH
SE-5
(19)
Backrest shoulder LH

T1: 13.7 (1.40, 10.1)
T2: 22 (2.24, 16.2)
T3: 24.5 (2.5, 18.1)
General Description
SEATS
B: CAUTION
When removing the front seat from a side airbag loaded vehicle, follow cautions given in the airbag section.
C: PREPARATION TOOL
1. GENERAL TOOL
TOOL NAME
Long nose pliers
Hog ring pliers
TORX T50
REMARKS
Used for removing the hog ring.
Used for installing the hog ring.
Used for removing and installing the inner seat belt.
SE-6
Front Seat
SEATS
2. Front Seat
B: INSTALLATION
A: REMOVAL
CAUTION:
The airbag system is fitted with a backup power
source. After disconnecting the battery ground
cable, the airbag may deploy if you do not wait
for 20 seconds before starting the repair of airbag system.
1) While pressing the headrest lock button, remove
the headrest.
NOTE:
Tighten the slide rail installing bolt gradually in several steps to the specified torque in the order as
(4)
(1)
(2)
(3)
SE-00479
Tightening torque:
Refer to COMPONENT of General Description. <Ref. to SE-2, COMPONENT, General
Description.>
SE-00003
2) Tilt forward the backrest, and slide the seat forward.

3) Remove the rear bolt cover, and remove the two
bolts at the rear side of slide rail.
4) Slide the seat backward, and remove the two
bolts at the front side of slide rail.
5) Remove the battery ground cable, and wait for
6) Disconnect the connector under the seat.
Seat belt warning light connector (Drivers side).
Side airbag connector (Model with side airbag)
Seat heater connector (Model with seat heater)
Power seat connector (Model with power seat)
C: DISASSEMBLY
1. MANUAL SEAT
1) Remove the seat from vehicle. <Ref. to SE-7,
REMOVAL, Front Seat.>
2) Remove the seat lifter cover using a flat tip
screwdriver and loosen the inner bolt to remove
seat lifter lever.
SE-00290
3) Remove the hook (A) and detach reclining lever

cover.
(A)
SE-00474
SE-00404
SE-7
Front Seat
SEATS
4) Remove the screws (A) and clips (B), and then

detach the seat side cover outside.
7) Remove the two bolts from reclining hinge on

each side.
(B)
(B)
(A)
(A)
SE-00405
5) Loosen the screws to detach seat side cover inside.
SE-00408
SE-00406

8) Remove the clips and hooks, and then detach

the backrest back cover.
SE-00334
SE-00407
9) Remove the lock clip, and then remove the lumber support lever.
SE-00414
SE-8
Front Seat
SEATS
10) Remove the hooks at the rear side of backrest.
15) Remove the hooks (A), and then remove the

seat cushion frame assembly.
(A)
SE-00335
SE-00338
11) Remove the cover frame (A).
16) Remove the hog rings (A), and then remove the
seat cushion cover from seat cushion pad.
(A)
SE-00337
12) Remove the headrest lock bushing.
: (A)
NOTE:
Push outside to remove it from the inside of seat.
17) Remove the bolt of sliding adjustment bar and

connecting wire.
SE-00243
SE-00340
13) Pull out the backrest frame assembly.

14) Remove the hog rings (A) on the front side of
backrest, and then remove the backrest cover from
backrest.
: (A)
SE-00339
SE-00372
SE-9
Front Seat
SEATS
18) Remove the bolts, and then remove the slide

rail.
3) Disconnect the connector of reclining motor from

the back of seat cushion.
SE-00383
4) Remove the screw (A) and clips (B), and then

disconnect the seat switch connector to remove
seat side cover outside.
(B)
SE-00409
19) Remove the hooks and hog rings at the bottom

of headrest, and then remove the headrest cover
from headrest.
(A)
(B)
SE-00411
5) Remove the screw (A) and clip (B), and then remove the seat side cover inside.
(B)
(A)
SE-00342
2. POWER SEAT
SE-00412
1) Remove the seat from vehicle. <Ref. to SE-7,

REMOVAL, Front Seat.>
2) Remove the seat switch knob.

SE-00407
SE-00410
SE-10
Front Seat
SEATS
7) Remove the two bolts from the reclining hinge on

each left and right side.
10) Remove the hooks at the rear side of backrest.
SE-00335
NOTE:
For the seat with side airbag, the airbag module installation side is secured with hog rings (A).
(A)
SE-00413
8) Remove the clips and hooks, and then detach

the backrest back cover.
SE-00415
11) Remove the cover frame (A).
(A)
SE-00334
9) Remove the lock clip, and then remove the lumber support lever.
SE-00337
12) Remove the headrest lock bushing.

NOTE:
Push outside to remove it from the inside of seat.
SE-00414
SE-00243
13) Pull out the backrest frame assembly.
SE-11
Front Seat
SEATS
14) Remove the two bolts on each left and right

side, and then remove the reclining motor assembly.
18) Remove the hooks (A), and then remove the

seat cushion from seat cushion frame.
(A)
(A)
SE-00391
SE-00388

backrest, and then remove the backrest cover from
backrest.
seat cushion cover from seat cushion pad.
: (A)
: (A)
SE-00372
16) Remove the clip (A) and straps (B) on the back
of seat cushion.
SE-00339
20) Remove the hooks and hog rings at the bottom

of headrest, and then remove the headrest cover
from headrest.
(B)
(A)
SE-00342
SE-00389
17) Remove the bolt (A) and hook (B) on left and
right side, and then remove the seat cushion frame
from slide rail assembly.
(B)
(A)
D: ASSEMBLY
CAUTION:
When the backrest cover is not installed securely, the side airbag module may not be deployed properly, therefore keep strictly to the
following procedure.
Be careful not to stain or damage the backrest cover during assembly.
Always use new hog rings.
Secure the hog ring using hog ring pliers.
Install the hog rings to the specified points
securely and make sure that no wrinkle or twisting on the backrest cover.
SE-00416
SE-12
Front Seat
SEATS
1. MANUAL SEAT
2. SEATING SENSOR
NOTE:
When installing the inner seat belt assembly, follow the procedure described in Front Seat Belt.
<Ref. to SB-13, INNER SEAT BELT ASSEMBLY,
INSTALLATION, Front Seat Belt.>
Install the backrest assembly and seat cushion
assembly in the following procedure.
1) Temporarily tighten the four reclining hinge
bolts.
2) Place the backrest in the most upright position.
(For manual seat, ensure the reclining mechanism
locked securely.)
3) Tighten the reclining hinge bolts (1) (4) in two
or three steps by gradually increasing the torque
until they reach the specified torque.
Make sure the passengers seat belt warning light

illuminates when applying load to the rear surface
of passengers seat cushion. If not, replace the seat
cushion pad with a new one.
(2)
(1)
(4)
(A)
(3)
(B)
SE-00514
(A) Vehicle inside

(B) Vehicle outside

Tightening torque:
Refer to COMPONENT of General Description. <Ref. to SE-2, COMPONENT, General
Description.>
2. POWER SEAT
NOTE:
Refer to MANUAL SEAT for installation of backrest assembly and seat cushion assembly. <Ref. to
SE-13, MANUAL SEAT, ASSEMBLY, Front Seat.>
E: INSPECTION
1. SEAT COVER
Check that no tear or fray on the backrest cover
and seat cushion cover.
NOTE:
When the side airbag equipped model has tear or
fray on the door side of backrest cover, the side airbag may not be deployed properly. Replace it with
new one in such a case.
SE-13
SE-00418
Rear Seat
SEATS
3. Rear Seat
4) Remove the bolts which secure the bottom of

backrest.
A: REMOVAL
1. SEDAN MODEL
1) Remove the two hooks while lifting up the rear
seat cushion.
SE-00344
5) Remove the anchor part on backrest side from

the hook on body side (A) while lifting up the backrest to detach it from vehicle.
SE-00343
2) Remove the hook (A) by pushing it backward

while lifting up the front side of seat cushion to detach seat cushion.
(A)
(A)
SE-00346
2. WAGON MODEL
2) Remove the two hooks while lifting up the rear
seat cushion.
SE-00345
3) Remove the lower anchor bolt of rear center seat

belt.
SE-00343
EI-00675
SE-14
Rear Seat
SEATS
3) Remove the hook (A) by pushing it backward

while lifting up the front side of seat cushion to detach seat cushion.
NOTE:
The backrest cannot be detached when the hinge
assembly side does not mate with the backrest pin
position.
8) Remove the lower anchor bolt (A) of outer seat
belt and backrest shoulder bolt (B).
(A)
(B)
(A)
SE-00349
9) Remove the backrest shoulder with lifting it up.
SE-00397
4) Remove the headrest, and then tilt the backrest

forward.
6) Remove the hinge assembly CTR bolts.
SE-00350
10) Remove the belt cover (A) from backrest shoulder cover, and then pull out the seat belt.
(A)
SE-00153
7) Remove the backrest from hinge assembly LH

(hinge assembly RH).
SE-00351
B: INSTALLATION
1. SEDAN MODEL
NOTE:
After installing the backrest, make sure that each
seat belt operates normally.
Make sure that they are secured on each hook of
vehicle side.
SE-00348
SE-15
Rear Seat
SEATS
Tightening torque:
Refer to COMPONENT of General Description. <Ref. to SE-4, REAR SEAT (SEDAN
MODEL), COMPONENT, General Description.>

backrest.
2. WAGON MODEL
NOTE:
After installing the backrest, make sure that each
seat belt operates normally.
Make sure that they are secured on each hook of
vehicle side.
Tightening torque:
Refer to COMPONENT of General Description. <Ref. to SE-5, REAR SEAT (WAGON
MODEL), COMPONENT, General Description.>
: (A)
SE-00353
6) Remove both sides of armrest hinge covers, and

loosen the screws to remove armrest.
C: DISASSEMBLY
1. SEDAN MODEL
1) Remove the rear seat. <Ref. to SE-14, SEDAN
MODEL, REMOVAL, Rear Seat.>
2) Remove the headrest.
3) Remove the nuts, and then detach the trunk
through assembly.
SE-00354
7) Remove the hook, and then detach the center

through cover.
SE-00347
4) Remove the hog rings (A) on the rear side of

backrest.
: (A)
SE-00355
8) Remove the hook, and then remove the armrest

cover.
SE-00352
SE-00356
SE-16
Rear Seat
SEATS
9) Remove the hook and hog ring, and then remove the headrest cover.
2) Remove the hooks at the bottom of backrest assembly LH, and then turn over the backrest cover
to remove the hog rings (A) and hooks (B).
(A)
(B)
SE-00357

seat cushion.
SE-00359

backrest, and then remove the backrest cover.
(A)
(A)
: (A)
SE-00399
seat cushion cover.
SE-00360
4) Remove the bolts, and then remove the backrest

latch.
: (A)
SE-00398
SE-00361
2. WAGON MODEL
1) Remove the rear seat. <Ref. to SE-14, WAGON
5) Loosen the screws to remove the armrest from

backrest assembly RH.
SE-00358
SE-17
Rear Seat
SEATS
NOTE:
Armrest cannot be removed when backrest assembly RH side does not mate with armrest side pin position.
6) After this operation, refer to the step 2) to disassemble backrest assembly RH.
7) Remove the hook, and then remove the armrest
cover.
seat cushion cover.
: (A)
SE-00398
D: ASSEMBLY
SE-00356
8) Remove the hook and hog ring, and then remove the headrest cover.
NOTE:
Do not contaminate or damage the cover.
While installing the hog rings, prevent the seat
from getting wrinkled.
CAUTION:
Always use new hog rings.
Secure the hog ring using hog ring pliers.
Install the hog rings to the specified points
securely and be sure to prevent backrest cover
from wrinkle or twisting.
E: INSPECTION
Check that no tear or fray on the seat cover.
SE-00357

seat cushion.
: (A)
SE-00399
SE-18
Seat Heater System

SEATS
4. Seat Heater System

A: REMOVAL
1. SEAT HEATER UNIT
2) Remove the backrest cover and seat cushion
cover of front seat. <Ref. to SE-7, DISASSEMBLY,
Front Seat.>
3) Remove the hog ring, and then remove the seat
heater unit.
SE-00082
2. SEAT HEATER SWITCH

2) Remove the seat heater switch from console
box.
B: INSTALLATION
1. SEAT HEATER UNIT
2. SEAT HEATER SWITCH

SE-19
Seat Heater System

SEATS
SE-20
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.
23.
Page
Door Lock Control System ........................................................................10
Keyless Entry System ...............................................................................15
Front Inner Remote ...................................................................................27
Front Outer Handle ...................................................................................28
Front Door Latch and Door Lock Actuator Assembly................................29
Front Door Lock Actuator ..........................................................................30
Rear Inner Remote....................................................................................31
Rear Outer Handle ....................................................................................32
Rear Door Latch and Door Lock Actuator Assembly ................................33
Rear Door Lock Actuator...........................................................................34
Rear Gate Outer Handle ...........................................................................35
Rear Gate Latch Assembly .......................................................................36
Trunk Lid Lock Assembly ..........................................................................38
Front Hood Lock Assembly .......................................................................39
Remote Openers.......................................................................................40
Ignition Key Lock.......................................................................................42
Key Lock Cylinders ...................................................................................43
Keyless Entry Control Module...................................................................44
Body Integrated Module ............................................................................45
Keyless Transmitter ..................................................................................46
Immobilizer Control Module ......................................................................48
Immobilizer Antenna .................................................................................49
General Description
SECURITY AND LOCKS
A: COMPONENT
1. DOOR LOCK ASSEMBLY
Model without double lock
(A)
(3)
T2
(1)
T3
(4)
(5)
T1
(2)
(B)
(5)
(3)
T3
T2
(1)
T1
(6)
SL-00271
(A)
Front
(B)
Rear
(1)
(2)
Inner remote ASSY

Front door latch & door lock actuator ASSY
(4)
(5)
(6)
(3)
Door outer handle
Key cylinder
Striker
T1: 6.5 (0.66, 4.8)
T2: 7.5 (0.76, 5.5)
Rear door latch & door lock actuator ASSY
T3: 18 (1.8, 13.3)
SL-2
General Description
SECURITY AND LOCKS
Model with double lock

(8)
(A)
(3)
(1)
(4)
T2
T3
(9)
(5)
T2
T1
(2)
(B)
(5)
(3)
T3
(1)
T1
(6)
(7)
T2
SL-00272
(A)
Front
(B)
Rear
(1)
(2)
Inner remote ASSY

Front door latch & door lock actuator ASSY
(6)
Rear door latch & door lock actua- Tightening torque: Nm (kgf-m, ft-lb)
tor ASSY
T1: 6.5 (0.66, 4.8)
Outer handle bracket
T2: 7.5 (0.76, 5.5)
Key cylinder cover A
T3: 18 (1.8, 13.3)
Key cylinder cover B
(3)
(4)
(5)
Door outer handle

Key cylinder (switch)
Striker
(7)
(8)
(9)
SL-3
General Description
SECURITY AND LOCKS
2. TRUNK LID AND REAR GATE LOCK

Model without double lock
(B)
(A)
(1)
T1
(1)
T3
(3)
(4)
(5)
T3
(2)
T4
(6)
T2
(2)
SL-00309
(A)
Trunk
(B)
Rear gate
(1)
(2)
(3)
(4)
(5)
Cable
Striker
Trunk lid lock ASSY
Rear gate outer handle
Rear gate actuator
(6)
Rear gate latch
SL-4

T1: 7.5 (0.76, 5.5)
T2: 25 (2.5, 18.4)
T3: 7.35 (0.75, 5.39)
T4: 18 (1.8, 13.3)
General Description
SECURITY AND LOCKS
Model with double lock

(B)
(A)
(1)
T1
(1)
T3
(3)
(4)
(5)
T3
(2)
T4
(6)
T2
(2)
SL-00273
(A)
Trunk
(B)
Rear gate
(1)
(2)
(3)
(4)
(5)
Cable
Striker
Trunk lid lock ASSY
Rear gate outer handle
Rear gate actuator
(6)
Rear gate latch ASSY
SL-5

T1: 7.5 (0.76, 5.5)
T2: 25 (2.5, 18.4)
T3: 7.35 (0.75, 5.39)
T4: 18 (1.8, 13.3)
General Description
SECURITY AND LOCKS
3. FRONT HOOD LOCK AND REMOTE OPENERS

(3)
(2)
(5)
(6)
(C)
(B)
(4)
(5)
(6)
(4)
(1)
T
(7)
(4)
(A)
T
SL-00275
(A)
Sedan model
(B)
Wagon model
(1)
(2)
(3)
(4)
Front hood lock ASSY

Lever ASSY
Lever ASSY bracket
Cable
(5)
(6)
(7)
Cover
Pull handle ASSY
Striker
SL-6
(C)
Hood

T: 33 (3.36, 24.2)
General Description
SECURITY AND LOCKS
4. IMMOBILIZER SYSTEM
(4)
(2)
(1)
(3)
SL-00276
(1)
Antenna
(2)
Immobilizer indicator light (LED

bulb)
NOTE:
Body integrated unit location for RHD model is symmetrically opposite.
SL-7
(3)
(4)

Transponder
General Description
SECURITY AND LOCKS
5. KEYLESS ENTRY SYSTEM
(2)
(1)
(3)
(5)
(4)
SL-00277
(1)
(2)
Keyless Entry Control Module

Rear gate latch switch (Wagon)
(3)
(4)
Door switch
B: CAUTION
repairing the audio, control module, etc. which are
provided with memory functions, record the memory contents before disconnecting the ground cable
from battery. Otherwise, these contents are erased
upon disconnection.
Adjust the parts to the specifications described in
this manual if so designated.
After reassembly, ensure the functional parts operate smoothly.
The 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 the electrical test equipment on these circuits.
Be careful not to damage the airbag system wiring harness when servicing the ignition key cylinder.
SL-8
(5)
Power window main switch
General Description
SECURITY AND LOCKS
C: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
925580000
DESCRIPTION
PULLER
REMARKS
Used for removing trim clip.
ST-925580000
2. GENERAL TOOL
TOOL NAME
Circuit tester
Drill
REMARKS
Used for replacing ignition key lock.
SL-9
Door Lock Control System

SECURITY AND LOCKS
2. Door Lock Control System

A: WIRING DIAGRAM
1. DOOR LOCK CONTROL
<Ref. to WI-248, WIRING DIAGRAM, Keyless Entry System.>
B: INSPECTION
1. SYMPTOM CHART
Symptom
The door lock control system does
not operate.
The door lock switch does not operate.

A specific door lock actuator does not
operate.
The key cylinder lock switch does not

operate. (Model with double lock)
The double lock does not operate.

(Model with double lock)
Repair order
Reference
1. Check the fuse.
<Ref. to SL-11, CHECK FUSE,
INSPECTION, Door Lock Control
System.>
2. Check the power supply and ground circuit for
<Ref. to SL-11, CHECK POWER
body integrated unit.
SUPPLY AND GROUND CIRCUIT,
System.>
3. Check the door lock switch and circuit.
<Ref. to SL-11, CHECK DOOR
LOCK SWITCH, INSPECTION,
Door Lock Control System.>
4. Check the door lock actuator and circuit.
LOCK ACTUATOR AND CIRCUIT,
System.>
Check the door lock switch.
LOCK SWITCH, INSPECTION,
Door Lock Control System.>
Check the door lock actuator and circuit.
LOCK ACTUATOR AND CIRCUIT,
System.>
Check the key cylinder lock switch and circuit.
<Ref. to SL-13, CHECK KEY CYLINDER LOCK SWITCH AND CIRCUIT, INSPECTION, Door Lock
Control System.>
Check the door lock actuator (double lock) and cir- <Ref. to SL-14, CHECK DOOR
cuit.
LOCK ACTUATOR (DOUBLE
LOCK) AND CIRCUIT, INSPECTION, Door Lock Control System.>
SL-10

SECURITY AND LOCKS
2. CHECK FUSE
Step
CHECK FUSE.
Remove and visually check the fuse No. 3 (in
the fuse and relay box) and No. 7 (in the fuse
and relay box).
Check
Yes
Replace the fuse
with a new one.
No
Check the power
supply and ground
circuit. <Ref. to
SL-11, CHECK
POWER SUPPLY
AND GROUND
CIRCUIT,
INSPECTION,
Door Lock Control
System.>
Yes
Go to step 2.
No
Check the harness
for open or short
circuit between
body integrated
unit and fuse.
Step
Check
CHECK POWER SUPPLY.
integrated unit.
2) Measure the voltage between harness connector terminal and chassis ground.
Measure the resistance between harness con- ?
nector terminal and chassis ground.
(B281) No. 8, 9, 22 Chassis ground:
The power supply Repair the harand ground circuit ness.

are OK.
4. CHECK DOOR LOCK SWITCH
Step
CHECK DOOR LOCK SWITCH.
Check the input from door lock switch to body
integrated unit using Subaru Select Monitor.
link connector.
3) Select {body integrated unit} from main
menu.
5) Check the input to body integrated unit by
operating the door lock switch.
CHECK DOOR LOCK SWITCH CIRCUIT.
1) Disconnect the body integrated unit harness connector.
2) Measure the resistance between the harness connector terminal and chassis ground
when moving the door lock switch to LOCK.
Check
Is the normal input signal displayed when the door lock
switch is moved to LOCK/
UNLOCK?
Yes
The door lock
switch is OK.
No
Go to step 2.

?
Go to step 3.
Go to step 4.
SL-11

SECURITY AND LOCKS
Step
Measure the resistance between the harness
connector terminal and chassis ground when
the door lock switch is moved to UNLOCK.
1) Disconnect the door lock switch harness
connector.
2) Measure the resistance between the door
lock switch terminals when moving the door
lock switch to LOCK.
LHD model:
(D7) No. 4 No. 7:
RHD model:
(D7) No. 4 No. 14:
Measure the resistance between the door lock
switch terminals when moving the door lock
switch to UNLOCK.
LHD model:
(D7) No. 5 No. 7:
RHD model:
(D7) No. 5 No. 14:
Check
?
Yes
The door lock
switch is OK.
No
Go to step 4.

?
Go to step 5.
Replace the door

lock switch.

?
Check the harness Replace the door

for open circuits or lock switch.
shorts between
the body integrated unit and the
door lock switch.
5. CHECK DOOR LOCK ACTUATOR AND CIRCUIT
Step
Check
Yes
CHECK OUTPUT SIGNAL.
Measure the voltage between the harness connector terminal and chassis ground of body
integrated unit when moving the door lock
switch to LOCK.
Measure the voltage between the harness connector terminal and chassis ground of body
integrated unit when moving the door lock
switch to UNLOCK.
CHECK POWER WINDOW MAIN SWITCH
OUTPUT SIGNAL.
Measure the voltage between the harness connector terminal of power window main switch
and chassis ground when moving the door lock
switch to LOCK.
SL-12
No
Replace the body
integrated unit.
<Ref. to SL-45,
Body Integrated
Module.>
Replace the body

integrated unit.
<Ref. to SL-45,
Body Integrated
Module.>
Replace the power

window main
switch. <Ref. to
GW-9, Power Window Control
Switch.>

SECURITY AND LOCKS
Step
Check
CHECK POWER WINDOW MAIN SWITCH
OUTPUT SIGNAL.
Measure the voltage between the harness connector terminal of power window main switch
and chassis ground when moving the door lock
switch to UNLOCK.
CHECK DOOR LOCK ACTUATOR.
Is the door lock actuator OK?
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 SL36, Rear Gate Latch Assembly.>
Yes
Go to step 5.
No
Replace the power
window main
switch. <Ref. to
GW-9, Power Window Control
Switch.>

for open or short lock actuator.
circuit between
body integrated
unit and door lock
actuator.
6. CHECK KEY CYLINDER LOCK SWITCH AND CIRCUIT
Step
CHECK KEY CYLINDER LOCK SWITCH CIRCUIT.
turning the key cylinder lock switch to LOCK.
CHECK KEY CYLINDER LOCK SWITCH CIRCUIT.
Measure the resistance between harness connector terminal and chassis ground when turning the key cylinder lock switch to UNLOCK.
CHECK KEY CYLINDER LOCK SWITCH.
1) Disconnect the key cylinder lock switch
connector.
2) Measure the resistance between key cylinder lock switch terminals when turning the key
cylinder lock switch to LOCK.
Terminals
No. 1 No. 2
CHECK KEY CYLINDER LOCK SWITCH.
Measure the resistance between key cylinder
lock switch terminals when turning the key cylinder lock switch to UNLOCK.
Terminals
No. 2 No. 3
Check
?
Yes
Go to step 2.
No
Go to step 3.

?
Key cylinder lock

switch is OK.
Go to step 3.

?
Go to step 4.
Replace the key

cylinder lock
switch.

?
Check the harness Replace the key

for open or short cylinder lock
circuits between
switch.
body integrated
unit and key cylinder lock switch.
SL-13

SECURITY AND LOCKS
7. CHECK DOOR LOCK ACTUATOR (DOUBLE LOCK) AND CIRCUIT
Step
Measure the voltage between body integrated
unit harness connector terminal and chassis
ground when turning the key cylinder lock
switch to LOCK.
Measure the voltage between body integrated
unit harness connector terminal and chassis
ground when turning the key cylinder lock
switch to UNLOCK.
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.>
Check
Yes
No
Replace the body
integrated unit.
Replace the body

integrated unit.
Is the door lock actuator normal?
SL-14

for open or short lock actuator.
circuits between
body integrated
unit and door lock
actuator.
Keyless Entry System

SECURITY AND LOCKS
3. Keyless Entry System

A: WIRING DIAGRAM
1. KEYLESS ENTRY
<Ref. to WI-248, WIRING DIAGRAM, Keyless Entry System.>
B: ELECTRICAL SPECIFICATION
1. CUSTOMIZE SETTING OF SELECT UNLOCK
Switching from all door unlock to select unlock, or select unlock to all door unlock are performed with following procedure.
1) Close the drivers door, and then open it.
2) Insert the key to ignition switch, and then turn the ignition switch from OFF to ON for more than 10 times
within 15 seconds. Complete the procedure in step 1) through 2) within 45 seconds. When the procedures
are completed correctly, the buzzer beeps once. If the buzzer does not beep, repeat the procedures from
step 1).
3) Close the drivers door.
4) While depressing the door lock switch to lock side, turn the ignition switch from OFF to ON.
5) While depressing the door lock switch to unlock side, turn the ignition switch from ON to OFF, and then release the door lock switch. Complete the procedure in step 3) through 5) within 30 seconds. When the procedures are completed correctly, the buzzer beeps twice and door lock, unlock operates automatically. When
the buzzer does not beep, repeat the procedures from step 1).
6) Remove the key from ignition switch, and then complete the procedure.
7) Operate the key button to check that the setting is changed.
2. KEYLESS ENTRY CONTROL MODULE
To
i96
4 3 2 1
8 7 6 5
SL-00228
Remarks
Power supply (Backup)
Ground
Terminal No.
3 (OUTPUT)
4
7
Battery voltage cannot be measured because of digital signal.
Battery voltage is constantly present.
0 V is constantly present.
SL-15

SECURITY AND LOCKS
3. BODY INTEGRATED UNIT
8 7
6 5
4 3
2 1
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9
35 34
33 32 31 30
29 28 27 26
25 24
7 6
5 4
3 2 1
20 19 18 17 16 15 14 13 12 11 10 9 8
25 24 23
30 29 28
27 26
22 21
7 6 5 4
3 2 1
19 18 17 16 15 14 13 12 11 10 9 8
26 25 24
28 27
23 22
21 20
SL-00229
Remarks
Ignition switch (ON)
Door and rear gate lock actuator
(Model without double lock)
Front double lock actuator RH, door
and rear gate lock actuator (Model
with double lock)
Terminal No.
A1 (INPUT)
A7 (OUTPUT)
Door and rear gate lock actuator
A8 (OUTPUT)
Keyless entry control module

Double lock condition detecting
switch (Model with double lock)
Trunk lid switch or rear gate latch
switch
Rear door switch RH
Front door switch RH
Ground
A9 (INPUT)
A16 (OUTPUT)
A18 (INPUT)
A19 (INPUT)
A21
0 V is present when opening the rear door RH.

0 V is present when opening the front door RH.
Battery voltage is present when pressing the TRUNK button of keyless
transmitter.
Battery voltage is present when pressing the UNLOCK button of keyless
transmitter.
Front door actuator drivers side

(Model without double lock)
A23 (OUTPUT)
Room light
Power supply
Turn signal & hazard circuit
Ground
Battery voltage is present when pressing the UNLOCK button of keyless

transmitter.
Communication line (Cannot be measured because of digital signal)
Battery voltage is present when pressing the LOCK button of keyless
transmitter.
0 V is present when opening the trunk lid or rear gate.
A22 (OUTPUT)
Rear door switch LH

Front door switch LH
Power supply
Front double lock actuator RH
(Model with double lock)

transmitter.
A17 (INPUT)
Trunk lid actuator
Power window main switch (door

lock switch)
Battery voltage is present when ignition switch is turned ON.
A26
A27
A31 (INPUT)
A32 (INPUT)
A34
A35 (OUTPUT)
B3 (INPUT)
B7
B12 (OUTPUT)
B22
CAN communication line (Cannot be measured because of digital signal)

0 V is present when opening the rear door LH.
0 V is present when opening the front door LH.
transmitter.
0 V is present when pressing the UNLOCK button of keyless transmitter.
0 V is present when opening the door.
0 V is present when pressing the LOCK button or UNLOCK button of
keyless transmitter.
SL-16

SECURITY AND LOCKS
Remarks
Power supply
Power supply
Key warning switch
Ground
Ground
Registration connector
Terminal No.
C1
C2
C7 (INPUT)
C8
C9
C22
Battery voltage is present when inserting the key into ignition switch.
0 V is present when connecting the registration connector.
C: INSPECTION
1. SYMPTOM CHART
Symptom
None of the functions of keyless entry
system operate.
Repair order
1. Check the keyless transmitter battery.
2. Check the fuse.
3. Check the keyless entry control module.
4. Check the power supply, ground circuit and

registration connector circuit for the body integrated module.
5. Check the key warning switch.
6. Check the door switch.
7. Check the body integrated unit.

The keyless transmitter cannot be
registered.
2. Check registration connector circuit.
4. Check the door lock switch signal.
SL-17
Reference
<Ref. to SL-19, CHECK KEYLESS
TRANSMITTER BATTERY AND
FUNCTION, INSPECTION, Keyless
Entry System.>
<Ref. to SL-20, CHECK FUSE,
INSPECTION, Keyless Entry System.>
ENTRY CONTROL MODULE,
<Ref. to SL-21, CHECK BODY INTEGRATED UNIT POWER SUPPLY,
GROUND CIRCUIT AND REGISTERED CONNECTOR CIRCUIT,
<Ref. to SL-23, CHECK KEY WARNING SWITCH, INSPECTION, Keyless
Entry System.>
SWITCH, INSPECTION, Keyless
Entry System.>
<Ref. to LAN(diag)-2, Basic Diagnostic Procedure.>
Entry System.>
<Ref. to SL-21, CHECK REGISTRATION CONNECTOR., INSPECTION,
Keyless Entry System.>
Entry System.>
<Ref. to SL-25, CHECK DOOR LOCK
Entry System.>

SECURITY AND LOCKS
Symptom
Repair order
Door lock or unlock does not operate. 1. Check the keyless transmitter battery.
NOTE:
If the door lock control system does
not operate when using the door lock
switch, check the door lock control 2. Check the keyless entry control module.
system. <Ref. to SL-10, INSPECTION, Door Lock Control System.>
4. Check the door switch.

Trunk lid unlock does not operate.
(Sedan model)
2. Check the keyless entry control module.
4. Check the trunk lid lock actuator.

Hazard light does not operate.
1. Check the hazard light operation.

Room light does not operate.
1. Check the room light operation.

Ignition switch illumination does not
operate.
1. Check the ignition switch illumination.
SL-18
Reference
Entry System.>
Entry System.>
Entry System.>
Entry System.>
Entry System.>
<Ref. to SL-25, CHECK TRUNK LID
LOCK ACTUATOR, INSPECTION,
<Ref. to SL-24, CHECK HAZARD
LIGHT OPERATION, INSPECTION,
<Ref. to SL-24, CHECK ROOM
LIGHT OPERATION, INSPECTION,
<Ref. to SL-26, CHECK IGNITION
SWITCH ILLUMINATION, INSPECTION, Keyless Entry System.>

SECURITY AND LOCKS
2. CHECK KEYLESS TRANSMITTER BATTERY AND FUNCTION
Step
CHECK KEYLESS TRANSMITTER BATTERY.
1) Remove the battery from keyless transmitter. <Ref. to SL-46, DISASSEMBLY, Keyless
Transmitter.>
2) Check the battery voltage. <Ref. to SL-46,
INSPECTION, Keyless Transmitter.>
CHECK KEYLESS TRANSMITTER.
Register the keyless transmitter which operates normally on other vehicles to inspection
target vehicle. <Ref. to SL-46, REGISTRATION OF KEYLESS TRANSMITTER,
REPLACEMENT, Keyless Transmitter.>
1) Close all the doors and rear gate of inspection target vehicle.
2) Using keyless transmitter, lock and unlock
the doors and rear gate of inspection target
vehicle.
3) Using keyless transmitter, unlock the trunk
lid of inspection target vehicle. (Sedan model)
Register the keyless transmitter of inspection
target vehicle to another vehicle which operates keyless system normally. <Ref. to SL-46,
REGISTRATION OF KEYLESS TRANSMITTER, REPLACEMENT, Keyless Transmitter.>
Check
Yes
No
Replace the keyless transmitter
battery. <Ref. to
SL-46, Keyless
Transmitter.>
Is the inspection target vehicle Go to step 3.

operates lock, unlock and trunk
lid unlock normally?
Due to vehicle
malfunction, continue the keyless
entry system diagnosis.
Is the keyless transmitter regis- Go to step 4.

tered correctly?
Replace the keyless transmitter.

<Ref. to SL-46,
REGISTRATION
OF KEYLESS
TRANSMITTER,
REPLACEMENT,
Keyless Transmitter.>
Replace the keyless transmitter.
<Ref. to SL-46,
REGISTRATION
OF KEYLESS
TRANSMITTER,
REPLACEMENT,
Keyless Transmitter.>

Is the vehicle operates lock,
Keyless transmitCheck the registered keyless transmitter.
unlock and trunk lid unlock nor- ter is normal.
1) Close all the doors and rear gate of the
mally?
vehicle which operates keyless system normally.
2) Using keyless transmitter, lock and unlock
the doors and rear gate of vehicle.
3) Using keyless transmitter, unlock the trunk
lid of inspection target vehicle. (Sedan model)
CAUTION:
Be sure to reset the keyless transmitter, which is registered from other vehicle to inspection target
vehicle, and the vehicle, to which is registered keyless transmitter, to the condition of before inspection. (Register the keyless transmitter to original condition.)
SL-19

SECURITY AND LOCKS
3. CHECK FUSE
Step
CHECK FUSE.
the fuse and relay box) and No. 7 (in the fuse
and relay box).
Check
Yes
Replace the fuse
with a new one.
No
Check the power
supply and ground
circuit. <Ref. to
SL-21, CHECK
POWER SUPPLY, GROUND
CIRCUIT AND
REGISTERED
CONNECTOR
CIRCUIT,
INSPECTION,
4. CHECK KEYLESS ENTRY CONTROL MODULE
Step
(DTC)
link connector.
3) Select {Body integrated unit} from main
menu.
4) Select the {Diagnostic Trouble Code}.
5) Check that the DTC is displayed.
CHECK POWER SUPPLY.
1) Disconnect the keyless entry control module harness connector.
2) Measure the voltage between the harness
CHECK KEYLESS ENTRY CONTROL MODULE CIRCUIT.
(i84) No. 9 (i96) No. 3:
Check
Yes
Is DTC B0500 Keyless UART Go to step 2.
com. Malfunction displayed?
No
Keyless entry control module is normal.
Check the harness

for open circuits
and shorts
between the keyless entry control
module and fuse.

?
Go to step 4.
Repair the harness.

?
Replace the key- Repair the harless entry control ness.

module. <Ref. to
SL-44, Keyless
Entry Control Module.>
SL-20

SECURITY AND LOCKS
5. CHECK BODY INTEGRATED UNIT POWER SUPPLY, GROUND CIRCUIT AND REGISTERED CONNECTOR CIRCUIT
Step
CHECK REGISTRATION CONNECTOR INPUT VOLTAGE.
Measure the voltage between the body integrated module harness connector and chassis
ground.
CHECK POWER SUPPLY OF BODY INTEGRATED UNIT.
integrated unit.
CHECK BODY INTEGRATED UNIT GROUND
CIRCUIT.
integrated unit.
2) Measure the resistance between the harness connector terminal and chassis ground.
Check
Yes
No
Check the registration connector for
disconnection, and
the harness for
short.
Check the harness

for open or short
fuse.

?
Check the body

Repair the harintegrated unit.
ness.
<Ref. to
LAN(diag)-2, Basic
6. CHECK REGISTRATION CONNECTOR.
Step
Check
CHECK REGISTRATION CONNECTOR IN- Is the voltage more than 10 V?
PUT VOLTAGE.
1) Disconnect the registration connector.
2) Measure the voltage between the body
integrated unit harness connector and chassis
ground.
CHECK REGISTRATION CONNECTOR IN- Is the voltage 0 V?
PUT VOLTAGE.
1) Connect the registration connector.
2) Measure the voltage between the body
integrated unit harness connector and chassis
ground.
SL-21
Yes
Go to step 2.
No
Repair the harness.
Registration connector circuit is

OK.
Repair the harness.

SECURITY AND LOCKS
7. CHECK DOOR SWITCH
Step
CHECK DOOR SWITCH CIRCUIT.
Measure the voltage between the body integrated unit harness connector terminal and
chassis ground.
Front door RH:
LHD model
RHD model
Front door LH:
LHD model
RHD model
Rear door RH:
Rear door LH:
Rear gate:
CHECK DOOR SWITCH CIRCUIT.
Measure the voltage between the body integrated unit harness connector terminal and
chassis ground.
Front door RH:
LHD model
RHD model
Front door LH:
LHD model
RHD model
Rear door RH:
Rear door LH:
Rear gate:
CHECK DOOR SWITCH.
1) Disconnect the door switch harness connector.
2) Measure the resistance between door
switch terminals.
(R12) Front RH door switch:
(R9) Front LH door switch:
(R16) Rear RH door switch:
(R22) Rear LH door switch:
No. 1 No. 3:
Rear gate latch switch (Wagon model):
(D46) No. 1 No. 2:
Check
Is the voltage 0 V when each
door or rear gate is opened?
Yes
Go to step 2.
No
Go to step 3.
Is the voltage more than 10 V The door switch is Go to step 3.

when each door or rear gate is OK.
closed?

M when door switch is
pushed?
SL-22
Go to step 4.
Replace the door

switch.

SECURITY AND LOCKS
Step
CHECK DOOR SWITCH.
Measure the resistance between door switch
terminals.
(R12) Front RH door switch:
(R9) Front LH door switch:
(R16) Rear RH door switch:
(R22) Rear LH door switch:
No. 1 No. 3:
Rear gate latch switch (Wagon model):
(D46) No. 1 No. 2:
Check
Yes
No
Is the resistance less than 1 Check the harness Replace the door
when door switch is released? for open or short switch.
door switch.
8. CHECK KEY WARNING SWITCH

Step
1
CHECK FUSE.
the main fuse box).
CHECK KEY WARNING SWITCH CIRCUIT.
integrated unit.
2) Insert the key into ignition switch. (LOCK
position)
CHECK KEY WARNING SWITCH CIRCUIT.
1) Remove the key from ignition switch.
CHECK KEY WARNING SWITCH.
1) Disconnect the key warning switch harness
connector.
2) Insert the key into ignition switch. (LOCK
position)
3) Measure the resistance between key warning switch terminals.
(B350) No. 3 No. 4:
(B350) No. 3 No. 4:
Check
Yes
Replace the fuse
with a new one.
No
Go to step 2.
Go to step 4.
Is the voltage 0 V?
The key warning

switch is OK.
Go to step 4.

?
Go to step 5.
Replace the key

warning switch.

M?
Check the follow- Replace the key

warning switch.
ing:
Harness for
open circuits and
shorts between
the key warning
switch and fuse
Harness for
open or short
between the body
integrated unit and
key warning switch
SL-23

SECURITY AND LOCKS
9. CHECK ROOM LIGHT OPERATION
Step
Check
CHECK ROOM LIGHT OPERATION.
Does the room light illuminate?
Make sure the room light illuminates when the
room light switch is turned to ON.
CHECK HARNESS BETWEEN ROOM LIGHT Is the resistance less than 10
AND BODY INTEGRATED UNIT.
?
1) Disconnect the body integrated unit harness connector and room light harness connector.
2) Measure the resistance between the body
integrated unit harness connector terminal and
room light harness connector terminal.
(B280) No. 3 (R52) No. 2:
Yes
Go to step 2.
No
Check the room
light circuit.
The room light

Check the harness
operation circuit is for open or short
OK.
room light.
10.CHECK HAZARD LIGHT OPERATION
Step
CHECK HAZARD LIGHT OPERATION.
Make sure the hazard light blinks when hazard
CHECK OUTPUT TO HAZARD LIGHT.
connector.
link connector.
menu.
6) Select {ECM customizing}.
7) Check {Hazard answer-back setup}, and
then switch to ON setting if necessary.
9) When operating the LOCK/UNLOCK button
of keyless transmitter, check the hazard output
signal of body integrated unit.
CHECK CIRCUIT OF HAZARD LIGHT.
integrated unit.
2) Disconnect the turn signal & hazard unit
harness connector.
(B280) No. 12 (B32) No. 8:
Check
Does the hazard light blink?
Yes
Go to step 2.
Is output signal present when Go to step 3.

operating the keyless transmitter LOCK/UNLOCK button?

?
SL-24
No
Check the hazard
light circuit.
Check the body
integrated unit.
<Ref. to
LAN(diag)-2, Basic
Check the body

Repair the harintegrated unit.
ness.
<Ref. to
LAN(diag)-2, Basic

SECURITY AND LOCKS
11.CHECK TRUNK LID LOCK ACTUATOR
Step
CHECK TRUNK LID LOCK ACTUATOR.
connector.
link connector.
menu.
7) When operating the TRUNK button of keyless transmitter, check the trunk unlock output
signal of body integrated unit.
CHECK THE CIRCUIT OF TRUNK LID ACTUATOR.
2) Disconnect the trunk lid actuator harness
connector.
connectors.
(i84) No. 22 (R186) No. 2:
CHECK THE GROUND CIRCUIT OF TRUNK
LID ACTUATOR.
1) Disconnect the trunk lid actuator harness
connector.
Check
Yes
Is output signal present when Go to step 2.
operating the keyless transmitter TRUNK button?
No
Check the body
integrated unit.
<Ref. to
LAN(diag)-2, Basic

?
Go to step 3.
Repair the harness.

?
Check the trunk lid Repair the harlock actuator.

ness.
<Ref. to SL-38,
Trunk Lid Lock
Assembly.>
Check
Is the normal input signal displayed when the door lock
switch is moved to LOCK/
UNLOCK?
Yes
The door lock
switch is OK.
No
Go to step 2.

?
Go to step 3.
Go to step 4.
12.CHECK DOOR LOCK SWITCH
Step
Check the input signal from door lock switch to
body integrated module using Subaru Select
Monitor.
link connector.
menu.
5) Check the input signal to body integrated
unit by operating the door lock switch.
2) Measure the resistance between the harness connector terminal and chassis ground
when moving the door lock switch to LOCK.
SL-25

SECURITY AND LOCKS
Step
the door lock switch is moved to UNLOCK.
1) Disconnect the door lock switch harness
connector.
2) Measure the resistance between the door
lock switch terminals when moving the door
lock switch to LOCK.
LHD model:
(D7) No. 4 No. 7:
RHD model:
(D7) No. 4 No. 14:
Measure the resistance between the door lock
switch terminals when moving the door lock
switch to UNLOCK.
LHD model:
(D7) No. 5 No. 7:
RHD model:
(D7) No. 5 No. 14:
Check
?
Yes
The door lock
switch is OK.
No
Go to step 4.

?
Go to step 5.
Replace the door

lock switch.

?

for open circuits or lock switch.
shorts between
the body integrated unit and the
door lock switch.
13.CHECK IGNITION SWITCH ILLUMINATION
Step
CHECK FUSE.
the main fuse box).
CHECK POWER SUPPLY.
1) Disconnect the ignition switch illumination
harness connector.
CHECK IGNITION SWITCH ILLUMINATION
CIRCUIT.
integrated unit and ignition switch illumination
harness connector.
2) Measure the resistance between body integrated unit harness connector terminal and
ignition switch illumination harness connector
terminal.
(B280) No. 4 (B224) No. 1:
Check
Yes
Replace the fuse
with a new one.
No
Go to step 2.
Check the harness

for open circuits
and shorts
between the ignition switch illumination and fuse.

?
Check the harness

for open circuits
and shorts
between the body
integrated unit and
ignition switch illumination.
SL-26
Replace the ignition switch illumination bulb with a

new one. <Ref. to
LI-40, REMOVAL,
Ignition Switch Illumination.>
Front Inner Remote

SECURITY AND LOCKS
4. Front Inner Remote

A: REMOVAL
2) Remove the back cover (1) of inner remote.
3) Remove the outer cable (2).
4) Remove the wire end ball (3).
5) Remove the screws (4), and detach the inner remote handle.
(4)
(3)
(1)
(2)
(4)
SL-00279
B: INSTALLATION
NOTE:
Make sure the inner remote works correctly after installation.
C: INSPECTION
1) Check the door opener and door lock cable for
deformation. When it is deformed, straighten it because failure operations may occur. When it is unrepairable, replace the front door latch & door lock
actuator assembly.
2) Check the lever, rod and wire for smooth operation.
SL-27
Front Outer Handle

SECURITY AND LOCKS
5. Front Outer Handle
CAUTION:
Do not apply excessive force to remove the
handle from door panel. Otherwise door panel
may be deformed.
A: REMOVAL
1. MODEL WITHOUT DOUBLE LOCK
1) Raise the front door glass to the top position.
3) Remove the wire from front inner remote. <Ref.
to SL-27, REMOVAL, Front Inner Remote.>
5) Remove the rod clamps (1).
6) Remove the bolts (2), and then detach the front
outer handle.
B: INSTALLATION
NOTE:
Make sure the outer handle works correctly after installation.
C: INSPECTION
1) Check the rod for deformation.
2) Check the lever and rod for smooth operation.
(1)
(2)
SL-00280
2. MODEL WITH DOUBLE LOCK

3) Remove the wire from front inner remote. <Ref.
5) Remove the bolt (3), and then remove the key
cylinder cover B (4).
6) Remove the rod clamps (1).
7) Remove the bolt (2), and then remove the key
cylinder.
8) Remove the key cylinder cover A, and then detach the front outer handle.
(1)
(2)
(3)
(4)
SL-00313
SL-28
Front Door Latch and Door Lock Actuator Assembly

SECURITY AND LOCKS
6. Front Door Latch and Door

Lock Actuator Assembly
A: REMOVAL
3) Remove the wires from front inner remote. <Ref.
5) Remove the front door glass. <Ref. to GW-11,
REMOVAL, Front Door Glass.>
6) Remove the rear sash. <Ref. to GW-16, REMOVAL, Front Regulator and Motor Assembly.>
7) Remove the key cylinder cover B, and remove
the key rod from key cylinder. (Model with double
lock)
8) Open the handle rod cover of latch assembly.
SL-00281
10) Remove the front door latch & door lock actuator assembly, and disconnect the connector.
B: INSTALLATION
NOTE:
Make sure the lock works correctly after installation.
C: INSPECTION
1) Check the rod, outer wire and inner wire for deformation. When it is deformed, straighten it because failure operations may occur. When it is
unrepairable, replace the front door latch & door
lock actuator assembly.
SL-29
Front Door Lock Actuator

SECURITY AND LOCKS
7. Front Door Lock Actuator
2. Model with double lock
A: REMOVAL
1) Remove the front door latch & door lock actuator
assembly. <Ref. to SL-29, REMOVAL, Front Door
Latch and Door Lock Actuator Assembly.>
2) Remove the pawl of front door latch security cover, and then remove the cover. (Model without double lock)
3) Remove the screw from the front door latch and
door lock actuator, and then remove the door lock
actuator. (Model without double lock)
6 5 4 3 2 1
SL-00283
DOOR ACTUATOR RH:

Terminal No.
No. 5 (+) and No. 1 ()
No. 1 (+) and No. 5 ()
No. 6 (+) and No. 1 ()
No. 1 (+) and No. 6 ()
DOOR ACTUATOR LH:
(1)
Terminal No.
No. 2 (+) and No. 6 ()
No. 6 (+) and No. 2 ()
SL-00282
(1) Front door lock actuator
No. 1 (+) and No. 6 ()
B: INSTALLATION
No. 6 (+) and No. 1 ()
NOTE:
C: INSPECTION
1) Disconnect the door lock actuator harness connector.
2) Connect the battery to door lock actuator terminals.
If defective, replace the door lock actuator.
1. Model without double lock
2 1
SL-00235
Terminal No.
No. 2 (+) and No. 1 ()
No. 1 (+) and No. 2 ()
Actuator operation
Unlocked Locked
Locked Unlocked
Double lock released
Double lock set
Double lock set Double
lock released
Actuator operation
Unlocked Locked
Locked Unlocked
SL-30
Actuator operation
Unlocked Locked
Locked Unlocked
Double lock set
lock released
Rear Inner Remote

SECURITY AND LOCKS
8. Rear Inner Remote

A: REMOVAL
2) Remove the back cover (1) of inner remote.
3) Remove the outer cable (2).
4) Remove the wire end ball (3).
5) Remove the screws (4), and detach the inner remote handle.
(4)
(3)
(1)
(2)
(4)
SL-00279
B: INSTALLATION
NOTE:
Make sure the inner remote works correctly after installation.
C: INSPECTION
1) Check the door opener and door lock cable for
deformation. When it is deformed, straighten it because failure operations may occur. When it is unrepairable, replace the rear door latch & door lock
actuator assembly.
3) Check the child safety lock for correct operations.
SL-31
Rear Outer Handle

SECURITY AND LOCKS
9. Rear Outer Handle

A: REMOVAL
1) Raise the rear door glass to the top position.
4) Remove the rear door latch assembly. <Ref. to
SL-33, REMOVAL, Rear Door Latch and Door Lock
Actuator Assembly.>
5) Remove the wire from wire clamp (1) of outer
handle.
6) Remove the two bolts.
(1)
SL-00284
7) Detach the outer handle bracket. (Model with

double lock)
8) Detach the rear outer handle.
CAUTION:
Do not apply excessive force to remove the
handle from door panel. Otherwise door panel
may be deformed.
B: INSTALLATION
NOTE:
C: INSPECTION
1) Check the wires for deformation. When it is deformed, straighten it because failure operations
may occur. When it is unrepairable, replace the
rear door latch & door lock actuator assembly.
2) Check the lever and wire for smooth operation.
SL-32
Rear Door Latch and Door Lock Actuator Assembly

SECURITY AND LOCKS
10.Rear Door Latch and Door

Lock Actuator Assembly
A: REMOVAL
3) Remove the wires from rear inner remote. <Ref.
to SL-31, REMOVAL, Rear Inner Remote.>
6) Remove the rear sash. <Ref. to GW-25, REMOVAL, Rear Regulator and Motor Assembly.>
7) Take out the wire from wire clamp of outer handle.
8) Detach the outer handle bracket. (Model with
double lock)
SL-00285
10) Disconnect the connectors, and then remove

the rear door latch & door lock actuator assembly.
B: INSTALLATION
NOTE:
C: INSPECTION
1) Check the wires for deformation. When it is deformed, straighten it because failure operations
may occur. When it is unrepairable, replace the
rear door latch & door lock actuator assembly.
2) Check the lever and wire for smooth operation.
SL-33
Rear Door Lock Actuator

SECURITY AND LOCKS
11.Rear Door Lock Actuator
2. Model with double lock
A: REMOVAL
1) Remove the rear door latch & door lock actuator
assembly. <Ref. to SL-33, REMOVAL, Rear Door
Latch and Door Lock Actuator Assembly.>
2) Remove the pawl of rear door latch security cover, and then remove the cover. (Model without double lock)
3) Remove the screw from the rear door latch and
door lock actuator, and then remove the door lock
actuator. (Model without double lock)
6 5 4 3 2 1
SL-00283
DOOR ACTUATOR RH:

Terminal No.
No. 5 (+) and No. 1 ()
No. 1 (+) and No. 5 ()
No. 6 (+) and No. 1 ()
No. 1 (+) and No. 6 ()
DOOR ACTUATOR LH:
(1)
Terminal No.
No. 2 (+) and No. 6 ()
No. 6 (+) and No. 2 ()
SL-00282
(1) Rear door lock actuator
No. 1 (+) and No. 6 ()
B: INSTALLATION
No. 6 (+) and No. 1 ()
NOTE:
C: INSPECTION
1) Disconnect the door lock actuator harness connector.
2) Connect the battery to door lock actuator terminals.
If defective, replace the door lock actuator.
1. Model without double lock
2 1
SL-00235
Terminal No.
No. 2 (+) and No. 1 ()
No. 1 (+) and No. 2 ()
Actuator operation
Unlocked Locked
Locked Unlocked
Double lock set
lock released
Actuator operation
Unlocked Locked
Locked Unlocked
SL-34
Actuator operation
Unlocked Locked
Locked Unlocked
Double lock set
lock released
Rear Gate Outer Handle

SECURITY AND LOCKS
12.Rear Gate Outer Handle

A: REMOVAL
2) Remove the rear gate garnish. <Ref. to EI-76,
REMOVAL, Rear Gate Garnish.>
3) Remove the two nuts to take out the rear gate
outer handle.
4) Remove the rear gate outer handle cable.
(1)
SL-00239
(1) Rear gate handle cable
B: INSTALLATION
NOTE:
C: INSPECTION
1) Check the rear gate handle cable for deformation.
2) Check the rear gate outer handle and rear gate
handle cable for smooth operation.
SL-35
Rear Gate Latch Assembly

SECURITY AND LOCKS
13.Rear Gate Latch Assembly
5) Disconnect the each connector and rear gate

handle cable.
A: REMOVAL
3) Remove the two screws.
(1)
(2)
(2)
SL-00240
4) Remove the rear gate latch cover. (Model with

double lock)
(3)
(2)
SL-00301
(3)
(1) Rear gate handle cable

(2) Rear gate lock actuator connector
(3) Rear gate latch switch connector
(1)
6) Remove the rear gate latch assembly.

SL-00286
(1) Clip
(2) Claw
(3) Hook
B: INSTALLATION
NOTE:
C: INSPECTION
1) Disconnect the rear gate lock actuator harness
connector.
2) Connect the battery to rear gate lock actuator
terminals.
2 1
SL-00235
Terminal No.
No. 2 (+) and No. 1 ()
No. 1 (+) and No. 2 ()
SL-36
Actuator operation
Unlocked Locked
Locked Unlocked
Rear Gate Latch Assembly

SECURITY AND LOCKS
Replace the rear gate latch assembly if faulty.

3) Check the rear gate handle cable for deformation.
4) Check the lever and rear gate handle cable for
smooth operation.
SL-37
Trunk Lid Lock Assembly

SECURITY AND LOCKS
14.Trunk Lid Lock Assembly
2) Connect the battery to trunk lid actuator terminals.
A: REMOVAL
1) Disconnect the connectors and detach the trunk
opener cable.
2) Remove the two bolts to remove trunk lid lock
assembly.
3 2 1
SL-00255
Terminal No.
No. 2 (+) and No. 1 ()
SL-00243

1) Disconnect the connectors and detach the trunk
opener cable.
2) Remove the two bolts and clip to remove trunk
lid lock assembly.
Actuator operation
Locked Unlocked
If defective, replace the trunk lid actuator.

3) Check the striker for deformation or abnormal
wear.
4) Check the safety lever for improper movement.
5) Check other levers and the spring for rust formation and unsmooth movement.
6) Check the trunk opener cable for smooth operation.
SL-00308
B: INSTALLATION
NOTE:
Apply grease to the movable part.
C: INSPECTION
1) Disconnect the trunk lid actuator harness connector.
SL-38
Front Hood Lock Assembly

SECURITY AND LOCKS
15.Front Hood Lock Assembly

A: REMOVAL
2) Remove the bolts, and then detach the front
hood lock assembly.
3) Remove the release cable from lock assembly.
SL-00287
B: INSTALLATION
NOTE:
Apply grease to the movable part.
Make sure the release cable works correctly after
installation.
C: ADJUSTMENT
Loosen the bolt, and adjust the lock assembly while
moving it up and down.
SL-00290
D: INSPECTION
1) Check the striker for deformation 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-39
Remote Openers
SECURITY AND LOCKS
16.Remote Openers
6) Remove the cable from trunk lid lock assembly.
A: REMOVAL
(1)
1. FRONT HOOD OPENER

1) Remove the release cable from hood lock.
2) Remove the bolt, and then detach the opener lever.
(2)
SL-00248
(1) Trunk lid lock ASSY

(2) Cable
3. FUEL FLAP OPENER

SL-00291
2. TRUNK LID OPENER

2) Remove the center pillar lower trim, side sill cover, rear pillar lower trim and floor mat on the drivers
side. Remove the clip holding cable.
3) Remove the bolt, and then detach the opener
pull handle.

2) Remove the center pillar lower trim, side sill cover, rear pillar lower trim and floor mat on the drivers
side. Remove the clip holding cable.
3) Remove the bolt, and then detach the opener
pull handle.
(B)
(A)
(1)
(2)
(2)
(1)
(3)
(1)
SL-00312
(A)
(B)
(1)
(2)
(3)
(3)
SL-00302
(1) Cover
(2) Pull handle ASSY
(3) Cable
4) Remove the cable from opener pull handle.

5) Remove the trunk lid lock assembly from trunk
lid.
Sedan model
Wagon model
Cover
Pull handle ASSY
Cable
4) Remove the cable from opener pull handle.

5) Remove the rear quarter trim RH. <Ref. to EI-63,
SL-40
Remote Openers
SECURITY AND LOCKS
6) Rotate the fuel lock inside of the quarter panel to

90 and remove. (Either right or left turn)
SL-00265
B: INSTALLATION
1. FRONT HOOD OPENER
2. TRUNK LID OPENER

3. FUEL FLAP OPENER

C: INSPECTION
Make sure the front hood, trunk lid and fuel flap
open and close smoothly.
SL-41
Ignition Key Lock

SECURITY AND LOCKS
17.Ignition Key Lock
Switch position
LOCK
ACC
A: REPLACEMENT
2) Remove the steering column. <Ref. to PS-23,
REMOVAL, Tilt Steering Column.>
3) Secure the steering column in a vise. Remove
the bolt with a drill.
ON
ST
Terminal No.
No. 3 and No. 4

No. 3 and No. 1
and No. 4
No. 3 and No. 6
No. 3 and No. 1
No. 3 and No. 2
and No. 6
If NG, replace the ignition switch.
SL-00024
4) Remove the ignition key lock.

5) Using a new bolt, tighten the bolts all the way.
SL-00025
B: INSPECTION
1) Remove the instrument panel lower panel.
2) Remove the lower column cover.
3) Unfasten the fixing clip which secures harness,
and then disconnect the connector of the ignition
switch from body harness.
4) Turn the ignition key plate to each position and
check the continuity between terminals of ignition
connector.
3 2 1
6 5 4
SL-00266
SL-42
Standard
Less than 1
Less than 1
Less than 1
Key Lock Cylinders

SECURITY AND LOCKS
18.Key Lock Cylinders

A: REPLACEMENT
3) Remove the sealing cover.
4) Remove the rod clamp. Remove the bolt. Replace the key cylinder (1).
(1)
SL-00292

3) Remove the sealing cover.
4) Remove the bolt (2), and remove the key cylinder cover (1).
5) Remove the rod clamp. Remove the bolt (3). Replace the key cylinder.
(3)
(1)
(2)
SL-00303
SL-43
Keyless Entry Control Module

SECURITY AND LOCKS
19.Keyless Entry Control Module

A: REMOVAL
3) Remove the screw, then remove the keyless entry control module while disconnecting the connector.
SL-00293
B: INSTALLATION
SL-44
Body Integrated Module

SECURITY AND LOCKS
20.Body Integrated Module
B: INSTALLATION
A: REMOVAL
NOTE:
If removing the body integrated module, check the
following items.
If removing the body integrated module, check
the current setting and note it. <Ref. to LAN(diag)17, CONFIRMATION OF CURRENT SETTING,
When removing the body integrated module, reconfigure the select unlock as necessary. <Ref. to
SL-15, CUSTOMIZE SETTING OF SELECT UNLOCK, ELECTRICAL SPECIFICATION, Keyless
Entry System.>
If replacing the body integrated module, check the
following items.
For model with immobilizer, prepare new immobilizer key and security ID plate.
2) Remove the instrument panel lower panel on
drivers side. <Ref. to EI-56, REMOVAL, Instrument Panel Assembly.>
3) Disconnect the connector of body integrated
module.
NOTE:
Make sure it comforms to the current setting condition after installation. <Ref. to LAN(diag)-17,
CONFIRMATION OF CURRENT SETTING, OPERATION, Subaru Select Monitor.>
Make a registration of immobilizer for the model
with immobilizer. For detailed operation procedure,
refer to IMMOBILIZER REGISTRATION MANUAL.
CAUTION:
Be careful to keep water and other foreign materials away from body integrated module.
4) Remove the body integrated module from the
body integrated module mounting bracket using flat
tip screwdriver.
CAUTION:
Be careful not to damage the unit when removing it forcibly from the bracket.
5) Remove the clutch pedal stopper arm. (MT model) <Ref. to CL-26, REMOVAL, Clutch Pedal.>
6) Remove two body integrated module bracket
mounting bolts, and remove the bracket.
SL-00295
SL-45
Keyless Transmitter
SECURITY AND LOCKS
21.Keyless Transmitter
NOTE:
Battery discharge occurs during the measurement.
Complete the measurement within 5 seconds.
A: DISASSEMBLY
1. KEYLESS TRANSMITTER BATTERY
NOTE:
To prevent static electricity damage to the keyless
transmitter printed circuit board, touch the steel
area of building with hand to discharge static electricity carried on body or clothes before disassembling the keyless transmitter.
1) Remove the screw from keyless transmitter, and
remove the keyless transmitter battery (1).
2) Remove the printed board (3) from rubber (2).
Except for EK model
(3)
(A)
SL-00066
(A) Resistance 47
(1)
Tester connection
(+)
Battery
Positive terminal
()
Battery
Ground terminal
Standard
2.5 3.0 V
If NG, replace the battery. (Use CR1620 or equivalent.)
(2)
D: REPLACEMENT
SL-00427
1. REGISTRATION OF KEYLESS TRANSMITTER
EK model
NOTE:
A maximum of four keyless transmitter can be
registered for each individual vehicle.
When replacing or adding the keyless transmitter, new registration of keyless transmitter is necessary.
When replacing the keyless transmitter, registration to immobilizer system is also necessary.
1) Remove the keyless transmitter from the ignition
switch.
2) Remove the lower trim cover at drivers side,
then connect the registration connectors. (1 pole
white connector)
3) Press the door lock switch (1) located under the
power window main switch to UNLOCK. (Make
sure the room light blinks and buzzer sounds, and
then system is in registration mode.)
SL-00065
B: ASSEMBLY
Install in the reverse order of disassembly.
C: INSPECTION
Measure the voltage between the keyless transmitter battery (+) terminal and () terminal.
AUTO
(1)
LOCK
SL-00296
SL-46
Keyless Transmitter
SECURITY AND LOCKS
4) While pressing the door lock switch to UNLOCK,

press twice the button of keyless transmitter to be
registered.
5) When the registration is completed normally, the
door lock actuator will lock unlock. If the lock
unlock operation is not carried out, repeat the procedure 4).
If changing from registration mode to clear mode,

you cannot go to clear mode unless completing the
registration mode. The reverse case is same as
this.
NOTE:
When pressing the keyless transmitter button,
slowly press for first and second (press longer for
second) to check operation of door lock actuator.
Do not press the button of keyless transmitter
more than twice.
Do not batter the button of keyless transmitter.
6) Repeat the steps 4) if there is an additional keyless transmitter to be registered.
7) Pull out the registration connector, and install the
lower trim cover at drivers side.
NOTE:
The transmitter can be registered only when the
door lock switch is remain pushed to UNLOCK.
Continuing to press the door lock switch to UNLOCK again allows to be registered although the
door lock switch is released for once.
When adding the keyless transmitter, re-registration of keyless transmitter which was already registered is necessary.
2. CLEAR OF KEYLESS TRANSMITTER

1) Remove the keyless transmitter from ignition
switch.
2) Remove the lower trim cover at drivers side,
then connect the registration connectors. (1 pole
white connector)
3) Press the door lock switch located under the
power window main switch to LOCK. (Make sure
the room light blinks and buzzer sounds, and system becomes in clear mode.)
4) While pressing door lock switch to LOCK, insert
and remove the key on ignition switch 10 times
within 10 seconds.
5) When the clearing is completed normally, the
door lock actuator will lock unlock. If the lock
unlock operation is not carried out, repeat the procedure 4).
6) Pull out the registration connector, and install the
lower trim cover at drivers side.
NOTE:
The transmitter can be cleared only when the
door lock switch is remain pushed to LOCK.
Continuing to press the door lock switch to LOCK
again allows to be cleared although the door lock
switch is released for once.
SL-47
Immobilizer Control Module

SECURITY AND LOCKS
22.Immobilizer Control Module

A: NOTE
The control of immobilizer system is carried out in
B: REMOVAL
<Ref. to SL-45, REMOVAL, Body Integrated Module.>
C: INSTALLATION
SL-48
Immobilizer Antenna
SECURITY AND LOCKS
23.Immobilizer Antenna
A: REMOVAL
2) Remove the screws, and detach the upper column cover and lower column cover.
SL-00258

4) Disconnect the immobilizer antenna connector
(A) and ignition switch lighting connector (B).
5) Loosen the screw and release the lock (D) at opposite side using flat-tip screwdriver (1), and then
detach the immobilizer antenna (C).
(C)
(B)
(A)
(1)
(D)
SL-00315
CAUTION:
Do not apply excessive force to remove the immobilizer antenna and lock. Otherwise they
may be broken because those parts are the
products made of a plastic.
B: INSTALLATION
SL-49
Immobilizer Antenna
SECURITY AND LOCKS
SL-50
SUNROOF/T-TOP/CONVERTIBLE TOP
(SUNROOF)
SR
1.
2.
3.
4.
5.
6.
7.
Page
Sunroof Control System ..............................................................................5
Glass Lid .....................................................................................................6
Sunroof Assembly .......................................................................................9
Sunroof Motor ...........................................................................................11
Sunroof Switch ..........................................................................................14
Sunshade ..................................................................................................16
General Description
SUNROOF/T-TOP/CONVERTIBLE TOP (SUNROOF)
A: COMPONENT
1. SEDAN MODEL
(2)
(4)
(1)
(9)
T1
(8)
(7)
(5)
(5)
(3)
(6)
(9)
T2
T1
SR-00120
(1)
(2)
(3)
(4)
Glass lid
Weatherstrip
Guide rail cover
Sunshade
(5)
Drain tube
(6)
(7)
(8)
(9)
Motor ASSY
Frame ASSY
Deflector
TORX bolt
SR-2

T1: 4.5 (0.46, 3.3)
T2: 6.0 (0.61, 4.4)
General Description
2. WAGON MODEL
(2)
(3)
(1)
(4)
(5)
(8)
T2
(7)
T1
(6)
(7)
T1
T1
T1
T1
T1
(5)
SR-00102
(1)
(2)
(3)
(4)
Glass lid (Front)

Glass lid (Rear)
Sunshade
Frame ASSY
(5)
(6)
(7)
(8)
Drain tube
Cover (Front and rear)
Frame bracket
Motor ASSY
SR-3

T1: 7.5 (0.76, 5.3)
T2: 4.5 (0.46, 3.0)
General Description
B: CAUTION
replacing the audio, control unit, and other parts
provided with memory functions, record the memory contents before disconnecting the battery
ground cable in order to prevent memory deletion.
Connect the connectors securely for reassembly.
C: PREPARATION TOOL
1. GENERAL TOOL
TOOL NAME
Circuit tester
TORX T20
REMARKS
Used for measuring resistance and
voltage.
Used for removing and installing sunroof motor, glass lid (Sedan model)
and sunshade.
SR-4
Sunroof Control System

2. Sunroof Control System

A: WIRING DIAGRAM
1. SUNROOF
<Ref. to WI-316, WIRING DIAGRAM, Sunroof Control System.>
B: INSPECTION
Symptom
Water leakage
Booming noise, wind noise and other noise

Motor noise
Failure of sunroof
(Motor operates properly.)
Motor does not rotate or rotate improperly.
Failure turn of glass lid
Inspection order
(1) Check roof panel and glass lid for improper or poor sealing.
(2) Check drain tube for clogging.
(3) Check sunroof frame seal and body for improper fit.
(1) Check glass lid and roof panel for improper clearance.
(2) Check sunshade and roof trim for improper clearance.
(1) Check installing part of motor for looseness.
(2) Check gears and bearings for wear.
(3) Check cable for wear.
(4) Check cable pipe for deformities.
(1) Check guide rail for foreign particles.
(2) Check guide rail for improper installation.
(3) Check parts for mutual interference.
(4) Check cable slider for improper clinching.
(5) Check cable for improper installation.
(1) Check fuse for blown out.
(2) Check switch for improper function.
(3) Check motor for incorrect terminal voltage.
(4) Check the relay for improper operation.
(5) Check poor grounding system.
(6) Check harness for open or short and terminals for poor connections.
Check guide rail for foreign particles.
Failure turn of glass lid while driving rough road.

Glass lid has auto-reverse function. When applied above specified force to the glass lid, the lid turns back
and stops. When operating the glass lid (open or close) while driving the rough road, the lid judges vibration
as a force and may causes failure turns. When the failure turn is occurred, the initialize operation is required
with following procedure.
1. INITIALIZE OPERATION (SEDAN MODEL)

1) Tilt up the glass lid.
2) Release the switch once, and press the tilt up switch again for 15 seconds.
3) When the glass lid is raised a little and returned to tilt up position, release the switch for the moment. (Initialization of position detecting function)
4) Keep pressing the tilt up switch within 5 seconds from releasing the switch, glass lid tilts down slides
open slides close operation automatically. (Time gap of more than 5 seconds will result in cancellation of
position detecting function.)
5) Initialize operation is completed.
2. INITIALIZE OPERATION (WAGON MODEL)

1) Apply the force to glass lid in the direction of glass lid open while glass lid (rear) is closing, and then reverse the lid five times in a row.
However, in the following situation, the initialize operation is canceled.
When the lid is fully closed once during auto-reverse operation five times in a row.
When the interval of auto-reverse operation is more than 30 seconds once.
2) When the operation of glass lid shift to brink operation*, fully close the lid on switch operation.
3) Initialize operation is completed.
*Brink operation: Although keep pressing the switch, glass lid operates only at a moment when the switch is pressed.
SR-5
Glass Lid
3. Glass Lid
2) Pull out the cover (A) toward arrow mark, and

then remove the nut (B).
A: REMOVAL
1. SEDAN MODEL
1) Completely close the glass lid, and then open
the sunshade.
2) Remove the cover (A), and then remove the
TORX bolts (B).
(A)
CAUTION:
TORX bolts are applied with thread locker. If
they are removed, replace with new ones.
(A)
(B)
SR-00104
3) Remove the glass lid (front) carefully.
3. WAGON MODEL (REAR)

1) Tilt up the glass lid (front), and then open the
sunshade.
2) Remove the cover (A), and then remove the nut
(B).
(B)
SR-00091
3) Remove the glass lid carefully.
2. WAGON MODEL (FRONT)

1) Open the sunshade.
(A)
(B)
SR-00103
3) Remove the glass lid carefully.
SR-6
Glass Lid
B: INSTALLATION
2. WAGON MODEL
Loosen the glass lid installation nuts, and then adjust the height by adding (max: four pieces) or extracting (min: zero piece) shims (B) (standard: two
pieces) which installed between glass lid (A) and
body.
C: ADJUSTMENT
1. SEDAN MODEL
Loosen the glass lid mounting TORX bolts (A),
and then adjust the height on lid side.
Difference in height between glass lid and roof
panel L:
2.01.0 mm (0.0790.039 in)
Difference in height between glass lid and roof

panel L:
2.01.0 mm (0.0790.039 in)
(B)
(A)
(B)
L
(A)
SR-00077
SR-00124
D: FORCED DRIVE
If glass lid dose not operate or is not supplied with
power, move the glass lid using the emergency
handle (wrench)*.
*: Emergency handle (L shape general purpose
hexagon wrench)
Sedan model: bolt width 4 mm (0.16 in)
Wagon model: bolt width 5 mm (0.20 in)
SR-7
Glass Lid
1. SEDAN MODEL
1) Remove the spot map light. <Ref. to LI-34, REMOVAL, Spot Map Light.>
2) Insert the wrench securely until it touches the
motor shaft edge.
3) Turn the wrench, and move the glass lid.
Turning right, the glass lid open.
Turning left, the glass lid close.
5) Turn the wrench to right, and close the glass lid

(front and rear).
SR-00101
CAUTION:
After forced drive, the initialize operation is required. <Ref. to SR-5, INSPECTION, Sunroof
Control System.>
SR-00099
2. WAGON MODEL
1) Slide the slider (A) to vehicle rearward (C), and
remove the sun shade from slider by raising the rod
(B).
(C)
(B)
(A)
SR-00118
CAUTION:
Be careful not to damage the adjacent parts
with rod end when moving the glass lid with
emergency handle.
2) Slide the sunshade forward.
3) Remove the plug in the rear side of roof trim.
SR-00100
4) Insert the wrench securely until it touches the

motor shaft edge.
SR-8
Sunroof Assembly
4. Sunroof Assembly
3) Disconnect the harness connector of motor assembly.
A: REMOVAL
1. SEDAN MODEL
2) Remove the roof trim. <Ref. to EI-67, SEDAN
MODEL, REMOVAL, Roof Trim.>
3) Disconnect the harness connector of sunroof
motor.
4) Remove the glass lid. <Ref. to SR-6, SEDAN
MODEL, REMOVAL, Glass Lid.>
5) Remove the drain tube from frame assembly.
6) Remove the assist rail bracket (front) (A) and
sunroof bracket (rear) (B).
SR-00080
4) Remove the front and rear glass lid. <Ref. to SR6, WAGON MODEL (FRONT), REMOVAL, Glass
Lid.> <Ref. to SR-6, WAGON MODEL (REAR),
REMOVAL, Glass Lid.>
5) Remove the installation bolts (A) on rear side
frame bracket of frame assembly.
(B)
(A)
SR-00078
(A)
7) Remove the nuts, and then remove the frame

assembly.
SR-00081
6) Remove the drain tube from frame assembly.

7) Remove the frame bracket (A).
SR-00079
2. WAGON MODEL
2) Remove the roof trim. <Ref. to EI-67, WAGON
SR-9
Sunroof Assembly
8) Remove the bolts (B) and nuts (C), and then remove the frame assembly.
(B)
(B)
(A)
(C)
(A)
SR-00082
B: INSTALLATION
CAUTION:
Be careful not to snag the harness.
NOTE:
Be sure to connect the harness connector.
When installing the drain tube, insert it securely
into drain pipe.
Length A:
SR-00005
C: DISASSEMBLY
1) Remove the sunroof motor. <Ref. to SR-11, REMOVAL, Sunroof Motor.>
2) Remove the sunshade. <Ref. to SR-16, REMOVAL, Sunshade.>
D: ASSEMBLY
SR-10
Sunroof Motor
5. Sunroof Motor
7) Disconnect the harness connector (A), and then

remove the motor assembly mounting bolt (B) and
nuts (C).
A: REMOVAL
CAUTION:
When removing the clip, use great care not to
damage the roof trim.
Never rotate the sunroof motor after removing it.
(C)
(A)
1. SEDAN MODEL
1) Completely close the glass lid.
4) Disconnect the harness connector, loosen the
TORX bolts, and then remove the motor assembly.
(B)
(C)
SR-00089
B: INSTALLATION
CAUTION:
When installing the motor assembly, be careful
not to move the sunroof cable.
SR-00121
CAUTION:
When removing the motor assembly, secure
the cable wires to prevent moves.
2. WAGON MODEL
1) Fully close the glass lid (front) and glass lid
(rear).
3) Remove the luggage room light. <Ref. to LI-36,
REMOVAL, Luggage Room Light.>
4) Remove the roof trim. <Ref. to EI-67, WAGON
5) Pass the seat belt tongue (A) located on center
of rear seat through the hole, and then pull it out to
the opposite side of trim.
(B)
(A)
SR-00036
6) Remove the clips, and then drop the rear end of

roof trim.
SR-11
Sunroof Motor
1. SEDAN MODEL
1) Align the coulisse assembly and link assembly in the same position.
(1)
(2)
(4)
(3)
SR-00094
(1)
(2)
(3)
(4)
Front
Coulisse ASSY
Link ASSY
4.7 mm (0.185 in)
2) Install the motor assembly.

3) Connect the harness connector of motor assembly, and then connect the battery ground cable to battery.
4) Perform the initialize operation of motor.
(1) Tilt up the glass lid.
(2) Release the switch once, and press the tilt up switch again for 15 seconds.
(3) When the glass lid is raised a little and on tilt up position, release the switch for the moment.
(4) Keep pressing the tilt up switch within 5 seconds from releasing the switch, glass lid tilts down
slides open slides close operation automatically, and then initialize operation is completed.
5) Check the operation of sunroof with following table.
Operation
(1) Glass lid closes completely.
(2) Glass lid tilt up to the top position.
(3) Glass lid lowers completely.
(4) Glass lid opens completely.
(5) Glass lid closes 150 mm (5.91 in) away from completely closed position.
(6) Glass lid closes completely.
6) Install the trim in the reverse order of removal.
SR-12
Switch position
Close
Tilt up
Tilt down
Open
Close
Close
Sunroof Motor
2. WAGON MODEL
Check that the wedge of glass lid (front) bracket part is contacting in the direction of vehicle front.
At this time, the lid is at fully open position.
(1)
(3)
(2)
(4)
SR-00095
(1)
(2)
(3)
(4)
Front
Wedge
Glass lid (Front)
Glass lid (Rear)
1) Install the motor assembly.

2) After the installation of motor assembly, check again that the wedge of glass lid (front) bracket part is contacting in the direction of vehicle front.
3) Connect the harness connector of motor assembly, and then connect the battery ground cable to battery.
4) Perform the initialize operation of motor.
When replacing the motor with a new one, fully close the glass once and perform the initialization of position, because the movement of glass lid shifts to brink operation.
When reusing the motor, operate the auto-reverse function five times in a row to shifts brink operation, and
then perform the initialization of position.
5) Check the operation of sunroof with following table.
Operation
(1) Glass lid (front) and glass lid (rear) closes completely.
(2) Glass lid (front) tilt up to the ventilating position.
(3) Glass lid (front) tilts up to top position, and glass lid (rear) opens near the completely
open position.
(4) Glass lid (rear) opens completely.
(5) Glass lid (rear) closes on 150 mm (5.91 in) from rear end of tilted up glass lid (front).
(6) Glass lid (rear) closes completely, and then glass lid (front) tilt down to the ventilating
position.
(7) Glass lid (front) lowers, and then glass lid (front) and glass lid (rear) closes completely.
6) Install the trim in the reverse order of removal.
SR-13
Switch position
Close
Open
Open
Open
Close
Close
Close
Sunroof Switch
6. Sunroof Switch
C: INSPECTION
A: REMOVAL
1. SEDAN MODEL

2) Remove the spot map light lens (A) and sunroof
switch mounting screws (B).
Measure the sunroof switch resistance.
R128
5 4 3 2 1
(A)
LI-00313
R187
5 4 3 2 1
SR-00098
(B)
LI-00314
3) Disconnect the harness connector, and then remove the sunroof switch.
Switch position
Terminal No.
Open
1 and 3
Close
3 and 4
Tilt up
4 and 5
Tilt down
3 and 4
B: INSTALLATION
Connector
No.
Standard
Less than
1
Less than
1
Less than
1
Less than
1
R128
R187
2. WAGON MODEL
Measure the sunroof switch resistance.
R128
5 4 3 2 1
SR-00041
Switch position
Open
Close
SR-14
Terminal No.
1 and 3
3 and 4
Standard
Less than 1
Less than 1
Sunroof Switch
NOTE:
If glass lid does not operate or is not supplied with
power, move the glass lid using the emergency
handle. <Ref. to SR-7, FORCED DRIVE, Glass
Lid.>
SR-15
Sunshade
7. Sunshade
2. WAGON MODEL
A: REMOVAL
1) Remove the frame assembly.

2) Remove the shade stopper (A) of sunshade.
1. SEDAN MODEL
1) Remove the glass lid. <Ref. to SR-6, SEDAN
MODEL, REMOVAL, Glass Lid.>
2) Loosen the TORX bolts, and remove sunshade
bracket (front).
(A)
SR-00093
3) Pull out the sunshade (A) from sunroof frame.
(A)
B: INSTALLATION
SR-00122
3) Pull out the sunshade until sunshade bracket

(rear) is shown, loosen the TORX bolts, and remove sunshade.
SR-00123
SR-16
SR-00086
Sunshade
C: INSPECTION
1. CHECK FOR MOVING LOAD OF SUNSHADE
1) Attach a spring balance to sunshade edge using
a cloth.
SR-00087
2) Pull the spring balance to measure moving load

of the sunshade.
Moving load of sunshade:
Standard value
18.05.0 N (1.80.5 kgf, 133.7 lbf)
NOTE:
Moving load is larger at the beginning of pulling a
spring balance, so take a spring balance reading
while sunshade sliding smoothly.
3) If moving load exceeds specifications, check the
glass lid, sunshade and frame assembly for improper installation.
SR-17
Sunshade
SR-18
EI
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.
Page
Front Grille ................................................................................................24
Front Hood Grille.......................................................................................25
Front Under Cover ....................................................................................26
Floor Under Protector................................................................................27
Fuel Tank Protector...................................................................................28
Mud Guard ................................................................................................29
Front Bumper ............................................................................................30
Rear Bumper.............................................................................................37
Cowl Panel ................................................................................................39
Roof Spoiler ..............................................................................................40
Side Sill Spoiler .........................................................................................41
Side Protector ...........................................................................................42
Side Garnish .............................................................................................44
Rear Quarter Protector..............................................................................45
Roof Molding .............................................................................................46
Roof Rail ...................................................................................................47
Door Trim ..................................................................................................48
Instrument Panel Lower Cover..................................................................50
Glove Box..................................................................................................51
Console Box..............................................................................................53
Center Console .........................................................................................54
Instrument Panel Assembly ......................................................................56
Lower Inner Trim .......................................................................................60
Upper Inner Trim .......................................................................................62
Rear Quarter Trim .....................................................................................63
Sun Visor...................................................................................................65
Assist Grip.................................................................................................66
Roof Trim ..................................................................................................67
Rear Gate Trim .........................................................................................69
Rear Shelf Trim .........................................................................................70
Trunk Room Trim ......................................................................................71
Floor Mat ...................................................................................................73
Luggage Floor Box....................................................................................74
Trunk Lid Garnish......................................................................................75
Rear Gate Garnish ....................................................................................76
Heat Shield Cover .....................................................................................77
Ornament ..................................................................................................78
General Description
A: COMPONENT
1. FRONT GRILLE
(3)
(1)
(2)
EI-00627
(1)
Front grille
(2)
Front grille emblem
(3)
Front grille clip
2. UNDER COVER
EI-00681

T: 14 (1.42, 10.3)
EI-2
General Description
3. UNDER PROTECTOR
(2)
(3)
(4)
(4)
(1)
EI-00799
(1)
(2)
Floor under protector

Fuel tank protector RH
(3)
Fuel tank protector LH
EI-3
(4)
Plastic nut
General Description
4. FRONT HOOD GRILLE
(1)
(2)
(3)
EI-00707
(1)
Front hood grille
(2)
Grille duct upper
EI-4
(3)
Grille duct lower
General Description
5. FRONT BUMPER
T2
T2
(9)
T2
(7)
(10)
(11)
T2
T2
(14)
(12)
(8)
(1)
(13)
T1
(5)
(2)
(6)
(4)
(3)
EI-00795
(1)
(2)
(3)
(4)
(5)
(6)
Bumper face
Towing hook cover
Fog light cover
Lower side bracket
Upper bracket
Side bracket
(7)
(8)
(9)
(10)
(11)
(12)
Energy absorber foam upper

Energy absorber foam lower
Main beam reinforcement
Main beam bracket
Bracket support
Energy absorber side
EI-5
(13)
(14)
Lower center bracket

Radiator guide

T1: 7.5 (0.77, 5.53)
T2: 33 (3.4, 24)
General Description
6. REAR BUMPER (SEDAN MODEL)
(3)
(8)
T3
T3
(9)
T2
(4)
(1)
T2
(6)
(2)
(7)
(5)
T1
EI-01116
(1)
(2)
(3)
(4)
(5)
Bumper face
Exhaust end cover
Beam upper rear
Bracket corner
Lower bracket
(6)
(7)
(8)
(9)
Bumper side support upper

Bumper side support lower
Beam main reinforcement
Bumper beam bracket
EI-6

T1: 2 (0.2, 1.48)
T2: 7.5 (0.77, 5.53)
T3: 33 (3.4, 24)
General Description
7. REAR BUMPER (WAGON MODEL)
(3)
(8)
T3
T3
(9)
T2
(1)
(4)
T2
(6)
(2)
(7)
(5)
T1
EI-01117
(1)
(2)
(3)
(4)
(5)
Bumper face
Exhaust end cover
Beam upper rear
Bracket corner
Lower bracket
(6)
(7)
(8)
(9)
Bumper side support upper

Bumper side support lower
Beam main reinforcement
Bumper beam bracket
EI-7

T1: 2 (0.2, 1.48)
T2: 7.5 (0.77, 5.53)
T3: 33 (3.4, 24)
General Description
8. MUD GUARD
(2)
(1)
EI-00835
(1)
Front mud guard
(2)
Rear mud guard
9. COWL PANEL
(4)
(3)
(1)
(2)
(4)
(3)
(1)
(2)
Cowl panel
Weather strip
EI-01078
(3)
Cover cowl panel
EI-8
(4)
Cowl side panel
General Description
10.ROOF SPOILER
(1)
(3)
(2)
T
EI-01079
(1)
(2)
Roof spoiler
High-mounted stop light
(3)

T: 4.5 (0.46, 3.32)
Washer nozzle
11.SIDE SILL SPOILER

(3)
(2)
(1)
EI-01080
(1)
Side sill spoiler
(2)
Double-sided tape
EI-9
(3)
Air flap side sill end
General Description
12.ROOF MOLDING
(1)
(3)
T
(2)
T
(4)
(2)
(4)
T
(3)
T
EI-00752
(1)
(2)
Roof molding
Roof carrier attachment
(3)
(4)
Clip
Roof carrier attachment bracket

T: 4.5 (0.46, 3.32)
13.SIDE PROTECTOR
(2)
(1)
EI-00829
(1)
Front door protector
(2)
Rear door protector
EI-10
General Description
14.SIDE GARNISH
(4)
(3)
(1)
(2)
EI-00800
(1)
(2)
Front fender garnish

Front door garnish
(3)
Rear door garnish
(4)
Rear quarter garnish
15.TRUNK LID GARNISH
EI-00806
EI-11
General Description
16.REAR GATE GARNISH
(6)
(1)
(2)
(4)
(3)
(5)
EI-00807
(1)
(2)
Rear gate garnish

Ornament
(3)
(4)
License plate light

Rear fog light or back-up light
EI-12
(5)
(6)
Back-up light or rear fog light

License plate light bracket
General Description
17.DOOR TRIM
(4)
(3)
(9)
(6)
(5)
(12)
(7)
(4)
(5)
(6)
(8)
(3)
(2)
(7)
(8)
(9)
(1)
(10)
(11)
EI-00714
(1)
(2)
(3)
(4)
Front door trim

Gusset cover
Upper weather strip
Inner remote cover
(5)
(6)
(7)
(8)
Door grip
Door grip bracket upper
Door grip frame
Door grip bracket lower
EI-13
(9)
(10)
(11)
(12)
Power window switch

Step light cover
Speaker cover
Rear door trim
General Description
18.CONSOLE BOX
(8)
(6)
(10)
(9)
(1)
(2)
(7)
(3)
(11)
(12)
A
A
(13)
(4)
(5)
EI-00812
(1)
(2)
(3)
(4)
(5)
Upper lid
Console cover
Seat heater switch
Front cup holder
Console box outer
(6)
(7)
(8)
(9)
(10)
Rear lid
Rear cup holder
Ash tray
Lid hinge
Parking brake lever boot
EI-14
(11)
(12)
Console pocket
Front accessory power supply
socket
(13)
Console box harness
General Description
19.INSTRUMENT PANEL
T
(2)
(9)
T
(1)
(3)
(10)
(11)
(13)
(7)
(4)
(14)
(12)
(6)
(15)
(8)
(5)
EI-01057
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Steering support beam bracket

Instrument panel pad & frame
ASSY
Instrument panel side cover
Glove box lower cover
Console side panel RH
Console side panel LH
(8)
(9)
Console side garnish

Instrument panel lower cover
upper
(10)
Instrument panel lower cover

under
(11)
(12)
Ash tray holder

Front accessory power supply
socket
EI-15
(13)
(14)
(15)
Console front panel (AT model)

Console front panel (MT model)
Shift lever boot

T: 25 (25.5, 18.4)
General Description
(1)
(2)
(4)
(3)
(8)
(9)
(10)
(6)
(12)
(11)
(5)
(7)
(14)
(13)
EI-00814
(1)
(2)
(3)
(4)
(5)
Air vent side duct

Air vent center duct
Instrument panel pad & frame
Air vent defroster grille
Air vent side grille
(6)
Navigation unit bracket (Model

with navigation system)
(7)
(8)
(9)
Glove box panel

Center console frame
Air vent center grille
EI-16
(10)
(11)
(12)
(13)
(14)
Audio bracket (LH)

Audio bracket (RH)
Center panel
Glove box
Glove box lid
General Description
20.INNER TRIM (SEDAN MODEL)
(21)
(20)
(18)
(19)
(17)
(13)
(16)
(15)
(5)
(10)
(22)
(14)
(11)
(1)
(8)
(6)
(9)
(12)
(23)
(24)
(3)
(7)
(2)
(4)
(11)
EI-00715
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)

Front pillar lower trim
Front outside scuff plate
Front inside scuff plate
Center pillar lower trim
Seat belt lower anchor bolt cover
Rear outside scuff plate
Rear inside scuff plate
Seat belt shoulder anchor adjuster
button
(11)
Bolt cover (Model with curtain airbag)
(20)
Curtain airbag guide center

(Model with curtain airbag)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
Center pillar inner protector lower

Center pillar inner protector upper
Front pillar inner protector lower
Front pillar inner protector upper
Roof side inner protector front
Roof side inner protector center
Roof side inner protector rear
Curtain airbag guide front (Model
with curtain airbag)
(21)
Curtain airbag guide rear (Model

(22)
(23)
Rear quarter trim

Rear quarter trim front (Model with
curtain airbag)
(24)
Rear quarter trim rear (Model with

curtain airbag)
EI-17
General Description
21.INNER TRIM (WAGON MODEL)
(21)
(20)
(18)
(19)
(17)
(23)
(16)
(22)
(13)
(15)
(5)
(24)
(14)
(10)
(11)
(11)
(1)
(8)
(6)
(12)
(9)
(3)
(7)
(2)
(4)
EI-00716
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)

Front pillar lower trim
Front outside scuff plate
Front inside scuff plate
Center pillar lower trim
Seat belt lower anchor bolt cover
Rear outside scuff plate
Rear inside scuff plate
Seat belt shoulder anchor adjuster
button
(11)
Bolt cover (Model with curtain airbag)
(19)
Curtain airbag guide front (Model

(12)
(13)
(14)
(15)
(16)
(17)
(18)
Center pillar inner protector lower

Center pillar inner protector upper
Front pillar inner protector lower
Front pillar inner protector upper
Roof side inner protector front
Roof side inner protector center
Roof side inner protector rear
(20)
Curtain airbag guide center

(Model with curtain airbag)
(21)
Curtain airbag guide rear (Model

(22)
(23)
(24)
Rear quarter front pillar trim

Rear quarter rear pillar trim
Rear quarter lower trim
EI-18
General Description
22.REAR GATE TRIM
(1)
(2)
(3)
EI-00808
(1)
Rear gate panel upper trim
(2)
Rear gate panel pillar trim
(3)
Rear gate panel lower trim
23.ROOF TRIM (SEDAN MODEL)
EI-00755
EI-19
General Description
24.ROOF TRIM (WAGON MODEL)
EI-00756
25.TRUNK ROOM TRIM

(5)
(1)
(4)
(2)
(6)
(3)
EI-00722
(1)
(2)
Trunk lid trim

Trunk lid arm cover
(3)
(4)
Trunk room mat

Trunk side trim
EI-20
(5)
(6)
Combination light cover

Trunk room end cover
General Description
26.LUGGAGE FLOOR MAT
(5)
(7)
(4)
(2)
(6)
(1)
(3)
EI-00757
(1)
(2)
(3)
Front floor mat

Floor box (RH)
Floor box (LH)
(4)
(5)
(6)
Center floor mat

Side floor mat (RH)
Side floor mat (LH)
EI-21
(7)
Luggage floor end cover
General Description
27.ROOM INNER PARTS
(4)
(1)
(2)
T
T
T
T
(3)
T
T
(3)
E
T
T
E
EI-00789
(1)
(2)
Room mirror
Sun visor
(3)
(4)

T: 7.5 (0.77, 5.53)
Assist grip
Coat hook (Wagon model)
28.HEAT SHIELD COVER

(5)
(6)
(3)
(1)
(4)
(2)
EI-00798
(1)
Front heat shield cover (5AT

model)
(3)
Center heat shield cover (Turbo

model)
(2)
Front heat shield cover (4AT

model and MT model)
(4)
Center heat shield cover (Nonturbo model)
EI-22
(5)
(6)
Rear heat shield cover RH

Rear heat shield cover LH
General Description
B: PREPARATION TOOL
TOOL NAME
Clip remover
Clip clamp pliers
REMARKS
Used for removal of trim.
Used for removal of various clips and clamps.
EI-23
Front Grille
2. Front Grille
A: REMOVAL
1) Open the hood.
2) Remove the push clips (A) and front grille clips
(B) from each side of front grille.
(B)
(B)
(A)
(A)
EI-00551
3) Pull lower side of the front grille forward, remove

hooks (A), and then remove the front grille from vehicle body.
(A)
EI-00552
B: INSTALLATION
EI-24
Front Hood Grille

3. Front Hood Grille
2) Insert the hooks (B) of the front hood duct into

holes (A) of the front hood.
A: REMOVAL
2) Remove the front hood insulator. <Ref. to EB13, FRONT HOOD INSULATOR, REMOVAL,
Front Hood.>
3) Remove the screws (A) and clip (B), and remove
the front hood duct.
(A)
(B)
(B)
EI-00634
3) Install the front hood duct with the screws (A)

and clip (B).
(B)
(A)
(A)
EI-00632
4) Loosen the nuts (A), remove the clip (B), and

then remove the front hood grille.
(A)
(A)
EI-00632
(A)
(B)
(A)
EI-00633
B: INSTALLATION
1) Fit the clip (B) of front hood grille, and install the
front hood grille using nuts (A).
(A)
(B)
(A)
EI-00633
Tightening torque:
4.5 Nm (0.46 kgf-m, 3.32 ft-lb)
EI-25
Front Under Cover

4. Front Under Cover

A: REMOVAL
2) Remove the clips (A), (C) and bolts (B) in front
fender, and then remove the front under cover.
Large type (Turbo model)
(C)
(A)
(A)
(B)
EI-00735
Large type (DOHC non-turbo model)
(A)
(A)
(B)
EI-00635
Small type (SOHC non-turbo model)
(A)
(A)
(A)
(B)
(A)
EI-00636
B: INSTALLATION
Tightening torque:
14 Nm (1.42 kgf-m, 10.3 ft-lb)
EI-26
Floor Under Protector

5. Floor Under Protector

A: REMOVAL
NOTE:
Plate type lift can not be used.
2) Remove the push turn clips (A) and bolts (B),
and remove the floor under protector.
(A)
(A)
(B)
(A)
(A)
(B)
(A)
(A)
(A)
(B)
(A)
(A)
(A)
EI-00637
B: INSTALLATION
EI-27
Fuel Tank Protector

6. Fuel Tank Protector

A: REMOVAL
2) Remove the bolts (A) and plastic nuts (B), and
then remove the fuel tank protector.
(A)
(A)
(B)
(B)
(A)
(B)
(A)
(B)
(A)
(A)
EI-00638
B: INSTALLATION
Tightening torque:
Bolt
17.5 Nm (1.78 kgf-m, 12.9 ft-lb)
EI-28
Mud Guard
7. Mud Guard
A: REMOVAL
1. FRONT MUD GUARD
1) Jack-up the vehicle.
3) Loosen the screws and clips to remove mud
guard.
EI-00639
2. REAR MUD GUARD

1) Jack-up the vehicle.
3) Loosen the screws and clips to remove mud
guard.
EI-00640
B: INSTALLATION
1. FRONT MUD GUARD
2. REAR MUD GUARD

EI-29
Front Bumper
8. Front Bumper
2. FRONT BUMPER BEAM ASSEMBLY
A: REMOVAL

FRONT BUMPER FACE, REMOVAL, Front
Bumper.>
4) Remove the energy absorber foam from bumper
beam.
1. FRONT BUMPER FACE

3) Turn over the front mud guard, and remove the
clips connecting the fender and bumper.
EI-00575
5) Remove the bolts, and remove the bumper

beam assembly from vehicle body.
EI-00572
4) Remove the clips at the lower side of bumper.
EI-00576
NOTE:
After all bolts are removed, raise the whole bumper
beam a little to remove it from vehicle body.
6) Remove the bolts and nuts, and disassemble the
bumper beam.
EI-00573
5) Disconnect the fog light connector. (Model with

fog light)
6) Remove the bumper from vehicle body.
7) Remove the fog light from bumper face. <Ref. to
LI-21, REMOVAL, Front Fog Light Assembly.>
EI-30
EI-00577
Front Bumper
7) Remove the clips, and remove the radiator

guide.
EI-00801
8) Remove the bolts and clips, and remove the

bumper lower center bracket.
EI-00578
B: INSTALLATION
1. FRONT BUMPER FACE
2) Fit the slider (A) to the guide plate (B) securely.
(B)
(A)
EI-00571
2. FRONT BUMPER BEAM ASSEMBLY

Tightening torque:
Refer to COMPONENT of General Description. <Ref. to EI-5, FRONT BUMPER, COMPONENT, General Description.>
EI-31
Front Bumper
C: REPAIR
1. COATING METHOD FOR PP BUMPER
Process
No.
Process name
Job contents
(1)
Bumper installation
Place the bumper on a paint worktable as

required. Use the paint worktable conforming
to inner shape of bumper when possible.
(2)
Masking
Degreasing, cleaning
Primer paint
Drying
Top coat paint (I)
Drying
Top coat paint (II)
Drying
10
11
Inspection
Masking removal
EI-00234
(1) Bumper
(2) Set bumper section
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 to all parts to be painted, using spray gun. Use primer (clear).
Dry at normal temperature [10 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.
Non-colored
Metallic paint
Use section (block) paint for top coat.
Use section (block) paint for top coat.
Paint to be used (for each color):
Paint to be used (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)
Film thickness: 15 20
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 [more than 10 min.
Not required.
at 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 to be used:
Metallic paint
Hardener PB
Thinner T-301
Not required.
Mixing ratio:
Clear coat vs. hardener = 6:1
(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 at 80C (176F).
Paint check.
Remove masking tape applied in process No. 2.
EI-32
Front Bumper
2. REPAIR INSTRUCTIONS FOR COLORED PP BUMPER

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. Damages limited to the shallow scratches that cause only a change in the luster
of the base material or coating, can be almost fully restored. Before repairing a damaged area, explain this
point to the customer and obtain an understanding about the matter. Repair methods are outlined below,
based on a classification of the extent of damage.
1) Minor damage causing only a change in the lustre of the bumper due to a light touch
Almost restorable.
Process
No.
1
2
Process name
Cleaning
Sanding
Finish
Job contents
Clean the area to be repaired using water.
Grind the repairing area with #500 sand paper in a feathering motion.
Resin section
Coated section
Repeatedly apply wax to the affected area
using a soft cloth (such as flannel). RecomPerform either the same process as for the
mended wax: NITTO KASEI Soft 99 TIRE
resin section or process No. 18 and subseWAX BLACK, or equivalent.
quent in the 3) section, depending on the
Polish the waxed area with a clean cloth after 5 degree and nature of damage.
to 10 minutes.
2) Deep damage caused by scratching with fences, etc.

A dent cannot be repaired but a whitened or swelled part can be removed.
Process
No.
1
Process name
Cleaning
Removal of damaged area
Sanding
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 operSame as Process No. 3 in the 1) section.
ations in the 3) section.
EI-33
Front Bumper
3) Deep damage such as a break or hole that requires filling

Much of the peripheral grained surface must be sacrificed for repair. 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
No.
1
2
Process name
Bumper removal
Removal of parts
Job contents
Remove the bumper as required.
Remove the parts built into bumper as required.
(1)
Bumper placement
Place the bumper on a paint worktable as

required.
It is recommended to use the paint worktable
conforming to internal shape of bumper.
(2)
Surface preparation
EI-00234
(1) Bumper
(2) Set bumper section
Remove dust, oil, etc. from areas to be repaired and surrounding areas, using a suitable solvent
(NRM No. 900 Precleno, white gasoline, or alcohol, etc.).
(3)
(1)
6
7
Cutting
Sanding (I)
Cleaning
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
bumpers base surface. Then, bevel or veeout the affected area using a knife or grinder.
(4)
(2)
EI-00235
(1) Paint surface

(2) PP base surface
(3) 20 30 mm (0.79 1.18 in)
(4) 3 mm (0.12 in)
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.
(1)
Temporary welding
(2)
(3)
(1) Welded point (Use heater gun and PP welding rod)

(2) PP base surface
(3) Beveled section
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-34
EI-00236
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.
(2)
(2)
Welding
(3)
(1)
EI-00237
(1) Welding rod

(2) Melt hatched area
(3) Section
NOTE:
Melt the sections indicated by hatched area.
Do not melt the 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)
EI-00042
11
Masking
12
Cleaning/ degreasing
13
Primer coating
14
Leave unattended
15
Primer surfacer
coating
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 coat of primer at a spraying pressure of 245 343 kPa (2.5 3.5 kg/cm2, 36
50 psi) with a spray gun.
Leave the repaired area unattended at 20C (68F) for 10 to 15 minutes until primer is half-dry.
NOTE:
If dirt or dust comes in contact with the coated area, wipe it off with a cloth 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)
Coating film thickness: 40 50
EI-35
Front Bumper
Process
No.
16
17
18
Process name
Drying
Sanding (III)
Cleaning/ degreasing
19
Top coat (I)
20
Leave unattended
21
Top coat (II)
22
Drying
23
24
25
26
Inspection
Masking removal
Parts installation
Bumper installation
Job contents
Allow the coated surface to dry for 20 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.
Non-colored
Use a block coating method.
Recommended paint:
Suncryl (SC)
No. 307 Flex Hardener
SC Reducer (thinner)
Mixing ratio:
Suncryl (SC) vs. No. 307 Flex Hardener = 3 : 1
(2.5 3.5 kg/cm2, 36 50 psi)
Metallic paint
Use a block coating method.
Recommended paint:
Suncryl (SC)
Mixing ratio:
(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.
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
Not required.
Mixing ratio:
(2.5 3.5 kg/cm2, 36 50 psi)
Allow the coated surface to dry for 2 hours at 20C (68F) or 30 minutes at 60C (140F).
NOTE:
Do not allow the temperature to exceed 80C (176F) since this will deform the PP substrate.
Carefully check the condition of the repaired area.
Remove the masking tape applied in Process No. 11 and 13.
Install parts on the bumper in reverse order of removal.
Install the bumper.
EI-36
Rear Bumper
9. Rear Bumper
Sedan model: trunk side trim
A: REMOVAL
1. REAR BUMPER FACE
<Ref. to LI-25, REMOVAL, Rear Combination Light
Assembly.>
3) Remove the two clips.
EI-00583
Wagon model: rear quarter lower trim
EI-00579
4) Turn over the mud guard, and remove the bolt

(A) inside wheel house, and the clips (B) on the
lower side of bumper.
NOTE:
For model with McIntosh Audio, remove the woofer
cover.
(A)
(B)
EI-00584
EI-00580
5) Remove the clips on the lower side of rear

bumper.
EI-00585
7) Remove the rear bumper from vehicle body.
EI-00581
6) Remove the service hole cover, and remove the

bolt.
EI-00802
NOTE:
Do not pull with a excessive force. Otherwise the
bracket installation area may be damaged.
Remove from the end in order.
EI-37
Rear Bumper
2. REAR BUMPER BRACKET

1) Remove the rear bumper face from vehicle
body.
2) Remove the rear bumper bracket corner from
vehicle body. (both sides)
3) Remove the nuts, and remove the beam main

reinforcement from vehicle body.
EI-00803
4) Remove the nuts, and remove the bumper beam

bracket and beam upper rear from vehicle body.
EI-00587
3) Remove the lower brackets from vehicle body.

Sedan model: 2 places
EI-00804
B: INSTALLATION
1. REAR BUMPER FACE
EI-00641
1) Install the beam upper rear to vehicle body.

2) Install the bumper face to vehicle body.
Wagon model: 4 places
NOTE:
If the bumper face is easily come off the beam upper rear, adjust the hook area of the bracket side.
Tightening torque:
<Ref. to EI-6, REAR BUMPER (SEDAN MODEL), COMPONENT, General Description.>
EI-00588
3. REAR BUMPER BEAM ASSEMBLY
2. REAR BUMPER BRACKET

2) Remove the rear bumper face. <Ref. to EI-37,
REAR BUMPER FACE, REMOVAL, Rear
Bumper.>
3. REAR BUMPER BEAM ASSEMBLY

C: REPAIR
Refer to the description for front bumper repair.
<Ref. to EI-30, REMOVAL, Front Bumper.>
EI-38
Cowl Panel
10.Cowl Panel
5) Remove the cowl panel side and clip (A).
A: REMOVAL
(A)
1) Open the hood.

2) Remove the wiper arm. <Ref. to WW-16, REMOVAL, Front Wiper Arm.>
3) Remove the weather strip clip, and remove the
weather strip.
EI-00790
6) Remove the clips (A), and remove the cowl panel.
EI-00642
NOTE:
If the weather strip clip is removed with excessive
force, the weather strip may be damaged. Be sure
to use a clip remover to remove.
:(A)
B: INSTALLATION
EB-00141
4) Remove the clip, and remove the cover cowl

panel.
EI-00643
EI-39
EI-00644
Roof Spoiler
11.Roof Spoiler
A: REMOVAL
3) Disconnect the connector of the high mounted
stop light and the washer hose of rear washer.
4) Remove the nut and plastic caps.
EI-00828
5) Remove the clips, and remove the roof spoiler.
EI-00646
B: INSTALLATION
Tightening torque:
4.5 Nm (0.46 kgf-m, 3.32 ft-lb)
EI-40
Side Sill Spoiler

12.Side Sill Spoiler

A: REMOVAL
Remove the clips (two for front fender arch area, six for side sill spoiler lower area), and remove the side
spoiler.
(3)
(1)
(2)
EI-00733
(1)
Side sill spoiler
(2)
Packing
(3)
B: INSTALLATION
NOTE:
For the rearmost clip securing side sill spoiler, install through the end cover.
(1)
(2)
(3)
EI-00791
(1) Vehicle body

(2) End cover
(3) Side sill spoiler
EI-41
End cover
Side Protector
13.Side Protector
A: REMOVAL
(2)
(1)
EI-00829
(1)
Front door protector
(2)
Rear door protector
1) Slide in a thin thread (A) of 0.8 mm (0.031 in) diameter or less (fishing line etc.) between body and
protector, cut the double-sided tape, and pull the
protector toward you, and remove the clip using clip
remover.
If the double-sided tape remains thick on the surface due to interfacial peeling, apply the solvent after slicing off the double-sided tape using a cutter.
(A)
(A)
(B)
(C)
EI-00478
(A) Panel
(B) Side protector
(C) Double-sided tape
EI-00153
NOTE:
To optimize the effect of solvent, slide the thread
along body without removing the double-sided tape
on the surface of body and spoiler.
If it is difficult to detach the double-sided tape,
warm up to approx. 40C (104F).
2) Apply masking tape around the double-sided

tape remaining on the surface of body or spoiler.
3) Apply solvent uniformly on double-sided tape using a brush.
CAUTION:
Do not use the solvent to the body which is
repaired with lacquer paint.
Wipe off immediately when the solvent is
touched on surface of the body or spoiler.
Solvent:
3M 8907 or equivalent
EI-42
Side Protector
4) Cover the area where solvent is applied using

plastic wrap (A), and then heat the double-sided
tape for 5 to 10 minutes in 40 60C (104
140F) using a heat lamp (B).
(A)
Double-sided tape:
3M 5531-5 or equivalent
2) Heat the adhering part using a heat lamp.
Body side: 40 60C (104 140F)
Protector side: 20 30C (68 86F)
3) Detach the double-sided tape backing sheet,
align the clip position, and then adhere to the body
using care to avoid air entering.
CAUTION:
To keep the adhesion, do not wash the vehicle
within 24 hours from installation.
(B)
EI-00155
(A)
(B)
EI-00156
CAUTION:
Do not heat the double-sided tape until the surface becomes white and excessively dried.
5) Remove the double-sided tape using a plastic
spatula.
6) After completely removing the double-sided
tape, detach the masking tape and clean the surface using a cotton cloth damped with white gasoline.
B: INSTALLATION
1) Apply primer to the protector surface where the
double-sided tape to be adhered, and then adhere
the double-sided tape as shown in the figure.
(1)
(1)
EI-00536
(1) Double-sided tape: thickness 1.2 mm (0.047 in),

width 5mm (0.197 in)
Primer:
3M K-500 or equivalent
EI-43
Side Garnish
14.Side Garnish
A: REMOVAL
(E)
(E)
(B)
(A)
(D)
(A)
(C)
(A)
(A)
(B)
(B)
EI-01085
(A)
(B)
Black clip
White clip
(C)
(D)
Red clip
Gray clip
(E)
Green clip
1) Remove the side sill spoilers, and remove the front fender garnish and rear quarter garnish. <Ref. to EI41, REMOVAL, Side Sill Spoiler.>
2) For removal of side garnish, refer to the removal procedure of Side Protector. <Ref. to EI-42, REMOVAL,
Side Protector.>
B: INSTALLATION
Check the color of clip, and then install in the reverse order of removal.
EI-44
Rear Quarter Protector

15.Rear Quarter Protector

A: REMOVAL
1) Remove the side sill spoilers. <Ref. to EI-41, REMOVAL, Side Sill Spoiler.>
2) Remove the clips (A) with rotating it rearward using the fender arch as a fulcrum, and then remove
the rear quarter protector.
: (A)
EI-00734
B: INSTALLATION
EI-45
Roof Molding
16.Roof Molding
5) Remove the nuts, and remove the roof carrier attachment.
A: REMOVAL
2) Remove the roof carrier attachment cover, and
remove the bolts. (2 places for each side)
EI-00658
3) Pull the roof molding upward, and remove it from

vehicle body.
(2)
(1)
EI-00659
(5)
B: INSTALLATION
CAUTION:
Replace the clip with new one when the broken
pin grommet is found during the removal of
roof molding. When the body side cap or clip is
damaged, or the roof molding is lifted or peeled
from body, be sure to repair them correctly, because those troubles may cause the water leakage.
(4)
(3)
EI-00660
(1)
(2)
(3)
(4)
(5)
Locating pin
Roof molding
Cap
Clip
Grommet
Tightening torque:
7.5 Nm (0.77 kgf-m, 5.53 ft-lb)
EI-46
Roof Rail
17.Roof Rail
A: REMOVAL
2) Remove the six nuts.
F
(A)
D
A
(B)
(C)
(D)
(E)
(F)
EI-00834
B: INSTALLATION
CAUTION:
When removing or installing the roof rail, be
careful not to scratch the body panel with the
stud bolt of roof rail.
Tightening torque:
7.5 Nm (0.76 kgf-m, 5.53 ft-lb)
EI-47
Door Trim
18.Door Trim
4) Loosen the screws.
A: REMOVAL
2) Remove the cover (A) at inner remote area.
(A)
EI-00651
5) Remove the clips, and disconnect each connector and wire to remove door trim.
Front door trim
EI-00649
3) Push the root of hand grip upward, and remove

the hand grip cover by twisting it to the vehicle
frontward direction.
EI-00652
Rear door trim

EI-01025
LH SIDE Counterclockwise
RH SIDE Clockwise
NOTE:
If the above procedure does not work, use a flat-tip
screw driver to pry out the upper side of hand grip
cover to remove, with the protection tape attached
to both the door trim and flat-tip screwdriver.
EI-01026
EI-48
EI-00656
Door Trim
B: INSTALLATION
NOTE:
Be careful not to install the hand grip cover and
plate clip of hand grip in the wrong direction.
Hand grip cover (front and rear door)
Convex upward
Lower side of the hand grip cover for front door

has pawl part.
The lowest clip of rear door faces the opposite direction
EI-00655
EI-00653
Bottom clip of the front door faces the opposite

direction
EI-00654
EI-49
Instrument Panel Lower Cover

19.Instrument Panel Lower Cover

A: REMOVAL
2) Remove the front door inside scuff plate (A) and
front pillar lower trim (B). <Ref. to EI-60, REMOVAL, Lower Inner Trim.>
(A)
(B)
EI-00758
3) Remove the clips, and remove the instrument

panel lower cover under.
EI-00759
4) Loosen the screw (A), disconnect the connectors, and remove the instrument panel lower cover
upper.
:(B)
(A)
EI-00760
(B) Clip
B: INSTALLATION
EI-50
Glove Box
20.Glove Box
6) Remove the clip, and remove the glove box lower cover.
A: REMOVAL
3) Remove the console front panel.
EI-00764
7) Remove the console side panel.
: (A)
EI-00761
(A) Hook
NOTE:
For AT model, remove the ring indicator.
For MT model, remove the shift knob.
4) Remove the console side garnish.
EI-00765
8) Remove the instrument panel side cover, and remove the clip.
: (A)
EI-00762
(A) Hook
: (A)
5) Remove the front inside scuff plate (A) and front

pillar lower trim (B). <Ref. to EI-60, REMOVAL,
Lower Inner Trim.>
EI-00766
(A) Clip
9) Remove the screw, and remove the glove box.
(A)
(B)
EI-00763
: (A)
(A) Clip
EI-51
EI-00767
Glove Box
B: INSTALLATION
EI-52
Console Box
21.Console Box
A: REMOVAL
2) Remove the parking brake lever cover.
EI-00810
3) Remove the bolts and clips.
EI-00811
4) Disconnect the connector, and remove the console box.
B: INSTALLATION
EI-53
Center Console
22.Center Console
6) Remove the clip at the console side panel tip.
A: REMOVAL
3) Remove the console front panel.
EI-00769
7) Remove the passenger side front inside scuff

plate (A) and front pillar lower trim (B). <Ref. to EI60, REMOVAL, Lower Inner Trim.>
: (A)
EI-00761
(A) Hook
NOTE:
For AT model, remove the ring indicator.
For MT model, remove the shift knob.
4) Loosen the screw, remove the hook, and remove the console side garnish.
(A)
(B)
EI-00763
8) Remove the clip, and remove the glove box lower cover.
: (A)
EI-00762
(A) Hook
EI-00764

EI-00768
EI-54
Center Console
9) Remove the screws, and remove the console

side panel.
EI-00770
10) Loosen the screws to pull out the audio unit assembly, and disconnect the connector to remove
audio unit.
EI-00794
NOTE:
Audio unit assembly can be removed without removing the console side panel.
B: INSTALLATION
EI-55
Instrument Panel Assembly

23.Instrument Panel Assembly
10) Remove the screw at the side of center console.
A: REMOVAL
1. INSTRUMENT PANEL (EXCLUDING
STEERING SUPPORT BEAM)
CAUTION:
Be careful to the harness of airbag system
when servicing the instrument panel. Damage
may cause the system malfunction.
2) Remove the front pillar upper trim. <Ref. to EI62, REMOVAL, Upper Inner Trim.>
4) Remove the center console. <Ref. to EI-54, REMOVAL, Center Console.>
7) Remove the combination meter assembly. <Ref.
to IDI-16, REMOVAL, Combination Meter.>
8) Remove the screws.
EI-00771
11) Remove the center air vent grille of instrument

panel. <Ref. to AC-44, CENTER GRILLE, REMOVAL, Air Vent Grille.>
12) Remove the screws.
EI-00772
13) Remove the screws at side of passenger side

instrument panel.
EI-00605
9) Remove the driver side instrument panel side

cover, and remove the screws.
EI-00773
14) Remove the bolts securing passenger side airbag module to the steering support beam.
EI-00609
EI-00610
15) Disconnect the connectors, and remove the instrument panel from vehicle body.
EI-56

NOTE:
If necessary, make matching marks for easy reassembly.
When storing the removed instrument panel, be
sure to prepare a table or the like to put instrument
panel on to prevent damage.
16) Remove the side air vent grille. <Ref. to AC-44,
REMOVAL, Air Vent Grille.>
17) Remove the heater vent duct. <Ref. to AC-46,
REMOVAL, Heater Vent Duct.>
18) Loosen the screws to remove center console
frame.
21) Loosen the screws to remove glove box striker.
EI-00614
22) Remove the pawl, and remove the passengers

airbag module.
EI-00774
19) Loosen the screws to remove meter bracket.
EI-00615
2. STEERING SUPPORT BEAM

INSTRUMENT PANEL (EXCLUDING STEERING
SUPPORT BEAM), REMOVAL, Instrument Panel
Assembly.>
2) Remove the steering shaft assembly. <Ref. to
PS-23, REMOVAL, Tilt Steering Column.>
3) Remove each harness clip, and remove the harness from steering support beam.
EI-00612
20) Loosen the screws to remove instrument panel

matching pins.
NOTE:
4) Remove the bolt and remove steering support
beam.
EI-00613
EI-00775
EI-57

8) Loosen the bolts on the center console side.
5) Remove the steering support beam bracket.
EI-00617
EI-00620
9) Disconnect each connector, and remove the instrument assembly.
3. INSTRUMENT PANEL ASSEMBLY (INCLUDING STEERING SUPPORT BEAM)

CAUTION:
Be careful to the harness of airbag system
when servicing the instrument panel. Damage
may cause the system malfunction.
1) Remove the front pillar upper trim. <Ref. to EI62, REMOVAL, Upper Inner Trim.>
5) Remove the steering shaft assembly. <Ref. to
PS-23, REMOVAL, Tilt Steering Column.>
6) Remove the driver side instrument panel side
cover, and remove the bolts.
NOTE:
B: INSTALLATION
1. INSTRUMENT PANEL (EXCLUDING
STEERING SUPPORT BEAM)
1) Insert the matching pins (3 places) on the instrument panel tip into the grommet (A) and (B) on the
body panel side.
(B)
(A)
(B)
EI-00621
2) Check the inserted state of matching pins, and

pull the harness around.
3) Tighten the instrument panel with screw, and recheck the installation of instrument panel and the
state of pulled harness.
EI-00776
7) Remove the bolts at the side of passenger side

instrument panel.
NOTE:
How to install insulator and pad;
Adhesive
Use polyurethane adhesive. When assembling the
instrument panel assembly, wait until the adhesive
has evaporated to prevent filling of the smell in the
compartment.
Double-sided tape
Use commercial double-sided tape. (Use doublesided adhesive tape having extra-strength.)
EI-00777
EI-58

Location
(1)
(2)
(2)
EI-01087
(1) 10 mm (0.39 in)

(2) 40 mm (1.57 in)
Make clearance for 10 mm (0.39 in) from instrument panel front edge, and 40 mm (1.57 in) from
both side edges when taping.
2. STEERING SUPPORT BEAM

1) Temporarily tighten the steering support beam
with bolt, and pull the harness around.
2) Make sure that there is no mutual interference in
each pedal, and tighten the each bolt.
Tightening torque:
25 Nm (25.5 kgf-m, 18.4 ft-lb)
3. INSTRUMENT PANEL ASSEMBLY (INCLUDING STEERING SUPPORT BEAM)

1) Insert the matching pins (3 places) on the instrument panel tip into the grommet (A) and (B) on the
body panel side.
(B)
(A)
(B)
EI-00621
2) Check the inserted state of matching pins, and

pull the harness around.
3) Temporarily tighten the steering support beam
with bolt, and pull the harness around.
4) Make sure that there is no mutual interference in
each pedal, and tighten the each bolt.
Tightening torque:
25 Nm (25.5 kgf-m, 18.4 ft-lb)
EI-59
Lower Inner Trim

24.Lower Inner Trim
5) Remove the clip (A), and remove the inside scuff

plate.
A: REMOVAL
1) Remove the hook, and remove the inside scuff
plate.
(A)
: (B)
EI-00781
(B) Hook
: (A)
EI-00778
6) Remove the door molding (A) and door catcher

cover (B), and then remove the outside scuff plate.
(A) Hook
2) Remove the door molding (A), and remove the

outside scuff plate.
(A)
(A)
(B)
:(C)
: (B)
:(D)
EI-00782
(C) Hook with plate clip

(D) Clip
EI-00779
7) Remove the clips of the center pillar lower trim.
(B) Clip
3) Remove the clip (A), and remove the front pillar

lower trim.
(A)
EI-00783
EI-00780

EI-60
Lower Inner Trim

8) Remove the center pillar lower trim while pushing the pawl part on the upper and lower side of
dropout prevention clip.
EI-00784
B: INSTALLATION
EI-61
Upper Inner Trim

25.Upper Inner Trim
5) Remove the center pillar upper trim.
A: REMOVAL
1) From the top side of trim, remove the metal clip
using flat tip driver.
EI-00787
6) Remove the seat belt lower anchor bolt cover.

EI-00785
CAUTION:
When the metal clip has been removed or damaged, replace both of the trim and metal clips
with new ones.
2) Remove the front pillar upper trim.
: (A)
EI-00788
(A) Clip
7) Remove the seat belt lower anchor bolt, and pull

out the seat belt from center pillar upper trim.
EI-00786
3) Remove the front inside scuff plate, rear inside

scuff plate and center pillar lower trim. <Ref. to EI60, REMOVAL, Lower Inner Trim.>
4) Remove the cap on the upper side of pillar trim,
and remove the bolt inside. (Model with curtain airbag)
SB-00145
B: INSTALLATION
EI-00562
EI-62
Rear Quarter Trim

26.Rear Quarter Trim
3) Remove the cap on the upper side of trim, and

remove the bolt inside.
A: REMOVAL
1. SEDAN MODEL (MODEL WITHOUT
CURTAIN AIRBAG)
2) Remove the rear quarter trim.
EI-00562
4) Remove the bolts (A), and remove the quarter

trim (front).
(A)
(A)
EI-00838
2. SEDAN MODEL (MODEL WITH CURTAIN

AIRBAG)
2) Turn over the trim, and remove the quarter trim
rear by pressing the claw (A) of metal clip using flat
tip screwdriver or the like.
EI-00839
3. WAGON MODEL
1) Remove the rear seat cushion and backrest
shoulder. <Ref. to SE-14, WAGON MODEL, REMOVAL, Rear Seat.>
2) Remove the cap on the upper side of pillar trim,
and remove the bolt inside. (Model with curtain airbag)
(A)
EI-00562
:(B)
EI-00682
(B) Hook
CAUTION:
When the metal clip has been removed or damaged, replace both of the trim and metal clips
with new ones.
EI-63
Rear Quarter Trim

3) Remove the clip, and remove the quarter front

pillar trim.
8) Remove the screws (A) and bolts (B), and remove the quarter lower trim.
(A)
(B)
(A)
(B)
EI-00840
EI-00567
4) Remove the quarter rear pillar trim.
NOTE:
Remove the screw cover on the tonneau cover
installing part.
Pull out the shopping bag hook, remove the
screw on back.
B: INSTALLATION
1. SEDAN MODEL
2. WAGON MODEL
EI-00564

6) Remove the luggage floor end cover.
EI-00570
7) Remove the woofer cover. (Model with McIntosh

Audio)
EI-00622
EI-64
Sun Visor
27.Sun Visor
A: REMOVAL
1) Remove the cover, loosen the mounting screws,
and remove the sun visor.
EI-00661
2) Disconnect the connector. (Model with vanity

mirror light)
3) Press the (A) on both side using flat tip driver,
pull the sun visor hook and remove it.
(A)
(A)
EI-00662
B: INSTALLATION
EI-65
Assist Grip
28.Assist Grip
A: REMOVAL
1) Remove the screw cover, and remove the screw
inside.
2) Pull the left side of assist grip toward you, and rotate the right side of it counterclockwise to remove.
EI-00809

4) Remove the bolts, and remove the assist grip
bracket.
(A)
EI-01065
(A) Grommet
B: INSTALLATION
CAUTION:
Be sure to install the grommet to assist grip
bracket.
When install the assist grip without grommet, it
may cause the faulty returning.
EI-66
Roof Trim
29.Roof Trim
2. WAGON MODEL
A: REMOVAL

3) Remove the room light. <Ref. to LI-35, REMOVAL, Room Light.>
4) Remove the luggage room light. <Ref. to LI-36,
REMOVAL, Luggage Room Light.>
5) Remove the sun visor. <Ref. to EI-65, REMOVAL, Sun Visor.>
6) Remove the assist grip. <Ref. to EI-66, REMOVAL, Assist Grip.>
7) Remove the upper inner trim. <Ref. to EI-62, REMOVAL, Upper Inner Trim.>
WAGON MODEL, REMOVAL, Rear Quarter
Trim.>
1. SEDAN MODEL
6) Remove the select lever. (AT model)
<Ref. to CS-7, REMOVAL, Select Lever.>
8) Remove the room light. <Ref. to LI-35, REMOVAL, Room Light.>
9) Remove the sun visor. <Ref. to EI-65, REMOVAL, Sun Visor.>
10) Remove the assist grip. <Ref. to EI-66, REMOVAL, Assist Grip.>
11) Remove the upper inner trim. <Ref. to EI-62,
REMOVAL, Upper Inner Trim.>
13) Remove the sunroof opening trim. (Model with
sunroof)
CAUTION:
Do not remove the roof end trim with excessive
force. Otherwise roof trim may be damaged.
Roof trim and roof end trim are fastened by rivets.
9) Remove the sunroof opening trim. (Model with
sunroof)
EI-00501
10) Remove the coat hook.
EI-00501
14) Remove the clips and each harness, and remove the roof trim.
15) Pull out the roof trim from vehicle.
EI-00668
11) Remove the clips and each harness, pull out

the rear center seat belt, and remove the roof trim.
EI-00667
EI-67
Roof Trim
CAUTION:
Do not remove the roof end trim with excessive
force. Otherwise roof trim may be damaged.
EI-00669
B: INSTALLATION
1. SEDAN MODEL
2. WAGON MODEL
EI-68
Rear Gate Trim

30.Rear Gate Trim
5) Remove the clips (A), remove the rear gate lower trim.
A: REMOVAL
1) Remove the clips (A), and remove the rear gate
pillar trim.
(A)
(A)
EI-01066
6) Remove the rear gate weather strip.

:(A)
EI-00670
2) Remove the clips, and detach the rear gate upper trim.
EI-00673
NOTE:
to use a clip remover to remove.
EI-00671
3) Remove the cover in the inner handle, loosen

the inside screw.
4) Turn over the weather strip, and remove the
clips.
EB-00141
B: INSTALLATION
EI-00674
EI-69
Rear Shelf Trim

31.Rear Shelf Trim
B: INSTALLATION
A: REMOVAL

3) Remove the high-mounted stop light. <Ref. to LI33, REMOVAL, High-mounted Stop Light.>
WAGON MODEL, REMOVAL, Rear Seat.>
5) Remove the lower anchor bolt of rear center seat
belt.
NOTE:
Securely insert the vehicle body panel into the hook
of rear shelf trim center, and then install the rear
shelf trim.
(2)
(1)
(3)
(1) Hook
(2) Rear shelf trim
(3) Vehicle body panel
EI-00675
6) After disconnecting the high-mounted stop light

harness connector (A) and removing the five clips,
remove the rear shelf trim with pulling it frontward.
(A)
EI-00676
EI-70
EI-00739
Trunk Room Trim

32.Trunk Room Trim
2) Remove the trim clips (A), and remove the trunk

room end cover.
A: REMOVAL
1. TRUNK LID TRIM
1) Remove the trim clips and stopper rubbers, and
remove the trunk lid trim.
(A)
:(B)
EI-00624
(B) Clip
EI-00628
2) Remove the clip (A) of trunk side trim, and then

remove the trunk lid arm cover.
(A)
3) Remove the rear seat backrest, and then remove the trim clips at the front side of trunk side
trim. <Ref. to SE-14, WAGON MODEL, REMOVAL, Rear Seat.>
EI-00625
EI-00629
2. TRUNK ROOM TRIM

1) Remove the trunk room mat.
4) Insert the flat tip driver from the lower side of

trunk hook, and then remove the trunk hook with rotating it 90.
EI-00841
EI-00623
EI-71
Trunk Room Trim

5) Remove the trim clips, and remove the trunk

side trim.
EI-00626
B: INSTALLATION
1. TRUNK LID TRIM
2. TRUNK ROOM TRIM

EI-72
Floor Mat
33.Floor Mat
A: REMOVAL
3) Remove the console box. <Ref. to EI-53, Console Box.>
4) Remove the console side panel. <Ref. to EI-54,
REMOVAL, Center Console.>
5) Remove the lower inner trim. <Ref. to EI-60, REMOVAL, Lower Inner Trim.>
6) Remove the footrest. (MT model)
7) Remove the clips from floor mat.
8) Remove the mat hook on both side.
9) Remove the mat from toe board area.
10) Remove the mat from rear heater duct.
11) Roll the mat, and then take it out of opened rear
door.
EI-00677
B: INSTALLATION
NOTE:
Secure the mat firmly with hook and clip.
Insert the mat edge firmly into the groove of side
sill cover.
EI-73
Luggage Floor Box

34.Luggage Floor Box

A: REMOVAL
1) Remove the luggage floor mat.
2) Remove the clips, and remove the luggage floor
box.
EI-00678
B: INSTALLATION
EI-74
Trunk Lid Garnish

35.Trunk Lid Garnish

A: REMOVAL
1) Remove the license plate, and loosen the bolts
(A).
(A)
EI-00568
2) Remove the clip in the upper corner of trunk lid

garnish.
EI-01031
3) Remove the trunk lid garnish in the order from

the end of it, by accessing it through the gap between trunk lid garnish and trunk lid panel.
EI-01032
B: INSTALLATION
Tightening torque:
7.5 Nm (0.77 kgf-m, 5.53 ft-lb)
EI-75
Rear Gate Garnish

36.Rear Gate Garnish

A: REMOVAL
2) Remove the clip (A), and remove the rear gate
panel side cover.
(A)
EI-00569
3) Remove the hexagon cap nut.
EI-00630
4) Remove the nuts, disconnect each connector,

and remove the rear gate garnish.
EI-00631
B: INSTALLATION
EI-76
Heat Shield Cover

37.Heat Shield Cover

A: REMOVAL
1. FRONT HEAT SHIELD COVER
Remove the four bolts to remove front heat shield
cover.
(A)
DI-00211
(A) Transmission mount
2. CENTER HEAT SHIELD COVER

Remove the nut and bolt to remove center heat
shield cover.
EI-00679
3. REAR HEAT SHIELD COVER

1) Remove the muffler. <Ref. to EX(H4SO 2.0)-13,
REMOVAL, Muffler.> <Ref. to EX(H4DOTC)-12,
REMOVAL, Muffler.>
2) Remove the four bolts to remove rear heat shield
cover.
EI-00680
B: INSTALLATION
EI-77
Ornament
38.Ornament
A: INSTALLATION
1. LETTER MARK
Adhere the letter mark with following dimension.
Sedan model
A
(b)
(a)
(1)
(2)
(3)
A
(a)
(C)
(2)
A-A
(a)
(1)
Apply the apply tape with aligning

the cut out to the end of trunk lid
garnish.
Letter mark
(b)
(2)

R stop on the top end of trunk lid
garnish.
Apply tape
EI-78
B-B
EI-00815
(c)
Align the slit of apply tape to panel

end.
(3)
Ornament
Wagon model
(3)
(b)
(a)
(2)
(4)
A
(C)
(a)
(2)
(1)
A-A
B-B
EI-00816
(a)
(1)
(2)

the cut out to the end of rear gate
panel.
Letter mark
Apply tape
(b)
(3)

outer bottom end of rear gate garnish.
Rear gate garnish
(c)
Align the slit of apply tape to panel

end.
(4)
2. AWD STICKER
Apply the AWD sticker from inside of glass with following dimension.
Sedan model
(2)
(a)
(1)
(3)
(4)
EI-00741
(a)
(1)
(2)

the cut out to the end of rear glass
center.
1 mm (0.04 in)
Gradation end of ceramic print
(with rear wiper)
(3)

(without rear wiper)
EI-79
(4)
End of rear glass
Ornament
Wagon model (RH side)

(a)
(4)
(2)
(1)
(1)
(b)
(3)
EI-00742
Wagon model (LH side)
(a)
(4)
(2)
(1)
(1)
(b)
(3)
EI-00743
(a)
(1)
(2)

the cut out to the ceramic print.
1 mm (0.04 in)
Glass antenna wire
(b)
(3)
Molding
(4)
EI-80
Front side of vehicle
EB
1.
2.
3.
4.
5.
6.
7.
8.
9.
Page
Front Hood ................................................................................................13
Front Fender .............................................................................................16
Front Door .................................................................................................17
Front Sealing Cover ..................................................................................20
Rear Door..................................................................................................21
Rear Sealing Cover...................................................................................24
Trunk Lid ...................................................................................................25
Rear Gate..................................................................................................27
General Description
A: SPECIFICATION
1. SIDE
(A)
(B)
(D)
(C)
(F)
(E)
(G)
(1)
(2)
(2)
(A)
(3)
(3)
(B)
(4)
(C)
(6)
(4)
(5)
(4)
(7)
(D)
(8)
(G)
(E),(F)
EB-00176
(1)
(2)
(3)
Front hood panel

Front fender panel
Front door panel
Section
(A)
(B)
(C)
(D)
(E), (F)
(G)
(4)
(5)
(6)
Rear door panel

Rear quarter panel
Door panel
Part
Front hood panel to Front fender panel
Front fender panel to Front door panel
Front door panel to Rear door panel
Rear door panel to Rear quarter panel
Door panel to Side sill
Rear door panel to Rear quarter lower protector
EB-2
(7)
(8)
Side sill
Rear quarter lower protector
Standard value
3.51.0 mm (0.140.04 in)
4.651.0 mm (0.180.04 in)
5.11.0 mm (0.200.04 in)
4.61.0 mm (0.180.04 in)
6.01.0 mm (0.240.04 in)
5.01.0 mm (0.200.04 in)
General Description
2. FRONT
(2)
(C)
(E)
(B)
(A)
(D)
(1)
(A)
(3)
C1
(3)
(1)
C2
(4)
(C)
(B)
(5)
(4)
(1)
(D)
(5)
(E)
EB-00177
(1)
(2)
Front bumper
Front grille
Section
(A)
(B)
(3)
(4)
Front hood panel

Headlight
Part
Front bumper to Front grille (Longitudinal direction)
Front hood panel to Front bumper
(C)
Front hood panel to Headlight
(D)
(E)
Front fender panel to Headlight

Front fender panel to Front bumper
EB-3
(5)
Front fender panel
Standard value
1.00.7 mm (0.040.03 in)
4.0 6.0 mm (0.16 0.24 in)
C1: 6.01.0 mm (0.240.04 in)
C2: 5.01.0 mm (0.200.04 in)
1.01.0 mm (0.040.04 in)
1.00.7 mm (0.040.03 in)
General Description
3. REAR (SEDAN MODEL)
(6)
(F)
(D)
(G)
(C)
(B)
(A)
(E)
(3)
(A)
F2
(4)
(2)
(6)
(5)
(2)
(1)
(B)
(C)
F1
(4)
(4)
(1)
(F)
(4)
(4)
(5)
(4)
(3)
G1
(D)
(E)
G2
(G)
EB-00178
(1)
(2)
Trunk lid panel

Section
(A)
(B)
(C)
(D)
(E)
(F)
(G)
(3)
(4)
Rear bumper
Rear fender panel
Part
Trunk lid garnish to Rear bumper
Trunk lid garnish to Rear combination light
Trunk lid panel to Rear combination light
Trunk lid panel to Rear fender panel
Rear fender panel to Rear bumper
Rear fender panel to Fuel filler flap lid (Longitudinal
direction)
Rear fender panel to Fuel filler flap lid (Lateral direction)
EB-4
(5)
(6)
Fuel filler flap lid

Trunk lid garnish
Standard value
7.01.0 mm (0.280.04 in)
4.01.0 mm (0.160.04 in)
3.51.0 mm (0.140.04 in)
3.51.0 mm (0.140.04 in)
1.00.7 mm (0.040.03 in)
F1: 3.70.5 mm (0.150.02 in)
F2: 3.40.5 mm (0.130.02 in)
G1, G2: 3.50.5 mm (0.140.02 in)
General Description
4. REAR (WAGON MODEL)

(E)
(1)
(5)
(D)
(C)
(G)
(H)
(B)
(3)
(F)
(A)
(A)
(2)
(C)
G2
(7)
(6)
(3)
(5)
(8)
(1)
G1
(D)
(B)
(7)
(7)
(G)
(9)
(7)
(8)
(7)
(2)
(4)
H1
(E)
H2
(H)
(F)
EB-00179
(1)
(2)
(3)
Rear gate panel

Rear bumper
Section
(A)
(B)
(C)
(D)
(E)
(F)
(G)
(H)
(4)
(5)
(6)
Roof panel
Rear gate glass
Door quarter glass
Part
Rear gate panel to Rear bumper
Rear gate panel to Rear combination light
Rear gate glass to Rear combination light
Rear gate glass to Rear quarter glass
Roof panel to Roof spoiler
Rear fender panel to Rear bumper
Rear fender panel to Fuel filler flap lid (Longitudinal
direction)
Rear fender panel to Fuel filler flap lid (Lateral direction)
EB-5
(7)
(8)
(9)
Rear fender panel

Fuel filler flap lid
Roof spoiler
Standard value
8.01.0 mm (0.310.04 in)
5.01.0 mm (0.200.04 in)
5.51.0 mm (0.220.04 in)
4.01.5 mm (0.160.06 in)
5.51.0 mm (0.220.04 in)
1.00.7 mm (0.040.03 in)
G1: 3.70.5 mm (0.150.02 in)
G2: 3.40.5 mm (0.130.02 in)
H1, H2: 3.50.5 mm (0.140.02 in)
General Description
B: COMPONENT
1. FRONT HOOD
(1)
T2
(3)
T2
(4)
(2)
(5)
(6)
T1
EB-00148
(1)
(2)
(3)
Front hood panel

Front hood insulator
Front hood hinge
(4)
(5)
(6)
Intake duct weather strip

Front hood weather strip
Front hood striker
EB-6

T1: 33 (3.4, 24.5)
T2: 24.5 (2.5, 18.1)
General Description
2. FRONT FENDER PANEL
EB-00145

T: 7.4 (0.75, 5.5)
EB-7
General Description
3. FRONT DOOR PANEL
(7)
(1)
(5)
(2)
(8)
T4
T3
T2
(4)
T1
T3
(6)
T2
(3)
EB-00149
(1)
(2)
(3)
(4)
(5)
Front door panel

Sealing cover
Front door weather strip
Checker
Upper hinge
(6)
(7)
(8)
Lower hinge
Door trim bracket upper
Door trim bracket lower
EB-8

T1: 7.4 (0.75, 5.5)
T2: 24.5 (2.5, 18.1)
T3: 29.4 (3.0, 21.7)
T4: 32.3 (3.3, 23.8)
General Description
4. REAR DOOR PANEL
(1)
(7)
(5)
T3
T1
(2)
(8)
T2
T4
T3
(4)
T2
(6)
(3)
EB-00150
(1)
(2)
(3)
(4)
(5)
Rear door panel

Sealing cover
Rear door weather strip
Checker
Upper hinge
(6)
(7)
(8)
Lower hinge
Door trim bracket upper
Door trim bracket lower
EB-9

T1: 7.4 (0.75, 5.5)
T2: 24.5 (2.5, 18.1)
T3: 29.4 (3.0, 21.7)
T4: 32.3 (3.3, 23.8)
General Description
5. TRUNK LID PANEL
(1)
(8)
(2)
T1
(7)
T2
(3)
(6)
(4)
(5)
EB-00161
(1)
(2)
(3)
(4)
Trunk lid panel

License plate light cover
Trunk lid garnish
Trunk lid lock ASSY
(5)
(6)
(7)
(8)
Trunk lid trim

Trunk lid arm cover
Trunk lid arm ASSY
Torsion bar
EB-10

T1: 17.6 (1.8, 12.9)
T2: 14 (1.43, 10.3)
General Description
6. REAR GATE PANEL
(2)
T3
T3
(3)
T1
(1)
T2
(4)
EB-00182
(1)
(2)
Rear gate damper stay

Hinge
(3)
(4)
Rear gate panel

Rear gate side panel cover
C: CAUTION
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 to support
the panel.
Be careful not to lose small parts.
EB-11

T1: 7.5 (0.76, 5.5)
T2: 14.0 (1.43, 10.3)
T3: 25.0 (2.6, 18.4)
General Description
D: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
925610000
DESCRIPTION
WRENCH
REMARKS
Used for removing and installing door hinge.
REMOVER
Used for removing and installing trunk torsion

bar.
ST-925610000
927780000
ST-927780000
2. GENERAL TOOL
TOOL NAME
Support jack
Clip remover
REMARKS
Used for supporting door panel.
Used for removing various types of clips.
EB-12
Front Hood
2. Front Hood
3. FRONT HOOD HINGE
A: REMOVAL
1) Remove the bolts, and remove the front hood

panel. <Ref. to EB-14, FRONT HOOD PANEL, REMOVAL, Front Hood.>
1. FRONT HOOD INSULATOR

1) Open the hood.
2) Release the clips to remove the front hood insulator.
EB-00138
2) Remove the clips, and remove the cowl side

panel front.
EB-00139
2. FRONT HOOD WEATHER STRIP

1) Open the hood.
2) Remove the clips, and remove the front hood
weather strip (A) and intake duct weather strip (B).
(C)
(A)
(D)
EB-00142
3) Remove the clamp (A) of the window washer

hose, and remove bolt of the hinge.
(B)
(A)
EB-00140
(C) Clip
(D) Weather strip clip
NOTE:
to use clip remover to remove.
EB-00141
EB-13
EB-00143
Front Hood
4. FRONT HOOD STRIKER

1) Open the hood.
2) Remove the bolt, and remove the front hood
striker.
7) Remove the bolts, and remove the front hood

panel from front hood hinge.
EB-00138
B: INSTALLATION
EB-00144
1. FRONT HOOD INSULATOR
5. FRONT HOOD PANEL
1) Open the front hood to remove the window

washer hose.
NOTE:
Be careful not to catch the window washer hose in.
2. FRONT HOOD WEATHER STRIP

3. FRONT HOOD HINGE

Tightening torque:
24.5 Nm (2.5 kgf-m, 18.1 ft-lb)
4. FRONT HOOD STRIKER
EB-00137
2) Remove the front hood insulator.

<Ref. to EB-13, FRONT HOOD INSULATOR, REMOVAL, Front Hood.>
3) Remove the front hood weather strip.
<Ref. to EB-13, FRONT HOOD WEATHER STRIP,
REMOVAL, Front Hood.>
4) Remove the front hood striker.
<Ref. to EB-14, FRONT HOOD STRIKER, REMOVAL, Front Hood.>
5) Remove the front hood duct. (Turbo model)
<Ref. to EI-25, REMOVAL, Front Hood Grille.>
6) Remove the window washer hose and nozzle.
<Ref. to WW-19, REMOVAL, Front Washer Nozzle.>

Tightening torque:
33.0 Nm (3.4 kgf-m, 24.5 ft-lb)
5. FRONT HOOD PANEL

Tightening torque:
24.5 Nm (2.5 kgf-m, 18.1 ft-lb)
C: ADJUSTMENT
1) Adjust the clearance between front hood panel
and front fender panel. Clearance must be equal at
both sides. For the dimension of clearance, refer to
SPECIFICATIONS in General Description.
<Ref. to EB-2, SPECIFICATION, General Description.>
EB-14
Front Hood
2) Use a hinge mounting bolts to align the front

hood longitudinally and laterally.
EB-00138
3) Adjust the height at the front end of hood. <Ref.

to SL-39, ADJUSTMENT, Front Hood Lock Assembly.>
4) Rotate the hood buffer to adjust lateral height.
EB-00164
EB-15
Front Fender
3. Front Fender
A: REMOVAL
2) Remove the side sill spoilers. <Ref. to EI-41, REMOVAL, Side Sill Spoiler.>
REMOVAL, Front Bumper.>
5) Remove the headlight assembly. <Ref. to LI-14,
REMOVAL, Headlight Assembly.>
7) Remove the cowl panel side.
EB-00147
8) Remove the bolt, and remove the front fender

panel.
EB-00146
B: INSTALLATION
2) Install with attention to make uniform clearance
between front fender panel and front hood panel.
For the dimension of clearance, refer to SPECIFICATIONS in General Description. <Ref. to EB-2,
Tightening torque:
7.4 Nm (0.75 kgf-m, 5.5 ft-lb)
EB-16
Front Door
4. Front Door
11) Remove the front door weather strip.
A: REMOVAL
1. FRONT DOOR PANEL
3) Remove the outer mirror assembly. <Ref. to
GW-19, REMOVAL, Outer Mirror Assembly.>
4) Remove the front door speaker. <Ref. to ET-6,
REMOVAL, Front Speaker.>
5) Pull back the sealing cover. <Ref. to EB-20, REMOVAL, Front Sealing Cover.>
6) Remove the gusset and front door glass. <Ref.
to GW-11, REMOVAL, Front Door Glass.>
7) Remove the door sash and front door regulator
and motor. <Ref. to GW-16, REMOVAL, Front
Regulator and Motor Assembly.>
8) Remove the front door latch assembly. <Ref. to
SL-29, REMOVAL, Front Door Latch and Door
Lock Actuator Assembly.>
9) Remove the front outer handle. <Ref. to SL-28,
REMOVAL, Front Outer Handle.>
10) Remove the screw to remove the door trim
bracket.
(A)
(A)
(B)
EB-00155
(A) Pin clip

(B) Weather strip clip
NOTE:
EB-00141
12) Remove the bolts and nuts to remove the door

checker.
EB-00154
13) Remove the front door. <Ref. to EB-17,

FRONT DOOR ASSEMBLY, REMOVAL, Front
Door.>
EB-00152
2. FRONT DOOR ASSEMBLY

2) Remove the front pillar lower trim. <Ref. to EI-60,
REMOVAL, Lower Inner Trim.>
3) Remove the instrument panel lower cover or
glove box lower cover. <Ref. to EI-50, REMOVAL,
Instrument Panel Lower Cover.> or <Ref. to EI-51,
REMOVAL, Glove Box.>
EB-17
Front Door
4) Disconnect the connector of door harness from

body harness.
B: INSTALLATION
1. FRONT DOOR PANEL
Tightening torque:
<Ref. to EB-8, FRONT DOOR PANEL, COMPONENT, General Description.>
2. FRONT DOOR ASSEMBLY

EB-00151
5) Put a wooden block on jack and place jack under

the front door. Support the door with a jack to protect it from damage.
1) Put a wooden block on jack and place the front

door on that.
EB-00013
2) Apply grease to the sliding area of door hinges,

and install the door hinge to vehicle.
3) Install the front door to upper hinge and lower
hinge adjusting by jack.
4) Tighten the bolt of door checker.
5) Connect the door harness connector, and install
the instrument panel lower cover.
6) Install the front pillar lower trim.
EB-00013
6) Remove the bolt from the door checker.
Tightening torque:
<Ref. to EB-8, FRONT DOOR PANEL, COMPONENT, General Description.>
EB-00014
7) Remove the door-side bolts for upper and lower

hinges to remove front door panel.
C: ADJUSTMENT
1) Using the ST, loosen the body-side bolts of upper and lower hinges to align the position of front
door panel longitudinally and laterally.
ST 925610000
DOOR HINGE WRENCH
ST
EB-00015
8) Remove the door hinge from vehicle.

EB-00016
EB-18
Front Door
2) Loosen the screws (A), and tap the striker (B)

using plastic hammer to adjust the gap between
rear end surface of front door panel and front end
surface of rear door.
CAUTION:
Do not use an impact wrench. Welding area on
the striker nut plate is easily broken.
(A)
(B)
EB-00017
EB-19
Front Sealing Cover

5. Front Sealing Cover

A: REMOVAL
3) Remove the front speaker. <Ref. to ET-6, REMOVAL, Front Speaker.>
4) Pull back the sealing cover.
NOTE:
Carefully remove the butyl tape. Excessive force
will easily break the cover.
If cover gets broken, replace it with a new one.
EB-00018
B: INSTALLATION
2) When replacing the sealing cover, use the butyl
tape.
3) Press the butyl tape-applied area firmly to prevent any floating on surface.
Butyl tape:
3M8626 or equivalent
NOTE:
Apply a uniform bead of butyl tape.
Attach the sealing cover, keeping it from becoming wrinkled.
Breaks in the bead will allow water leakage and
contamination.
C: INSPECTION
If the sealing cover gets damaged, replace it with a
new one.
EB-20
Rear Door
6. Rear Door
10) Remove the rear door inner weather strip.
A: REMOVAL
(A)
1. REAR DOOR PANEL
(A)

3) Remove the rear speaker. <Ref. to ET-9, REMOVAL, Rear Speaker.>
4) Pull back the sealing cover. <Ref. to EB-24, REMOVAL, Rear Sealing Cover.>
6) Remove the door sash and rear door regulator
and motor assembly. <Ref. to GW-25, REMOVAL,
Rear Regulator and Motor Assembly.>
7) Remove the rear door latch. <Ref. to SL-33, REMOVAL, Rear Door Latch and Door Lock Actuator
Assembly.>
8) Remove the rear outer handle. <Ref. to SL-32,
REMOVAL, Rear Outer Handle.>
9) Remove the screw to remove the door trim
bracket.
(B)
EB-00156
(A) Pin clip

(B) Weather strip clip
NOTE:
EB-00141
11) Remove the bolts and nuts to remove the door

checker.
EB-00154
EB-00152
12) Remove the rear door. <Ref. to EB-21, REAR

DOOR ASSEMBLY, REMOVAL, Rear Door.>
2. REAR DOOR ASSEMBLY

EB-21
Rear Door
7) Remove the door-side bolts for upper and lower

hinges to remove the rear door panel.
3) Remove the center pillar inner protector lower.
SB-00144
4) Remove the harness holder (A), and disconnect

the door harness connector inside pillar.
EB-00015
8) Remove the door hinge from vehicle.
B: INSTALLATION
1. REAR DOOR PANEL
(A)
Tightening torque:
<Ref. to EB-9, REAR DOOR PANEL, COMPONENT, General Description.>
EB-00153
5) Put a wooden block on jack and place jack under

the rear door. Support the rear door with the jack to
protect it from damage.
2. REAR DOOR ASSEMBLY

1) Put a wooden block on jack and place the rear
door on that.
EB-00013
EB-00013
6) Remove the bolt from the door checker.
EB-00014
2) Apply grease to sliding area of the door hinges.

3) Install the rear door to upper hinge and lower
hinge adjusting by jack.
4) Tighten the bolt of door checker.
5) Connect the door harness connector, and install
the center pillar inner protector.
6) Install the center pillar lower trim.
Tightening torque:
<Ref. to EB-9, REAR DOOR PANEL, COMPONENT, General Description.>
EB-22
Rear Door
C: ADJUSTMENT
1) Open the rear door, loosen the door-side bolts of
upper and lower hinges to align the position of rear
door panel longitudinally and laterally.
EB-00015
2) Loosen the screws (A), and tap the striker (B)

using plastic hammer to adjust the gap between
rear end surface of rear door panel and body surface.
CAUTION:
Do not use an impact wrench. Welding area on
the striker nut plate is easily broken.
(A)
(B)
EB-00017
EB-23
Rear Sealing Cover

7. Rear Sealing Cover

A: REMOVAL
3) Pull back the sealing cover.
NOTE:
Carefully remove the butyl tape. Excessive force
will easily break the cover.
If cover gets broken, replace it with a new one.
EB-00018
B: INSTALLATION
2) When replacing the sealing cover, use the butyl
tape.
3) Press the butyl tape-applied area firmly to prevent any floating on surface.
Butyl tape:
3M8626 or equivalent
NOTE:
Apply a uniform bead of butyl tape.
Attach the sealing cover, keeping it from becoming wrinkled.
Breaks in the bead will allow water leakage and
contamination.
C: INSPECTION
If the sealing cover gets damaged, replace it with a
new one.
EB-24
Trunk Lid
8. Trunk Lid
8) Remove the bolts to remove the trunk lid arm.
A: REMOVAL
1. TORSION BAR
1) Open the trunk lid.
2) Using the ST, remove the torsion bar from the
hinge link.
ST 927780000
REMOVER
CAUTION:
During removal and installation, carefully handle the torsion bar, because it will generate reactive force.
EB-00157
3. TRUNK LID PANEL

2) Open the trunk lid to remove the trunk lid trim
and trunk lid arm cover. <Ref. to EI-71, TRUNK
ROOM TRIM, REMOVAL, Trunk Room Trim.>
3) Disconnect the connector to remove the trunk lid
harness.
4) Remove the trunk lid lock assembly. <Ref. to SL38, REMOVAL, Trunk Lid Lock Assembly.>
5) Remove the trunk lid garnish. <Ref. to EI-75,
REMOVAL, Trunk Lid Garnish.>
6) Remove the license plate light cover.
ST
EB-00067
3) Remove the right/left torsion bars.
2. TRUNK LID ARM

2) Open the trunk lid to remove the trunk lid trim,
trunk lid arm cover and trunk room trim. <Ref. to EI71, TRUNK ROOM TRIM, REMOVAL, Trunk Room
Trim.>
3) Disconnect the trunk lid release cable. <Ref. to
SL-38, REMOVAL, Trunk Lid Lock Assembly.>
4) Disconnect each connector, and remove the
harness clip.
5) Remove the trunk lid mounting bolts to remove
the trunk lid panel from trunk lid arm.
EB-00159
7) Remove the bolts to remove the trunk lid panel

from the trunk lid arm.
EB-00066
EB-00066
6) Remove the torsion bar from the trunk lid hinge

link. <Ref. to EB-25, TORSION BAR, REMOVAL,
Trunk Lid.>
B: INSTALLATION
1. TORSION BAR
2) Apply grease to the rotating area of hinges and
of torsion bar.
EB-25
Trunk Lid
2. TRUNK LID ARM

Tightening torque:
<Ref. to EB-10, TRUNK LID PANEL, COMPONENT, General Description.>
3. TRUNK LID PANEL

around the trunk lid panel. For the dimension of
clearance, refer to SPECIFICATIONS in General
Description. <Ref. to EB-2, SPECIFICATION,
Tightening torque:
14 Nm (1.43 kgf-m, 10.3 ft-lb)
EB-26
Rear Gate
9. Rear Gate
12) Remove the rubber duct (A) connection, and

pull out the harness and washer hose from the rear
gate.
A: REMOVAL
1. REAR GATE PANEL
2) Open the rear gate.
4) Remove the rear gate garnish. <Ref. to EI-76,
REMOVAL, Rear Gate Garnish.>
5) Remove the rear wiper arm. <Ref. to WW-20,
REMOVAL, Rear Wiper Arm.>
6) Remove the rear wiper motor. <Ref. to WW-21,
WAGON MODEL, REMOVAL, Rear Wiper Motor.>
7) Remove the rear gate outer handle. <Ref. to SL35, REMOVAL, Rear Gate Outer Handle.>
8) Remove the rear gate latch assembly. <Ref. to
SL-36, REMOVAL, Rear Gate Latch Assembly.>
10) Remove harness clip of each connector from
the rear gate panel.
11) Remove the weather strip clips (A), and remove the rear gate panel weather strip.
(A)
EB-00020
13) Before removing the rear gate damper stay,

prevent the rear gate from closing using prop or the
like.
CAUTION:
If the prop comes off, operators may get injured
and vehicle may get damaged. Make sure to
support the rear gate with secure material to
prevent injury or damage.
EB-00069
14) Remove the mounting bolts of rear gate damper stay.
:(A)
EB-00162
NOTE:
EB-00022
EB-00141
EB-27
Rear Gate
15) Remove the rear gate hinge bolts, and remove

the rear gate panel.
4) Remove the clips and then detach the rear combination light covers.
EB-00023
LI-00295
5) Remove the mounting bolt (A), and remove the

damper stay.
16) Remove the rear gate hinge from vehicle.
2. REAR GATE DAMPER STAY

CAUTION:
Do not damage piston rods and oil seals.
Never disassemble cylinders: They contain
gas.
1) Open the rear gate.
2) Before removing the rear gate damper stay, prevent the rear gate from closing using prop or the
like.
CAUTION:
(A)
EB-00158
B: INSTALLATION
1. REAR GATE PANEL
between rear gate panel and body. For the dimension of clearance, refer to SPECIFICATIONS in
General Description. <Ref. to EB-2, SPECIFICATION, General Description.>
Tightening torque:
<Ref. to EB-11, REAR GATE PANEL, COMPONENT, General Description.>
EB-00069
3) Remove the mounting bolts of rear gate damper

stay.
EB-00022
EB-28
Rear Gate

1) Prevent the rear gate from closing using prop or
the like.
CAUTION:
2) Lift the body side slightly with piston rods fully

extended, and secure the body side with vise.
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 rear gate damper stay gas completely.
(1)
(2)
(3)
(4)
(7)
(5)
EB-00069

Tightening torque:
<Ref. to EB-11, REAR GATE PANEL, COMPONENT, General Description.>
C: DISPOSAL
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 sack as shown in the figure.
(1)
(2)
EB-00031
(1) Rear gate damper stay

(2) Vinyl sack
NOTE:
Prevent the vinyl sack from being caught by drill
cutting edge.
EB-29
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(6)
Body side
Door side
190 mm (7.48 in)
10 mm (0.39 in)
Piston rod
Cylinder
Portion to be drilled
EB-00032
Rear Gate
EB-30
CC
1.
2.
3.
4.
5.
6.
7.
Page
Cruise Control Unit......................................................................................4
Cruise Control Command Switch ................................................................5
Stop Light & Brake Switch...........................................................................6
Clutch Switch ..............................................................................................7
Inhibitor Switch............................................................................................8
Neutral Position Switch ...............................................................................9
General Description
A: COMPONENT
(6)
(7)
(1)
(4)
(5)
(8)
(3)
(2)
CC-00263
(1)
(2)
(3)

Stop light & brake switch
(4)
Cruise indicator light & cruise set

indicator light
(5)

(TCM) (AT model)
CC-2
(6)
(7)
(8)
Inhibitor switch (AT model)

Neutral position switch (MT model)
Clutch switch (MT model)
General Description
B: CAUTION
Before disassembling or reassembling parts, always disconnect the battery ground cable from battery. When repairing the audio, control module, etc.
which are provided with memory functions, record
the memory contents before disconnecting the
ground cable from battery. Otherwise, the memory
will be erased.
Adjust the parts to specifications specified in this
manual.
After reassembly, ensure functional parts operate properly.
C: PREPARATION TOOL
TOOL NAME
Circuit tester
TORX BIT T30
REMARKS
Used for removing and
installing drivers airbag
module.
CC-3
Cruise Control Unit

2. Cruise Control Unit

A: NOTE
The control of cruise control system is carried out in
Engine control module (ECM).
B: REMOVAL
<Ref. to FU(H4SO 2.0)-34, REMOVAL, Engine
Control Module (ECM).> <Ref. to FU(H4SO 2.5)36, REMOVAL, Engine Control Module (ECM).>
<Ref. to FU(H4DOTC)-35, REMOVAL, Engine
Control Module (ECM).> <Ref. to FU(H6DO)-34,
REMOVAL, Engine Control Module (ECM).>
C: INSTALLATION
<Ref. to FU(H4SO 2.0)-34, INSTALLATION, Engine Control Module (ECM).> <Ref. to FU(H4SO
2.5)-36, INSTALLATION, Engine Control Module
(ECM).> <Ref. to FU(H4DOTC)-35, INSTALLATION, Engine Control Module (ECM).> <Ref. to
FU(H6DO)-34, INSTALLATION, Engine Control
Module (ECM).>
CC-4
Cruise Control Command Switch

3. Cruise Control Command

Switch
8) Remove one screw to remove the cruise control

command switch from lower cover.
A: REMOVAL
WARNING:
Before servicing, be sure to read the notes in
the AB section for proper handling of the
drivers airbag module. <Ref. to AB-4, CAUTION, General Description.>
1) Set the front wheels in straight ahead position.
4) Using TORX BIT T30 (Tamper resistant type),
loosen the two TORX bolts which secure drivers
airbag module.
CC-00182
B: INSTALLATION
C: INSPECTION
Measure the cruise control command switch resistance.
1 2 3
(1)
CC-00018
(1) TORX BIT T30
CC-00252
5) Disconnect the airbag module connector on

back of the airbag module. <Ref. to AB-10, PROCEDURE, Airbag Connector.>
7) Remove the four screws to remove the lower
cover from steering wheel.
Switch
CANCEL
SET/COAST
RESUME/
ACCEL
CANCEL
SET/COAST
RESUME/
ACCEL
MAIN
Area
Terminal No.
Standard
ALL
OFF
2 and 3
Approx. 4 k
ON
ON
2 and 3
2 and 3
Less than 1
Approx. 250
ON
2 and 3
Approx. 1500
OFF
ON
1 and 2
1 and 2
More than 1 M
Less than 1
If NG, replace the cruise control command switch.
CC-00181
CC-5
Stop Light & Brake Switch

4. Stop Light & Brake Switch

A: REMOVAL
2) Disconnect the connector from stop light & brake
switch, and then remove the switch. <Ref. to BR45, REMOVAL, Stop Light Switch.>
B: INSTALLATION
C: INSPECTION
Measure the resistance of brake switch (A) and
stop light switch (B).
(A)
2 1
4 3
(B)
1 2 3 4
CC-00022
Switch
Brake
Stop
Light
Pedal
Released
Depressed
Released
Depressed
Terminal No.
1 and 4
1 and 4
2 and 3
2 and 3
Standard
Less than 1
More than 1 M
More than 1 M
Less than 1
If NG, replace the stop light & brake switch.
CC-6
Clutch Switch
5. Clutch Switch
A: REMOVAL
2) Disconnect the connector from clutch switch,
and then remove the switch. <Ref. to CL-27, DISASSEMBLY, Clutch Pedal.>
B: INSTALLATION
C: INSPECTION
Measure the clutch switch resistance.
CC-00023
Switch
Clutch
Pedal
Released
Depressed
Terminal No.
1 and 2
1 and 2
Standard
Less than 1
More than 1 M
If NG, replace the clutch switch.
CC-7
Inhibitor Switch
6. Inhibitor Switch
A: REMOVAL
2) Disconnect the connector from inhibitor switch,
and then remove the switch. <Ref. to 4AT-52, REMOVAL, Inhibitor Switch.>
B: INSTALLATION
C: INSPECTION
Measure the inhibitor switch resistance.
6 5 4 3 2 1
12 11 10 9 8 7
CC-00024
Selector lever
position
P
N
Except P and N
Terminal No.
Standard
7 and 12
Less than 1
Less than 1
More than 1 M
If NG, replace the inhibitor switch.
CC-8

7. Neutral Position Switch

A: REMOVAL
2) Disconnect the connector from neutral position
switch, and then remove the switch. <Ref. to 5MT41, BACK-UP LIGHT SWITCH AND NEUTRAL
POSITION SWITCH, REMOVAL, Switches and
Harness.>
B: INSTALLATION
C: INSPECTION
Measure the neutral position switch resistance.
2 1
MT-00110
Gear shift position

Neutral position
Other positions
Terminal No.
1 and 2
Standard
Less than 1
More than 1 M
If NG, replace the neutral position switch.
CC-9

CC-10

(DIAGNOSTICS)
CC(diag)
1.
2.
3.
4.
5.
6.
7.
8.
Page
Engine Control Module (ECM) I/O Signal ...................................................6
Subaru Select Monitor.................................................................................8
Diagnostics with Phenomenon..................................................................10

CRUISE CONTROL SYSTEM (DIAGNOSTICS)

A: PROCEDURE
1
2
3
Step
CHECK MALFUNCTION INDICATOR LIGHT.
Ensure the malfunction indicator light illuminates.
CHECK CRUISE INDICATOR LIGHT.
Ensure the cruise indicator light blinks.
CHECK CRUISE CONTROL MAIN SWITCH
OPERATION.
Check the cruise control main switch operation. (Ensure the cruise indicator light illuminates.)
Check
Yes
light illuminate?
No
Go to step 2.
Does the cruise indicator light

blink?
Is the cruise control main
switch turned on? (Does the
cruise indicator light illuminate?)
Go to step 5.
Go to step 3.
Go to step 4.
CHECK CRUISE CONTROL SET OPERATION.

Check the cruise control set operation.
PERFORM CRUISE CANCEL CONDITIONS
DIAGNOSIS.
Perform the cruise cancel conditions diagnosis.
Can the cruise control be set

while driving at more than 40
km/h (25 MPH)?
Is DTC displayed?
Go to step 6.
Go to phenomenon 1. <Ref. to
CC(diag)-10,
DIAGNOSTIC
PROCEDURE
WITH PHENOMENON, Diagnostics
with Phenomenon.>
Go to step 5.
Go to List of Diagnostic Trouble

Code (DTC).
<Ref. to CC(diag)12, List of Diagnostic Trouble
Code (DTC).>
CHECK CRUISE SET INDICATOR LIGHT.

Does the cruise set indicator
Ensure the cruise set indicator light illuminates. light illuminate?
Go to step 7.
CHECK VEHICLE SPEED IS HELD WITHIN

SET SPEED.
Make sure the vehicle speed is held within set
speed.
CHECK RESUME/ACCEL OPERATION.

Does the vehicle speed
Go to step 9.
Check the RESUME/ACCEL switch operation. increase or return to set speed
after RESUME/ACCEL switch
has been pressed?
Is vehicle speed held within set Go to step 8.

speed 3 km/h (2 MPH)?
(Make an inspection on a level
road.)
CC(diag)-2
CC(diag)-10,
DIAGNOSTIC
PROCEDURE
with Phenomenon.>
CC(diag)-10,
DIAGNOSTIC
PROCEDURE
with Phenomenon.>
CC(diag)-10,
DIAGNOSTIC
PROCEDURE
with Phenomenon.>
CC(diag)-10,
DIAGNOSTIC
PROCEDURE
with Phenomenon.>

Step
CHECK SET/COAST OPERATION.
Check the SET/COAST switch operation.
10
CHECK CANCEL OPERATION.

Check the CANCEL switch operation.
11
CHECK CRUISE CONTROL RELEASE OPERATION.

Check the cruise control release operation.
12

13

Check
Does the vehicle speed
decrease after SET/COAST
switch has been pressed?
No
CC(diag)-10,
DIAGNOSTIC
PROCEDURE
with Phenomenon.>
Is the cruise control released Go to step 11.
Go to phenomeafter CANCEL switch has been
non 7. <Ref. to
pressed?
CC(diag)-10,
DIAGNOSTIC
PROCEDURE
with Phenomenon.>
Go to phenomeafter brake pedal has been
non 8. <Ref. to
depressed?
CC(diag)-10,
DIAGNOSTIC
PROCEDURE
with Phenomenon.>
Go to phenomeafter shifting to the neutral
non 9. <Ref. to
position?
CC(diag)-10,
DIAGNOSTIC
PROCEDURE
with Phenomenon.>
Is the cruise control released Finish the diagno- Go to phenomeafter depressing the clutch
sis.
non 10. <Ref. to
pedal?
CC(diag)-10,
DIAGNOSTIC
PROCEDURE
with Phenomenon.>
CC(diag)-3
Yes
Go to step 10.
General Description
A: CAUTION
Airbag system wiring harness is routed near the cruise control command switch.
CAUTION:
All airbag system wiring harnesses and connectors are yellow. Do not use the electrical test equipment on these circuits.
Be careful not to damage the airbag system wiring harness when servicing the cruise control command switch.
B: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
24082AA230
DESCRIPTION
CARTRIDGE
REMARKS
Troubleshooting for electrical system
22771AA030
SUBARU SELECT
MONITOR KIT
Troubleshooting for electrical system

ST24082AA230
ST22771AA030
2. GENERAL TOOL
TOOL NAME
Circuit tester
REMARKS
C: INSPECTION
Measure the battery voltage and specific gravity of electrolyte.
Standard voltage:
12 V or more
Specific gravity:
More than 1.260
CC(diag)-4


A: LOCATION
(6)
(7)
(1)
(4)
(5)
(8)
(3)
(2)
CC-00263
(1)
(2)
(3)
(4)

Stop and brake switch
Cruise indicator light and cruise
set indicator light
(5)

(TCM) (AT model)
(7)
Neutral position switch (MT

model)
(6)
Inhibitor switch (AT model)
(8)
CC(diag)-5


To A: B134
7 6 5 4 3
17 16 15 14 13 12 11
27 26 25 24 23 22 21
34 33
32 31
To B: B135
2 1
10 9 8
20 19 18
30 29 28
To C: B136
7 6 5 4 3
2 1
19 18 17 16 15 14 13 12 11 10 9 8
23 22 21 20
25 24
27 26
35 34
31 30 29 28
33 32
To D: B137
6 5
4 3 2 1
16 15 14 13 12 11 10 9 8 7
27 26 25 24 23 22 21 20 19 18 17
30 29 28
35 34 33 32 31
7 6 5 4 3 2 1
17 16 15 14 13 12 11 10 9 8
23 22 21 20 19 18
25 24
31 30
27 26
29 28
CC-00197
2.0 L turbo model, 3.0 L model, 2.5 L EC, K4 and EK model

Content
Main power
supply
VB (CONTROL 1)
VB (CONTROL 2)
Command Switch
Brake switch 1
(Brake switch)
Brake switch 2
(Stop light switch)
Main switch
Ground
Terminal No.
B6
B5
C11
C9
C8
C7
GND (CONTROL 1)
GND (CONTROL 2)
Measurement Condition and I/O Signal

(Idling with ignition ON: Except cruise set light)
Battery voltage is present when the main power is turned ON.
0 V voltage is present when the main power is turned OFF.
0 V voltage is present when the command switch is turned to CANCEL position.
Approx. 1 V voltage is present when the command switch is turned to SET/
COAST position.
Approx. 3 V voltage is present when the command switch is turned to
RESUME/ACCEL position.
Approx. 4 V voltage is present when the command switch is released.
Battery voltage is present when the brake pedal is released.
0 V voltage is present when the brake pedal is depressed.
Battery voltage is present when the brake pedal is depressed.
0 V voltage is present when the brake pedal is released.
0 V voltage is present while the main switch is pressed or turned on.
Battery voltage is present when the main switch is turned OFF.
D2
D1
Ignition switch
D14
C10
D9
Neutral signal (AT model)
D9
Battery voltage is present when the ignition switch is turned ON.

0 V voltage is present when the ignition switch is turned OFF.
0 V voltage is present when the clutch pedal is depressed.
Battery voltage is present when the clutch pedal is released.
0 V voltage is present when the shift lever is set in any position except neutral.
Approx. 5 V voltage is present when the shift lever is set in neutral position.
Approx. 5 V voltage (4AT model) or battery voltage (5AT model) is present
when the shift lever is set in any position except P or N.
0 V voltage is present when the shift lever is set in P or N position.
CC(diag)-6

2.0 L non-turbo model, 2.5 L KS, KA model

Content
Main power
supply
VB (CONTROL 1)
VB (CONTROL 2)
Command Switch
Brake switch 1
(Brake switch)
Brake switch 2
(Stop light switch)
Main switch
Ground
Terminal No.
C3
C4
C21
D12
D13
D14
GND (CONTROL 1)
GND (CONTROL 2)
Measurement Condition and I/O Signal

(Idling with ignition ON: Except cruise set light)
Battery voltage is present when the main power is turned ON.
0 V voltage is present when the main power is turned OFF.
0 V voltage is present when the command switch is turned to CANCEL position.
Approx. 1 V voltage is present when the command switch is turned to SET/
COAST position.
Approx. 3 V voltage is present when the command switch is turned to
RESUME/ACCEL position.
Approx. 4 V voltage is present when the command switch is released.
Battery voltage is present when the brake pedal is released.
0 V voltage is present when the brake pedal is depressed.
Battery voltage is present when the brake pedal is depressed.
0 V voltage is present when the brake pedal is released.
0 V voltage is present while the main switch is pressed or turned on.
Battery voltage is present when the main switch is turned OFF.
C5
C6
Ignition switch
B13
D22
B12
Neutral signal (AT model)
B12
Battery voltage is present when the ignition switch is turned ON.

0 V voltage is present when the ignition switch is turned OFF.
0 V voltage is present when the clutch pedal is depressed.
Battery voltage is present when the clutch pedal is released.
0 V voltage is present when the shift lever is set in any position except neutral.
Approx. 5 V voltage is present when the shift lever is set in neutral position.
Approx. 5 V voltage is present when the shift lever is set in any position
except P or N.
0 V voltage is present when the shift lever is set in P or N position.
B: WIRING DIAGRAM
<Ref. to WI-134, WIRING DIAGRAM, Cruise Control System.>
CC(diag)-7


<Ref. to CC(diag)-4, SPECIAL TOOL, PREPARATION TOOL, General Description.>
A: OPERATION
For the on-board diagnosis function of the cruise
control system, use Subaru Select Monitor.
The on-board diagnosis function operates under
two categories, which are used depending on the
type of problems;
1) Cruise Control 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 memory in ECM 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 control main switch is
turned OFF.
2) Real-time Diagnosis:
Real-time diagnosis function is used to determine
whether or not the input signal system is in good order, according to the signal emitted from switches,
sensors, etc.
(1) Vehicle cannot be driven at cruise speed
when problem occurs in the cruise control system or its associated circuits.
(2) Monitor the signal conditions from switches
and sensors.
CC-00029

connector.
IM-00084

connector.
5) Start the engine and turn the cruise control main
switch to ON.
(1)
2. CRUISE CANCEL CONDITIONS DIAGNOSIS

CC-00045
(1) Power switch
CC-00028

Monitor.

On the system selection display screen, select the
{Engine} and press the [YES] key. Press the [YES]
key after the information of engine type is displayed.
8) Drive vehicle at least 40 km/h (25 MPH) with
cruise speed set.
CC(diag)-8

9) If the cruise speed is canceled by itself (without

doing any cancel operations), DTC will display on
the screen when selecting the {Check Cancel
Code} and pressing the [YES] key on the engine
malfunction diagnosis display screen.
CAUTION:
When performing diagnostics, observe the
legal speed of the road.
DTC will also displayed when cruise control
cancel is effected by driver. Do not confuse.
Put a co-worker in the vehicle to assist the diagnosis during driving.
NOTE:
DTC will be cleared by turning ignition switch or
cruise control main switch to OFF.
3. REAL-TIME DIAGNOSIS
2) Turn the ignition switch and cruise control main
switch to ON.
key.
6) Press the [YES] key after the information of engine type is displayed.
7) On the Cruise Control Diagnosis display
8) Make sure that normal indication is displayed
when operated as follows:
Depress/release the brake pedal. (Stop light
switch and brake switch turn ON.)
Turn the main switch to ON.
Turn the CANCEL switch to ON.
Turn ON the SET/COAST switch.
Turn ON the RESUME/ACCEL switch.
Depress or release the clutch pedal.
Place the shift lever in any position except neutral.
NOTE:
MANUAL.
For DTC, refer to List of Diagnostic Trouble
Code (DTC). <Ref. to CC(diag)-12, List of Diagnostic Trouble Code (DTC).>
CC(diag)-9

6. Diagnostics with Phenomenon

A: DIAGNOSTIC PROCEDURE WITH PHENOMENON
Phenomenon
Cruise control main switch is
not turned to ON. (Cruise
indicator light does not illuminate.)
Cruise control cannot be set.
Checking item
(1) Check the cruise indicator
light.
(2) Check the cruise control
command switch.
(1) Check the cruise control
command switch.
(2) Check the stop light switch
and brake switch.
(3) Check the clutch switch.
(4) Check the neutral position switch.

(5) Check the vehicle speed
sensor.
10
Cruise set indicator light does

not illuminate.
Check the cruise set indicator

light.
Vehicle speed is not held

within set speed 3 km/h (2
MPH).
Vehicle speed does not
increase or does not return to
set speed after RESUME/
ACCEL switch has been
pressed.
Vehicle speed does not
decrease after SET/COAST
switch has been pressed.
Cruise control is not released
after CANCEL switch has
been pressed.
after brake pedal has been
depressed.
after shifting to the neutral
position.
after clutch pedal has been
depressed.
Inspect the vehicle speed

sensor.
Check the RESUME/ACCEL
switch.
Check the SET/COAST

switch.
Check the CANCEL switch.
Check the stop light switch

and brake switch.
Check the neutral position
switch.
Check the clutch switch.
Reference
<Ref. to CC(diag)-11, CHECK CRUISE INDICATOR
LIGHT AND CRUISE SET INDICATOR LIGHT., Diagnostics with Phenomenon.>
<Ref. to CC(diag)-15, DTC 11, 15, 21 AND 24 CRUISE
CONTROL COMMAND SWITCH, Diagnostic Procedure
<Ref. to CC(diag)-18, DTC 12 AND 25 STOP LIGHT
SWITCH AND BRAKE SWITCH, Diagnostic Procedure
<Ref. to CC(diag)-21, DTC 13 CLUTCH SWITCH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to CC(diag)-24, DTC 14 NEUTRAL POSITION
SWITCH, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
<Ref. to CC(diag)-32, DTC 22 AND 32 VEHICLE SPEED
SENSOR, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
<Ref. to CC(diag)-11, CHECK CRUISE INDICATOR
LIGHT AND CRUISE SET INDICATOR LIGHT., Diagnostics with Phenomenon.>
<Ref. to CC(diag)-32, DTC 22 AND 32 VEHICLE SPEED
SENSOR, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>

<Ref. to CC(diag)-18, DTC 12 AND 25 STOP LIGHT
SWITCH AND BRAKE SWITCH, Diagnostic Procedure
<Ref. to CC(diag)-24, DTC 14 NEUTRAL POSITION
SWITCH, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
<Ref. to CC(diag)-21, DTC 13 CLUTCH SWITCH, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
CC(diag)-10

B: CHECK CRUISE INDICATOR LIGHT AND CRUISE SET INDICATOR LIGHT.

TROUBLE SYMPTOM:
Cruise control can be set, but the cruise indicator light & cruise set indicator light do not illuminate.
Step
CHECK CRUISE INDICATOR LIGHT &
CRUISE SET INDICATOR LIGHT.
1) Perform the self-diagnosis for combination
meter. <Ref. to IDI-3, SELF-DIAGNOSIS,
2) Check the cruise indicator light & cruise set
indicator light illuminate.
CHECK LAN COMMUNICATION CIRCUIT
ERROR DISPLAY.
1) Turn the ignition switch to ON again after
completing self-diagnosis.
2) Check that communication error is displayed on the odo/trip meter in combination
meter.
Check
Yes
Does the cruise indicator light Go to step 2.
& cruise set indicator light illuminate?
No
Replace the meter
case assembly.
<Ref. to IDI-16,
Combination
Meter.>
Is the error code Er xx displayed on odo/trip meter?
Replace the ECM.

<Ref. to FU(H4SO
2.0)-34, Engine
Control Module
(ECM).> <Ref. to
FU(H4SO 2.5)-36,
Engine Control
Module (ECM).>
<Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
<Ref. to
FU(H6DO)-34,
Engine Control
Module (ECM).>
CC(diag)-11
Check the LAN

communication circuit. <Ref. to
LAN(diag)-2, Basic

7. List of Diagnostic Trouble Code (DTC)

A: LIST
DTC
11
Item
Main switch
12
Stop and brake switch
13
Clutch switch
14
Neutral switch
15
Cancel switch
16
Ignition switch
Contents of diagnosis
Main switch of cruise control command switch is turned
to OFF, and then the cruise control is released.
Reference
This DTC is indicated
without operating the main
switch. <Ref. to CC(diag)15, DTC 11, 15, 21 AND
24 CRUISE CONTROL
COMMAND SWITCH,
Diagnostic Procedure with
Diagnostic Trouble Code
(DTC).>
Stop light switch or brake switch is turned to ON, and
then the cruise control is released.
without depressing the
brake pedal. <Ref. to
CC(diag)-18, DTC 12
AND 25 STOP LIGHT
SWITCH AND BRAKE
SWITCH, Diagnostic Procedure with Diagnostic
Clutch switch is turned to ON, and then the cruise control This DTC is indicated
is released.
without depressing the
brake pedal. <Ref. to
CC(diag)-21, DTC 13
CLUTCH SWITCH, Diagnostic Procedure with
(DTC).>
Neutral position switch is turned to ON, and then the
cruise control is released.
without shifting to neutral
position. <Ref. to
CC(diag)-24, DTC 14
NEUTRAL POSITION
Cancel switch is turned to ON, and then the cruise con- This DTC is indicated
trol is released.
without operating the cancel switch. <Ref. to
CC(diag)-15, DTC 11, 15,
21 AND 24 CRUISE CONTROL COMMAND
Ignition switch is turned to OFF, and then the cruise con- This DTC is indicated
trol is released.
without operating the ignition switch. <Ref. to
CC(diag)-29, DTC 16
IGNITION SWITCH, Diagnostic Procedure with
(DTC).>
CC(diag)-12

DTC
21
Item
Cruise Control Switch Mal- When the ignition switch is turned to ON, each switch of
function When Ignition
cruise control command switch is already turned to ON.
Switch Is Turned To ON
22
Vehicle Speed Variation

Malfunction
23
Engine Related Sensor

Malfunction
24
Cruise Control Related

Switch Malfunction
25
Brake Switch Input Circuit

Malfunction
26
Engine speed signal
32
Out of Vehicle Speed of

Cruise Control Operation
Reference
without operating the main
switch. <Ref. to CC(diag)15, DTC 11, 15, 21 AND
24 CRUISE CONTROL
COMMAND SWITCH,
Diagnostic Procedure with
(DTC).>
Malfunction of vehicle speed signal variation is detected. <Ref. to CC(diag)-32,
DTC 22 AND 32 VEHICLE
SPEED SENSOR, Diagnostic Procedure with
(DTC).>
Malfunction related to engine is detected.
<Ref. to EN(H4SO
2.0)(diag)-2, Basic Diagnostic Procedure.> <Ref.
to EN(H4SO 2.5)(diag)-2,
Basic Diagnostic Procedure.> <Ref. to
EN(H4DOTC)(diag)-2,
Basic Diagnostic Procedure.> <Ref. to
EN(H6DO)(diag)-2, Basic
Command switch malfunction is detected. (When the
This DTC is indicated with
switch is being pressed ON for an abnormal period of
normal operation. <Ref. to
time (about two minutes), open circuit is detected.)
CC(diag)-15, DTC 11, 15,
21 AND 24 CRUISE CONTROL COMMAND
Malfunction of brake switch input circuit in ECM is
<Ref. to CC(diag)-18,
detected.
DTC 12 AND 25 STOP
LIGHT SWITCH AND
BRAKE SWITCH, Diagnostic Procedure with
(DTC).>
Abnormal increase of engine speed is detected.
Cruise in more than 2nd
Gear is placed in Neutral, 1st or Reverse positions.
shift position.
Controlled vehicle speed decreased under the limit
This DTC is displayed
during cruising.
though the vehicle speed
Set operation was performed out of vehicle speed
is increased to the speed
available for setting.
available for cruise set and
Resume operation was performed without memorized set operation was pervehicle speed.
formed again. <Ref. to
CC(diag)-32, DTC 22
AND 32 VEHICLE SPEED
SENSOR, Diagnostic Procedure with Diagnostic
CC(diag)-13

DTC
33
Item
WAIT is prohibited after
operating accelerator
pedal.
34
Prohibited when accelerator pedal position large is

continued.
35
Prohibited when vehicle

speed feedback unavailable.
41
VDC/TCS operation
42
High speed CAN communication malfunction
43
ABS/VDC malfunction
44
Body integrated module

malfunction
45
Meter malfunction
Controlled vehicle speed increased above the limit during cruising.
Reference
when driving at higher
speed than appropriate
cruise control speed. In
this case, lower the vehicle speed to the speed
available for cruise set,
and perform cruise set
operation again.
The vehicle has been driven at higher speed than set
vehicle speed for an abnormal period of time (about 10
when driving for a long
minutes) during cruise driving.
period of time at higher
speed than appropriate
cruise set vehicle speed
by operating accelerator
pedal. In this case,
release the cruise set.
Set vehicle speed cannot keep because of some reaThis DTC is displayed
sons (steep uphill, parking brake, abnormal decrease of when driving condition is
not suitable for cruise conengine output, etc.) during cruise driving.
trol. Perform cruise set
operation again after eliminating the estimated
cause.
Vehicle dynamics control (VDC) or TCS is operated dur- This DTC is displayed
ing cruise driving or cruise setting.
when driving condition is
not suitable for cruise control. Perform cruise set
operation again after eliminating the estimated
cause.
High speed CAN communication malfunction is detected <Ref. to LAN(diag)-2,
during cruise driving or cruise setting.
Basic Diagnostic Procedure.>
ABS or vehicle dynamics control (VDC) system malfunc- <Ref. to ABS(diag)-2,
tion is detected during cruise driving or cruise setting.
Basic Diagnostic Procedure.> or <Ref. to
VDC(diag)-2, Basic Diagnostic Procedure.>
Body integrated module system malfunction is detected <Ref. to LAN(diag)-2,
during cruise driving or cruise setting.
Combination meter malfunction is detected during cruise <Ref. to LAN(diag)-2,
driving or cruise setting.
CC(diag)-14

8. Diagnostic Procedure with Diagnostic Trouble Code (DTC)

A: DTC 11, 15, 21 AND 24 CRUISE CONTROL COMMAND SWITCH
TROUBLE SYMPTOM:
Cruise control cannot be set. (Cancelled immediately.)
Cruise control cannot be released.
WIRING DIAGRAM:
SET/
COAST
SWITCH
RESUME/
ACCEL
SWITCH
CRUISE CONTROL
COMMAND SWITCH
CANCEL
SWITCH
MAIN
SWITCH
ST3
STEERING
ROLL CONNECTOR
B68
B122
B138
36
LHD :
RHD :
B21
C11
C7
E2
LHD : LHD MODEL

RHD : RHD MODEL
*
C: B136 ECM
: TERMINAL No. RANDOM

ARRANGEMENT
B122
ST3
B68
B21
C: B136
B138
1 2 3
1
2 3
4 5 6 7 8
1 2 3 4
5 6 7 8
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
5 6
1 2 3 4
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
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
CC-00265
CC(diag)-15

RESUME/
ACCEL
SWITCH
CRUISE CONTROL
COMMAND SWITCH
SET/
COAST
SWITCH
CANCEL
SWITCH
MAIN
SWITCH
ST3
STEERING
ROLL CONNECTOR
B68
LHD : B122
36
RHD : B83
B21
C21
D14
E2
C: B136
ST3
B68
1 2 3
1
2 3
4 5 6 7 8
B122
B83
1 2 3 4
5 6 7 8
LHD : LHD MODEL

RHD : RHD MODEL
D: B137
ECM
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
: TERMINAL No.
RANDOM
ARRANGEMENT
C: B136
5 6
1 2 3 4
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
D:
B137
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
28 29
30 31
26 27
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
CC-00266
CC(diag)-16

Step
CHECK CRUISE CONTROL COMMAND
SWITCH.
to AB-15, REMOVAL, Drivers Airbag Module.>
2) Disconnect the harness connector of cruise
control command switch.
(ST3) No. 1 (+) Chassis ground ():
(ST3) No. 3 (+) Chassis ground ():
INSPECTION FOR CANCEL SWITCH.
2) Remove the cruise control command
switch. <Ref. to CC-5, REMOVAL, Cruise Control Command Switch.>
3) Measure the resistance between switch terminals when CANCEL switch is pressed and
not pressed.
Terminals
No. 2 No. 3:
CHECK SET/COAST SWITCH.
Measure the resistance between switch terminals when SET/COAST switch is pressed and
not pressed.
Terminals
No. 2 No. 3:
CHECK RESUME/ACCEL SWITCH CIRCUIT.
Measure the resistance between switch terminals when RESUME/ACCEL switch is pressed
and not pressed.
Terminals
No. 2 No. 3:
Check
Yes
Go to step 2.
No
Check the harness
for open or short
circuit between
cruise control
command switch
and ECM.

when CANCEL switch is
pressed?
Is the resistance approx. 4 k
when CANCEL switch is not
pressed?
Replace the cruise

control command
switch. <Ref. to
CC-5, Cruise Control Command
Switch.>

when SET/COAST switch is
pressed?
when SET/COAST switch is
not pressed?
when RESUME/ACCEL
switch is pressed?
when RESUME/ACCEL switch
is not pressed?
CC(diag)-17
Go to step 4.
Replace the cruise

control command
switch. <Ref. to
CC-5, Cruise Control Command
Switch.>
Replace the ECM. Replace the cruise
<Ref. to FU(H4SO control command
2.0)-34, Engine
switch. <Ref. to
Control Module
CC-5, Cruise Con(ECM).> <Ref. to trol Command
FU(H4SO 2.5)-36, Switch.>
Engine Control
Module (ECM).>
<Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
<Ref. to
FU(H6DO)-34,
Engine Control
Module (ECM).>

B: DTC 12 and 25 STOP LIGHT SWITCH AND BRAKE SWITCH

TROUBLE SYMPTOM:
WIRING DIAGRAM:
BATTERY
SBF-1
SBF-3
F/B No.8
IGNITION
RELAY
SBF-9
F/B No.4
STOP LIGHT SWITCH

AND BRAKE SWITCH
STOP LIGHT
SWITCH
CLUTCH SWITCH (MT)

2
1
MT
4
BRAKE
SWITCH
2
1
B107
F5
F9
FUSE & RELAY BOX
3
B65
C8
C9
C10
MT
F: B159
ECM
C: B136
B107
B65
1 2
1 2
3 4
F: B159
1
5
2
6
C: B136
3
8
4
9
5 6
1 2 3 4
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
CC-00267
CC(diag)-18

2.0 L non-turbo model, 2.5 L for KS, KA model

BATTERY
SBF-1
SBF-3
F/B No.8
IGNITION
RELAY
SBF-9
F/B No.4
STOP LIGHT SWITCH

AND BRAKE SWITCH
STOP LIGHT
SWITCH
CLUTCH SWITCH (MT)

2
1
MT
4
BRAKE
SWITCH
2
1
B107
F5
F9
FUSE & RELAY BOX
3
B65
D13
D12
D22
MT
F: B159
ECM
D: B137
B107
B65
1 2
1 2
3 4
D: B137
F: B159
1
5
2
6
3
8
4
9
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
28 29
30 31
26 27
CC-00268
CC(diag)-19

Step
Check
Yes
CHECK STOP LIGHT SWITCH AND BRAKE Is the voltage more than 10 V? Go to step 2.
SWITCH CIRCUIT.
2) Disconnect the stop light switch and brake
switch harness connector.
CHECK STOP LIGHT SWITCH AND BRAKE Is the voltage more than 10 V? Go to step 3.
SWITCH CIRCUIT.
Measure the voltage between harness connector terminal and chassis ground.
CHECK STOP LIGHT SWITCH AND BRAKE

SWITCH CIRCUIT.
2) Disconnect the harness connector of ECM.
3) Measure the resistance between ECM harness connector terminal and stop light switch
and brake switch harness connector terminal.
2.0 L turbo model, 3.0 L model, 2.5 L EC,
K4 and EK model:
(B136) No. 8 (B65) No. 3:
(B136) No. 9 (B65) No. 1:
2.0 L non-turbo model, 2.5 L KS, KA model:
(B137) No. 13 (B65) No. 3:
(B137) No. 12 (B65) No. 1:
CHECK STOP LIGHT SWITCH AND BRAKE
SWITCH.
Remove and check the stop light switch and
brake switch. <Ref. to CC-6, Stop Light &
Brake Switch.>
No
Check fuse No.
8 (in fuse & relay
box).
Check the harness for open or
short between
stop light/brake
switch and fuse &
relay box.
Check fuse No.
4 (in fuse & relay
box).
short between
stop light/brake
switch and fuse &
relay box.
Repair the harness.

?
Go to step 4.
Are the stop light switch and

brake switch OK?
Replace the ECM. Replace the stop

<Ref. to FU(H4SO light switch and
2.0)-34, Engine
brake switch.
Control Module
(ECM).> <Ref. to
FU(H4SO 2.5)-36,
Engine Control
Module (ECM).>
<Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
<Ref. to
FU(H6DO)-34,
Engine Control
Module (ECM).>
CC(diag)-20

C: DTC 13 CLUTCH SWITCH

TROUBLE SYMPTOM:
WIRING DIAGRAM:
2.5 L EC, K4 and EK model
BATTERY
SBF-1
SBF-3
F/B No.8
IGNITION
RELAY
SBF-9
F/B No.4
STOP LIGHT SWITCH

AND BRAKE SWITCH
STOP LIGHT
SWITCH
CLUTCH SWITCH (MT)

2
1
MT
4
BRAKE
SWITCH
2
1
B107
F5
F9
FUSE & RELAY BOX
3
B65
C8
C9
C10
MT
F: B159
ECM
C: B136
B107
B65
1 2
1 2
3 4
F: B159
1
5
2
6
C: B136
3
8
4
9
5 6
1 2 3 4
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
CC-00267
CC(diag)-21


BATTERY
SBF-1
SBF-3
F/B No.8
IGNITION
RELAY
SBF-9
F/B No.4
STOP LIGHT SWITCH

AND BRAKE SWITCH
STOP LIGHT
SWITCH
CLUTCH SWITCH (MT)

2
1
MT
4
BRAKE
SWITCH
2
1
B107
F5
F9
FUSE & RELAY BOX
3
B65
D13
D12
D22
MT
F: B159
ECM
D: B137
B107
B65
1 2
1 2
3 4
D: B137
F: B159
1
5
2
6
3
8
4
9
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
28 29
30 31
26 27
CC-00268
CC(diag)-22

Step
CHECK CLUTCH SWITCH CIRCUIT.
2) Disconnect the clutch switch harness connector.
CHECK CLUTCH SWITCH CIRCUIT.
2) Disconnect the ECM harness connector.
3) Measure the resistance between clutch
switch harness connector terminal and ECM
harness connector terminal.
2.5 L EC, K4 and EK model:
(B107) No. 2 (B136) No. 10:
(B107) No. 2 (B137) No. 22:
CHECK CLUTCH SWITCH.
Remove and check the clutch switch. <Ref. to
CC-7, Clutch Switch.>
Check
Yes
No
Check fuse No.
4 (in fuse & relay
box).
short between
clutch switch and
fuse & relay box.

?
Go to step 3.
Repair the harness.
Is the clutch switch OK?
Replace the ECM. Replace the clutch

<Ref. to FU(H4SO switch.
2.0)-34, Engine
Control Module
(ECM).> <Ref. to
FU(H4SO 2.5)-36,
Engine Control
Module (ECM).>
CC(diag)-23

D: DTC 14 NEUTRAL POSITION SWITCH

TROUBLE SYMPTOM:
WIRING DIAGRAM:
2.0 L turbo model, 3.0 L model
D: B137
B19
D9
ECM
B: B55
TCM
D: B137
B: B55
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
9
18
24
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
24 25
18 19 20 21 22 23
26 27
30 31
28 29
CC-00219
CC(diag)-24

2.5 L EC, K4 and EK model
D: B137
D9
ECM
INHIBITOR SWITCH
P
12
AT
MT
11
B12
12
7
T3
T7
B25
T2
NEUTRAL
POSITION
SWITCH
T2
B25
MT
: MT MODEL
AT
: AT MODEL
B25
B12
T7
1 2
1 2 3 4
5 6 7 8
9 10 11 12
1 2 3 4 5 6
7 8 9 10 11 12
D: B137
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
28 29
30 31
26 27
CC-00269
CC(diag)-25

B: B135
B12
ECM
INHIBITOR SWITCH
P
11
AT
MT
12
B12
7
12
T3
T7
B25
2
STARTER MOTOR
T2
NEUTRAL
POSITION
SWITCH
T2
B14
B25
LHD : B122
B83
36
RHD :
MT
: MT MODEL
AT
: AT MODEL
B21
E2
LHD : LHD MODEL

RHD : RHD MODEL
B25
1 2
B12
B83
T7
B122
1 2 3 4
5 6 7 8
1 2 3 4 5 6
7 8 9 10 11 12
B: B135
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
: TERMINAL No. RANDOM

ARRANGEMENT
B21
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33
34 35 36 37 38 39 40 41
42 43
44 45
46 47
48 49 50 51 52 53 54
1 2 3 4
5 6 7 8
9 10 11 12
CC-00270
CC(diag)-26

5
6
Step
CHECK VEHICLE FOR SPECIFICATION.
Check the vehicle for destination and specification.
CHECK NEUTRAL POSITION SWITCH.
link connector.
2) Turn the ignition switch and Subaru Select
3) Select {Engine} from the main menu.
4) Then, select {Current Data Display &
Save}.
5) Check the neutral position switch signal by
shifting the select lever to P or N range.
CHECK TCM OUTPUT VOLTAGE.
2) Measure the voltage between TCM harness connector terminal and chassis ground.
CHECK HARNESS BETWEEN TCM AND
ECM.
TCM and ECM.
3) Measure the resistance between TCM harness connector terminal and ECM harness
connector terminal.
(B137) No. 9 (B55) No. 19:
CHECK TRANSMISSION TYPE.
2) Disconnect the inhibitor switch harness
connector.
2) Disconnect the starter motor harness connector.
3) Measure the resistance between inhibitor
ground.
Check
Is the vehicle turbo model or
3.0 L model?
Yes
Go to step 2.
No
Go to step 5.
Is ON displayed in the Subaru

Select Monitor when the select
lever is in P or N range?
Or is OFF displayed in the
Subaru Select Monitor when
the select lever is in other than
P or N range?
Replace the ECM. Go to step 3.

<Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
<Ref. to
FU(H6DO)-34,
Engine Control
Module (ECM).>
Is the voltage more than 10 V Go to step 4.

when the select lever is in
other than P or N range?
Or is the voltage less than 1 V
when the select lever is in P
or N range?
Is the resistance less than 10 Replace the ECM.
?
<Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
<Ref. to
FU(H6DO)-34,
Engine Control
Module (ECM).>
Inspect the TCM.

<Ref. to 5AT(diag)2, Basic Diagnostic Procedure.>
Is the transmission type AT?

Go to step 6.
Go to step 7.
Go to step 9.
Check the harness
for open or short
between inhibitor
switch and ECM.

?
Go to step 8.
Repair the harness.
CC(diag)-27
Repair the wiring

harness.

10
11
Step
Remove and check the inhibitor switch. <Ref.
to CC-8, Inhibitor Switch.>
Check
Is the inhibitor switch OK?
CHECK NEUTRAL POSITION SWITCH CIRCUIT.

2) Disconnect the neutral position switch harness connector.
CHECK NEUTRAL POSITION SWITCH CIRCUIT.
2) Measure the resistance between neutral
position switch harness connector terminal and
chassis ground.
CHECK NEUTRAL POSITION SWITCH.
Remove and check the neutral position switch.
<Ref. to CC-9, Neutral Position Switch.>
Yes
No
Replace the ECM. Replace the inhibi<Ref. to FU(H4SO tor switch.
2.0)-34, Engine
Control Module
(ECM).> <Ref. to
FU(H4SO 2.5)-36,
Engine Control
Module (ECM).>
Go to step 10.
Check the harness
for open or short
between neutral
position switch and
ECM.

?
Go to step 11.
Is the neutral position switch

OK?
Replace the ECM. Replace the neu<Ref. to FU(H4SO tral position switch.
2.0)-34, Engine
Control Module
(ECM).> <Ref. to
FU(H4SO 2.5)-36,
Engine Control
Module (ECM).>
CC(diag)-28
Repair the harness.

E: DTC 16 IGNITION SWITCH

TROUBLE SYMPTOM:
WIRING DIAGRAM:
IGNITION
SWITCH
BATTERY
SBF-7
F/B No.12
D14
SBF-1
D: B137
ECM
D: B137
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
24 25
18 19 20 21 22 23
26 27
30 31
28 29
CC-00220
CC(diag)-29

IGNITION
SWITCH
BATTERY
SBF-7
F/B No.12
B13
SBF-1
B: B135
ECM
B: B135
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
CC-00271
CC(diag)-30

Step
Check
Yes
CHECK IGNITION SWITCH CIRCUIT.
Is the voltage more than 10 V? Check poor con1) Turn the ignition switch to OFF.
tact in ECM con2) Disconnect the ECM harness connector.
nector.
K4 and EK model:
CC(diag)-31
No
Check fuse No.
12 (in fuse & relay
box).
short circuit
between ignition
switch and ECM.

F: DTC 22 AND 32 VEHICLE SPEED SENSOR

DIAGNOSIS:
Disconnection or short circuit of vehicle speed sensor system.
TROUBLE SYMPTOM:
Cruise control cannot be set. (Cancelled immediately.)
Step
Check
CHECK ABS WARNING LIGHT.
Does the ABS warning light
continue to illuminate?
2) After the combination meter initial operation
is completed, confirm that the ABS warning
light continues to illuminate.
CHECK LAN COMMUNICATION CIRCUIT

ERROR DISPLAY.
Check that the communication error is displayed on the odo/trip meter in combination
meter.
Is the error code Er xx displayed on odo/trip meter?
CC(diag)-32
Yes
Check ABSCM or
VDCCM <Ref. to
ABS(diag)-2,
Basic Diagnostic
Procedure.> or
<Ref. to
VDC(diag)-2,
Basic Diagnostic
Procedure.>
Check the LAN
LAN(diag)-2, Basic
No
Go to step 2.
Replace the ECM.

<Ref. to FU(H4SO
2.0)-34, Engine
Control Module
(ECM).> <Ref. to
FU(H4SO 2.5)-36,
Engine Control
Module (ECM).>
<Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
<Ref. to
FU(H6DO)-34,
Engine Control
Module (ECM).>
IM(diag)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Page
Immobilizer Control Module I/O Signal........................................................7
Subaru Select Monitor.................................................................................8
Read Diagnostic Trouble Code (DTC) ........................................................9
Diagnostics Chart for Immobilizer Indicator Light......................................11


A: PROCEDURE
Step
CHECK IMMOBILIZER INDICATOR LIGHT.
1) Turn the ignition switch to OFF or ACC.
2) Wait for more than 60 seconds.
Check
Yes
Does the immobilizer indicator Go to step 2.
light blink?
CHECK KEY SWITCH.

Remove the key from ignition switch.

light blink within 1 second after
removing ignition key?

CHECK ENGINE START.
Turn the ignition switch to START.

light off?
Does the starter operate?
Check the LAN
LAN(diag)-2, Basic
Does the starter operate?
Go to step 6.
CHECK ENGINE START.

CHECK ENGINE START.

CHECK INDICATION OF DTC ON DISPLAY. Is the DTC displayed on

screen?
link connector. <Ref. to IM(diag)-8, Subaru
Select Monitor.>
3) Turn the ignition switch and Subaru Select
4) Read DTC on display.
IM(diag)-2
Immobilizer system is OK.

Go to step 8.
No
Check the immobilizer warning light
circuit. <Ref. to
IM(diag)-11,
CHECK IMMOBILIZER INDICATOR CIRCUIT,
INSPECTION,
Diagnostics Chart
for Immobilizer
Indicator Light.>
Check the key
switch circuit.
<Ref. to IM(diag)13, CHECK KEY
SWITCH CIRCUIT, INSPECTION, Diagnostics
Chart for Immobilizer Indicator
Light.>
Go to step 4.
Check the DTC
display (body integrated unit). Go to
step 7.
Check the LAN

LAN(diag)-2, Basic
Check the DTC
display (ECM). Go
to step 7.
Repair the related
parts.

Step
with Diagnostic Trouble Code (DTC).
<Ref. to IM(diag)-17, Diagnostic Procedure
4) Read DTC again.
Check
Is the DTC displayed on
screen?
IM(diag)-3
Yes
No
Inspect using the Finish the diagnoDiagnostic Proce- sis.
dure with Diagnostic Trouble Code
(DTC). <Ref. to
IM(diag)-17, Diagnostic Procedure
with Diagnostic
Trouble Code
(DTC).>
General Description
A: CAUTION
CAUTION:
All airbag system wiring harnesses and connectors are yellow. Do not use the electrical
test equipment on these circuits.
wiring harness.
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 the ignition switch

to 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.
ON
(1)
OFF
5
(2)
IM-00003
(1) Ignition switch position

(2) Sec.
IM-00001
When turning the ignition switch to ON or

OFF while diagnostic items are being checked,
do not allow keys with different ID codes close
to the ignition switch. If the ignition key is in a
key holder, remove it from the holder before
carrying out diagnosis.
If the engine fails to start with a registered ignition key, detach the ignition key from ignition
switch and wait for approx. 1 second until immobilizer indicator light begins to flash. And
then start the engine again.
Before checking the diagnostic items, obtain
all keys for the vehicle to be checked possessed by owner.
IM-00002
IM(diag)-4
General Description
B: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
24082AA230
DESCRIPTION
CARTRIDGE
REMARKS
22771AA030
SUBARU SELECT
MONITOR KIT

ST24082AA230
ST22771AA030
2. GENERAL TOOL
TOOL NAME
Circuit tester
REMARKS
IM(diag)-5


A: LOCATION
(4)
(2)
(1)
(3)
IM-00083
(1)
(2)
Antenna
Immobilizer indicator light (LED
bulb)
(3)
NOTE:
Body integrated unit location for RHD model is symmetrically opposite.
IM(diag)-6
(4)
Transponder
Immobilizer Control Module I/O Signal

4. Immobilizer Control Module

I/O Signal
A: WIRING DIAGRAM
1. IMMOBILIZER
<Ref. to WI-246, WIRING DIAGRAM, Immobilizer
System.>
IM(diag)-7

5) Turn the ignition switch to ON (engine OFF), and

the Subaru Select Monitor switch to ON.
A: OPERATION
(1)
CC-00045
(1) Power switch
6) Using the Subaru Select Monitor, call up DTCs

and various data, then record them.
CC-00028

Monitor.

(DTC) FOR ENGINE AND BODY INTEGRATED UNIT
Refer to Read Diagnostic Trouble Code for information about how to indicate DTC. <Ref. to IM(diag)-9, Read Diagnostic Trouble Code (DTC).>
3. COMMUNICATION LINE CHECK
CC-00029

connector.
side).
IM-00084
NOTE:
The communication line between ECM and body
integrated module can be checked in System Operation Check Mode. This is referred to as Communication line check.
2) On the System operation check mode display,
select the {security system}.
3) Start the communication line check.
4) Is Communication Line not Shorted displayed
on screen?
If displayed, go to step 5).
If NO, go to step 6).
5) After diagnostic results, it is determined that the
circuit is not shorted. Finish the communication line
check.
6) If a problem is detected, repair the trouble
cause. <Ref. to IM(diag)-22, DTC P1572 IMM CIRCUIT FAILURE (EXCEPT ANTENNA CIRCUIT),
Code (DTC).>

connector.
CAUTION:
IM(diag)-8


Code (DTC)
A: OPERATION
1. ECM
screen, select the {Engine Control System} and
4) On the Engine Diagnosis display screen, select the {Diagnostic Code(s) Display}, and then
5) On the Diagnostic Code(s) Display display
screen, select the {Current Diagnostic Code(s)} or
{History Diagnostic Code(s)}, and then press the
[YES] key.
NOTE:
For detailed concerning DTC, refer to the List of
DTC. <Ref. to IM(diag)-15, LIST, List of Diagnostic

screen, select the {Integ. unit mode} and press the
[YES] key.
3) Press the [YES] key after the {Integ. unit mode}
is displayed.
4) On the Integ. unit mode failure diag display
screen, select the {Diagnostic Code(s) Display}
NOTE:
For detailed concerning DTC, refer to the List of
DTC. <Ref. to IM(diag)-15, LIST, List of Diagnostic
IM(diag)-9
Clear Memory Mode


A: OPERATION
1. ECM
screen, select the {Engine Control System} and
4) On the Engine Diagnosis display screen, select the {Clear Memory} and press the [YES] key.
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 execute this procedure, turn the ignition switch to ON.
Wait 3 seconds before starting the engine.

screen, select the {Integ. unit mode} and press the
[YES] key.
3) Press the [YES] key after the {Integ. unit mode}
is displayed.
4) On the Integ. unit mode failure diag display
[YES] key.
screen, turn the Subaru Select Monitor and ignition
switch to OFF.
NOTE:
IM(diag)-10
Diagnostics Chart for Immobilizer Indicator Light

8. Diagnostics Chart for Immobilizer Indicator Light

A: INSPECTION
1. CHECK IMMOBILIZER INDICATOR CIRCUIT
WIRING DIAGRAM:
BATTERY
SBF-9
SBF-1
F/B No.7
RHD
LHD
IGNITION
SWITCH
F/B No.12
SBF-4
R167
13
11
R98
i102
i53
RHD
M/B No.8
LHD
COMBINATION METER
A:
i10
IMMOBILIZER
INDICATOR
LIGHT
A1
A2
A17
A:
C2
A33
A1
i84
B: B280
B7
C9
B22
C8
LHD : LHD MODEL

RHD : RHD MODEL
C: B281
i102
A:
i10
A:
i84
i53
6 7 8 9 10
1 2 3 4 5
11 12 13 14 15 16 17 18 19 20 21 22
B: B280
1 2 3
4 5
6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
23 24 25
26 27
28 29 30
21 22
1 2 3 4
5 6 7 8
9 10 11 12 13 14 15 16 17 18
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
C: B281
4 5 6 7
1 2 3
8 9 10 11 12 13 14 15 16 17 18 19
27 28
22 23
24 25 26
20 21
IM-00086
IM(diag)-11

Step
3) Connect the resistor (100 ) between body
integrated unit harness connector terminal
(i84) No. 33 and chassis ground.
CIRCUIT.
Measure the resistance between body integrated unit harness connector terminal and
chassis ground.
CHECK BODY INTEGRATED UNIT IGNITION
CIRCUIT.
OFF)
2) Measure the voltage between body integrated unit harness connector terminal and
chassis ground.
CHECK BODY INTEGRATED UNIT POWER
SUPPLY CIRCUIT.
chassis ground.
Check
Yes
light illuminate?
No
Go to step 5.

?
Go to step 3.
Repair the open

circuit of body integrated unit ground
circuit.
Check the harness

for open or short
circuit between
body integrated
unit and ignition
switch.
Is the voltage more than 10 V? Replace the body

integrated unit
<Ref. to SL-45,
Body Integrated
Module.> and
replace the all ignition keys (including transponder).
Execute the registration procedure
next. Refer to
REGISTRATION
MANUAL FOR
IMMOBILIZER.
Check the harness

for open or short
circuit between
body integrated
unit and fuse.
CHECK COMBINATION METER CIRCUIT.

2) Measure the voltage between the combination meter harness connector terminal and
chassis ground.
CHECK COMBINATION METER CIRCUIT.
Measure the resistance between body inte?
grated unit harness connector terminal and
combination meter harness connector terminal.
(i84) No. 33 (i10) No. 17:
IM(diag)-12
Check the harness

for open or short
circuit between
combination meter
and fuse.
LED bulb malfunc- Repair the hartion. Replace the ness/connector.

combination meter
case assembly.
<Ref. to IDI-16,
Combination
Meter.>

2. CHECK KEY SWITCH CIRCUIT

WIRING DIAGRAM:
BATTERY
M/B No.14
KEY WARNING
SWITCH
C7
B350
C: B281
B350
1 2 3 4
C: B281
4 5 6 7
1 2 3
8 9 10 11 12 13 14 15 16 17 18 19
27 28
22 23
24 25 26
20 21
IM-00078
IM(diag)-13

Step
1) Disconnect the harness connector from key
warning switch.
2) Turn the ignition switch to ACC or LOCK
(with key inserted).
3) Measure the voltage between key warning
ground.
1) Insert the ignition key to ignition switch.
(OFF or ACC)
No. 3 No. 4:
1) Remove the ignition key from ignition
switch.
No. 3 No. 4:
CHECK HARNESS BETWEEN KEY WARNING SWITCH AND BODY INTEGRATED
UNIT.
1) Disconnect the harness connector from key
warning switch.
3) Measure the resistance between key warning switch harness connector terminal and
body integrated unit harness connector terminal.
(B350) No. 4 (B281) No. 7:
Check
Yes
No
Check the harness
for open or short
circuit between
key warning switch
and fuse.

?
Go to step 3.
Replace the key

warning switch.

M?
Go to step 4.
Replace the key

warning switch.

?
Replace the body

integrated unit
<Ref. to SL-45,
Body Integrated
Module.> and
next. Refer to
REGISTRATION
MANUAL FOR
IMMOBILIZER.
Repair the harness between key

warning switch
and body integrated unit.
IM(diag)-14

9. List of Diagnostic Trouble Code (DTC)

A: LIST
1. ECM
DTC
P0513
P1570
P1571
P1572
P1574
P1576
P1577
P1578
Item
Index No.
<Ref. to IM(diag)-17, DTC P0513 INCORIncorrect immobilizer key (Use of
RECT IMMOBILIZER KEY, Diagnostic ProIncorrect Immobilizer Key
unregistered key in body integrated
unit)
(DTC).>
<Ref. to IM(diag)-18, DTC P1570
ANTENNA
Faulty antenna
ANTENNA, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to IM(diag)-21, DTC P1571 REFERReference code incompatibility
ENCE CODE INCOMPATIBILITY, DiagnosReference Code Incompatibility between body integrated unit and
tic Procedure with Diagnostic Trouble Code
ECM
(DTC).>
<Ref. to IM(diag)-22, DTC P1572 IMM CIREGI Immobilizer CommuniCommunication failure between
CUIT FAILURE (EXCEPT ANTENNA CIRcation
body integrated unit and ECM
CUIT), Diagnostic Procedure with Diagnostic
(Except Antenna Circuit)
<Ref. to IM(diag)-25, DTC P1574 KEY COMKey Immobilizer Communica- Failure of body integrated unit to verMUNICATION FAILURE, Diagnostic Procetion
ify key (transponder) ID code
<Ref. to IM(diag)-25, DTC P1576 EGI CONTROL MODULE EEPROM, Diagnostic ProEGI Control Module EEPROM
ECM malfunctioning
(DTC).>
<Ref. to IM(diag)-25, DTC P1577 IMM CONTROL MODULE EEPROM, Diagnostic ProIMM Control Module EEPROM Body integrated unit malfunctioning
(DTC).>
Reference code incompatibility
<Ref. to IM(diag)-26, DTC P1578 METER
Meter malfunctioning
FAILURE, Diagnostic Procedure with Diagcombination meter
nostic Trouble Code (DTC).>
NOTE:
Perform the engine DTC when the DTC except for immobilizer DTC is detected.
<Ref. to EN(H4SO 2.0)(diag)-66, List of Diagnostic Trouble Code (DTC).> <Ref. to EN(H4SO 2.5)(diag)-70,
List of Diagnostic Trouble Code (DTC).> <Ref. to EN(H4DOTC)(diag)-55, List of Diagnostic Trouble Code
(DTC).> <Ref. to EN(H6DO)(diag)-66, List of Diagnostic Trouble Code (DTC).>
IM(diag)-15


DTC
B0401
Item
M collation NG
Reference code incompatibility between body integrated
unit and combination meter
Incorrect immobilizer key
(Use of unregistered key in
body integrated unit)
Faulty antenna
B0402
B0403
Immobilizer Key collation NG
E/G request NG
Communication failure
between body integrated unit
and ECM
Index No.
<Ref. to IM(diag)-26, DTC
P1578 METER FAILURE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
P0513 INCORRECT IMMOBILIZER KEY, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).> <Ref. to IM(diag)18, DTC P1570 ANTENNA,
Diagnostic Procedure with Diagnostic Trouble Code (DTC).> or
P1574 KEY COMMUNICATION FAILURE, Diagnostic Procedure with Diagnostic Trouble
Code (DTC).>
P1572 IMM CIRCUIT FAILURE
(EXCEPT ANTENNA CIRCUIT), Diagnostic Procedure
with Diagnostic Trouble Code
(DTC).>
Relation between ECM and

DTC
P1578
P0513
P1570
P1574
P1572
NOTE:
Immobilizer system of 2.5 L EC, EK model and 3.0 L model perform the starter relay control. When the
body integrated unit detect the inconformity of reference code, immediately out put the starter relay cut signal
to ECM, and then ECM stop the starter relay operation. In this case, engine does not start, and DTC is not
recorded in ECM. Check that the engine does not start on the DTC of body integrated unit.
DTC B0402 is recorded as freeze frame data when the ignition switch is turned to OFF. When trying to start
the engine with unregistered immobilizer key, DTC is not displayed on Subaru Select Monitor immediately.
Turn the ignition switch to OFF once and turn to ON again before checking DTC. At this time (when turning
the ignition switch to ON again), be careful that the DTC is displayed as freeze frame data even with the registered immobilizer key.
IM(diag)-16


A: DTC P0513 INCORRECT IMMOBILIZER KEY
Incorrect immobilizer key (Use of unregistered key in body integrated unit)
Step
Check
Yes
PERFORM TEACHING OPERATION ON IG- Is the teaching operation for all END.
NITION KEY.
keys completed?
Perform teaching operation on all keys of the
vehicle. Refer to REGISTRATION MANUAL
FOR IMMOBILIZER.
NITION KEY.
keys completed?
FOR IMMOBILIZER.
IM(diag)-17
No
Replace the ignition keys (including transponder)
which cannot be
registered. Go to
step 2.
Replace the body
integrated unit
<Ref. to SL-45,
Body Integrated
Module.> and
replace all the ignition keys (including transponder).
next. Refer to
REGISTRATION
MANUAL FOR
IMMOBILIZER.

B: DTC P1570 ANTENNA

Faulty antenna
WIRING DIAGRAM:
ANTENNA
C21
C20
1
2
B351
C: B281
B351
1 2
C: B281
4 5 6 7
1 2 3
8 9 10 11 12 13 14 15 16 17 18 19
27 28
22 23
24 25 26
20 21
IM-00079
IM(diag)-18

Step
CHECK ANTENNA CIRCUIT.
antenna. <Ref. to SL-49, Immobilizer
Antenna.>
3) Measure the resistance of antenna circuit.
(B351) No. 1 No. 2:
Measure the resistance between harness connector and chassis ground.
OFF)
2) Measure the voltage between harness connector and chassis ground.
Measure the voltage between harness connector and chassis ground.
CHECK BODY INTEGRATED UNIT FUNCTION.

2) Connect the harness connector to body
integrated unit.
3) Insert the key to ignition switch, and measure the changes in voltage between antenna
harness connectors.
Check
?
Yes
Go to step 2.
No
Replace the
antenna. <Ref. to
SL-49, Immobilizer Antenna.>

?
Repair the harness.
Go to step 3.

?
Repair the harness.
Go to step 4.
Is the voltage 0 V?
Go to step 5.
Repair the harness.
Is the voltage 0 V?
Go to step 6.

body integrated
unit and antenna,
because there is
short circuit with
battery voltage line
or ignition switch
ON line.
Replace the body
integrated unit
<Ref. to SL-45,
Body Integrated
Module.> and
next. Refer to
REGISTRATION
MANUAL FOR
IMMOBILIZER.
Is the voltage 30 to 30 V?
Go to step 7.
(Approx. 0.1 second after
inserting the key) Is the voltage
0 V? (Approx. 1 second after
inserting the key)
IM(diag)-19

Step
Check
CHECK IGNITION KEY (TRANSPONDER).
2) Start the engine using other keys that have
undergone the teaching operation, furnished
with vehicle.
IM(diag)-20
Yes
Replace all the
ignition keys
(including transponder). Execute
the registration
procedure next.
Refer to REGISTRATION MANUAL FOR
IMMOBILIZER.
No
Replace the body
integrated unit
<Ref. to SL-45,
Body Integrated
Module.> and
next. Refer to
REGISTRATION
MANUAL FOR
IMMOBILIZER.

C: DTC P1571 REFERENCE CODE INCOMPATIBILITY

Reference code incompatibility between body integrated unit and ECM
Step
Check
Yes
NITION KEY.
keys completed?
FOR IMMOBILIZER.
IM(diag)-21
No
Replace the ECM.
<Ref. to FU(H4SO
2.0)-34, Engine
Control Module
(ECM).> <Ref. to
FU(H4SO 2.5)-36,
Engine Control
Module (ECM).>
<Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
<Ref. to
FU(H6DO)-34,
Engine Control
Module (ECM).>
Replace the body
integrated unit
<Ref. to SL-45,
Body Integrated
Module.> and
next. Refer to
REGISTRATION
MANUAL FOR
IMMOBILIZER.

D: DTC P1572 IMM CIRCUIT FAILURE (EXCEPT ANTENNA CIRCUIT)

Communication failure between body integrated unit and ECM
WIRING DIAGRAM:
BATTERY
SBF-1
SBF-4
IGNITION
SWITCH
F/B No.12
F/B No.7
SBF-9
A1
C2
B7
i84
B28
C9
A:
B18
C8
: 2.0 L TURBO MODEL,

3.0 L MODEL AND
2.5 L EC, K4, EK MODEL
B22
*2
D19 B25
: 2.0 L NA MODEL AND

2.5 L KS, KA MODEL
* *
*1
2
1
D27 B33
M/B No.8
B: B135
B: B280
ECM
D: B137
A:
i84
1 2
3 4
5 6
7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25
26 27 28 29
30 31 32 33
34 35
B: B280
C: B281
C: B281
1 2 3
4 5
6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
23 24 25
26 27
28 29 30
21 22
4 5 6 7
1 2 3
8 9 10 11 12 13 14 15 16 17 18 19
27 28
22 23
24 25 26
20 21
D: B137
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
28 29
30 31
26 27
B: B135
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
IM-00087
IM(diag)-22

Step
SUPPLY CIRCUIT.
chassis ground.
SUPPLY CIRCUIT.
OFF)
chassis ground.
CIRCUIT.
chassis ground.
CHECK HARNESS BETWEEN BODY INTEGRATED UNIT AND ECM.
body integrated unit and ECM.
ECM connector terminal.
2.0 L non-turbo model, 2.5 L KS, KA
model
(B280) No. 18 (B135) No. 25:
K4, EK model
(B280) No. 18 (B137) No. 19:
CHECK HARNESS BETWEEN BODY INTEGRATED UNIT AND ECM.
Measure the resistance between body integrated unit harness connector terminal and
ECM connector terminal.
model
(B280) No. 28 (B135) No. 33:
K4, EK model
(B280) No. 28 (B137) No. 27:
Check
Yes
No
Check the harness
for open or short
circuit between
body integrated
unit and fuse.
Check the harness

for open or short
circuit between
body integrated
unit and ignition
switch.

?
Go to step 4.
Repair the open

circuit of body integrated unit ground
circuit.

?
Go to step 5.
Repair the open

circuit of harness
ECM.

?
Go to step 6.
Repair the open

circuit of harness
ECM.
IM(diag)-23

Step
CHECK HARNESS OF COMMUNICATION
LINE.
OFF)
chassis ground.
(B280) No. 18, No. 28 (+) Chassis
ground ():
CHECK HARNESS OF COMMUNICATION
LINE.
Measure the voltage between harness connector terminal and engine ground.
model
(B135) No. 25, 33 (+) Engine ground
():
K4, EK model
(B137) No. 19, 27 (+) Engine ground
():
CHECK ECM BY COMMUNICATION LINE
CHECK.
1) Connect the harness connector to ECM.
3) Start the communication line check. <Ref.
to IM(diag)-8, COMMUNICATION LINE
CHECK, OPERATION, Subaru Select Monitor.>
Check
Is the voltage 0 V?
Yes
Go to step 7.
No
body integrated
unit and ECM,
because there is
short circuit with
or ignition switch
ON line.
Is the voltage 0 V?
Go to step 8.

body integrated
unit and ECM,
because there is
short circuit with
or ignition switch
ON line.
Does Communication Line not Replace the body

Shorted appear on the
integrated unit
screen?
<Ref. to SL-45,
Body Integrated
Module.> and
next. Refer to
REGISTRATION
MANUAL FOR
IMMOBILIZER.
IM(diag)-24
Replace the ECM.

<Ref. to FU(H4SO
2.0)-34, Engine
Control Module
(ECM).> <Ref. to
FU(H4SO 2.5)-36,
Engine Control
Module (ECM).>
<Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
<Ref. to
FU(H6DO)-34,
Engine Control
Module (ECM).>
Perform the registration procedure
next. Refer to
REGISTRATION
MANUAL FOR
IMMOBILIZER.

E: DTC P1574 KEY COMMUNICATION FAILURE

Failure of body integrated unit to verify key (transponder) ID code
Step
CHECK BODY INTEGRATED UNIT FUNCTION.
Insert the key to ignition switch (LOCK position), and measure the changes in voltage
between antenna connectors.
Check
Yes
Is the voltage 30 to 30 V?
Go to step 2.
(Approx. 0.1 second after
inserting the key) Is the voltage
0 V? (Approx. 1 second after
inserting the key)
CHECK IGNITION KEY (TRANSPONDER).

2) Start the engine using other keys that have
undergone the teaching operation, furnished
with vehicle.
No
Replace the body
integrated unit
<Ref. to SL-45,
Body Integrated
Module.> and
next. Refer to
REGISTRATION
MANUAL FOR
IMMOBILIZER.
Replace all the
Replace the body
ignition keys
integrated unit
(including tran<Ref. to SL-45,
sponder). Execute Body Integrated
the registration
Module.> and
procedure next.
replace the all igniRefer to REGIS- tion keys (includTRATION MANing transponder).
UAL FOR
Execute the regisIMMOBILIZER.
tration procedure
next. Refer to
REGISTRATION
MANUAL FOR
IMMOBILIZER.
F: DTC P1576 EGI CONTROL MODULE EEPROM

ECM malfunctioning
1. REPLACE ECM
Replace the ECM. <Ref. to FU(H4SO 2.0)-34, Engine Control Module (ECM).> <Ref. to FU(H4SO 2.5)-36,
Engine Control Module (ECM).> <Ref. to FU(H4DOTC)-35, Engine Control Module (ECM).> <Ref. to
FU(H6DO)-34, Engine Control Module (ECM).>
Perform the registration procedure next. Refer to REGISTRATION MANUAL FOR IMMOBILIZER.
G: DTC P1577 IMM CONTROL MODULE EEPROM

Body integrated unit malfunctioning
1. REPLACE BODY INTEGRATED UNIT

Replace the body integrated unit <Ref. to SL-45, Body Integrated Module.> and replace the all ignition keys
(including transponder). Execute the registration procedure next. Refer to REGISTRATION MANUAL FOR
IMMOBILIZER.
IM(diag)-25

H: DTC P1578 METER FAILURE

Reference code incompatibility between body integrated unit and combination meter
1. CHECK LAN COMMUNICATION SYSTEM

Inspect LAN communication system in the following situation. <Ref. to LAN(diag)-2, Basic Diagnostic Procedure.>
DTC of body integrated unit B0300, B0301, B0302, B0111 or B0321 is displayed.
Er IU or Er LC is displayed in odo/trip meter on combination meter.
2. REPLACE COMBINATION METER

Replace the combination meter. <Ref. to IDI-16, Combination Meter.> Execute the registration procedure of
all immobilizer part (combination meter and etc.) next. Refer to REGISTRATION MANUAL FOR IMMOBILIZER.
NOTE:
When the combination meter has been replaced, be sure to perform the registration procedure of immobilizer.
Engine may not start when the combination meter which removed from the model with immobilizer to the
model without immobilizer. When installed wrong one, correct with the following procedure.
(2) Reinstall the combination meter. (Install the combination meter for the model without immobilizer.)
(3) Disconnect the ground cable from battery, and reconnect one minute later.
(4) Turn the ignition switch to START, and check that the engine starts.
When the combination meter and body integrated unit are replaced at the same time, the registration procedure cannot be performed. In this case, it is necessary to write an ID newly to body integrated unit.
IM(diag)-26
LAN(diag)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Page
Control Module I/O Signal ...........................................................................9
Read Current Data ....................................................................................26
Function Setting (Customize)....................................................................27


A: PROCEDURE
CAUTION:
Subaru Select Monitor is required for reading DTC, performing diagnosis and reading current data.
Remove foreign matter (dust, water and oil etc.) from the body integrated unit connector during removal and installation.
For the model with immobilizer, registration of immobilizer may be needed after the replacement of
controller and etc. For detail procedure, refer to REGISTRATION MANUAL FOR IMMOBILIZER.
NOTE:
To check harness for broken wires or short circuits, shake it while holding it or the connector.
Check List for Interview <Ref. to LAN(diag)-3, Check List for Interview.>
Step
1) Ask the customer when and how the trouble occurred using interview check list. <Ref. to
LAN(diag)-3, Check List for Interview.>
2) Check the display of freeze frame data.
(Combination meter, odo/trip meter)
BASIC INSPECTION.
Check the components which might affect
body control. <Ref. to LAN(diag)-5, INSPECTION, General Description.>
1) Read the DTC. <Ref. to LAN(diag)-14,
Check
Is freeze frame data displayed?
Yes
Go to step 3.
No
Go to step 2.

influence the body control
problem normal?
Go to step 3.
Repair or replace
each unit.
Is DTC displayed?
Go to step 5.
Go to step 4.
NOTE:
LAN(diag)-30, COMMUNICATION FOR INITIALIZING IMPOSSIBLE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
2) Record all DTCs and freeze frame data.
PERFORM THE GENERAL DIAGNOSTICS. Is result of inspection OK?
Inspect using General Diagnostics Table.
<Ref. to LAN(diag)-81, General Diagnostic
Table.>
Is DTC displayed?
LAN(diag)-20, CLEAR MEMORY MODE,
3) Read DTC. <Ref. to LAN(diag)-14, READ
DIAGNOSTIC TROUBLE CODE (DTC),
LAN(diag)-2
LAN system is nor- Go to step 5.

mal.
Repeat step 5 until Finish the diagnoDTC is not shown. sis.


A: CHECK
Inspect the following items about the vehicles state.
1. DISPLAY OF FREEZE FRAME DATA

Freeze frame data is displayed in odo/trip meter.
Timing
When and how often are they displayed?

Always
Sometimes
Only once
Which freeze frame data is displayed? (Record them all)
Er IU (Fail in the body integrated unit)
Er HC (Fail of high-speed CAN)
Er LC (Fail of low-speed CAN)
Er (Fails of both high-speed and low-speed CAN)
Er EG (Fail of EGI communication counter)
Er TC (Fail of TCM communication counter)
Er Ab (Fail of vehicle dynamics control (VDC)/ABS communication counter)
OFF
ACC
START
2. DISPLAY IN COMBINATION METER

Display in combination
meter
Center display
Display of other indicators
OK / NG
OK / NG
OK / NG
ON / OFF
ON / OFF
ON / OFF
a) Display of temperature gauge

b) Display of fuel gauge
c) Display of ambient temperature
d) Malfunction indicator light
e) SPORT indicator light (AT warning light)
f) ABS warning light/Vehicle dynamics control (VDC) warning
light
g) Immobilizer indicator light
h) Seat belt warning light (Drivers seat)
i) Seat belt warning light (Passengers seat)
ON / Blink / OFF
ON / OFF
ON / OFF
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
Yes / No
Yes / No
Yes / No
Yes / No
Yes / No
Yes / No
Yes / No
Yes / No
Yes / No
Yes / No
Yes / No
Yes / No
3. SYMPTOMS
Behavior of vehicle
Illumination volume control is not available.

Rear wiper does not operate.
Wiper deicer does not operate.
Rear defogger does not operate.
Door lock does not operate.
Trunk/rear gate lock does not operate
Drivers door lock does not operate.
Shift lock does not operate.
Rear fog light does not come on.
Double lock does not operate. (EK model)
Heater cock valve does not operate.
Key illumination blinks.
LAN(diag)-3


Driving condition
At standstill (While idling)

When the vehicle is running
Vehicle speed
When accelerating
Acceleration
Decelerating (With braking)
Deceleration
Decelerating (Without braking) Deceleration
Flat road
Uphill
Downhill
Gravel road
Bumpy road
Snowy road
Does it occur when operating any part?
Operated part:
Trouble Symptom:
Are other troubles occurred?
From where:
Trouble Symptom:
LAN(diag)-4
km/h (MPH)
km/h (MPH) to km/h (MPH)
General Description
When repairing the harness, connect the wires

using soldering and protect it with insulating tape,
etc.
A: CAUTION
1. SRS AIRBAG SYSTEM
body integrated unit and twisted pair line.
(A)
CAUTION:
Be careful not to damage the Airbag system
wiring harness when servicing the body integrated unit and LAN system.
LAN00080
(A) Soldering and protection with insulating tape
2. LAN SYSTEM
Bus line of LAN system is twisted pair line. Be
careful not to bypass or partly unbind the twisted
pair line.
Do not make clearance between bus lines (CAN
High, CAN Low).
Difference of bus line length should be within 10
cm (3.94 in).
Fray near the connector should be within 8 cm
(3.94 in).
(A)
LAN00081
(A) Bypass wire connection
If the characteristics of the twisted pair line is

changed, it may cause extremely weakness to the
noise.
B: INSPECTION
items which might affect body integrated unit malfunctions.
1) Measure the battery voltage and check electrolyte.
Standard voltage: 12 V, or more
2) Check the fuse condition.
Make sure that ampere of the fuse is setting value,
and it is not blown out.
3) Check the connecting condition of harness and
harness connector.
4) Confirm settings of body integrated unit are corresponded to vehicle equipment. <Ref. to LAN(diag)-18, REGISTRATION BODY INTEGRATED
UNIT (EQUIPMENT SETTING), OPERATION,
5) Confirm setting are corresponded to vehicle
equipment by function setting (ECM customizing)
of body integrated unit. <Ref. to LAN(diag)-20,
FREEZE FRAME DATA, OPERATION, Subaru
Select Monitor.>
6) Confirm Factory initial setting of body integrated unit registrations is Market.
7) Confirm key illumination does not blink with ignition switch turned to ON.
LAN(diag)-5
General Description
C: PREPARATION TOOL
1. SPECIAL TOOL
ILLUSTRATION
TOOL NUMBER
24082AA230
DESCRIPTION
CARTRIDGE
REMARKS
22771AA030
SUBARU SELECT
MONITOR KIT

ST24082AA230
ST22771AA030
2. GENERAL TOOL
TOOL NAME
Circuit tester
REMARKS
LAN(diag)-6


A: LOCATION
(8)
(11)
(5)
(7)
(6)
(9)
(12)
(4)
(3)
(2)
(10)
(1)
LAN00101
(1)
(2)
(3)
(4)
(5)

Auto A/C control unit
Navigation module
(Antenna)
(6)
(7)
(8)
(9)
A/C control panel

Center display
(TCM)
(10)
(11)

ABSCM&H/U or VDCCM&H/U (In
engine compartment)
(12)
Odo/trip meter
Combination meter
(3)
(1)
(2)
LAN00102
LAN(diag)-7
LAN00103

(5)
(6)
(4)
LAN00104
LAN00105
(7)
(8)
LAN00007
LAN00106
(9)
(11)
(10)
LAN00107
8
P
R
N
D
60
km/h
140
40
160
20
180
SPORT
E
CRUISE
(12)
SET
LAN00111
LAN(diag)-8
LAN00008


A:
B: B280
i84
C: B281
1 2 3
4 5
6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
23 24 25
26 27
28 29 30
21 22
1 2
3 4
5 6
7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25
26 27 28 29
30 31 32 33
34 35
4 5 6 7
1 2 3
8 9 10 11 12 13 14 15 16 17 18 19
27 28
22 23
24 25 26
20 21
LAN00012
Connector
No.
Terminal No.
Signal (V or )
Ignition switch ON
(engine OFF)
NOTE
B281
C2
10 13 V
Always
B280
i84
i84
i84
B281
B281
B280
B281
B281
B7
A1
A24
A21
C9
C8
B22
C7
C23
10 13 V
10 13 V
10 13 V
Always
Ignition ON
ACC ON
Less than 1
Always
10 13 V
10 13 V
When ignition key inserted

When brake pedal depressed
i84
A10
4.5 5.5 V
Small light ON
i84
A2
0.5 4.5 V
i84
A25
Less than 1
Ground circuit
i84
B281
A5
C17
10 13 V
10 13 V
Rear fog light input
B281
C4
10 13 V
Rear fog light output

Headlight input
Door switch input
Drivers seat
Door switch input
Passengers seat
Door switch input
Rear RH seat
B280
B281
B13
C16
10 13 V
10 13 V
Small light ON
Front fog light ON
Small light ON
Front fog light ON
Rear fog light ON
Rear fog light ON
Headlight ON (Both of Hi, Lo)
i84
A19
Less than 1 V (10 13 V at OFF)
Drivers door open (ON)
i84
A32
Passengers door open (ON)
i84
A18
Rear RH door open (ON)
Description
System control power
supply
Backup power supply
ACC power supply
Ground
Key warning switch

Stop light switch
Illumination volume
(Vi1)
Illumination volume
(Vi 2)
Illumination volume
(Vi 3)
Illumination output
Front fog light input
LAN(diag)-9

Connector
No.
Terminal No.
Signal (V or )
Ignition switch ON
(engine OFF)
NOTE
i84
A31
Rear LH door open (ON)
i84
A17
Trunk/Rear gate open (ON)
i84
A30
10 13 V (at dimmer ON)
i84
A15
Less than 1
Extinct the clock and audio illumination

Door lock switch ON
i84
A29
Less than 1
Door lock switch ON
i84
i84
A34
A7
10 13 V
10 13 V
Manual, door key switch ON
i84
A8
10 13 V
Manual, door key switch ON
i84
A22
10 13 V
When the trunk open signal

received with keyless entry
(Sedan model)
Key/shift lock power

supply
B281
C1
10 13 V
Shift lock output
B280
B6
10 13 V
i84
A14
Less than 1
Ignition switch ON, at P range,

foot brake ON
Wiper deicer switch ON
B280
B14
Less than 1
Wiper deicer relay ON
i84
A28
Less than 1
Rear defogger switch ON
Description
Door switch input
Rear LH seat
Door switch
Trunk/Rear gate
Illumination control
switch
Manual switch (LOCK)
Manual switch
(UNLOCK)
Door lock power supply
All door LOCK output
All door UNLOCK output
Trunk/Rear gate
UNLOCK output
Wiper deicer switch

Wiper deicer relay output
Rear defogger switch
Rear defogger relay
output
Shift switch (ON)
Shift switch (UP)
Shift switch (DOWN)
P range switch
B281
B16
Less than 1
Rear defogger relay ON
B281
B281
B281
B281
C26
C15
C25
C13
Less than 1
Less than 1
Less than 1
Less than 1
At Manual mode
At Manual mode UP
At Manual mode DOWN
Impact sensor
B281
C5
Less than 1
Impact sensor ON
Fuel level sensor
B281
B281
B281
C19
C3
C10
0 102.3
0.5 4.5 V
Less than 1
SIG
GND
i84
A4
Less than 1
Drivers seat belt worn
i84
A13
Less than 1
Passengers seat belt worn
i84
A20
Less than 1
Drivers seat belt worn
B281
C24
Less than 1
Passengers seat belt worn
B281
C11
B281
B281
B281
C6
C18
C27
Sedan 10 13 V
Wagon 0 5 V
Less than 1
Less than 1
Less than 1
Rear wiper switch ON

Rear washer switch ON
B280
B21
10 13 V
B280
B1
B280
B8
10 13 V
Less than 1
B1 B8 1 or less
Ambient sensor
Seat belt switch
(drivers seat)
Seat belt switch
(passengers seat)
(drivers seat)
(passengers seat)
Sedan/Wagon identification switch
Rear wiper switch (ON)
Rear wiper switch (INT)
Rear washer switch
Rear wiper power supply
Rear wiper ON output
Rear wiper return
LAN(diag)-10

At wiper reversing

Connector
No.
Terminal No.
Signal (V or )
Ignition switch ON
(engine OFF)
Room light output
B280
B3
Less than 1
Key ring illumination

output
B280
B4
Less than 1
Turn hazard output
B280
B12
Less than 1
Keyless buzzer output
i84
A6
Less than 1
Immobilizer pilot light
i84
A33
Less than 1
B280
i84
B12
A9
Less than 1
2 10 V
When LOCK, UNLOCK with keyless entry

Ignition key removed, driver door
open
When operating keyless entry
answer back
When operating keyless entry
answer back
At ignition key removed, immobilizer operating
Kick down switch ON
At keyless entry signal received
B280
B20
B280
B30
Between B20 B30

Serial communication
At communicating
(sending and receiving)
i84
A26
i84
A25
Between A25 A26

At communicating
B280
B26
B280
B27
Between B25 B27

At communicating
(Model with auto A/C)
B281
C20 C21
B18
(Back-up
B28)
Description
Kick down switch

Keyless communication
High-speed CAN circuit
(Hi)
High-speed CAN circuit
(Lo)
Low-speed CAN circuit
1 (Hi)
1 (Lo)
2 (Hi)
2 (Lo)
Immobilizer antenna
Immobilizer communication
(Main)
communication
B280
B280
B19
LAN(diag)-11
NOTE

B: WIRING DIAGRAM
SYSTEM CONTROL POWER SUPPLY
C2
C13
"P" RANGE SWITCH
BACKUP POWER SUPPLY
B7
C26
SHIFT SWITCH (ON)
IGNITION POWER SUPPLY
A1
C15
SHIFT SWITCH (UP)
ACC POWER SUPPLY
A24
C25
SHIFT SWITCH (DOWN)
GROUND
A21
C19
FUEL LEVEL SENSOR
GROUND
C9
GROUND
C8
GROUND
B22
KEY WARNING SWITCH
C7
STOP LIGHT SWITCH

(AT MODEL)
ILLUMINATION OUTPUT
FRONT FOG LIGHT INPUT
REAR FOG LIGHT INPUT
REAR FOG LIGHT OUTPUT
HEADLIGHT INPUT
DOOR
SWITCH
INPUT
DRIVER'S SEAT
PASSENGER'S SEAT
REAR SEAT (RIGHT SIDE)
REAR SEAT (LEFT SIDE)
AMBIENT SENSOR (SIG)

AMBIENT SENSOR (GND)
A4
SEAT BELT SWITCH (DRIVER'S SEAT)
A13
C23
A20
A2
A10
ILLUMINATION
VOLUME
C3
C10
B27
A25
C11
SEDAN / WAGON IDENTIFICATION SWITCH
A5
C17
C22
REGISTRATION MODE SWITCH

(EXCEPT FOR EK MODEL)
KEYLESS COMMUNICATION
C4
B13
C16
A19
A32
A18
A31
TRUNK / REAR GATE

ENGINE HOOD SWITCH
A17
A16
ILLUMINATION CONTROL SWITCH (CLOCK)
A30
HEATER COCK VALVE OUTPUT
B15
A:
i84
B: B280
C: B281
BODY
INTEGRATED
UNIT
A9
B20
B30
HIGH-SPEED CAN CIRCUIT (HI)

HIGH-SPEED CAN CIRCUIT (LO)
A26
LOW-SPEED CAN CIRCUIT 1 (HI)
A27
LOW-SPEED CAN CIRCUIT 1 (LO)
B26
LOW-SPEED CAN CIRCUIT 2 (HI)
B25
LOW-SPEED CAN CIRCUIT 2 (LO)
C20
C21
MANUAL SWITCH (LOCK)

MANUAL SWITCH (UNLOCK)
DOOR LOCK POWER SUPPLY
ALL DOORS LOCK OUTPUT
ALL DOORS UNLOCK OUTPUT
DRIVER'S SEAT DOOR LOCK
TRUNK / REAR GATE UNLOCK OUTPUT
DOUBLE LOCK OUTPUT (EK MODEL)
SHIFT LOCK POWER SUPPLY
SHIFT LOCK OUTPUT
B18
B28
A15
A29
A34
A7
A8
REAR WIPER SWITCH (ON)

REAR WIPER SWITCH (INT)
C28
REAR WASHER SWITCH
B21
REAR WIPER POWER SUPPLY
A23
B1
REAR WIPER ON OUTPUT
A22
B8
REAR WIPER RETURN
A35
C1
B6
B3
ROOM LIGHT OUTPUT
B4
KEY RING ILLUMINATION OUTPUT
B12
TURN HAZARD OUTPUT

IMMOBILIZER PILOT LIGHT
A33
WIPER DEICER RELAY OUTPUT
B14
C22
REAR DEFOGGER SWITCH

(MODEL WITH MANUAL A/C)
A28
REAR DEFOGGER RELAY OUTPUT
B16
B11
(BLUE)
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
IMMOBILIZER COMMUNICATION (MAIN)

IMMOBILIZER COMMUNICATION (BACKUP)
C6
A14
i84
IMMOBILIZER ANTENNA
C18
WIPER DEICER SWITCH
A:
SEAT BELT SWITCH (PASSENGER'S SEAT)

SEAT BELT WARNING LIGHT
(DRIVER'S SEAT)
(PASSENGER'S SEAT)
ALARM CONTROL ECM (EK MODEL)
B11
SECURITY HORN OUTPUT

B19
SUBARU SELECT MONITOR

COMMUNICATION
B: B280
1 2 3
4 5
6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
23 24 25
26 27
28 29 30
21 22
C: B281
4 5 6 7
1 2 3
8 9 10 11 12 13 14 15 16 17 18 19
27 28
22 23
24 25 26
20 21
LAN00108
LAN(diag)-12

C: LAN SYSTEM
(13)
(12)
(11)
(13)
(10)
(2)
(13)
(9)
(14)
(18)
(3)
(17)
(1)
(8)
(15)
(13)
(4)
(7)
(13)
(5)
(16)
(6)
LAN00109
(1)
(2)
(3)
(4)
(5)
(6)
(7)

ECM
TCM
VDC/ABSCM
Keyless entry receiver
A/C control unit
(8)
(9)
(10)
(11)
(12)
(13)
(14)
AudioA/C control panel

Navigation system
Center display
Combination meter
Clock
Exclusive communication line
IE-Bus (AV)
LAN(diag)-13
(15)
Subaru Select Monitor communication line
(16)
(17)

Low speed CAN (Body integrated
unit)
(18)
High speed CAN (Driving control)


A: OPERATION
(DTC)
CAUTION:
Do not connect scan tools except for Subaru
Select Monitor.
NOTE:
DTC is displayed in the sequence of inputting.
(When inputting more than two simultaneously,
DTC is displayed in the sequence of priority.)
When more than two DTCs are displayed, perform the diagnosis of top of them.
(A)
LAN00017
(A) Power switch
LAN00014

Monitor.
<Ref. to LAN(diag)-6, SPECIAL TOOL, PREPARATION TOOL, General Description.>

screen, select the {Integ. Unit mode} and press the
[YES] key.
8) On the Integ. Unit mode failuer diag display
screen, select the {Diagnostic Code(s) Display}
NOTE:
MANUAL.
Diagnostic Trouble Code (DTC). <Ref. to LAN(diag)-28, List of Diagnostic Trouble Code (DTC).>
ST
LAN00015

connector.
Data link connector is located in the lower portion of
the instrument panel (on the drivers side).
LAN00110
LAN(diag)-14


2) On the System Selection Menu display screen, select the {Integ. Unit mode} and press the [YES] key.
3) On the Integ. Unit mode failuer diag display screen, select the {Current Data Display & Save} and press
the [YES] key.
4) On the Current Data Display & Save display screen, select the {12 Data Display} and press the [YES]
key.
A support list contains both of analog and digital data, and they are shown in the following table.
3. DISPLAY OF ANALOG DATA

Items to be displayed
BATT Voltage (Control)
BATT Voltage (BACK UP)
ACC voltage
Illumination VR voltage
Illumi. output d-ratio
ambient temp sensor V
Ambient temperature
Fuel level voltage
key-lock solenoid V
number of regist.
Front Wheel Speed
VDC/ABS latest f-code
DTC display (Temporarily)
Blower fan steps

Fuel level resistance2
Fuel consumption
Coolant Temp.
0 2 level
0 102.3
cc/s
40 130C
NOTE
Body integrated unit input value
This is normal when the DTC is not input

though the this code is displayed
0: OFF, 1: Low, 2: More than 2 level
Body integrated unit output
m/s2
Vehicle lateral G
SPORT Shift Stages
Shift Position
Off delay time
Auto lock time
Unit of measure
10 15 V
10 15 V
10 15 V
10 15 V
05V
0 100%
05V
40 87.5C
08V
0 102.3
6 12 V
04
km/h
0 7 levels
0 7 levels
OFF, Short, Normal, Long
20, 30, 40, 50, 60 seconds
LAN(diag)-15
(0: light OFF, 6: fail, 7: ATF temperature

High/Low)
(8 is no input)

4. DISPLAY OF ON/OFF DATA

key-lock warning SW
Stop Light Switch
Front fog lamp SW input
Rear fog lamp SW input
lighting SW input
Door key-lock SW input
Door unlock SW input
Drivers door SW input
P-door SW input
Rear right door SW input
Rear left door SW input
R Gate SW input
Manual lock SW input
Manual unlock SW input
Lock SW (front hood)
Bright SW input
Tiptronic Mode Switch
TIP UPSW input
TIP DOWN SW input
P SW
R wiper ON SW input
R wiper INT SW input
R washer SW input
wiper deicer SW input
Rear Defogger SW
Drivers Seat SW input
P seatbelt SW input
Fr wiper input
Registration SW input
Identification SW input
Rr defogger output
lock actuat. LOCK output
All seat UNLOCK output
D-seat UNLOCK output
R gate/trunk UNLK output
Double lock output
R wiper output
Shift Lock Solenoid
Key locking output
wiper deicer SW input
Starter cutting output
Hazard Output
Keyless Buzzer Output
Horn Output
Siren Output
D-belt warning light O/P
P-belt warning light O/P
Illumination lamp O/P
Room lamp output
key illumi. lamp o/p
Unit of measure
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
R fog lamp output
R fog lamp monitor
Immobilizer lamp output
Keyless operation 1
Keyless operation 2
CC Main Lamp
CC Set Lamp
SPORT Lamp
SPORT Blink
ATF Temperature Lamp
ATF Blink
Tire diameter abnormal 1
Tire diameter abnormal 2
SPORT Shift (UP)
SPORT Shift (DOWN)
SPORT Shift (buzzer 1)
SPORT Shift (buzzer 2)
ABS/VDC Judging
ADA Existence Judging
Small lamp SW
Headlamp
Headlight HI
Turn signal LH
Turn signal RH
Rr Defogger SW
Australia Judging Flag
Tire 18inch flag
Number of cylinders
Cam shaft specification
Turbo
E/G displacement (2.5L)
E/G displacement (3.0L)
E/G cooling fan
Heater cock valve
Power window (Up)
Power window (Down)
Keyless buzzer
Bright Request
P/W ECM Failure
Keyless Hook SW
Door lock SW (Open)
Door lock SW (Close)
Door Key SW (Open)
Door Key SW (Close)
Under hook registration
Hook registration end
Unlock request
Center display failure
NAVI Failure
IE Bus failure
LAN(diag)-16
Unit of measure
ON/OFF
ON/OFF
ON/OFF
Registration/Normal
Clear/Normal
On/Off
On/Off
On/Off
Blink/Off
On/Off
Blink/Off
On/Off
Blink/Off
UP/OFF
DOWN/OFF
ON/OFF
ON/OFF
ABS/VDC
Yes/No
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
Australia/Others
18 in/others
4 cylinders/6 cylinders
SOHC/DOHC
Turbo/Non-turbo
2.5 L/ OFF
3.0 L/ OFF
AT model/MT model
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
NG/OK
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
ON/OFF
OK/NG
OK/NG
Can not use

Auto A/C failure
EBD Warning Light
ABS Warning Light
VDC OFF flag
VDC/ABS OK B
VDC/ABS condition
Destinat.
Touch SW
Unit of measure
OK/NG
OK/OFF
OK/OFF
ON/OFF
OK/NG
04
0 16
0 64
NOTE:
MANUAL.
5. CONFIRMATION OF CURRENT SETTING

3) On the Integ. Unit mode failuer diag display screen, select the {Current Data Display & Save} and press
the [YES] key.
4) On the Current Data Display & Save display screen, select the {12 Data Display} and press the [YES]
key.
6) Display the following items and record the settings.
Required items for new registration (Except for system not equipped)
Item
Key No. to register
Off delay
Auto-lock
Rr defogger op. mode
Wiper deicer op. mode
Security Alarm Setup
Impact Sensor Setup
Alarm monitor delay setting
Lockout prevention
Impact Sensor
Siren setting
Answer-back buzzer setup
Hazard answer-back setup
Automatic locking setup
Ans.-back Buzzer
Auto locking
Door open warning (prevention of battery
run-out)
A/C ECM setting
P/W ECM setting
Center display failure
Wiper deicer
Rear fog light setting
Factory initial setting
Security setting (Specified security setting)
Item to confirm
1
2
3
4
OFF
Long
Normal
Short
60, 50, 40, 30, 20
OFF
Normal
Continuous
Normal
Continuous
ON
OFF
ON
OFF
ON
OFF
ON
OFF
Yes
No
Yes
No
ON
OFF
ON
OFF
ON
OFF
Yes
No
Yes
No
Yes
No
Yes
Yes
Yes
Yes
Yes
Manufacture
No
No
No
No
No
Market
Yes
No
LAN(diag)-17
Remarks
Registered ID type
Setting for lighting off time
(Unit sec.)
Optional setting
Optional setting
Optional setting
Optional setting
Not equipped
Not equipped
Model with auto A/C

Not equipped
Model with center display
Optional setting
Optional setting
Not change to Manufacture mode
Operate the selected security set.
(EK model)

6. REGISTRATION BODY INTEGRATED

UNIT (EQUIPMENT SETTING)
CAUTION:
Body integrated unit is core of LAN system, and
also can select the function of all vehicle system control. It is possible to control the original
functions of vehicle when registrations of body
integrated unit and function setting are corresponded to vehicle equipment.
If registrations and function setting are different from vehicle equipment, vehicle system
does not operate normally and diagnosis cannot be performed correctly. Pay attention to
items below.
Be sure to correspond registrations and
function settings to vehicle equipment.
Do not change the settings of vehicle improperly.
Confirm key illumination does not blink or
Factory initial setting of body integrated unit
registrations is Market. If Factory initial setting is set to Factory, key illumination blinks
with ignition key turned to ON to give warning
of unconfirmed settings.
Key illumination does not blink with ignition
switch turned to ON and go off with door
closed.
Be sure to register immobilizer if body integrated unit is replaced with a new one. (Model
with immobilizer)
Make a registration of immobilizer when the
parts replaced related to immobilizer. Refer to
REGISTRATION MANUAL FOR IMMOBILIZER.
connector.

Monitor to ON.
(A)
LAN00017
(A) Power switch

5) On the Each System Check display screen,
select the {Integ. Unit mode} and then select the
ECM customizing.
LAN00110
LAN(diag)-18

6) Change the setting with UP/DOWN key and press the [YES] key.
List of body integrated unit registration item
NOTE:
Setting is different depending on grade of vehicle.
Data
Initial setting
Registration
ON
21
A/C ECM setting
OFF
OFF
22
P/W ECM setting
OFF
23
Center display failure (OP)
OFF
24
Wiperdeicer (OP)
OFF
ON
OFF
ON
OFF
ON
OFF
ON
25
Rear fog light setting (OP)
OFF
OFF
26
Factory initial setting

(Reset of body integrated
unit)
Factory (Reset)
Factory
Market (Settlement)
Remarks
Illumination control does not operate if A/C ECM
setting is set to OFF in case of model with auto
A/C.
If A/C ECM setting is set to ON in case of model
without auto A/C, illumination change to night illumination and it is difficult to be recognized.
Be sure to set P/W ECM setting to OFF.
Auto-reverse function
Information may not be displayed on center display
if Center display failure is set to OFF in case of
model with center display.
ON signal does not output with operation of wiper
deicer switch if Wiperdeicer is set to OFF in
model with wiper deicer.
Vehicle is controlled in rear fog light equipped
mode.
Vehicle is controlled in rear fog light no-equipped
mode. (Be sure to set to OFF in model without
rear fog light.
If Factory initial setting is set to Factory, registrations of items above is changed to OFF. Be sure
to set to Market.
CAUTION:
It is possible to control the original functions of vehicle when registrations of body integrated unit
and function setting are corresponded to vehicle equipment.
When body integrated unit is new one or Factory mode, key illumination blinks to show equipment settings does not completed.
Be sure not to change Factory initial setting except installation of new body integrated unit.
NOTE:
Factory mode:
Body integrated unit has been not set yet. It can be recognized by key illumination blinking with ignition
switch turned to ON.
All body integrated units as part for repair are set to Factory mode. When replacing a body integrated
unit, be sure to perform the registration operation.
Market mode:
Each settings have been set. It can be recognized by key illumination coming on in concocting with room
light and going off with ignition switch turned to ON.
LAN(diag)-19

7) Perform the Factory setting. On the ECM customizing display screen of Subaru Select Monitor,
select the {Factory initial setting} and press the
[YES] key.
8) Change the mode from Factory into Market.
9) Replace the immobilizer cartridge, and register
the immobilizer key. (Model with immobilizer)
10) Perform the registration according to the procedures of IMMOBILIZER REGISTRATION MANUAL.
11) When key registration is completed, Do you
want to register remote engine start? is displayed.
Perform the registration only if equipped.
12) Perform the function setting (ECM customizing).
<Ref. to LAN(diag)-21, FUNCTION SETTING
(ECM CUSTOMIZING), OPERATION, Subaru Select Monitor.>
NOTE:
MANUAL.

{2. Each System Check} and press the [YES] key.
[YES] key.
3) Press [YES] key after displayed the information
of body integrated unit type.
[YES] key.
Display
Clear memory?
Clear function of DTC and
freeze frame data

screen, turn the ignition switch to OFF.
NOTE:

NOTE:
shown on display.
Freeze frame data will be memorized maximum
to 20.
If freeze frame data is not stored in memory correctly (caused by low power supply of body integrated unit), DTC will be displayed with ? on the
head of it in the Subaru Select Monitor display. This
shows it may be an unreliable reading.
LAN(diag)-20

9. FUNCTION SETTING (ECM CUSTOMIZING)

3) On the Integ. Unit mode failuer diag display screen, select the {ECM customizing} and press the [YES]
key.
4) Change the setting with UP/DOWN key and press the [YES] key.
List of function setting item (ECM customizing)
No.
Data
Initial
setting
value
Off delay time
Normal
Auto-lock time
30 sec.
Rr defogger op. mode
15 min.
Customize setting
Setting
OFF
Short
Normal
Long
0 60 seconds
15 min.
Continuation
15 min.
4
Wiper deicer op. mode
15 min.
Continuation
Security Alarm Setup
OFF
ON
OFF
ON
Impact Sensor Setup
OFF
OFF
Alarm monitor delay setting
ON
Lockout prevention
ON
ON
OFF
ON
OFF
Impact sensor (OP)
OFF
ON
OFF
10
Siren setting
OFF
ON
OFF
Remarks
Delay time below can be selected by setting.
After door closed
After key unlock
0 sec.
0 sec.
3 sec.
10 sec.
5 sec.
20 sec.
8 sec.
30 sec.
Workable when Auto locking is set to ON and Automatic
locking setup is ON
Time can be changed by 10 seconds: 0 (OFF) 60 (maximum).
Rear defogger stops in 15 minutes automatically after
Rear defogger repeats active condition for 15 minutes and
inactive condition for 2 minutes until switch is turned to OFF.
Wiper deicer stops in 15 minutes automatically after switch
is turned to ON.
Wiper deicer repeats active condition for 15 minutes and
inactive condition for 2 minutes until switch is turned to OFF.
Security alarm (horn or siren) in active condition
Security alarm in inactive condition
Workable when Impact Sensor Setup is set to ON
Impact sensor in active condition
Impact sensor in inactive condition
(Set Impact Sensor Setup of model without impact sensor
to OFF.)
After doors are locked by keyless entry system operated,
Alarm monitor starts in following time.
Delay time is 30 seconds.
Delay time is 0 second.
Lockout prevention in active condition
(Lockout prevention does not operate if safety knob is
locked by hand.)
Lockout prevention in inactive condition
Vehicle is controlled in impact sensor equipped mode. (Set
Impact sensor to OFF in model without impact sensor. If
Impact sensor is set to ON, hazard, horn or siren operate
after doors are locked by keyless entry system operated
(Alarm monitor starting).
Vehicle is controlled in impact sensor no-equipped mode.
Siren sounds when alarm operates.
(Set Siren setting to OFF in model without siren. Horn
does not sound if Siren setting is set to ON.)
Horn sounds when alarm operates.
LAN(diag)-21

No.
Data
Initial
setting
value
Customize setting
ON
11
Answer-back buzzer setup
ON
OFF
ON
12
Hazard answer-back setup
ON
OFF
ON
13
Automatic locking setup
ON
OFF
ON
14
Ans.-back Buzzer
ON
OFF
ON
15
Auto locking
ON
16
Initial Keyless Setting
17
Initial button setting
18
Initial Security setting
19
Passive Alarm (Not used)
20
Door open warning

(prevention of battery runout)
OFF
(Specification) Security
setup
OFF
OFF
Execution
Execution
21
OFF
Execution
ON
OFF
ON
OFF
ON
OFF
Remarks
Workable when Answer-back buzzer setup is set to ON
When lock/unlock is selected by keyless entry system operated, answer-back buzzer sounds.
When lock/unlock is selected by keyless entry system operated, answer-back buzzer does not sound.
Workable when Hazard answer-back setup is set to ON
When lock/unlock is selected by keyless entry system operated, hazard answer-back operates.
When lock/unlock is selected by keyless entry system operated, hazard answer-back does not operate.
Workable when Automatic locking setup is set to ON
When lock/unlock is selected by keyless entry system operated, automatic locking operates.
When lock/unlock is selected by keyless entry system operated, automatic locking does not operate.
Vehicle is controlled in answer-back buzzer equipped mode.
Vehicle is controlled in answer-back buzzer non-equipped
mode. (Set Ans.-back Buzzer to OFF in model without
answer back buzzer.)
Vehicle is controlled in auto locking equipped mode.
Vehicle is controlled in auto locking non-equipped mode.
(Set Auto locking to OFF in model without answer-back
buzzer.)
Settings of keyless entry system are initialized. (No. 2: 30

sec., No.11: ON, No.12: ON, No.13: ON, No.14: ON)
Settings of each function are initialized. (No. 1: Normal, No.

3: 15 min., No. 4: 15 min., No. 8: ON)
Settings of security system are initialized. (No. 5: OFF, No.

6: OFF, No. 7: ON, No.10: OFF)
Applicable to North America model (If Passive Alarm is set
to ON, nothing operates and there is no negative effect.)
If detecting door open for 30 minutes, room light, key illumination and door warning light are turned off to prevent battery run-out.
Room light, key illumination and door warning light is not
turned off.
Selected security settings in active condition (EK model)
Normally in active condition
5) After setting, make sure that vehicle equipment is same as the setting changed in the {Current Data Display & Save}.
CAUTION:
It is possible to control the original functions of vehicle when settings above are corresponded to
vehicle equipment.
Do not change the settings except for setting above during operation of equipment setting.
Be sure not to change Factory initial setting except in installation of new body integrated unit.
NOTE:
For details concerning operation procedure, refer to SUBARU SELECT MONITOR OPERATION MANUAL.
LAN(diag)-22

10.FUNCTION CHECK
In order to check the body integrated unit function,
inspect the body integrated unit and actuator using
Subaru Select Monitor without operating switches.
[YES] key.
screen, select the {System Operation Check Mode}
4) Select item to operate on the System Operation
Check Mode display screen with UP/Down key,
Function check
Heater cock valve output
lock actuat, LOCK output
All seat UNLOCK, output
Double lock Solenoid
Shift Lock Solenoid
key locking output
Horn output
LAN00018
5) Pressing [YES] starts, [NO] cancels the operation and [YES] returns to the System Operation
Check Mode display screen.
NOTE:
If not equipped (based on area or condition), process will not go on.
LAN(diag)-23


Code (DTC)
A: OPERATION
1. WITHOUT SUBARU SELECT MONITOR
NOTE:
Use the Subaru Select Monitor, because DTCs can
not be read out.

For details concerning DTC reading procedure, refer to Subaru Select Monitor. <Ref. to LAN(diag)14, READ DIAGNOSTIC TROUBLE CODE (DTC),
LAN(diag)-24
Clear Memory Mode


A: OPERATION
NOTE:
Use the Subaru Select Monitor for Clear Memory
Mode.

For detailed procedures of clearing DTC, refer to
SUBARU SELECT MONITOR. <Ref. to LAN(diag)-20, CLEAR MEMORY MODE, OPERATION,
LAN(diag)-25
Read Current Data

9. Read Current Data

A: OPERATION
[YES] key.
4) On the Data Display Menu screen, select the
{12 Data Display} and press the [YES] key.
<Ref. to LAN(diag)-15, DISPLAY OF ANALOG DATA, OPERATION, Subaru Select Monitor.> <Ref.
to LAN(diag)-16, DISPLAY OF ON/OFF DATA,
LAN(diag)-17, CONFIRMATION OF CURRENT
SETTING, OPERATION, Subaru Select Monitor.>
LAN(diag)-26
Function Setting (Customize)

10.Function Setting (Customize)

A: OPERATION
NOTE:
Applied to the Model with center display.
1) Display the information screen with pressing the
INFO switch of center display.
2) Select SET on the touch panel at the right top
of center display screen.
3) Select the item from A: Keyless entry or B:
Various setup on the touch panel.
(A)
(B)
LAN00112
4) Change the setting on the touch panel which

contains item to be changed.
5) Return to the information display screen and
complete it.
Function setting item list
Item
Keyless
Each function
Setting
Auto lock
Auto lock time setting
Answerback hazard
Room light delay time
Anti-lock out
Rear defogger
Wiper deicer

For detailed procedures of function setting (ECM
customizing), refer to SUBARU SELECT MONITOR. <Ref. to LAN(diag)-21, FUNCTION SETTING (ECM CUSTOMIZING), OPERATION,
LAN(diag)-27


A: LIST
DTC
None
Item
Communication for initializing
impossible
Open or short in Subaru
Select Monitor communication line.
None
DTC is not stored.
Internal error of combination meter.
B0100
Integ. unit system error
Body integrated unit internal error
B0101
BATT power supply (Control) error
Open or short in battery

power supply control circuit
B0102
BATT p/supply malfunction cont.
Open or short in BATT

power backup circuit
B0103
IGN power failure
Open or short in IGN

power supply circuit
B0104
ACC power failure
Open or short in ACC

power supply circuit
B0106
shift lock circuit Failure
Ground short of shift lock

circuit
B0107
R Fog lamp circuit Failure
Ground short of rear fog

circuit
B0201
High speed CAN fail error counter

abnormal
Malfunction of high-speed
CAN communication
B0202
CAN-HS bus off
Any unit is cut communication.
B0211
CAN-HS (EGI) data abnormal
Received error data from

ECM.
B0212
CAN-HS (TCM) data abnormal

TCM.
B0213
CAN-HS VDC/ABS data abnormal

VDC/ABS unit.
B0221
CAN-HS ECM no-receive data
Not received error data

from ECM.
B0222
CAN-HS TCM no-receive data

from TCM
LAN(diag)-28
NOTE
<Ref. to LAN(diag)-30, COMMUNICATION
FOR INITIALIZING IMPOSSIBLE, Diagnostic
(DTC).>
<Ref. to LAN(diag)-33, DIAGNOSTIC TROUBLE CODE (DTC) IS NOT STORED, Diagnostic
(DTC).>
<Ref. to LAN(diag)-33, DTC B0100 INTEG.
UNIT SYSTEM ERROR, Diagnostic Procedure
<Ref. to LAN(diag)-34, DTC B0101 BATT P/
SUPPLY MALFUNCTION CONT., Diagnostic
(DTC).>
<Ref. to LAN(diag)-36, DTC B0102 BATT P/
SUPPLY MALFUNCTION CONT., Diagnostic
(DTC).>
<Ref. to LAN(diag)-38, DTC B0103 IGNITION
POWER FAILURE, Diagnostic Procedure with
<Ref. to LAN(diag)-40, DTC B0104 ACC
POWER FAILURE, Diagnostic Procedure with
<Ref. to LAN(diag)-42, DTC B0106 SHIFT
LOCK CIRCUIT FAILURE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to LAN(diag)-44, DTC B0107 R FOG
LAMP CIRCUIT FAILURE, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to LAN(diag)-46, DTC B0201 CAN-HS
COUNTER ABNORMAL, Diagnostic Procedure
BUS OFF, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
ECM DATA ABNORMAL, Diagnostic Procedure
TCM DATA ABNORMAL, Diagnostic Procedure
VDC/ABS DATA ABNORMAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
ECM NO-RECEIVE DATA, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
TCM NO-RECEIVE DATA, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>

DTC
B0223
Item
CAN-HS VDC/ABS no-receive
data
from VDC/ABS unit.
B0300
CAN-LS malfunction
B0301
CAN-LS fail / error counter abnormal
Open or short in lowspeed CAN circuit, on

each side or both sides.
Malfunction of low-speed
CAN communication
B0302
CAN-LS bus off
Any unit is cut communication.
B0311
CAN-LS meter unit data abnormal

meter.
B0313
CAN-LS monitor data abnormal

monitor unit.
B0321
CAN-LS meter no-receive data

from meter
B0401
M collation NG
B0402
Immobilizer Key collation NG
B0403
E/G request NG
B0500
Keyless UART com. Malfunction
Malfunction related immobilizer

Open or short circuit in
keyless UART circuit
LAN(diag)-29
NOTE
VDC/ABS NO-RECEIVE DATA, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to LAN(diag)-65, DTC B0300 CAN-LS
MALFUNCTION, Diagnostic Procedure with
COUNTER ABNORMAL, Diagnostic Procedure
BUS OFF, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
METER UNIT DATA ABNORMAL, Diagnostic
(DTC).>
MONITOR DATA ABNORMAL, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
METER NO-RECEIVE DATA, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>
<Ref. to IM(diag)-15, List of Diagnostic Trouble
Code (DTC).>
Code (DTC).>
Code (DTC).>
<Ref. to LAN(diag)-79, DTC B0500 KEYLESS
UART COM. MALFUNCTION, Diagnostic Procedure with Diagnostic Trouble Code (DTC).>


NOTE:
DTC is displayed in the sequence of the amount of counter numbers.
When more than two DTCs are displayed, perform the diagnosis of top of them.
DIAGNOSIS:
Subaru Select Monitor communication line is open or shorted.
TROUBLE SYMPTOM:
Not communicable with Subaru Select Monitor.
WIRING DIAGRAM:
A:
i84
A1
B19
B: B280
10
IGNITION RELAY
B40
DATA LINK CONNECTOR
A:
i84
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
B40
B: B280
4 5 6 7
1 2 3
8 9 10 11 12 13 14 15 16 17 18 19
27 28
22 23
24 25 26
20 21
(BLACK)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
LAN00021
LAN(diag)-30

Step
Check
Is the ignition switch ON?
Yes
Go to step 2.
CHECK BATTERY.

terminal?
CHECK COMMUNICATION OF SUBARU SE- Are system and model year
Go to step 7.
LECT MONITOR.
displayed?
whether communication to other systems can
CHECK COMMUNICATION OF SUBARU SE- Are system and model year
Go to step 7.
LECT MONITOR.
displayed?
2) Disconnect the body integrated unit connector.
EACH CONTROL UNIT AND SUBARU SEM?
LECT MONITOR.
Go to step 8.
CHECK OUTPUT SIGNAL TO BODY INTE- Is the voltage less than 1 V?
GRATED UNIT.
2) Measure the voltage between body integrated unit and chassis ground.
Go to step 9.
BODY INTEGRATED UNIT AND DATA LINK ?
CONNECTOR.
Measure the resistance between body integrated unit and data link connector.
(B40) No. 10 (B280) No. 19:
CHECK INSTALLATION OF BODY INTEIs the body integrated unit con- Go to step 10.
GRATED UNIT CONNECTOR.
nector inserted into body inteTurn the ignition switch to OFF.
grated unit until the clamp
locks onto it?
LAN(diag)-31
No
Turn the ignition
switch to ON, and
select Integ. Unit
mode using Subaru Select Monitor.
Charge or replace
the battery.
Go to step 4.
Go to step 5.
Go to step 6.

control unit and
Subaru Select
Monitor.

control unit and
Subaru Select
Monitor.
Repair the harness and connector between body
integrated unit and
Subaru Select
Monitor.
Insert the body
integrated unit
connector into
body integrated
unit.

10
11
12
Step
OFF).
2) Measure the ignition voltage between body
integrated unit connector and chassis ground.
BODY INTEGRATED UNIT AND CHASSIS
GROUND.
3) Measure the harness resistance between
the body integrated unit and chassis ground.
Check
Yes
No
Repair the open
circuit of harness
between the body
integrated unit and
battery.

M?
Repair the poor

body integrated
unit and ground.
Go to step 12.
Is there poor contact at control Replace the body

unit ground and Subaru Select integrated unit.
Monitor?
<Ref. to SL-45,
Body Integrated
Module.>
Repair the poor

contact connector.
CAUTION:
When replacing body integrated unit on the model with immobilizer system, refer to REGISTRATION
MANUAL FOR IMMOBILIZER.
LAN(diag)-32

B: DIAGNOSTIC TROUBLE CODE (DTC) IS NOT STORED

DIAGNOSIS:
Freeze frame data in odo/trip meter is not cleared.
No trouble code is displayed on Subaru Select Monitor.
NOTE:
If DTC is not displayed on Subaru Select Monitor, LAN communication System should be OK.
Step
Check
CHECK FREEZE FRAME DATA WITH COM- Is the freeze frame data disBINATION METER.
played?
Perform the self-diagnosis of combination
meter.

Is the Yes displayed?
1) Display the current data of ECM using Subaru Select Monitor.
2) Check data of body integrated unit data
received.
1) Display the current data of ECM using Subaru Select Monitor.
2) Check data of body integrated unit counter
update.
Yes
No
nosis according to
freeze frame data.
Go to step 3.
Replace the combination meter.
<Ref. to IDI-16,
Combination
Meter.>
Go to step 4.
Replace the body
integrated unit.
<Ref. to SL-45,
Body Integrated
Module.>
Repair the poor
Replace the body
contact connector. integrated unit.
<Ref. to SL-45,
Body Integrated
Module.>
C: DTC B0100 INTEG. UNIT SYSTEM ERROR

System error in body integrated unit
TROUBLE SYMPTOM:
Check light comes on in the combination meter, and displays freeze frame data Er IU.
LAN communication immobilizer function may not be executed normally.
Step
CHECK ALL DTCS.
Check
Is DTC concerning ECM displayed?
Yes
Go to step 2.
CHECK DTC CONCERNING ECM.
Is output DTC on ECM concerning CAN communication

error?
Replace the body

integrated unit.
<Ref. to SL-45,
Body Integrated
Module.>
LAN(diag)-33
No
Replace the body
integrated unit.
<Ref. to SL-45,
Body Integrated
Module.>
DTC concerning
ECM.

D: DTC B0101 BATT P/SUPPLY MALFUNCTION CONT.

BATT power supply control circuit is open or shorted.
TROUBLE SYMPTOM:
No malfunction occurs with back-up power supply function.
NOTE:
When some B0102 BATT p/supply malfunction backup are output at the same time, all function of body integrated unit may not function.
WIRING DIAGRAM:
BATTERY
A:
MAIN SBF-11
i84
BACK-UP
POWER SUPPLY
LR B13
B:
B:
B52
C:
C2
B281
4 5 6 7
1 2 3
8 9 10 11 12 13 14 15 16 17 18 19
27 28
24 25 26
22 23
20 21
B:
A:
B280
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
B7 LR
WL
C: R168
WL C24
FB-18 No.7
MB-29 No.8
SYSTEM CONTROL
POWER SUPPLY
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
B52
i84
MICRO COMPUTER
B: B280
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
C9
BY
C8
C: R168
BY
BY B22
BY A21
C: B281
REF.TO GND-03
REF.TO GND-02
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
LAN00022
LAN(diag)-34

3
4
Step
CHECK FUSE (No. 7).
Check
Yes
No
Replace the fuse Go to step 2.
(No. 7). If the
replaced fuse has
blown out easily,
between fuse (No.
7) and body integrated unit.
Repair the harCONTINUITY CHECK OF WIRING HARness for open or
NESS.
shorted circuit
1) Disconnect the connector (B281) from body
between body inteintegrated unit.
grated unit and
2) Measure the voltage between body intefuse.
grated unit connector and chassis ground.
CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in body
Repair the poor
Go to step 4.
integrated unit connector?
contact connector.
CHECK BODY INTEGRATED UNIT HARIs the same DTC displayed?
Replace the body Temporary poor
NESS.
integrated unit.
contact occurs.
<Ref. to SL-45,
Body Integrated
3) Read DTC.
Module.>
LAN(diag)-35

E: DTC B0102 BATT P/SUPPLY MALFUNCTION CONT.

BATT power backup circuit is open or shorted.
TROUBLE SYMPTOM:
Engine malfunction indicator light may be illuminates.
Keyless entry, room light, key illumination does not operate.
En IU may display in combination meter.
NOTE:
When some B0101 BATT p/supply malfunction cont. are output at the same time, all function of body integrated unit may not function.
WIRING DIAGRAM:
BATTERY
A:
MAIN SBF-11
i84
BACK-UP
POWER SUPPLY
LR B13
B:
B:
B52
C:
C2
B281
4 5 6 7
1 2 3
8 9 10 11 12 13 14 15 16 17 18 19
27 28
24 25 26
22 23
20 21
B:
A:
B280
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
B7 LR
WL
C: R168
WL C24
FB-18 No.7
MB-29 No.8
SYSTEM CONTROL
POWER SUPPLY
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
B52
i84
MICRO COMPUTER
B: B280
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
C9
BY
C8
C: R168
BY
BY B22
BY A21
C: B281
REF.TO GND-03
REF.TO GND-02
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
LAN00022
LAN(diag)-36

3
4
Step
CHECK FUSE (No. 8).
Check
Yes
No
(No. 8). If the
replaced fuse has
blown out easily,
between fuse (No.
Repair the harCONTINUITY CHECK OF WIRING HARness for open or
NESS.
shorted circuit
1) Disconnect the connector (B280) from body
between body inteintegrated unit.
grated unit and
2) Measure the voltage between body intefuse.
grated unit connector and chassis ground.
CHECK POOR CONTACT IN CONNECTORS. Is there poor contact in body
Repair the poor
Go to step 4.
contact connector.
NESS.
integrated unit.
contact occurs.
<Ref. to SL-45,
Body Integrated
3) Read DTC.
Module.>
LAN(diag)-37

F: DTC B0103 IGNITION POWER FAILURE

IGN power supply circuit is open or shorted.
TROUBLE SYMPTOM:
Symptom that illuminating engine malfunction indicator light, Er HC high speed CAN error display may be
occurred.
WIRING DIAGRAM:
IGNITION SWITCH
BATTERY
OFF ACC ON
MAIN SBF-11
W
ACC
IG
A:
i84
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
A:
IG POWER SUPPLY
FB-37 No.12
YG
GR A8
A1 GR
B52
A24 YG
B:
B1
FB-28 No.31
ACC POWER SUPPLY
B72
B:
1 2 3
4 5
6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22
23 24 25
26 27
28 29 30
C:
A:
B280
B281
i5
4 5 6 7
1 2 3
8 9 10 11 12 13 14 15 16 17 18 19
27 28
24 25 26
22 23
20 21
B:
B52
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
i84
B: B280
MICRO COMPUTER
C: B281
C8
C9
BY
BY
BY B22
BY A21
A:
i5
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
B72
1 2 3
4 5 6
REF.TO GND-03
REF.TO GND-02
LAN00023
LAN(diag)-38

3
4
Step
Check
Yes
No
(No. 12). If the
replaced fuse has
blown out easily,
between fuse (No.
Repair the harness for open or
shorted circuit
fuse.
CONTINUITY CHECK OF WIRING HARNESS.

1) Disconnect the connector (i84) from body
integrated unit.
CHECK POOR CONTACT IN CONNECTOR. Is there poor contact in body
NESS.
3) Read DTC.
LAN(diag)-39
Repair the poor

Go to step 4.
contact connector.
integrated unit.
contact occurs.
<Ref. to SL-45,
Body Integrated
Module.>

G: DTC B0104 ACC POWER FAILURE

ACC power supply circuit is open or shorted.
TROUBLE SYMPTOM:
Rear wiper may not operate on ACC.
WIRING DIAGRAM:
IGNITION SWITCH
BATTERY
OFF ACC ON
MAIN SBF-11
W
ACC
IG
A:
i84
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
A:
IG POWER SUPPLY
FB-37 No.12
YG
GR A8
A1 GR
B52
A24 YG
B:
B1
FB-28 No.31
ACC POWER SUPPLY
B72
B:
1 2 3
4 5
6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22
23 24 25
26 27
28 29 30
C:
A:
B280
B281
i5
4 5 6 7
1 2 3
8 9 10 11 12 13 14 15 16 17 18 19
27 28
24 25 26
22 23
20 21
B:
B52
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
i84
B: B280
MICRO COMPUTER
C: B281
C8
C9
BY
BY
BY B22
BY A21
A:
i5
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
B72
1 2 3
4 5 6
REF.TO GND-03
REF.TO GND-02
LAN00023
LAN(diag)-40

3
4
Step
Check
Yes
No
(No. 31). If the
replaced fuse has
blown out easily,
between fuse (No.
Repair the harness for open or
shorted circuit
fuse.
CONTINUITY CHECK OF WIRING HARNESS.

1) Disconnect the connector (i84) from body
integrated unit.
CHECK POOR CONTACT IN CONNECTOR. Is there poor contact in body
CHECK BODY INTEGRATED UNIT HARIs DTC displayed?
NESS.
3) Read DTC.
LAN(diag)-41
Repair the poor

Go to step 4.
contact connector.
integrated unit.
contact occurs.
<Ref. to SL-45,
Body Integrated
Module.>

H: DTC B0106 SHIFT LOCK CIRCUIT FAILURE

Shift lock circuit is ground shorted.
TROUBLE SYMPTOM:
Key interlock does not unlock or lock.
WIRING DIAGRAM:
OC :
1 2
WL
GR
YR
FB-3
F/B FUSE No.8
(B)
WB
REF.TO POWER SUPPLY ROUTING

FB-28
FB-37
MB-28
F/B FUSE No.31 F/B FUSE No.12 M/B FUSE No.34
(ACC)
(IG)
(B)
1 2
WC
OC
STOP LIGHT
SWITCH
WC
OC
OC :
B64
WC :
B65
BrW
2 3
B64
WC :
B65
1 2
3 4
F: B159
3 4
8 9
F9
1 2
5 6
C1 WB
A1 GR
A24 YR
B:
B280
C:
B281
B116
1 2
3 4
5 6 7 8 9 10
A:
i84
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
B6
i84
B: B280
WC
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
OC
C: B281
SHIFT LOCK
SOLENOID
B
4 5 6 7
1 2 3
8 9 10 11 12 13 14 15 16 17 18 19
27 28
24 25 26
22 23
20 21
B116
A:
F: B159
C23 BrR
BrR F5
JOINT FUSE BOX
E
REF.TO GND-02
LAN00025
LAN(diag)-42

Step
CHECK HARNESS.
1) Disconnect the body integrated unit connector (B280).
2) Measure the resistance between body integrated unit connector and chassis ground.
CHECK HARNESS.
2) Disconnect the shift lock solenoid connector.
3) Measure the resistance between body integrated unit connector and shift lock solenoid
connector.
(B280) No. 6 (B116) No. 3:
2) Measure the internal resistance of shift lock
solenoid.
(B116) No. 3 No. 4:
2) Measure the resistance between shift lock
solenoid connector and chassis ground.
CHECK HARNESS.
2) Measure the resistance between body integrated unit connector (B280) and chassis
ground.
Check
Yes
Go to step 5.
No
Go to step 2.

?
Go to step 3.
Repair or replace
the open or short
circuit of harness.
Go to step 4.
Replace the shift

lock solenoid.

?
Temporary poor
contact occurs.
Check the connection of each terminals, and then
repair them if necessary.
Replace the body
integrated unit.
<Ref. to SL-45,
Body Integrated
Module.>
Replace the body

integrated unit.
<Ref. to SL-45,
Body Integrated
Module.>

M?
LAN(diag)-43
Repair or replace
the short circuit of
harness.

I:
DTC B0107 R FOG LAMP CIRCUIT FAILURE

Rear fog input/output circuits are ground shorted.
TROUBLE SYMPTOM:
Rear fog light does not come on or go off.
Indicator in the combination meter may not be goes off.
WIRING DIAGRAM:

B71
LG
V
28
FB-14
F/B FUSE No.16
(B)
26
FB-2
F/B FUSE No.1
(B)
1
9
2
10
3 4 5 6
11 12 13 14 15
7
16
8
17
B: B280
REAR FOG
LIGHT RELAY
1 2 3
4 5
6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
23 24 25
26 27
28 29 30
21 22
27
25
B225
B13
C: B281
4 5 6 7
1 2 3
8 9 10 11 12 13 14 15 16 17 18 19
27 28
22 23
24 25 26
20 21
REAR FOG LIGHT
C4
B: B280
C: B281
13
B225
REAR FOG
LIGHT SWITCH
ON
OFF
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
16
B71
E
REF. TO GROUND DISTRIBUTION
[GND-02]
LAN00026
LAN(diag)-44

Step
CHECK HARNESS.
CHECK HARNESS.
2) Disconnect the rear fog light relay.
3) Measure the resistance between body integrated unit connector and rear fog light relay
connector.
(B280) No. 13 (B225) No. 27:
CHECK HARNESS.
2) Disconnect the rear fog light relay.
Check
Yes
Temporary poor
contact.
No
Go to step 2.

?
Go to step 3.
Repair the open or


M?
Replace the body

integrated unit.
<Ref. to SL-45,
Body Integrated
Module.>
Repair or replace
harness.
LAN(diag)-45

J: DTC B0201 CAN-HS COUNTER ABNORMAL

High speed CAN communication of body integrated unit which monitoring the error data and non-received
data are faulty.
TROUBLE SYMPTOM:
Er HC is displayed in odo/trip meter.
Engine malfunction indicator light illuminates.
Step
CHECK HARNESS.
(B280) No. 20 No. 30:
CHECK HARNESS.
(B280) No. 20 No. 30:
CHECK HARNESS.
2) Measure the input voltage between harness connector and chassis ground while turning the ignition switch to ON.
CHECK HARNESS.
Read the data of body integrated unit data
received on ECM data display using Subaru
Select Monitor.
Check
Yes
Temporary poor
contact occurs.
No
Go to step 2.
Is the resistance more than 30 Repair or replace Go to step 3.

M?
the open circuit of
harness.

harness.

?

harness.
Go to step 6.

Read the data of body integrated unit counter
update on ECM data display using Subaru
Select Monitor.
LAN(diag)-46
Replace the body

integrated unit.
<Ref. to SL-45,
Body Integrated
Module.>
Temporary poor
Replace the body
contact occurs.
integrated unit.
Check the con<Ref. to SL-45,
nected condition of Body Integrated
connector, read
Module.>
the DTC again to
make sure that the
DTC is not output.

K: DTC B0202 CAN-HS BUS OFF

Locate the unit or CAN line which trouble occurs, and repair and replace it.
Not received data and error data may be detected at the same time.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B: B280
ECM
VDCCM & H/U

13
B30
B20
D26 C14
D18 C13
D: B137
*1
*2
B310
BODY INTEGRATED
UNIT
29
C: B136
STEERING ANGLE
SENSOR
TWISTED WIRE
2
1
3
B231
ABS
VDC
4AT
1 2 3 4
L
L
L
L
SOHC RHD MODEL;

(KA) RHD MODEL;
LHD MODEL;
(KS) LHD MODEL
*2
: EXCEPT FOR 2.0 L SOHC

RHD AND 2.5 L (KA) RHD
MODEL;
2.5 L (EC, K4) LHD MODEL;
3.0 L LHD MODEL
BY
B54
ABSCM & H/U

[GND-02]
TCM
B231
: 2.0
2.5
2.0
2.5
B301
A:
*1
11
26
A12 A3
5AT
A3 A4
ABS
VDC
5AT A:
1 2 3 4
10 11 12 13
19 20 21
D: B137
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
4AT A:
B54
5 6
14 15
7
16
22
8
17
23
9
18
24
B: B280
B54
4 5
6 7
1 2 3
8 9 10 11 12 13 14 15 16 17 18 19 20
23 24 25
26 27
28 29 30
21 22
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21
22 23 24
B310
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
B301
5
6
7
8
9
10
1 2 3 4
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
12
13
14
15
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
LAN00113
LAN(diag)-47

Step
CHECK TCM.
1) Disconnect the TCM connector (B54).
2) Perform the clear memory of body integrated unit. <Ref. to LAN(diag)-20, CLEAR
MEMORY MODE, OPERATION, Subaru
Select Monitor.>
3) Read DTC of body integrated unit.
1) Disconnect the steering angle sensor connector (B231).
2) Perform the clear memory mode of body
integrated unit. <Ref. to LAN(diag)-20, CLEAR
MEMORY MODE, OPERATION, Subaru
Select Monitor.>
3) Read DTC of body integrated unit.
2) Read the data between VDC/ABSCM and
ECM.
Check item:
Engine speed
Average front wheel speed (value on constant driving)
CHECK HARNESS.
(B280) No. 20 No. 30:
CHECK HARNESS.
(B280) No. 20 No. 30:
CHECK HARNESS.
integrated unit.
(B280) No. 20 No. 30:
CHECK HARNESS.
1) Disconnect the VDC/ABSCM connector
(ABS:B301, VDC:310).
ABS
(B301) No. 11 No. 26:
VDC
(B310) No. 13 No. 29:
Check
Is DTC (B0202) displayed?
Yes
Go to step 2.
No
Replace the TCM.
<Ref. to 4AT-142,
Transmission Control Device.> <Ref.
to 5AT-62, Transmission Control
Module (TCM).>
Replace the steering angle sensor.
<Ref. to VDC-17,
REPLACEMENT,
Steering Angle
Sensor.>
Is DTC (B0202) displayed?
Go to step 3.
Engine speed, front wheel

speed is correctly communicated. (Appears same value)
Replace the body

integrated unit.
<Ref. to SL-45,
Body Integrated
Module.>
Go to step 4.
Go to step 10.
Go to step 5.

?
Go to step 7.
Go to step 6.
Is the resistance more than 30 Open harness on Go to step 7.

M?
related line of body
integrated unit.
Repair or replace
the open circuit of
harness.
?
LAN(diag)-48
Go to step 8.
Go to step 9.

Step
CHECK VDC/ABSCM.
1) Disconnect the VDC/ABSCM connector
(ABS:B301, VDC:310).
2) Measure the resistance between VDC/
ABSCM terminals.
ABS
(B301) No. 11 No. 26:
VDC
(B310) No. 13 No. 29:
Check
?
CHECK ECM.
1) Disconnect the ECM connector (*1: B136, ?
*2: B137).
*1: 2.0 L SOHC RHD model, 2.5 L (KA)
RHD model, 2.0 L LHD model, 2.5 L (KS)
LHD model
(B136) No. 13 No. 14:
*2: Except for 2.0 L SOHC RHD and 2.5 L
(KA) RHD model, 2.5 L (EC, K4) LHD
model, 3.0 L LHD model
(B137) No. 18 No. 26:
10
CHECK HARNESS.
CHECK HARNESS.
CHECK DTC.
Read the DTC of ECM using Subaru Select
Monitor. <Ref. to EN(H4SO 2.0)(diag)-25,
READ DIAGNOSTIC TROUBLE CODE (DTC)
FOR ENGINE (NORMAL MODE), OPERATION, Subaru Select Monitor.> <Ref. to
EN(H4DOTC)(diag)-21, READ DIAGNOSTIC
TROUBLE CODE (DTC) FOR ENGINE (NORMAL MODE), OPERATION, Subaru Select
Monitor.>
11
12

? (Ground)
Yes
Go to step 9.
No
Open harness in
end resistance of
VDC/ABSCM.
Replace the VDC/
ABSCM. <Ref. to
ABS-6, ABS Control Module and
Hydraulic Control
Unit (ABSCM&H/
U).> <Ref. to VDC7, VDC Control
Module and
Hydraulic Control
Unit (VDCCM&H/
U).>
Repair or replace Open harness in
the open circuit of end resistance of
harness connec- ECM. Replace the
tor.
ECM. <Ref. to
FU(H4SO 2.0)-34,
Engine Control
Module (ECM).>
<Ref. to FU(H4SO
2.5)-36, Engine
Control Module
(ECM).> <Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
<Ref. to
FU(H6DO)-34,
Engine Control
Module (ECM).>
the ground short
circuit of the harness.

(Power)

harness.
Is DTC other than CAN communication displayed?

nosis according to
DTC.
LAN(diag)-49

13
14
Step
CHECK DTC.
Read the DTC of VDC/ABSCM using Subaru
Select Monitor. <Ref. to ABS(diag)-15, READ
DIAGNOSTIC TROUBLE CODE (DTC),
OPERATION, Subaru Select Monitor.> <Ref.
to VDC(diag)-16, READ DIAGNOSTIC TROUBLE CODE (DTC), OPERATION, Subaru
Select Monitor.>
CHECK DTC.
Read the DTC of TCM using Subaru Select
Monitor. <Ref. to 4AT(diag)-17, READ DIAGNOSTIC TROUBLE CODE (DTC), OPERATION, Subaru Select Monitor.> <Ref. to
5AT(diag)-16, READ DIAGNOSTIC TROUBLE CODE (DTC), OPERATION, Subaru
Select Monitor.>
Check
Yes
No
nosis according to
DTC.
Perform the diag- Replace the body

nosis according to integrated unit.
DTC.
<Ref. to SL-45,
Body Integrated
Module.>
LAN(diag)-50

L: DTC B0211 CAN-HS ECM DATA ABNORMAL

Defective data from ECM.
TROUBLE SYMPTOM:
Er HC or Er EG is displayed in odo/trip meter.
WIRING DIAGRAM:
B: B280
C: B136
ECM
B20
D26 C14
TWISTED WIRE
*1
*2
D18 C13
D: B137
B30
BODY INTEGRATED
UNIT
ABSCM & H/U

VDCCM & H/U
*1
: 2.0
2.5
2.0
2.5
L
L
L
L
SOHC RHD MODEL;

(KA) RHD MODEL;
LHD MODEL;
(KS) LHD MODEL
*2

MODEL;
3.0 L LHD MODEL
TCM
B: B280
4 5
6 7
1 2 3
8 9 10 11 12 13 14 15 16 17 18 19 20
23 24 25
26 27
28 29 30
21 22
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
D: B137
5 6
14 15 16
25 26 27
33 34 35
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
28 29
30 31
26 27
LAN00114
LAN(diag)-51

Step
CHECK ECM.
Read the DTC of ECM using Subaru Select
Monitor.
Check
LAN(diag)-52
Yes
No
Perform the diag- Replace the ECM.
nosis according to <Ref. to FU(H4SO
DTC.
2.0)-34, Engine
Control Module
(ECM).> <Ref. to
FU(H4SO 2.5)-36,
Engine Control
Module (ECM).>
<Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
<Ref. to
FU(H6DO)-34,
Engine Control
Module (ECM).>

M: DTC B0212 CAN-HS TCM DATA ABNORMAL

TCM error, or harness between the main harness splice and TCM is open or short, the connector is not connected securely and the terminal has poor caulking.
TROUBLE SYMPTOM:
SPORT indicator light blinks.
Er HC or Er tC is displayed in odo/trip meter.
WIRING DIAGRAM:
B: B280
B30
B20
BODY INTEGRATED
UNIT
ABSCM & H/U

VDCCM & H/U
4AT
A3 A4
5AT
A:
A12 A3
ECM
B54
TCM
B: B280
4 5
6 7
1 2 3
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22
23 24 25
26 27
28 29 30
5AT A:
B54
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
4AT A:
7
16
22
8
17
23
9
18
24
B54
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21
22 23 24
LAN00029
Step
CHECK TCM.
Select Monitor.>
Check
LAN(diag)-53
Yes
No
DTC.
(TCM).> <Ref. to

N: DTC B0213 CAN-HS VDC/ABS DATA ABNORMAL

VDC/ABSCM body error, or harness between the main harness splice and TCM is open or short, the connector is not connected securely and the terminal has poor caulking.
TROUBLE SYMPTOM:
ABS warning light and VDC warning light come on.
Er HC or Er Ab is displayed in odo/trip meter.
WIRING DIAGRAM:
B310
B: B280
29
13
VDCCM & H/U
B30
B20
BODY INTEGRATED
UNIT
STEERING ANGLE
SENSOR
2
1
3
B231
ABS
VDC
VDC
11
26
BY
ABS
ECM
B301
ABSCM & H/U
B: B280
4 5
6 7
1 2 3
8 9 10 11 12 13 14 15 16 17 18 19 20
23 24 25
26 27
28 29 30
21 22

[GND-02]
B310
B301
5
6
7
8
9
10
1 2 3 4
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
12
13
14
15
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
B231
1 2 3 4
LAN00030
LAN(diag)-54

Step
CHECK VDC/ABSCM.
Read the DTC of VDC/ABSCM using Subaru
Select Monitor.
Check
LAN(diag)-55
Yes
No
Perform the diag- Replace the VDC/
nosis according to ABSCM. <Ref. to
DTC.
ABS-6, ABS Control Module and
Hydraulic Control
Unit (ABSCM&H/
U).> <Ref. to VDC7, VDC Control
Module and
Hydraulic Control
Unit (VDCCM&H/
U).>

O: DTC B0221 CAN-HS ECM NO-RECEIVE DATA

Defective ECM. (If error is in the main harness, Diagnostic Trouble Code (DTC) P0600 High-speed CAN circuit is input simultaneously.)
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B: B280
C: B136
ECM
B20
D26 C14
TWISTED WIRE
*1
*2
D18 C13
D: B137
B30
BODY INTEGRATED
UNIT
ABSCM & H/U

VDCCM & H/U
*1
: 2.0
2.5
2.0
2.5
L
L
L
L
SOHC RHD MODEL;

(KA) RHD MODEL;
LHD MODEL;
(KS) LHD MODEL
*2

MODEL;
3.0 L LHD MODEL
TCM
B: B280
4 5
6 7
1 2 3
8 9 10 11 12 13 14 15 16 17 18 19 20
23 24 25
26 27
28 29 30
21 22
C: B136
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
D: B137
5 6
14 15 16
25 26 27
33 34 35
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
28 29
30 31
26 27
LAN00114
LAN(diag)-56

Step
CHECK HARNESS.
connectors.
(B280) No. 20 No. 30:
Check
(Standard 60 )
CHECK HARNESS.
connectors.
(B280) No. 20 No. 30:

? (End resistance or main
line is open)
LAN(diag)-57
Yes
No
Read the DTC of Go to step 2.
ECM. Perform the
diagnosis according to DTC. <Ref.
to EN(H4SO
2.0)(diag)-25,
READ DIAGNOSTIC TROUBLE
CODE (DTC) FOR
ENGINE (NORMAL MODE),
OPERATION,
Subaru Select
Monitor.> <Ref. to
EN(H4SO
2.5)(diag)-26,
CODE (DTC) FOR
OPERATION,
Subaru Select
Monitor.> <Ref. to
EN(H4DOTC)(diag
)-21, READ DIAGNOSTIC TROUBLE CODE (DTC)
FOR ENGINE
(NORMAL
MODE), OPERATION, Subaru
Select Monitor.>
<Ref. to
EN(H6DO)(diag)25, READ DIAGNOSTIC TROUBLE CODE (DTC)
FOR ENGINE
(NORMAL
Select Monitor.>
Go to step 3.
Related line of
body integrated
unit is open when
. Repair or
replace the open
circuit of harness.

Step
CHECK HARNESS.
1) Disconnect the ECM connector (*1: B136,
*2: B137).
LHD model
(B136) No. 13 No. 14:
(B137) No. 18 No. 26:
CHECK ECM.
1) Disconnect the ECM connector (*1: B136,
*2: B137).
LHD model
(B136) No. 13 No. 14:
(B137) No. 18 No. 26:
Check
? (End resistance standard
120 )
Yes
Go to step 4.
No
Go to step 5.

?
Read the DTC of

ECM. Perform the
to EN(H4SO
2.0)(diag)-25,
CODE (DTC) FOR
OPERATION,
Subaru Select
Monitor.> <Ref. to
EN(H4SO
2.5)(diag)-26,
CODE (DTC) FOR
OPERATION,
Subaru Select
Monitor.> <Ref. to
EN(H4DOTC)(diag
FOR ENGINE
(NORMAL
Select Monitor.>
<Ref. to
FOR ENGINE
(NORMAL
Select Monitor.>
End resistance is
open. Replace the
ECM. <Ref. to
FU(H4SO 2.0)-34,
Engine Control
Module (ECM).>
<Ref. to FU(H4SO
2.5)-36, Engine
Control Module
(ECM).> <Ref. to
FU(H4DOTC)-35,
Engine Control
Module (ECM).>
<Ref. to
FU(H6DO)-34,
Engine Control
Module (ECM).>
LAN(diag)-58

Step
Check
CHECK HARNESS.
1) Disconnect the ECM connector (*1: B136, ?
*2: B137).
LHD model
CHECK HARNESS.
1) Disconnect the body integrated unit connector (B280), ECM connector (*1: B136, *2:
B137), TCM connector (B54), ABS (B301)/
VDC (B310) CM connector.
2) Measure the input voltage between harness connector and chassis ground while turning the ignition switch to ON.
LAN(diag)-59
Yes
No
harness.
Repair or replace Read the DTC of

the short circuit of ECM. Perform the
harness.
to EN(H4SO
2.0)(diag)-25,
CODE (DTC) FOR
OPERATION,
Subaru Select
Monitor.> <Ref. to
EN(H4SO
2.5)(diag)-26,
CODE (DTC) FOR
OPERATION,
Subaru Select
Monitor.> <Ref. to
EN(H4DOTC)(diag
FOR ENGINE
(NORMAL
Select Monitor.>
<Ref. to
FOR ENGINE
(NORMAL
Select Monitor.>

P: DTC B0222 CAN-HS TCM NO-RECEIVE DATA

TCM error, or harness between the main harness splice and TCM is open or short, the connector is not connected securely and the terminal has poor caulking.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
B: B280
B30
B20
BODY INTEGRATED
UNIT
ABSCM & H/U

VDCCM & H/U
4AT
A3 A4
5AT
A:
A12 A3
ECM
B54
TCM
B: B280
4 5
6 7
1 2 3
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22
23 24 25
26 27
28 29 30
5AT A:
B54
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
4AT A:
7
16
22
8
17
23
9
18
24
B54
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21
22 23 24
LAN00029
LAN(diag)-60

Step
CHECK HARNESS.
1) Disconnect the TCM connector (B54)
4AT MODEL
(B54) No. 3 No. 12:
5AT MODEL
(B54) No. 3 No. 4:
CHECK TCM.
Select Monitor.>
Check
Is the resistance ?
Yes
No
Open harness in Go to step 2.
related lines of
TCM. Repair or
replace the open
circuit of harness.

DTC.
(TCM).> <Ref. to
LAN(diag)-61

Q: DTC B0223 CAN-HS VDC/ABS NO-RECEIVE DATA

Defective VDC/ABSCM. (If error is in the main harness, DTC P0600 High-speed CAN circuit is input at the
same time.)
TROUBLE SYMPTOM:
ABS warning light and VDC warning light come on.
WIRING DIAGRAM:
B310
B: B280
29
13
VDCCM & H/U
B30
B20
BODY INTEGRATED
UNIT
STEERING ANGLE
SENSOR
2
1
3
B231
ABS
VDC
VDC
11
26
BY
ABS
ECM
B301
ABSCM & H/U
B: B280
4 5
6 7
1 2 3
8 9 10 11 12 13 14 15 16 17 18 19 20
23 24 25
26 27
28 29 30
21 22

[GND-02]
B310
B301
5
6
7
8
9
10
1 2 3 4
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
12
13
14
15
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
B231
1 2 3 4
LAN00030
LAN(diag)-62

Step
CHECK HARNESS.
integrated unit.
(B280) No. 20 No. 30:
CHECK HARNESS.
integrated unit.
(B280) No. 20 No. 30:
CHECK HARNESS.
integrated unit.
CHECK HARNESS.
integrated unit.
connector terminal and chassis ground. (Ignition switch ON)
CHECK END RESISTANCE.
1) Disconnect the VDC/ABSCM harness connector.
2) Measure the resistance between VDC/
ABSCM connector terminals.
ABS
(B301) No. 11 No. 26:
VDC
(B310) No. 13 No. 29:
CHECK HARNESS.
1) Disconnect the body integrated unit connector (B280) and VDC/ABSCM connector
(ABS:B301, VDC:310).
ABS
(B301) No. 11 (B280) No. 30:
(B301) No. 26 (B280) No. 20:
VDC
(B310) No. 13 (B280) No. 20:
(B310) No. 29 (B280) No. 30:
Check
Yes
No
Read the DTC of Go to step 2.
VDC/ABSCM, and
perform the diagnosis according to
DTC.

?
Go to step 5.
Is the resistance ?
Open harness on Go to step 4.

related line of body
integrated unit.
Repair or replace
the open circuit of
harness.

harness.

125 ?

?
LAN(diag)-63
Go to step 7.
Go to step 3.
End resistance is
opened. Replace
the VDC/ABSCM.
<Ref. to ABS-6,
Control Unit
(ABSCM&H/U).>
<Ref. to VDC-7,
Control Unit
(VDCCM&H/U).>
Main wiring harness opened.
Repair or replace
the open circuit of
harness.

Step
Check
CHECK VDC/ABSCM.
Is DTC other than CAN com1) Connect all the connectors.
munication displayed?
2) Read the DTC of VDC/ABSCM using Subaru Select Monitor.
LAN(diag)-64
Yes
DTC concerning
VDC/ABSCM.
No
Temporary poor
contact occurs.
Check the connecting condition
of connector and
terminals.

R: DTC B0300 CAN-LS MALFUNCTION

Either end of low-speed CAN communication line is open or shorted, the connector is not connected properly, or the terminal has poor crimping.
TROUBLE SYMPTOM:
Er LC is displayed in odo/trip meter, but communicating function is OK.
WIRING DIAGRAM:
A:
22
B:
*2
i10
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
*1
*2
*1
*2
i77
4
i84
A27
WN
14
A26
WN
BODY
INTEGRATED
UNIT
CENTER
DISPLAY
B283
i92
ON
ON
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
CENTER
DISPLAY
i90
i90
B26
AE
B25
AE
11
B:
B280
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
CAN JOINT
CONNECTOR
A:
i84
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
i10
TWISTED PAIR LINE
21
COMBINATION METER
AUTO A/C
CONTROL
MODULE
1 2 3 4 5 6 7 8
8 10 11 12 13 14 15 16
B283
B280
i77
ON
: WITHOUT NAVIGATION
WN : WITH NAVIGATION
*1

ARRANGEMENT
AMONG 1, 2, 3, 4, 5 AND 6
*2

ARRANGEMENT
AMONG 7, 8, 9, 10, 11 AND 12
AE
: WITH AUTO A/C
1 2 3 4 5 6 7 8 9 10 11 12
i92
1 2
3 4
LAN00254
Step
CHECK DTC.
Read the DTC of body integrated unit using
CHECK DTC.
Check the DTC displayed in the body integrated unit.
CHECK DTC.
Turn the ignition switch to OFF and read the
DTC again.
Check
Is there any DTC other than
B0300?
Yes
No
nosis according to
other DTC.
Is the DTC displayed currently Check the connec- Go to step 3.
malfunctioning?
tion of harness
connector. Go to
step 3.
Is B0300 currently malfunction- Go to step 4.
Temporary poor
ing?
contact occurs.
LAN(diag)-65

10
Step
CHECK CURRENT DATA.
Connect the Subaru Select Monitor and display current data of the body integrated unit
(auto A/C fail).
Check
Is OK displayed?
Yes
Go to step 5.
CHECK AUTO A/C ECM.

2) Disconnect the auto A/C ECM connector
(B283).
3) Turn the ignition switch to ON and read the
DTC.
CHECK HARNESS.
1) Disconnect the body integrated unit connector (B280) and auto A/C control module
connector (B283).
2) Check for open and short circuits between
body integrated unit connector and auto A/C
control module connector.
(B283) No. 1 (B280) No. 26:
(B283) No. 11 (B280) No. 25:
CHECK CURRENT DATA.
(meter fail).
Does B0300 disappear?
Go to step 6.

2) Disconnect the combination meter connector.
CHECK HARNESS.
1) Disconnect the combination meter connector (i10).
the body integrated unit and combination
meter connectors.
(i10) No. 21 (i84) No. 27:
(i10) No. 22 (i84) No. 26:
CHECK HARNESS.
1) Disconnect the CAN junction connector
(i77) and the body integrated unit connector
(i84).
terminals.
(i84) No. 27 (i77) No. 1 6:
(i84) No. 26 (i77) No. 7 12:
No
Perform auto A/C
self-diagnosis.
<Ref. to AC(diag)10, OPERATION,
Diagnostic Chart
Go to step 7.
Is the harness in normal condi- Replace the auto Repair or replace

tion?
A/C ECM. <Ref. to the open or short
AC-32,
circuit of harness.
REMOVAL, Control Unit (Auto A/C
Model).>
Is OK displayed?
Go to step 8.
Is B0300 detected?
Go to step 10.

<Ref. to IDI-16,
Go to step 9.
Is the harness in normal condi- Replace the com- Repair or replace

tion?
bination meter.
the open or short
<Ref. to IDI-16,
circuit of harness.
Is the resistance less than

10?
NOTE:
The junction connector of i77 is in user defined
alignment.
LAN(diag)-66
Go to step 11.
Repair the short

circuit of harness
or replace harness.

11
12
13
14
Step
Check
CHECK HARNESS.
1) Disconnect the combination meter connec- 10?
tor.
2) Measure the resistance between the junction connector and the combination meter connector.
(i10) No. 21 (i77) No. 1 6:
(i10) No. 22 (i77) No. 7 12:
NOTE:
The junction connectors of i77 are in user defined alignment.
CHECK HARNESS.
connector (B283).
2) Measure the resistance between body integrated unit connector and auto A/C control
module connector.
(B283) No. 1 (B280) No. 26:
(B283) No. 11 (B280) No. 25:
CHECK HARNESS.
1) Connect the junction connector.
CHECK HARNESS.
(B280) No. 25 (+) Chassis ground():
(B280) No. 26 (+) Chassis ground():
(i84) No. 26 (+) Chassis ground():
(i84) No. 27 (+) Chassis ground():
Yes
Go to step 12.
No
Repair the open
circuit of harness
or replace harness.

10?
Go to step 13.
Repair the open

circuit of harness
or replace harness.

10?
Repair the short

circuit of harness
or replace harness.
Go to step 14.
Is the voltage 6 V or more?
Repair the short

circuit of harness
or replace harness.
Replace the body

integrated unit.
<Ref. to SL-45,
REMOVAL, Body
Integrated Module.>
LAN(diag)-67

S: DTC B0301 CAN-LS COUNTER ABNORMAL

Find the unit in which trouble occurs and open or short CAN line, and repair and replace them.
(Free running counter error may be detected at the same time from the unit in which the malfunction occurs.)
TROUBLE SYMPTOM:
Er LC is displayed in odo/trip meter.
WIRING DIAGRAM:
A:
22
i10
B:
*2
i10
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
*1
*2
*1
*2
i77
4
i84
A27
WN
14
A26
WN
BODY
INTEGRATED
UNIT
CENTER
DISPLAY
B283
i92
ON
ON
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
CENTER
DISPLAY
i90
i90
B26
AE
B25
AE
11
B:
B280
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
CAN JOINT
CONNECTOR
A:
i84
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
TWISTED PAIR LINE
21
COMBINATION METER
AUTO A/C
CONTROL
MODULE
1 2 3 4 5 6 7 8
8 10 11 12 13 14 15 16
B283
B280
i77
ON
*1

ARRANGEMENT
AMONG 1, 2, 3, 4, 5 AND 6
*2

ARRANGEMENT
AMONG 7, 8, 9, 10, 11 AND 12
AE
: WITH AUTO A/C
1 2 3 4 5 6 7 8 9 10 11 12
i92
1 2
3 4
LAN00254
Step
CHECK DTC.
CHECK DTC.
CHECK DTC.
DTC again.
Check
B0301?
Yes
No
nosis according to
other DTC.
malfunctioning?
tion of harness
connector. Go to
step 3.
Temporary poor
ing?
contact occurs.
LAN(diag)-68

10
11
Step
CHECK CURRENT DATA.
(auto A/C fail).
Check
Is OK displayed?
Yes
Go to step 5.
CHECK AUTO A/C ECM.

2) Disconnect the auto A/C ECM connector.
CHECK HARNESS.
connector (B283).
(B283) No. 1 (B280) No. 26:
(B283) No. 11 (B280) No. 25:
CHECK CURRENT DATA.
(meter fail).
Does the communications

error display disappear?
Go to step 6.

CHECK HARNESS.
meter connectors.
(i10) No. 21 (i84) No. 27:
(i10) No. 22 (i84) No. 26:
CHECK CURRENT DATA.
Check the current data of the body integrated
unit (center display fail).
CHECK CENTER DISPLAY.

2) Disconnect the center display connector
(i90 or i92).
No
Perform auto A/C
self-diagnosis.
Diagnostic Chart
Go to step 7.

tion?
AC-32,
circuit of harness.
Model).>
Is OK displayed?
Go to step 8.
Is B0301 detected?
Go to step 9.
Is the harness in normal condi- Go to step 10.

tion?
Is OK displayed?
Go to step 11.
Go to step 12.
LAN(diag)-69

<Ref. to IDI-16,
<Ref. to IDI-16,
Repair or replace
the open or short
circuit of harness.
Repair or replace
the center display.
<Ref. to ET-15,
REMOVAL, Navigation Display.>
Go to step 13.

12
13
14
15
16
17
Step
CHECK HARNESS.
1) Disconnect the body integrated unit connector (B280) and the center display connector
(i90 or i92).
the body integrated unit connector and the
center display connector.
Model with navigation
(i90) No. 6 (i84) No. 26:
(i90) No. 14 (i84) No. 27:
Model without navigation
(i92) No. 2 (i84) No. 26:
(i92) No. 4 (i84) No. 27:
CHECK AUTO A/C CONTROL MODULE.
1) Display the current data of body integrated
unit using Subaru Select Monitor.
2) Display the number of blower fan levels in
the analog data.
3) Read the data display when the number of
blower fan levels is changed on air conditioner
control part.
2) Display the door switch in analog data.
3) Read the display of data and combination
meter when each door is opened/closed.
HARNESS.
connector.
integrated unit and auto A/C control module
harness.
(B280) No. 26 (B283) No. 1:
(B280) No. 25 (B283) No. 11:
CHECK COMBINATION METER HARNESS.
integrated unit and combination meter connector.
(i84) No. 27 (i10) No. 21:
(i84) No. 26 (i10) No. 22:
Perform auto A/C control module self-diagnosis. <Ref. to AC(diag)-13, A/C CONTROL
SYSTEM SELF-DIAGNOSIS, OPERATION,
Check
Yes
No
Is the harness in normal condi- Replace the center Repair or replace
tion?
display. <Ref. to
the open or short
ET-15, REMOVAL, circuit of harness.
Navigation Display.>
Does the data display change? Go to step 14.
Go to step 15.
Do the body integrated unit

data indicator and combination meter indicator change
according to operation?
Go to step 15.
Go to step 16.

10?
Go to step 17.
Repair the open

circuit of harness
or replace harness.

10?
Go to step 18.
Repair the open

circuit of harness
or replace harness.
Is the self-diagnosis OK?
Go to step 18.
Replace the auto

A/C control module. <Ref. to AC32, REMOVAL,
Control Unit (Auto
A/C Model).>
LAN(diag)-70

18
19
20
Step
Check
Perform self-diagnosis for the combination
meter system. <Ref. to IDI-3, SELF-DIAGNOSIS, INSPECTION, Combination Meter System.>
CHECK THE BODY INTEGRATED UNIT.
Is Yes displayed?
Read the data of body integrated unit data
received on ECM data display using Subaru
Select Monitor.
CHECK THE BODY INTEGRATED UNIT.

Is Yes displayed?
Read the data of body integrated unit counter
update on ECM data display using Subaru
Select Monitor.
LAN(diag)-71
Yes
Go to step 19.
No
<Ref. to IDI-16,
Go to step 20.
Replace the body
integrated unit.
<Ref. to SL-45,
REMOVAL, Body
Integrated Module.>
Temporary poor
Replace the body
contact occurs.
integrated unit.
Check the connec- <Ref. to SL-45,
tion of connector. REMOVAL, Body
Integrated Module.>

T: DTC B0302 CAN-LS BUS OFF

Because of a lot of error data occurred, some units have been disconnected not to affect other units.
Communication failure from the unit in which error is occurred is input at the same time.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
A:
22
i10
B:
*2
i10
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
*1
*2
*1
*2
i77
4
i84
A27
WN
14
A26
WN
BODY
INTEGRATED
UNIT
CENTER
DISPLAY
B283
i92
ON
ON
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
CENTER
DISPLAY
i90
i90
B26
AE
B25
AE
11
B:
B280
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
CAN JOINT
CONNECTOR
A:
i84
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
TWISTED PAIR LINE
21
COMBINATION METER
AUTO A/C
CONTROL
MODULE
1 2 3 4 5 6 7 8
8 10 11 12 13 14 15 16
B283
B280
i77
ON
*1

ARRANGEMENT
AMONG 1, 2, 3, 4, 5 AND 6
*2

ARRANGEMENT
AMONG 7, 8, 9, 10, 11 AND 12
AE
: WITH AUTO A/C
1 2 3 4 5 6 7 8 9 10 11 12
i92
1 2
3 4
LAN00254
Step
CHECK DTC.
CHECK DTC.
CHECK DTC.
DTC again.
Check
B0302?
Yes
No
nosis according to
other DTC.
malfunctioning?
tion of harness
connector. Go to
step 3.
Temporary poor
ing?
contact occurs.
LAN(diag)-72

10
11
Step
CHECK CURRENT DATA.
(auto A/C fail).
Check
Is OK displayed?
Yes
Go to step 5.
CHECK AUTO A/C ECM.

2) Disconnect the auto A/C ECM connector.
CHECK HARNESS.
connector (B283).
(B283) No. 1 (B280) No. 26:
(B283) No. 11 (B280) No. 25:
CHECK CURRENT DATA.
(meter fail).
Go to step 6.
No
Perform auto A/C
self-diagnosis.
Diagnostic Chart
Go to step 7.

tion?
AC-32,
circuit of harness.
Model).>
Is OK displayed?
Go to step 8.

CHECK HARNESS.
meter connectors.
(i10) No. 21 (i84) No. 27:
(i10) No. 22 (i84) No. 26:
CHECK CURRENT DATA.
Check the current data of the body integrated
unit (center display fail).
Is B0302 detected?
Go to step 9.
Is OK displayed?
Go to step 11.

2) Disconnect the center display connector
(i90 or i92).
Go to step 12.
Is the harness in normal condi- Go to step 10.

tion?
LAN(diag)-73

<Ref. to IDI-16,
<Ref. to IDI-16,
Repair or replace
the open or short
circuit of harness.
Repair or replace
the center display.
<Ref. to ET-15,
REMOVAL, Navigation Display.>
Go to step 13.

12
13
14
15
16
17
Step
CHECK HARNESS.
1) Disconnect the body integrated unit connector (B280) and the center display connector
(i90 or i92).
the body integrated unit connector and the
center display connector.
Model with navigation
(i90) No. 6 (i84) No. 26:
(i90) No. 14 (i84) No. 27:
Model without navigation
(i92) No. 2 (i84) No. 26:
(i92) No. 4 (i84) No. 27:
2) Display the door switch in analog data.
3) Read the display of data and combination
meter when each door is opened/closed.
HARNESS.
connector.
integrated unit and auto A/C control module
harness.
(B280) No. 26 (B283) No. 1:
(B280) No. 25 (B283) No. 11:
CHECK COMBINATION METER HARNESS.
integrated unit and combination meter connector.
(i84) No. 27 (i10) No. 21:
(i84) No. 26 (i10) No. 22:
Perform auto A/C control module self-diagnosis. <Ref. to AC(diag)-13, A/C CONTROL
SYSTEM SELF-DIAGNOSIS, OPERATION,
Check
Yes
No
Is the harness in normal condi- Replace the center Repair or replace
tion?
display. <Ref. to
the open or short
ET-15, REMOVAL, circuit of harness.
Navigation Display.>
Do the body integrated unit

data indicator and combination meter indicator change
according to operation?
Go to step 14.
Go to step 15.

10?
Go to step 15.
Repair the open

circuit of harness
or replace harness.

10?
Go to step 16.
Repair the open

circuit of harness
or replace harness.
Go to step 17.
Replace the auto

A/C control module. <Ref. to AC32, REMOVAL,
Model).>
<Ref. to IDI-16,

Perform self-diagnosis for the combination
meter system. <Ref. to IDI-3, SELF-DIAGNOSIS, INSPECTION, Combination Meter System.>
LAN(diag)-74
Replace the body

integrated unit.
<Ref. to SL-45,
REMOVAL, Body
Integrated Module.>

U: DTC B0311 CAN-LS METER UNIT DATA ABNORMAL

Combination meter error, or harness between the main harness splice and combination meter is open or
short, the connector is not connected securely and the terminal has poor caulking.
TROUBLE SYMPTOM:
Er Lc is displayed in odo/trip meter.
WIRING DIAGRAM:
A:
A21
A22
COMBINATION METER
A:
i10
1 2
3 4
5 6
7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25
26 27 28 29
30 31 32 33
34 35
V
7
A:
i84
i10
(BLACK)
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
8
V
i77
1 2 3 4 5 6 7 8 9 10 11 12
A27
A26 V
TWISTED WIRE
i77
CAN JOINT
CONNECTOR
A:
i84
INTEGRATED UNIT
LAN00032
Step
Perform the self-diagnosis for combination
Check
LAN(diag)-75
Yes
Read the DTC
again, and then
perform the diagnosis according to
DTC displayed on
the top.
No
<Ref. to IDI-16,
Combination
Meter.>

V: DTC B0313 CAN-LS MONITOR DATA ABNORMAL

Center display unit error, or harness between the center display unit and combination meter is open or short,
the connector is not connected securely and the terminal has poor caulking.
TROUBLE SYMPTOM:
WIRING DIAGRAM:
11
i77
CAN JOINT CONNECTOR

MODEL WITHOUT
NAVIGATION SYSTEM
V
4
CENTER
DISPLAY
A:
BODY
INTEGRATED
UNIT
A27
A26
MODEL WITH
NAVIGATION SYSTEM
V
A:
A14
i84
CENTER
DISPLAY
P
TWISTED WIRE
A:
i103
i84
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
A:
i90
A:
i77
i103
1 2 3 4 5 6 7 8 9 10 11 12
1 2
3 4
(BLACK)
1 2 3 4 5 6 7 8
8 10 11 12 13 14 15 16
A6
i90
LAN00116
Step
Check
Is center display fail OK?
2) Read the fail display of center display.
CHECK NAVIGATION.
Is NAVI fail OK?
2) Read the display of NAVI fail.
LAN(diag)-76
Yes
Go to step 2.
No
Replace the center
display.
Replace the center Send the navigadisplay.

tion unit to repair
center.

W: DTC B0321 CAN-LS METER NO-RECEIVE DATA

Combination meter unit error, or harness between the main harness splice and combination meter unit is
open or short, the connector is not connected securely and the terminal has poor caulking.
TROUBLE SYMPTOM:
Fail mode occurs because the data is not received from combination meter unit.
WIRING DIAGRAM:
A:
A21
A22
COMBINATION METER
A:
i10
1 2
3 4
5 6
7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25
26 27 28 29
30 31 32 33
34 35
V
7
A:
i84
i10
(BLACK)
1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
8
V
i77
1 2 3 4 5 6 7 8 9 10 11 12
A27
A26 V
TWISTED WIRE
i77
CAN JOINT
CONNECTOR
A:
i84
INTEGRATED UNIT
LAN00032
LAN(diag)-77

Step
CHECK COMMUNICATION LINE.
2) Compare the data of body integrated unit
and combination meter using Subaru Select
Monitor.
Check item:
Engine speed
Each door switch
P switch
CHECK HARNESS.
1) Disconnect the body integrated unit, combination meter connector.
connectors.
(i10) No. 21 (i84) No. 27:
(i10) No. 26 (i84) No. 26:
CHECK HARNESS.
1) Disconnect the CAN joint connector (i77)
with connector of unit is disconnected.
connector.
(i10) No. 21 (i77) No. 1:
(i10) No. 26 (i77) No. 7:
(i84) No. 27 (i77) No. 2:
(i84) No. 26 (i77) No. 8:
CHECK HARNESS.
Measure the resistance between harness connector (i77) and chassis ground.
CHECK HARNESS.
2) Measure the voltage between harness connector (i77) and chassis ground.
Perform the self-diagnosis for combination
Check
Is the data displayed same?
Yes
Go to step 2.

?
Go to step 4.

?
Go to step 4.

?

harness.

harness.
Temporary poor
contact occurs.
LAN(diag)-78
No
Perform the selfdiagnosis for combination meter.
<Ref. to IDI-3,
SELF-DIAGNOSIS, INSPECTION,
Combination
Meter System.>
Go to step 3.
Repair or replace
the open circuit of
harness.
Check the connection of connector.

<Ref. to IDI-16,
Combination
Meter.>

X: DTC B0500 KEYLESS UART COM. MALFUNCTION

UART between keyless control unit and body integrated unit is open or shorted, connector is not connected
securely, the terminal has poor caulking.
TROUBLE SYMPTOM:
Door lock does not operate with keyless.
WIRING DIAGRAM:
i83
LR
A4
LR
FB-10
M/B FUSE No.28
(P)
i82
KEYLESS ENTRY
CONTROL MODULE
LR
ILLMINATION & BACK-UP

JOINT CONNECTOR
A:
LR
i84
A9
BY
INTEGRATED
UNIT
YG
YG
BY
i96
i97
BY
BY
GROUND JOINT
CONNECTOR
E
GB-3
i97
i96
A:
i84
i82
1 2 3 4
5 6 7 8
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
i83
1 2 3 4 5 6
7 8 9 10 11 12
LAN00039
LAN(diag)-79

Step
CHECK HARNESS.
1) Disconnect the body integrated unit connector (i84) and keyless entry control module
connector (i96).
2) Measure the resistance between harness.
(i84) No. 9 (i96) No. 3:
CHECK HARNESS.
Measure the resistance between harness connector and chassis ground.
CHECK HARNESS.
2) Measure the voltage between harness connector and chassis ground.
OPERATION CHECK.
Check the door lock operation when the doors
LOCK/UNLOCK using manual LOCK switch.
Check
?
Yes
Go to step 2.

M?

harness.

harness.
Does it operate on switch oper- Go to step 5.

ation?
OPERATION CHECK.
Does it operate?
1) Disconnect the key warning switch connector (B350).
2) Close all the door, and then perform the
LOCK/UNLOCK operation on keyless entry
operation.
LAN(diag)-80
No
Repair or replace
the open circuit of
harness.
Replace the body

integrated unit.
<Ref. to SL-45,
Body Integrated
Module.>
Check key warning Replace the keyswitch.
less entry control
module. <Ref. to
SL-44, Keyless
Entry Control Module.>


A: INSPECTION
Read the DTC or inspect and diagnose the following data in the current data display using Subaru Select
Monitor.
1. LAN SYSTEM
Item
Specifications
Operation
YES
DTC is not displayed.
NO
DTC.
Diagnostic code
DTC is not displayed when inspecting all DTCs.
Engine coolant
temperature
Check the current data display of

ECM, TCM and body integrated
unit, and make sure all data have
same values.
Same values
Inspect LAN system.
R defogger SW
It turns to ON when pressing

switch. (Low-speed CAN is OK)
Turns to ON.
Inspect rear defogger switch.
R defogger output
When switch input, it is output.
Output
Replace the body

integrated unit.
Door lock SW
When locked with door lock switch,

it turns to ON.
Turns to ON.
Inspect door lock

switch.
Door lock actuator
When locked with door lock switch,

it is output.
Output
Replace the body

integrated unit.
NOTE
If engine coolant temperature sensor is not OK,

inspect the sensor circuit.
Rear defogger switch is
connected with Lowspeed CAN.
If not operate with output,
check the rear defogger
relay.
Door lock switch is connected with Low-speed
CAN.

Item
Illumination VR
power supply
R fog light input
Specifications
Operation
Operate the illumination volume,
illumination light is controlled with
changing of data display voltage.
Check the fuel level resistance and
fuel level resistance 2. Both resistances are same.
When turned rear fog light switch to
ON, data display turns to ON.
YES
Illumination light is
controlled with
changing of data.
NO
Inspect the illumination volume.
Same values
Inspect body integrated unit.
Compare the input and

output values of body integrated unit.
Turns to ON.
Inspect rear fog

light switch.
R fog light output
When turned rear fog light switch to

ON, output turns to ON.
Turns to ON.
R wiper SW input
When rear wiper SW to ON, data

display turns to ON.
Turns to ON.
Inspect rear wiper

switch.
R wiper output
When rear wiper switch to ON, output signal turns to ON.
Turns to ON.
Replace the body

integrated unit.
Keyless Entry
Keyless entry LOCK/UNLOCK the

doors.
Operate
Brake SW
Shift lock solenoid
When brake pedal is depressed, it

turns to ON.
The shift lock releases when
depressing the brake pedal.
NOTE
Turns to ON.
Released
LAN(diag)-81
Inspect the keyless antenna.

Inspect brake
switch.
Inspect the shift
lock.
If not operate with output

turned to ON, check the
rear fog light relay.
If not operate with output

turned to ON, check the
rear wiper motor.
If the antenna is OK,
replace the body integrated unit.

Item
Body integrated
unit registration
function setting
Customize
Manual mode
Function check
Security
Specifications
Operation
YES
Does Vehicle equipment correspond to setting values?
Correspondence
When changing customize setting,

the registration completes correctly.
Switch the shift (UP/DOWN) on
Manual mode. Indicator is changed
in 1 2.
Each checking item operate correctly. (Except for not equipped)
After looking with keyless entry system and open the door, security
system is armed and the horn
sounds.
Registered
NO
Reconfigure the
values according to
vehicle equipment.
NOTE
Change
Inspect the shift

lever.
Operate
Inspect for nonfunctional actuator.
Inspect the security system.
Horn sounds.
(Security system
operates.)
LAN(diag)-82
WIRING SYSTEM SECTION

WIRING SYSTEM
WI

of SUBARU vehicles.

approval.
G2320GE8
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.
Page
Working Precautions .................................................................................15
Power Supply Circuit.................................................................................16
Ground Circuit ...........................................................................................30
Airbag System...........................................................................................51
Air Conditioning System............................................................................59
Anti-lock Brake System .............................................................................73
AT Control System ....................................................................................78
Audio System ..........................................................................................116
CAN Communication System..................................................................124
Charging System.....................................................................................128
Clock System ..........................................................................................129
Combination Meter System.....................................................................130
Cruise Control System ............................................................................134
Coolant Temperature System .................................................................149
Engine Electrical System ........................................................................150
Fuel Gauge System ................................................................................239
Full Time Dual-range System..................................................................240
Front Accessory Power Supply Socket System ......................................242
Headlight Beam Leveler System.............................................................243
Horn System ...........................................................................................245
Immobilizer System.................................................................................246
Keyless Entry System .............................................................................248
Back-up Light System .............................................................................257
Clearance Light and Illumination Light System .......................................259
Front Fog Light System...........................................................................267
Headlight System ....................................................................................269
Interior Light System ...............................................................................271
Rear Fog Light System ...........................................................................279
Stop Light System ...................................................................................281
Turn Signal Light and Hazard Light System............................................282
Navigation System ..................................................................................286
Oil Pressure Warning Light System ........................................................290
Parking Brake / Brake Fluid Level Warning Light System.......................291
Power Seat System.................................................................................293
Power Window System ...........................................................................294
Radiator Fan System ..............................................................................302
Rear Defogger System............................................................................304
Remote Control Mirror System................................................................306
Seat Belt Warning System ......................................................................308
Seat Heater System ................................................................................310
Starter System ........................................................................................312
Sunroof Control System ..........................................................................316
WIRING SYSTEM
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
Vehicle Dynamics Control System ..........................................................318

Front Wiper and Washer System ............................................................324
Rear Wiper and Washer System.............................................................326
Wiper Deicer System ..............................................................................328
Alarm Control System .............................................................................329
Rear Accessory Power Supply Socket System.......................................330
Harness Components Location...............................................................331
Front Wiring Harness ..............................................................................335
Bulkhead Wiring Harness (In Engine Compartment) ..............................337
Bulkhead Wiring Harness (In Compartment) ..........................................343
Engine Wiring Harness and Transmission Cord .....................................349
Instrument Panel Wiring Harness ...........................................................357
Rear Wiring Harness...............................................................................361
Door Cord................................................................................................367
Rear Wiring Harness and Trunk Lid Cord ...............................................371
Rear Wiring Harness and Rear Gate Cord .............................................373
Harness Repair Kit ..................................................................................375
WI-2

WIRING SYSTEM
5) The circuit is in good order. If a problem such as

a light failing to illuminate occurs, use the procedures outlined above to track down the malfunction.
A: BASIC PROCEDURES
The most important purpose of diagnostics is to determine which part is malfunctioning quickly, to
save time and labor.
2. IDENTIFICATION OF TROUBLE SYMPTOM

Determine what the problem is based on the symptom.
3. PROBABLE CAUSE OF TROUBLE

Look at the wiring diagram and check the systems
circuit. Then check the switch, relay, fuse, ground,
etc.
2. CIRCUIT CONTINUITY CHECKS

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.
4. LOCATION AND REPAIR OF TROUBLE

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 problem is encountered, check the component parts.
Continuity
No continuity
5. SYSTEM OPERATION CHECK
WI-00095
After repairing, ensure that the system operates

properly.
B: BASIC INSPECTION
1. VOLTAGE MEASUREMENT
3) Symbol indicates that continuity exists

between two points or terminals. For example,
when a switch position is at 3, continuity exists
among terminals 1, 3 and 6, as shown in the table
below.
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 lead of the voltmeter on
connector (A). The voltmeter will indicate a voltage.
3) Shift the positive lead to connector (B). The voltmeter will indicate no voltage.
Terminal
Switch Position
OFF
1
2
3
4
To power
supply
FUSE
(A)
Switch
Light
WI-00096
(B)
V
WI-00094
4) With the test set-up held as it is, turn the switch

ON. The voltmeter will indicate a voltage and, at the
same time, the light will come on.
WI-3

WIRING SYSTEM
3. HOW TO DETERMINE AN OPEN CIRCUIT
between that connector and the next connector

(farther from the power supply) is shorted.
1) WITH VOLTMETER:
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.
Test lamp
Shorted wiring
Fuse holder
WI-00099
Open circuit or wiring
2) WITH OHMMETER:
Disconnect all affected connectors, and check continuity between each connector and ground. When
the ohmmeter indicates continuity between a particular connector and a ground, that connector is
shorted.
V
No voltage is present
Shorted connector
Voltage is present
WI-00097
2) WITH OHMMETER:
Disconnect all connectors affected, and check continuity in the wiring between adjacent connectors.
When the ohmmeter indicates infinite, the wiring
is open.
Continuity exists.
Continuity does not exist.
Open circuit
WI-00100
C: HOW TO READ WIRING DIAGRAMS

1. WIRING DIAGRAM
Continuity exists.
Continuity does not exist.
WI-00098
4. HOW TO DETERMINE A SHORT CIRCUIT

1) WITH TEST LIGHT:
Connect a test light (rated at approx. 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 light goes
out when a connector is disconnected, the wiring
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.
4
Viewed from this direction
WI-00101
WI-4

WIRING SYSTEM
The number of poles or pins, presence of a lock are indicated in the sketch of each connector. In the
sketch, the highest pole number refers to the number of poles which the connector has. For example, the
sketch of the connector shown in figure indicates the connector has 9 poles.
Connector shown in wiring diagram
Connector used in vehicle

Sketch
Symbol
Number of poles
Double frames
Indicates a lock
is included.
Numbered in order from upper

right to lower left.
Indicates the number of poles.
Indicates a lock is included.
Numbered in order from upper

left to lower right
Single frame
WI-00102
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.
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.
i2
BR
RW
F4
1
3
i2
(A)
1 2
3 4
Wire color :
BR (No. 1 terminal)
RW (No. 3 terminal)
WI-00107
WI-00108
WIRING DIAGRAM:
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 the figure.
WI-5

WIRING SYSTEM
In the wiring diagram, connectors which have no

terminal number refer to one-pole types. Sketches
of these connectors are omitted intentionally.
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.
F10
B15
Y B
Marking color :
Reference color :
Black
Yellow
WI-00109
The following color codes are used to indicate

the colors of the wires.
Color code
L
B
Y
G
R
W
Br
Lg
Gr
P
Or
Sb
V
SA
SB
Color
Blue
Black
Yellow
Green
Red
White
Brown
Light green
Gray
Pink
Orange
Light blue
Purple
Sealed (Inner)
Sealed (Outer)
WI-03797
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 sec- No. of
tional area
strands/
strand diam2 eter
mm
0.3
0.5
0.75
0.85
1.25
2
3
5
8
YG
YL
SA
10
9
SB
YL
YG
22
SB
20
SA
SB
SB
YL
YG
2
1
SA
WI-00110
WI-6
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
Outside
diameter of
wiring
Allowable
current
Amps/
mm 40C (104F)
1.8
7
2.2 (or 2.0)
12
2.6 (or 2.4)
16
2.4 (or 2.2)
16
2.7 (or 2.5)
21
3.1 (or 2.9)
28
3.8 (or 3.6)
38
4.6 (or 4.4)
51
5.5
67

WIRING SYSTEM
Each unit is either 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.
Direct ground
Indirect terminal
ground
WI-00112
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.
GA
: ABS GROUND
GAB : AIRBAG GROUND
GE
: ENGINE GROUND
GR
: RADIO GROUND
GV
: VDC GROUND
GB
: BODY GROUND
GD
: REAR DEFOGGER GROUND
WI-03791
WI-7

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.
Relay type
Energizing circuit OFF
Energizing circuit ON
4-pole
Normally-open type
6-pole
Normally-closed type
4-pole
Mixed type
6-pole
Key to symbols:
: Current flows.
: Current does not flow.
WI-00114
WI-8

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 corresponds to the area
or system of the vehicle.
Symbol
F
B
E
T
D
i
R
AB
Wiring harness and cord

Front wiring harness
Bulkhead wiring harness
Engine wiring harness
Transmission cord
Door cord LH & RH, Rear gate cord
Rear door cord LH & RH, Rear defogger cord
Instrument panel wiring harness
Rear wiring harness,
Fuel tank cord,
Roof cord, Rear gate cord,
Rear defogger ground cord (Sedan model)
Airbag wiring harness
F58
F27
F19
F22
F34
F96
F47
F23
F100
F21
F5
F98
Each connector number

shown in wiring diagram
corresponds to that in
the vehicle.
FRONT TURN SIGNAL

LIGHT LH (UPPER)
2
BG
F19
FRONT TURN SIGNAL
LIGHT LH (LOWER)
3
BG
F22
F3
(GRAY)
F19
(GRAY)
1 2
WI-00115
WI-9

WIRING SYSTEM
D: SYMBOLS IN WIRING DIAGRAMS

A number of symbols are used in each wiring diagram to easily identify parts or circuits.
P-SUP-02
P-SUP-02
FUSE No. & RATING

SBF-6 30A
WIRE TRACING
ON EXTENDED
WIRING DIAGRAMS
No.1 20A
No.8 15A
No.2 15A
HEADLIGHT
RELAY
LH
3
R
BW
M
L
K
J
I
H
G
F
E
BG
H1
LOW
SMJ
RL
R
B:
YL
LB
2
1
P-SUP-04
P-SUP-03
P-SUP-03
P-SUP-04
P-SUP-03
P-SUP-04
No.5 10A
A: B51
F45
i5
B62
HIGH
P-SUP-04
D7
D4 LgB
HEADLIGHT LH
P-SUP-04
FUSE &
RELAY
BOX
(F/B)
LB
LW
GR
MB-5
HEADLIGHT
RELAY
BG G7
MB-10
FB-16
MB-11
M/B FUSE NO. 9 F/B FUSE NO. 11
(IG)
WR G4
SMJ
TO POWER SUPPLY CIRCUIT

MB-10
M/B FUSE NO. 8
P-SUP-04
D11 Or
5
G
2
RL
F38
P-SUP-04
RL
SYMBOLS OF
WIRE
CONNECTION
AND CROSSING
F36
POWER SUPPLY
CIRCUIT
H/L(2L)-01
MB-11
7
LW
F68
LR
3
LR
F39
CONNECTOR-1
2
No.9 15A
No.3 10A
HEADLIGHT
RELAY
RH
P-SUP-02
SBF-4 50A
RELAY
SBF-2 50A
SBF-1 100A
MAIN FUSE BOX (M/B)
SBF-3 50A
Example
C: B52
D: B152
E: B158
F23
F:
YL
F7
F44
DIMMER & PASSING

SWITCH
A1
B36
CONNECTOR-2
SMJ
REF. TO ST (MT)-01
REF. TO ST (AT)-01
OR WR
LY
RY
17
17
YB
16
16
13
13
LY
SPECIFICATION
CLASSIFICATION
LIGHTING SWITCH
OFF
HC
TC
OR : WITHOUT REAR DEFOGGER

WR : WITH REAR DEFOGGER
FB-34
HL
FB-35
HU
FB-37
HF
B61
FB-36
UP LOW PASS
LW B1
LW
G1
BL
R
YL
BR D10
R
YL
LW
A3
LW
1
3
2
HIGH
LOW
A2
HEADLIGHT RH
SPECIFICATION
CLASSIFICATION
F40
G: F41
B71
EL
G: F41
C: B52
YB
RY
REF. TO FOG (H6)-01
A: B51
1 2
3
4 5 6 7 8
SD : SEDAN
SD
P
WG
B112
DIODE
17
R3
SD
WG : WAGON
WG
(GRAY)
1
2 3
4 5 6 7
REF. TO FOG (H4)-01
DIODE
B99
HR
B112
F7
(BLACK)
F44
1 2
F23
(BLACK)
1 2 3 4
5 6 7 8
R4
PARKING
BRAKE
SWITCH
GROUND
R1
P
B97
HARNESS
REPAIR KIT
CONNECTOR SKETCH
REF. TO GND-02
WI-04721
1. RELAY
4. FUSE No. & RATING
A symbol used to indicate a relay.
2. CONNECTOR 1
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
3. WIRING CONNECTION
Some wiring diagrams are indicated in foldouts for
convenience. Wiring destinations are indicated
where necessary by corresponding symbols.
(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 G4 refers to No.
4 terminal of connector (G: F41) shown in the connector sketch.
WI-10

WIRING SYSTEM
6. CONNECTOR SKETCH
13.HARNESS REPAIR KIT
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.
The connector adapting to Harness repair kit is

shown as HR in the right-upper of connector number.
Refer to Harness Repair Kit for harness repair kit.
<Ref. to WI-375, SPECIFICATION, Harness Repair Kit.>
7. GROUND
Each grounding point can be located easily by referring to the corresponding wiring harness.
8. DIODE
A symbol is used to indicate a diode.
9. WIRE TRACING ON EXTENDED WIRING

DIAGRAMS
For a wiring 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
Symbol
Refers to wires which are

connected and branched
at the dot point.
Symbol
Refers to wires which are

crossed but not connected.
WI-00117
11.DC POWER SUPPLY CIRCUIT

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 DC POWER SUPPLY
CIRCUIT in the wiring diagram.
Accordingly, using the DC POWER SUPPLY CIRCUIT and wiring diagrams permits service personnel to understand the entire electrical arrangement
of a system.
12.CLASSIFICATION BY SPECIFICATION
When the wiring diagram differ according to vehicle
specifications, the specification difference is described by using abbreviations.
WI-11

WIRING SYSTEM
E: CONNECTOR SYMBOL IN WIRING HARNESS

A number of connector symbols are used in each wiring diagram to easily identify the wiring harness connectors.
WI-12

WIRING SYSTEM
Standard type: Female

Pole: From 1 to 8
Pole: From 9 to 20
Pole: More than 21
Standard type: Male
Water proof type: Female

Pole: From 1 to 8
Pole: From 9 to 20
Pole: More than 21
Water proof type: Male
WI-02445
WI-13

WIRING SYSTEM
F: ABBREVIATION IN WIRING DIAGRAMS

Abbr.
ABS
ACC
A/C
AD
AT
AU
A/B
A/F
ATF
AWD
B, BAT
CPC
D
DN
E
ELR
F/B
Full name
Antilock Brake System
Accessory
Air conditioner
Auto Down
Automatic transmission
Auto Up
Airbag
Air/Fuel (Air fuel ratio sensor)
Automatic transmission fluid
All Wheel Drive
Battery
Canister Purge Control
Drive Range
Down
Ground
Emergency Locking Retractor
Fuse & Relay box
FL1.5
Fusible Link 1.5 mm2

Headlight
Interface
Ignition
Illumination
Intermittent
Left Hand
Low
Motor
Main fuse box
Magnet
Middle
Manual transmission
Neutral Range
Optional Parts or Open
Parking Range
Passing
Reverse Range
Right Hand
Slow Blow Fuse
Starter
Switch
Tumble generated valve
Up
Vehicle Dynamics Control
Variable Valve Lift
Washer
H/L
I/F
IG
Illumi.
INT
LH
Lo
M
M/B
MG
Mi
MT
N
OCV
OP
P
PASS
R
RH
SBF
ST
SW
TGV
U, UP
VDC
VVL
WASH
WI-14
Working Precautions
WIRING SYSTEM
2. Working Precautions
A: PRECAUTIONS WHEN WORKING
WITH THE PARTS MOUNTED ON
THE VEHICLE
To connect, insert the connector until it snaps and

confirm that it is tightly connected.
Example
PUSH
PUSH
B: PRECAUTIONS IN TROUBLE DIAGNOSIS AND REPAIR OF ELECTRIC PARTS

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.
PUSH
LIFT
1) When working under a vehicle which is jackedup, always be sure to use rigid rack.
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 turned off.
LIFT
WI-00119
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 water-proof connectors (which are not
measurable from the wiring side), contact test
probes on the terminal side. Be careful not to bend
or damage the terminals.
WI-02757
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.
Tester probes
"Mini" test leads
WI-00120
7) Sensors, relays, electrical unit, etc., are sensitive to strong impacts.

Handle them with care so that they are not dropped
or mishandled.
WI-15

WIRING SYSTEM
3. Power Supply Circuit

A: WIRING DIAGRAM
P-SUP(L)-01
P-SUP(L)-01
1. LHD MODEL
MAIN FUSE BOX (M/B)
NO. 8
SBF-7
NO. 11
SBF-3
SBF-2
SBF-9
NO. 3
NO. 1
NO. 4
NO. 2
NO. 12
SBF-4
NO. 13
HORN
RELAY
R.DEF
RELAY
NO. 5
NO. 15
NO. 16
NO. 9
NO. 10
H/L
RELAY
LH
SBF-5
NO. 14
NO. 6
TAIL
RELAY
NO. 7
MAIN
FAN
RELAY-1
MAIN
SBF-1
H/L
RELAY
RH
SBF-6
SBF-8
FUSE & RELAY BOX (F/B)
NO. 27
NO. 20
NO. 13
NO. 6
NO. 28
NO. 21
NO. 14
NO. 7
NO. 29
NO. 22
NO. 15
NO. 8
NO. 1
NO. 30
NO. 23
NO. 16
NO. 9
NO. 2
NO. 31
NO. 24
NO. 17
NO. 10
NO. 3
NO. 32
NO. 25
NO. 18
NO. 11
NO. 4
NO. 33
NO. 26
NO. 19
NO. 12
NO. 5
WI-03895
WI-16
P-SUP(L)-02
BATTERY
P-SUP(L)-05
P-SUP(L)-05
P-SUP(L)-02
WIRING SYSTEM
BATTERY CURRENT
CURRENT FROM IGNITION
SWITCH IG TERMINAL
P-SUP(L)-03
P-SUP(L)-03
P-SUP(L)-04
P-SUP(L)-05
P-SUP(L)-05
P-SUP(L)-04
P-SUP(L)-04
MAIN
SBF-1 120A
OTHER CURRENT
B19 GB
H4 GOr

SWITCH ACC TERMINAL
F26
A:
F37
E:
F36
B: B143 G: B145
C:
F35
NO. 2 25A
H6
NO. 10 25A
MAIN FUSE BOX (M/B)
NO. 4 25A
NO. 8 20A
SBF-9 50A
SBF-7 50A
SBF-4 50A
SBF-3 50A
NO. 3 25A
NO. 5 20A
NO. 1 30A
A9
A7
A19
MAIN FAN
RELAY 1
WR
BW
BR
REAR DEFOGGER RELAY
2
1
3
SBF-2 50A
NO. 16 7.5A
GENERATOR
H6
W
H4
H: B186
F26
1 2 3
G: B145 (BROWN)
E:
F36
1 2
4 5
3
7
1
5
2
6
D1
E3
D8
D6
D2
D3
D9
G7
H8
E5
E6
B7
RB
RW
LR
RL
VG
LR
*1
WR
3
8
4
9
F35
(BLUE)
3 4 5
1 2
6 7 8 9 10 11 12
B: B143
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
H4
MB-9
MB-10
MB-8
MB-7
MB-6
MB-5
MB-29
C:
RL C10
D5
RY
D: B144 (BROWN)
H: B186
1
2 3
4 5 6 7 8
MB-4
: 4-CYLINDER ENGINE MODEL : YG

: 6-CYLINDER ENGINE MODEL : LW
MB-3
*1
MB-2
: 6-CYLINDER ENGINE MODEL
MB-1
H6
ALT-1
H4
ALT-2
H4
D7
WR
WB B11
BR
B1
D: B144
A:
1 2 3 4
10 11 12 13 14
F37
5 6 7 8 9
15 16 17 18 19 20
WI-03896
WI-17
P-SUP(L)-03
P-SUP(L)-05
SBF-5 30A
NO. 14 15A
NO. 12 15A
NO. 11 15A
SBF-8 30A
SBF-6 30A
HORN RELAY
NO. 13 7.5A
B16
HEADLIGHT RELAY LH
MAIN FUSE
BOX (M/B)
F37
NO. 9 15A
NO. 6 15A
NO. 7 15A
B: B143
TAIL & ILLUMINATION RELAY
C:
F35
D: B144
E:
F36
G: B145
H5
H6
WB
BW G4
H7
YR
WG H3
G6
WL
WR G5
G1
WY
B6
H1
C9
RG
RW
C8
RL
LY B15
E1
RB
H2
BW
E4
G3
GY
B8
C2
GY
H: B186
GW C1
G2
W
H4
GB C11
P-SUP(L)-05
A:
RB
RG
P-SUP(L)-02
HEADLIGHT RELAY RH
NO. 15 20A
P-SUP(L)-02
Br
B18 BrR
P-SUP(L)-03
WIRING SYSTEM
E:
F36
1 2
4 5
3
7
1
5
2
6
3
8
4
9
C:
F35
(BLUE)
3 4 5
1 2
6 7 8 9 10 11 12
B: B143
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
P-SUP(L)-04
P-SUP(L)-04
P-SUP(L)-04
MB-30
MB-28
MB-27
MB-26
MB-25
MB-24
MB-23
MB-22
MB-21
MB-20
MB-19
MB-18
MB-17
MB-16
MB-15
D: B144 (BROWN)
H: B186
1
2 3
4 5 6 7 8
MB-14
MB-31
MB-13
MB-12
MB-11
G: B145 (BROWN)
MB-32
H4 : 4 CYLINDER
ENGINE
MODEL
A:
1 2 3 4
10 11 12 13 14
F37
5 6 7 8 9
15 16 17 18 19 20
WI-03897
WI-18

N
P-SUP(L)-03
M
E
H
L
I
P-SUP(L)-04
P-SUP(L)-03
C:
E7
NO. 15 20A
NO. 2 20A
NO. 14 15A
E8
C4
Or
C20 WG
NO. 16 15A
NO. 29 15A
PARKING
SWITCH
B69
C21 GY
LR
E2
R
F6
NO. 28 15A
NO. 3 15A
NO. 17 15A
i5
B: R168
NO. 9 20A
A:
NO. 1 20A
FUSE &
RELAY BOX
(F/B)
NO. 8 20A
E6
E4
P-SUP(L)-02
OFF
NO. 27 15A
P-SUP(L)-03
B
ON
BW
P-SUP(L)-02
NO. 10 7.5A
P-SUP(L)-02
P-SUP(L)-04
WIRING SYSTEM
B52
D: B152
E: B158
B2
B6
A13
A7
BL C17
C5
V
BL B12
A11
B10
A4
LR
C2
RL
LR B13
F1
GL
E3
LB
WOr D10
E1
WL
WG A9
C23
W
LW C15
B4
LG
F: B159
WOr
OP
CONNECTOR
B69
1 2
3 4
E: B158
1 2
5 6
C:
3
7
F: B159 (BROWN)
4
8
1
5
2
6
3
8
4
9
D: B152
3 4
1 2
5 6 7 8 9 10
B228
1 2
3
4 5 6 7 8 9
10 11 12 13 14 15
A:
i5
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
FB-16
FB-15
FB-14
FB-13
FB-12
FB-11
FB-10
FB-9
FB-8
FB-7
FB-6
FB-5
FB-4
FB-3
FB-2
FB-1
B228
B: R168
1 2 3 4
10 11 12 13 14
5 6 7 8 9
15 16 17 18 19 20
B52
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
WI-03898
WI-19
P-SUP(L)-05
IGNITION SWITCH
OFF ACC ON ST
P-SUP(L)-02
P-SUP(L)-02
+B
ACC
IG1
IG2
WB
ST
P-SUP(L)-05
WIRING SYSTEM
WB
F8
F3
F2
IG 2 RELAY
NO. 7 15A
ACCESSORY RELAY
F7
E5
B72
FUSE &
RELAY BOX
(F/B)
A:
i5
C: B52
NO. 21 7.5A
NO. 22 15A
NO. 33 7.5A
NO. 32 7.5A
NO. 26 15A
NO. 25 15A
NO. 19 7.5A
NO. 12 15A
NO. 5 15A
NO. 18 10A
NO. 11 7.5A
NO.4 15A
NO. 31 7.5A
NO. 30 30A
NO. 24 15A
NO. 23 15A
NO. 20 10A
NO. 6 7.5A
NO. 13 20A
B: R168
D: B152
E: B158
F: B159
G: AB35
YR
GY
D1
D8
WL
GOr C1
D3
GY
GOr A3
D2
Br
GB C11
GY
H2
G2
BrR D4
H1
G1
R
GR C24
A8
GR
BrW A20
D9
GB
GL C16
A6
A5
GY
GB
D7
YR
C8
A1
YR
B18
F4
YB
GY
C7
YR
C3
YG
YR A17
B1
YG
YG A19
D6
YL
B: R168
5 6 7 8 9
15 16 17 18 19 20
3
7
4
8
C:
1
5
2
6
3
8
4
9
3 4
1 2
5 6 7 8 9 10
B228
1 2
3
4 5 6 7 8 9
10 11 12 13 14 15
A:
ST-2
ST-1
FB-46
FB-45
FB-44
FB-43
FB-42
FB-41
FB-40
FB-39
FB-38
FB-37
FB-36
FB-35
FB-34
FB-32
FB-30
FB-29
FB-33
D: B152
F: B159 (BROWN)
E: B158
1 2
5 6
FB-28
FB-27
FB-26
FB-25
FB-24
FB-23
FB-22
B
1 2 3
4 5 6
1 2
1 2 3 4
10 11 12 13 14
YW B14
YL A10
B72
FB-21
FB-17
P-SUP(L)-02
FB-20
P-SUP(L)-03
J
B
K
A
FB-19
P-SUP(L)-02
OP
CONNECTOR
B228
FB-18
P-SUP(L)-03
WL C19
WL B11
G: AB35
REF. TO GROUND
DISTRIBUTION
SYSTEM
[GND(L)-02]
i5
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
B52
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
WI-03899
WI-20

WIRING SYSTEM
No.
MB-1
MB-2
MB-4
MB-5
MB-6
MB-7
MB-8
MB-9
MB-10
MB-11
MB-12
MB-13
MB-14
MB-15
MB-16
MB-17
MB-18
MB-19
MB-20
MB-21
MB-22
MB-23
MB-24
MB-25
MB-26
MB-27
MB-28
MB-29
MB-30
MB-31
MB-32
ALT-1
ALT-2
Load
ABS control module
VDC control module
ABS control module
VDC control module
Sub fan relay
Mirror heater relay
Rear defogger
Main fan relay 2
Main fan motor
PWM controller
ECM
Main fan relay 2
Main fan relay 2
Headlight leveler LH
Headlight leveler RH
Lighting switch
OP connector
Combination meter
Headlight LH
Headlight RH
Dimmer/Passing switch
Lighting diode
OP connector
Horn (HI)
Horn (LO)
Horn switch
Oxygen (A/F) sensor relay
Main relay
Main relay
Main relay 2
Fuel pump relay
TCM
Data link connector
ECM
Key switch illumination
Key warning switch
Turn signal and hazard unit
Interior light
Spot map light
Power window circuit breaker
F/B fuse No. 16
Headlight leveler switch
Parking light switch
ECM
Combination meter
OP connector
No.
ST-1
ST-2
FB-2
FB-3
FB-4
FB-5
FB-6
FB-8
FB-9
FB-10
FB-11
FB-12
FB-13
FB-14
FB-17
FB-18
FB-19
FB-20
FB-21
FB-22
FB-23
FB-24
FB-25
FB-26
FB-27
FB-28
FB-29
FB-30
WI-21
Load
ECM (AT)
Starter relay
Starter relay
Rear fog light relay
Stop light switch
Mirror heater relay
Wiper deicer relay
Seat heater relay
Blower fan relay
Front fog light relay
Audio
Clock
Navigation unit
Step light LH
Step light RH
TV monitor
Luggage room light (Wagon model)
Trunk room light (Sedan model)
Clock
Seat heater switch
OP connector
Combination meter
LAN unit
Remote controlled mirror switch
Seat heater relay
Vanity mirror illumination LH
Vanity mirror illumination RH
Luggage room power socket
Seat heater switch
Front accessory power supply socket
Rear wiper motor
Rear washer motor
Audio
Clock
Distributor
Navigation unit
TV monitor
Front washer motor
OP connector
Front wiper motor
Front wiper switch
Front washer motor
A/C control panel
TCM
TV monitor

WIRING SYSTEM
No.
FB-32
FB-33
FB-34
FB-35
FB-36
FB-37
FB-38
FB-39
FB-41
FB-42
FB-44
FB-45
FB-46
Load
Brake switch
Clutch switch (MT/Cruise)
ECM
OP connector
Line end check connector
Sunroof control unit
Sunroof switch
Wiper deicer relay
Clock
Back-up light relay (5-speed AT model)
Back-up light switch (MT model)
Inhibitor switch (4-speed AT model)
Combination meter
ECM
Fuel pump relay
P-VIGN relay
Rear vehicle speed sensor (4-speed AT model)
TCM
Airbag control module
Power window relay
ABS control module
VDC control module
A/C control panel
A/C relay
Blower fan relay
FRESH/RECIRC actuator
Mode actuator
Pressure switch
Sub fan relay
Heater cock solenoid
WI-22

WIRING SYSTEM
P-SUP(R)-01
P-SUP(R)-01
2. RHD MODEL
MAIN FUSE BOX (M/B)
NO. 8
SBF-7
NO. 11
SBF-3
SBF-2
SBF-9
NO. 3
NO. 1
NO. 4
NO. 2
NO. 12
SBF-4
NO. 13
HORN
RELAY
R.DEF
RELAY
NO. 5
NO. 15
NO. 16
NO. 9
NO. 10
H/L
RELAY
LH
SBF-5
NO. 14
NO. 6
TAIL
RELAY
NO. 7
MAIN
FAN
RELAY-1
MAIN
SBF-1
H/L
RELAY
RH
SBF-6
SBF-8
NO. 27
NO. 20
NO. 13
NO. 6
NO. 28
NO. 21
NO. 14
NO. 7
NO. 29
NO. 22
NO. 15
NO. 8
NO. 1
NO. 30
NO. 23
NO. 16
NO. 9
NO. 2
NO. 31
NO. 24
NO. 17
NO. 10
NO. 3
NO. 32
NO. 25
NO. 18
NO. 11
NO. 4
NO. 33
NO. 26
NO. 19
NO. 12
NO. 5
WI-03900
WI-23

P-SUP(R)-02
BATTERY
P-SUP(R)-05
P-SUP(R)-05
P-SUP(R)-02
WIRING SYSTEM
BATTERY CURRENT
SWITCH IG TERMINAL
P-SUP(R)-03
P-SUP(R)-03
MAIN
SBF-1 120A
OTHER CURRENT
B19 GB
H4 GOr

SWITCH ACC TERMINAL
F26
A:
F37
E:
F36
B: B143 G: B145
C:
F35
H6
NO. 10 25A
MAIN FUSE BOX (M/B)
NO. 4 25A
NO. 8 20A
SBF-9 50A
SBF-7 50A
SBF-4 50A
SBF-3 50A
NO. 3 25A
NO. 5 20A
NO. 1 30A
A9
A7
A19
MAIN FAN
RELAY 1
WR
BW
BR
REAR DEFOGGER RELAY
2
1
3
SBF-2 50A
NO. 16 7.5A
GENERATOR
NO. 2 25A
H6
W
H4
H: B186
E3
D8
D6
D2
D3
D9
G7
H8
E5
E6
B7
RW
LR
RL
VG
LR
*1
BR
RL C10
D1
RB
H4
D5
RY
H4
D7
WR
BW B11
BR
B1
D: B144
P-SUP(R)-04
P-SUP(R)-04
1 2 3
G: B145 (BROWN)
E:
F36
1 2
4 5
3
7
MB-4
MB-2
D: B144 (BROWN)
H: B186
1
2 3
4 5 6 7 8
MB-1
ALT-1
F26
1
5
2
6
3
8
4
9
C:
F35
(BLUE)
3 4 5
1 2
6 7 8 9 10 11 12
B: B143
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
MB-9
P-SUP(R)-05
MB-10
MB-8
P-SUP(R)-05
MB-7
MB-6
P-SUP(R)-04
MB-5
: 4-CYLINDER ENGINE MODEL : YG

: 6-CYLINDER ENGINE MODEL : LW
MB-29
MB-3
H6
ALT-2
H4
A:
1 2 3 4
10 11 12 13 14
F37
5 6 7 8 9
15 16 17 18 19 20
WI-03901
WI-24

P-SUP(R)-03
P-SUP(R)-05
SBF-5 30A
NO. 14 15A
NO. 12 15A
NO. 11 15A
SBF-8 30A
SBF-6 30A
HORN RELAY
NO. 13 7.5A
B16
HEADLIGHT RELAY LH
MAIN FUSE BOX

(M/B)
A:
F37
NO. 9 15A
NO. 7 15A
NO. 6 15A
C:
F35
D: B144
E:
F36
G: B145
H5
H6
WB
BW G4
H7
YR
WG H3
WR G6
WR G5
G1
WY
B6
H1
C9
RG
C8
RL
LY B15
E1
RB
H2
BW
E4
G3
GY
B8
C2
GY
H: B186
GW C1
G2
W
H4
GB C11
P-SUP(R)-05
B: B143
RB
RG
P-SUP(R)-02
HEADLIGHT RELAY RH
NO. 15 20A
P-SUP(R)-02
Br
B18 BrR
P-SUP(R)-03
WIRING SYSTEM
G: B145 (BROWN)
E:
F36
1 2
4 5
3
7
1
5
2
6
3
8
4
9
C:
F35
(BLUE)
3 4 5
1 2
6 7 8 9 10 11 12
B: B143
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
P-SUP(R)-04
P-SUP(R)-04
P-SUP(R)-04
MB-30
MB-28
MB-27
MB-26
MB-25
MB-24
MB-23
MB-22
MB-21
MB-20
MB-19
MB-18
MB-17
MB-16
MB-15
D: B144 (BROWN)
H: B186
1
2 3
4 5 6 7 8
MB-14
MB-31
MB-13
MB-12
MB-11
: 4-CYLINDER
ENGINE
MODEL
MB-32
H4
A:
1 2 3 4
10 11 12 13 14
F37
5 6 7 8 9
15 16 17 18 19 20
WI-03902
WI-25

N
P-SUP(R)-03
M
E
H
L
I
P-SUP(R)-04
P-SUP(R)-03
C:
E7
NO. 15 20A
NO. 2 20A
NO. 14 15A
E8
C4
Or
C20 WG
NO. 16 15A
NO. 29 15A
PARKING
SWITCH
B69
C21 GY
LR
E2
R
F6
NO. 28 15A
NO. 3 15A
NO. 17 15A
i5
B: R168
NO. 9 20A
A:
NO. 1 20A
FUSE &
RELAY BOX
(F/B)
NO. 8 20A
E6
E4
P-SUP(R)-02
OFF
NO. 27 15A
P-SUP(R)-03
B
ON
BW
P-SUP(R)-02
NO. 10 7.5A
P-SUP(R)-02
P-SUP(R)-04
WIRING SYSTEM
B52
D: B152
E: B158
WR
B2
B6
A13
A7
C17
C5
V
BL B12
A11
B10
A4
LR
C2
RL
LR B13
F1
GL
WR D10
WG A9
E3
LB
LW C15
E1
WL
LG
B4
LG C23
F: B159
OP
CONNECTOR
E: B158
B69
1 2
5 6
1 2
3 4
3
7
B: R168
1 2 3 4
10 11 12 13 14
5 6 7 8 9
15 16 17 18 19 20
F: B159 (BROWN)
4
8
1
5
2
6
C:
3
8
4
9
D: B152
3 4
1 2
5 6 7 8 9 10
B228
1 2
3
4 5 6 7 8 9
10 11 12 13 14 15
FB-15
FB-14
FB-13
FB-12
FB-11
FB-10
FB-9
FB-8
FB-7
FB-6
FB-5
FB-4
FB-3
FB-2
FB-1
B228
A:
i5
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
B52
6 7 8 9 10 11
1 2 3 4 5
12 13 14 15 16 17 18 19 20 21 22 23 24
WI-03903
WI-26

P-SUP(R)-05
IGNITION SWITCH
OFF ACC ON ST
P-SUP(R)-02
P-SUP(R)-02
+B
ACC
IG1
IG2
WB
ST
P-SUP(R)-05
WIRING SYSTEM
WB
F8
F3
F2
IG 2 RELAY
NO. 7 15A
ACCESSORY RELAY
F7
E5
B72
FUSE &
RELAY
BOX (F/B)
A:
i5
C: B52
NO. 21 7.5A
NO. 22 15A
NO. 33 7.5A
NO. 32 7.5A
NO. 26 15A
NO. 25 15A
NO. 19 7.5A
NO. 12 15A
NO. 5 15A
NO. 18 10A
NO. 11 7.5A
NO.4 15A
NO. 31 7.5A
NO. 30 30A
NO. 24 15A
NO. 23 15A
NO. 20 10A
NO. 6 7.5A
NO. 13 20A
B: R168
D: B152
E: B158
F: B159
G: AB35
YR
GY
D1
D8
WL
GOr C1
D3
GY
GOr A3
D2
Br
GB C11
GY
G2
H2
H1
G1
BrR D4
GR C24
A8
GR
BrW A20
D9
G
GL C16
A5
GY
OrG A6
D7
YR
C8
A1
YR
B18
F4
YB
GY
C7
YR
C3
YG
YR A17
B1
YG
YG A19
D6
YL
B: R168
5 6 7 8 9
15 16 17 18 19 20
E: B158
1 2
5 6
3
7
C:
1
5
2
6
3
8
4
9
3 4
1 2
5 6 7 8 9 10
B228
1 2
3
4 5 6 7 8 9
10 11 12 13 14 15
A:
ST-2
ST-1
FB-46
FB-45
FB-44
FB-43
FB-42
FB-41
FB-40
FB-39
FB-38
FB-37
FB-36
D: B152
F: B159 (BROWN)
4
8
FB-35
FB-34
FB-33
FB-32
FB-30
FB-29
FB-28
FB-27
FB-26
FB-25
FB-24
FB-23
FB-22
B
1 2 3
4 5 6
1 2
1 2 3 4
10 11 12 13 14
YW B14
YL A10
B72
FB-21
FB-17
P-SUP(R)-02
FB-20
P-SUP(R)-03
J
B
K
A
FB-19
P-SUP(R)-02
OP
CONNECTOR
B228
FB-18
P-SUP(R)-03
WL C19
WL B11
G: AB35
REF. TO GROUND
DISTRIBUTION
SYSTEM
[GND(R)-02]
i5
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
B52
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
WI-03904
WI-27

WIRING SYSTEM
No.
MB-1
MB-2
MB-3
MB-4
MB-5
MB-6
MB-7
MB-8
MB-9
MB-10
MB-11
MB-12
MB-13
MB-14
MB-15
MB-16
MB-17
MB-18
MB-19
MB-20
MB-21
MB-22
MB-23
MB-24
MB-25
MB-26
MB-27
MB-28
MB-29
MB-30
MB-31
MB-32
Load
ABS control module
VDC control module
ABS control module
VDC control module
Audio amplifier (Model with McIntosh)
Sub fan relay
Mirror heater relay
Rear defogger
Main fan relay 2
Main fan motor
PWM controller
ECM
Main fan relay 2
Main fan relay 2
Headlight leveler LH
Headlight leveler RH
Lighting switch
OP connector
Combination meter
Headlight LH
Headlight RH
Dimmer/passing switch
Lighting diode
OP connector
Horn (HI)
Horn (LO)
Horn switch
Main relay
Main relay
Main relay 2
Fuel pump relay
TCM
Data link connector
ECM
Alarm control module
Key switch illumination
Key warning switch
Interior light
Spot map light
Power window circuit breaker
F/B fuse No. 16
Headlight leveler switch
No.
ALT-1
ALT-2
ST-1
ST-2
FB-2
FB-3
FB-4
FB-5
FB-6
FB-8
FB-9
FB-10
FB-11
FB-12
FB-13
FB-14
FB-17
FB-18
FB-19
FB-20
FB-21
FB-22
FB-23
FB-24
FB-25
FB-26
FB-27
FB-28
FB-29
WI-28
Load
ECM
Combination meter
OP connector
ECM (AT)
Starter relay
Starter relay
Stop light switch
Mirror heater relay
Wiper deicer relay
Seat heater relay
Blower fan relay
Audio
Clock
Navigation unit
Step light LH
Step light RH
TV monitor
Luggage room light (Wagon model)
Trunk room light (Sedan model)
Seat belt buzzer
Clock
Seat heater switch
OP connector
Combination meter
LAN unit
Remote controlled mirror switch
Seat heater relay
Vanity mirror illumination LH
Vanity mirror illumination RH
Luggage room power socket
Seat heater switch
Front accessory power supply socket
Rear wiper motor
Rear washer motor
Audio
Clock
Distributor
Navigation unit
TV monitor
Front washer motor
OP connector
Front wiper motor
Front wiper switch
Front washer motor
A/C control panel
TCM

WIRING SYSTEM
No.
FB-30
FB-32
FB-33
FB-34
FB-35
FB-36
FB-37
FB-38
FB-39
FB-41
FB-42
FB-44
FB-45
FB-46
Load
TV monitor
Brake switch
Clutch switch (MT/Cruise)
ECM
OP connector
Line end check connector
Sunroof control unit
Sunroof switch
Wiper deicer relay
Clock
Back-up light relay (5-speed AT model)
Back-up light switch (MT model)
Inhibitor switch (4-speed AT model)
Combination meter
ECM
Fuel pump relay
Ignition coil No. 1
Ignition coil No. 2
Ignition coil No. 3
Ignition coil No. 4
P-VIGN relay
Rear vehicle speed sensor (4-speed AT model)
TCM
Power window relay
ABS control module
VDC control module
A/C control panel
A/C relay
Blower fan relay
FRESH/RECIRC actuator
Mode actuator
Pressure switch
Sub fan relay
Heater cock solenoid
WI-29
F3
C:
F35
3 4 5
1 2
6 7 8 9 10 11 12
B
F23
(GRAY)
F6
F19
(GRAY)
HR
F21 (BLACK)
R51
(BLACK)
R54
(BLACK)
(BLUE)
HR
(BLACK)
F17
2 1
1 2
B228
1 2
3
4 5 6 7 8 9
10 11 12 13 14 15
(BLACK)
F27
GB-1
GB-2
F58
HR
F59
HR
R50
4 5 6 7
1 2 3
8 9 10 11 12 13 14 15 16
R52
1 2 3
WI-30
F106
1 2 3
1 2
3
F7
F23
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
HR
HR
16
B225
STARTER RELAY
(FOR 2.0L & 2.5L KS MODEL)
B225
MIRROR HEATER RELAY

B
32
B225
SEAT HEATER RELAY

B
40
B225
POWER WINDOW RELAY

B
20
MAIN FAA RELAY 2

(4-CYLINDER ENGINE MODEL)
F27
FWD SWITCH (4AT)

B
19
HEADLIGHT & FRONT

CLEARANCE LIGHT LH
F17
18
19
20 21
22
23
B90
R50
B32
TURN SIGNAL &

HAZARD MODULE
B
7
B228
OP CONNECTOR
B
7
F58
HEADLIGHT LEVELER LH
B
1
F19
FRONT TURN SIGNAL LIGHT LH

B
1
F21
FRONT FOG LIGHT LH

B
2
MAIN FAN MOTOR

(4 CYLINDER ENGINE MODEL)
GND(L)-01
3
F7
F35
R56
1 2
B225
10
8 9 11
12
24 25
26
27
28 29
GND(L)-01
R56
SPOT MAP LIGHT

B
1
R52
ROOM LIGHT
B
1
R54
VANITY MIRROR ILLUMI.

LIGHT LH
B
2
R51
VANITY MIRROR ILLUMI.

LIGHT RH
B
2
R55
SUNROOF CONTROL MODULE

(SEDAN)
B
4
C:
MAIN FUSE BOX (M/B)

B C12
HEADLIGHT & FRONT

CLEARANCE LIGHT RH
F59
HEADLIGHT LEVELER RH
B
1
F6
FRONT FOG LIGHT RH

B
2
F3
FRONT TURN
SIGNAL LIGHT RH
B
1
F106
PWM CONTROLLER
WIRING SYSTEM
Ground Circuit
4. Ground Circuit
A: WIRING DIAGRAM
1. LHD CHASSIS GROUND
A
GND(L)-03
B
GND(L)-02
B32
R55
1 2
3
4 5 6 7 8
1 2 3
4 5 6
1 2 3 4 5
6 7 8 9 10
F27
1
2 4 5
3
13
14 16 17
15
30
31
WI-03905
Ground Circuit
BY
1 2 3 4
B116
16
BY
GND(L)-04
GND(L)-03
R2
B98
3 4
1 2
5 6 7 8 9 10
4 5 6 7
1 2 3
8 9 10 11 12 13 14 15 16
8
17
1
10
2
11
3
12
4 5 6
13 14 15
A:
B54
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
HR
B: B143
B70
B71
7
16
GND(L)-04
i1
B360 (GRAY)
D: B152
1 2 3
4 5 6
3 4 5 6
11 12 13 14 15
GND(L)-04
BY
B
HR
(DARK GRAY)
HR
F23 (DARK GRAY)
HR
C
D
GB-4
F7
B231
GND(L)-02
B366
LAN MODULE
BY 15
B: B280
C: B281
C9
B36
GB-6
2
10
BY B22
B
BY
GND(L)-01
1
9
BY

BY C8
B81
BY
DIAGNOSIS TERMINAL
BY
D: B152

B D8
B116
AT SELECT LEVER
B
4
B350
KEY LOCK SOLENOID

B
1
2
B70
COMBINATION
SWITCH (WIPER)
23
24
B98
B350
B231
STEERING ANGLE SENSOR

BY
3
B184
BY
KEYLESS ENTRY CONNECTOR
B:
B55
B54
BY B21
A:
A14
B
BY A19
TCM (5AT)
B A5
B20
B
B: B143
MAIN FUSE BOX (M/B)
F7
B71
B
BY
YL
22
10
16
B
COMBINATION
SWITCH (LIGHTING)
B
2
B360
23
F109
HEADLIGHT RH
YL
2
F23
YW
THROUGH JOINT CONNECTOR
GND(L)-02
HEADLIGHT LH
YW 2
WIRING SYSTEM
7
16
8
17
9
18
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
7
16
22
8
17
23
i1
F109
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
C: B281
HR
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
22 23
24 25 26
27 28
20 21
B366
HR
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
9
18
24
B:
B55
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
B: B280
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
HR
(GRAY)
7
16
22
8
17
23
9
18
24
HR
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
WI-03906
WI-31
Ground Circuit
GND(L)-03
GND(L)-04
BY
BY
GB-5
GR
GB-7
B16
i29
AUDIO BRACKET GROUND

B
i99
GROUND JOINT CONNECTOR

B
1
i97

BY
1
B362
1
B
B347
FUEL PUMP RELAY

1
B
VDC SHIELD
JOINT CONNECTOR
B88
3
B
EVAPORATION THERMO
SWITCH (MANUAL A/C)
B29
BY
LO (AWD) SWITCH
10
BY
B116
6
BY
AT SELECT LEVER
BY
2
B
R2
i26
B
B98
GND(L)-02
B177
B86
WIPER DEICER
B16
BRAKE FLUID
LEVEL SWITCH
10
B
B77
BLOWER FAN RESISTOR

B
1
B10
A/C PRESSURE SWITCH

B
3
MODE ACTUATOR
(MANUAL A/C)
11
B12
B301
ABS CONTROL MODULE

B
15
4
B
INHIBITOR
SWITCH (SOHC)
B8
FRONT WIPER MOTOR

B
2
AUDIO
B
11
GND(L)-01
B310
BY A16
A: B282
VDC
CONTROL MODULE
B
6
GND(L)-03

BY A14
WIRING SYSTEM
(GRAY)
1
2
B29
HR
(BLACK)
GB-3
B10
B177
B347
1 2
1
4
2
B86
B8
1 2
3 4
1 2 3
4 5
2 1
B77
HR
1 2 3 4 5
6 7 8 9 10
HR
B116
B12
3 4
1 2
5 6 7 8 9 10
1 2 3 4
5 6 7 8
9 10 11 12
13
14
B362
1 2 3 4 5
1 2
15
HR
i97
i26
i99
1 2 3
4 5 6
7 8 9 10 11 12 13 14
3
4
B98
4 5 6 7
1 2 3
8 9 10 11 12 13 14 15 16
1 2 3 4 5 6
7 8 9 10 11 12
B310
B301
12
B88
5
7 8
6
A: B282
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
HR
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
5
6
7
8
9
10
1 2 3 4
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
WI-03907
WI-32
R142 (BLACK)
R25
(BLACK)
R43
1 2 3 4 5
6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
SD : SEDAN
GB-8
1
2
1 2
R32
R109 (BLACK)
R9
R16
R8
WG :
R26
SD :
R26
R58
1
R188
R12
R22
R107
WG :
R28
SD :
R28
1 2
3 4
5 6
1
2
3
C: B281
1 2 3 4
WI-33
OF : WITHOUT FUEL PUMP
CONTROL MODULE
2 1
4 3
R79
R122
i98
B97
i102
1 2 3 4 5
6 7 8 9 10
3 4
1 2
5 6 7 8 9 10
i100
4 5 6 7
1 2 3
8 9 10 11 12 13 14 15 16
1 2 3 4
5 6 7 8
9 10 11 12 13 14 15 16 17 18
BY
GND(L)-02
i102
R79
R107
FRONT SEAT BELT SWITCH RH

BY
1
R8
FRONT SEAT BELT SWITCH LH

BY
1
R58
BY
FUEL PUMP
TRAILER CONNECTOR
B
8
R167
BY
10
BY
GND(L)-02
GND(L)-02
B
11
1 2 3
4 5 6
R1
BY
20
R43
4
R58
BY
FUEL PUMP
B
6
B97
C11
C: B281

(WAGON)
R22
REAR DOOR SWITCH LH

BY
3
R16
REAR DOOR SWITCH RH

BY
3
WF
SEAT HEATER SWITCH

B
10
i98
BY

BY
3
i100
GND(L)-03
BY

B
1
3
R26
3
R26
3
R28
2
R25
R122
GND(L)-04
R142
CONDENSER (FUEL PUMP)

OF
B
2
WF
FUEL PUMP
CONTROL MODULE
B
5
R188
POWER SEAT LH
B
1
R109
POWER SEAT RH
B
1
R32
REAR ACCESSORY
POWER SUPPLY SOCKET
B
1
CONDENSER
(REAR DEFOGGER)
R12
FRONT DOOR SWITCH RH

B
3
R9
FRONT DOOR SWITCH LH

B
3
REAR COMBINATION
LIGHT LH (WAGON)
REAR COMBINATION
LIGHT RH (WAGON)
R28
REAR COMBINATION
LIGHT LH (SEDAN)
B
3
REAR COMBINATION
LIGHT RH (SEDAN)
GND(L)-04
Ground Circuit
WIRING SYSTEM
GND(L)-05
WG : WAGON
WF : WITH FUEL PUMP

CONTROL MODULE
GB-9
1 2 3 4 5 6
7 8 9 10 11 12
HR
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
27 28
20 21
22 23
24 25 26
WI-03908
D46
OM :
1
2
(BLACK)
D5
3
2 1
8 7 6 5 4
WM :
GAB-1
R66
R37
2
AIRBAG
CONTROL MODULE
GAB-2
GB-10
D39
D90
R77
D37
D44
D91
D87
R186
R19
R76
1 2 3
GB-11
R37
1
2 3
D5
i99
D7
4 3
2 1
10 9 8 7 6 5
1 2 3 4 5 6
7 8 9 10 11 12
1 2 3
4 5 6
7 8 9 10 11 12 13 14
WI-34
B
WG
28
27
H
D33
B
REAR GATE GROUND

(WAGON)
SD
GD
D83
1 2
3 4
5 6 7 8 9
10 11 12 13 14 15
18 19
16 17
20 21 22 23 24 25
D91
D87
R65
BACK-UP
LIGHT RH
D43
R60
1 2
3 4
1 2
3
4 5 6 7 8
D83
D5
B
i76
REMOTE CONTROLLED
REARVIEW MIRROR RH
(WITHOUT MIRROR HEATER)
R24
2
R19
BACK-UP
LIGHT LH
REAR DEFOGGER GROUND (SEDAN)
AB6
BW
BW
SD : SEDAN
GND(L)-04
R186
TRUNK RID ACTUATOR

B
1
i99
GROUND
JOINT CONNECTOR
B
2
D5
5
10
REMOTE CONTROLLED
REARVIEW MIRROR
(WITH MIRROR HEATER)
D90
REAR FOG LIGHT

B
1
D48
REAR DEFOGGER GROUND

B
D46
REAR GATE LATCH SWITCH

B
1
R60
HIGH-MOUNTED STOP
LIGHT (SEDAN)
R66
D39
D44
D7
GND(L)-05
POWER WINDOW
MAIN SWITCH
LICENSE PLATE LIGHT
HIGH-MOUNTED
STOP LIGHT
D43
REAR WIPER MOTOR

B
3
D37
LUGGAGE ROOM LIGHT

B
1
R76
LICENSE PLATE LIGHT LH

B
2
R77
LICENSE PLATE LIGHT RH

B
2
HIGH-MOUNTED STOP
LIGHT (REAR SPOILER)
GND(L)-05
WIRING SYSTEM
Ground Circuit
WG : WAGON
WM : WITH MIRROR HEATER

OM : WITHOUT MIRROR HEATER
GD
2 1
1 2
AB6 (YELLOW)
4 5 6
1 2 3
7 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27 28
WI-03909
Ground Circuit
WIRING SYSTEM
SB
11
Or
Or
19
18
B3
JOINT
CONNECTOR
B53
LgB 20
10
Or
Or
P
P
10 LgB
20
19
B11
BW
T4
TORQUE
CONVERTER
TURBINE S
PEED SENSOR
BW
Lg
5
Y
G
18
W
14
SB
VEHICLE
SPEED
SENSOR 2
GND(L)-06
B2
A8
P
6
16
A17
A16
G
9
TCU (4AT)
A15
A7
Lg
B: B55
A6
L
A: B54
12
GND(L)-06
2. LHD AT TRANSMISSION GROUND (4AT MODEL)
AT CONTROL
HR
B11 (GRAY)
B53
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
A:
B54
HR
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
22 23 24
17 18 19 20 21
B:
B55
HR
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
WI-03910
WI-35
Ground Circuit
WIRING SYSTEM
GND(L)-07
WR B16
YL B18
B12
BW
B11
YL
TCM (5AT)
WR
B: B55
BW A16
A: B54
GND(L)-07
3. LHD AT TRANSMISSION GROUND (5AT MODEL)
T4
W
WB
WB
T3
AT1
TORQUE
CONVERTER
TURBINE
SPEED
SENSOR 1
VEHICLE
SPEED
SENSOR 1
(BROWN)
AT1
B12
1 2 3
1 2 3 4
5 6 7 8
B11
1 2
HR
(GRAY)
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
A:
B54
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
HR
7
16
22
8
17
23
9
18
24
B:
B55
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
HR
(GRAY)
7
16
22
8
17
23
9
18
24
WI-03911
WI-36
Ground Circuit
WIRING SYSTEM
GND(L)-08
GND(L)-08
4. LHD ENGINE GROUND (2.0 L MODEL AND 2.5 L KS MODEL)

A: B134
B: B135
ECM
(FOR 2.0L &
2.5L KS MODEL)
A2
BR
BR
A7
BW
BW
C6
C5
BL
BL
C2
BL
C1
LR
LR
B6
R
LR
B5
R
REF. TO ENGINE ELECTRICAL

SYSTEM [E/G(LHU)-05]
34
35
36
37
52
B21
BL
BL
BL
BL
BR
IGNITION COIL &
IGNITOR ASSY
E2
BR

C: B136
CRANKSHAFT
POSITION
SENSOR
E10
(LIGHT GRAY)
E14
E15
(GRAY)
1 2
(BROWN)
(GRAY)
1
3
2
4
E78
1 2 3
4 5 6
1 2
C: B136
B21
HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
BR
BR
BW
BW
FRONT
OXYGEN (A/F)
SENSOR
E24
1 2 3 4
KNOCK
SENSOR
(DARK GRAY)
E12
E24
ELECTRIC
THROTTLE
RL
CAMSHAFT
POSITION
SENSOR
E14
E78
2
E15
E10
Or
E12
(BLACK)
GE
(BLACK)
A: B134
1 2
8 9 10
18 19 20
28 29 30
HR
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B: B135
HR
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
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
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
WI-03912
WI-37
Ground Circuit
WIRING SYSTEM
A: B134
B: B135
ECM (FOR 2.5L EC,K4 MODEL)
E10
(LIGHT GRAY)
E14
E15
(GRAY)
1 2
(BROWN)
1 2 3 4
(GRAY)
E24
E57
HR
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
B21
(BLACK)
1 2 3 4 5 6
1 2 3
4 5 6
1 2
B: B135
B4
D7
BW
BR
BR
D2
B1
BW
BW
D1
BL
D3
RL
34
35
BY
BY
BY
BY
36
BW
BW
37
BW
BW
B
B
BL
FRONT OXYGEN
(A/F) SENSOR
GE
(DARK GRAY)
KNOCK
SENSOR
E12
E12
BL
BW
BW
BR
BR
RL
CRANKSHAFT
POSITION
SENSOR
E2
E24
CAMSHAFT
POSITION
SENSOR
E14
E10
BL
B12
B
B
47
52
BL
ELECTRIC
THROTTLE
W
6
E15
BL
A7
R
B21
IGNITION
COIL &
IGNITOR
ASSY
E57
RL
A6
R

SYSTEM [E/G(LND)-05]

SYSTEM [E/G(LND)-06]
D: B137
GND(L)-09
GND(L)-09
5. LHD ENGINE GROUND (2.5 L EC, K4 MODEL)
(BLACK)
GE
D: B137 HR
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
A: B134
1 2
8 9 10
18 19 20
28 29 30
HR
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
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
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
WI-03913
WI-38
Ground Circuit
WIRING SYSTEM
A4
A5
YB
YB
YB
D2
RL
D3
RL
BL
D1
BL
B12
B
BL
A6
A7
BW
B4
BW
R
R
D7
B1
E45
BR
E33
BW
BR
BW
E32
BR
IGNITION
COIL NO. 3
IGNITION
COIL NO. 5
BL
B122
BL
B79
BW
E46
D: B137
JOINT
CONNECTOR
CHECK
CONNECTOR
2
BR
E31
ECM (3.0L MODEL)
B: B135
IGNITION
COIL NO. 2
BW
E34
IGNITION
COIL NO. 1

SYSTEM [E/G(LH6)-0708]
BW
IGNITION
COIL NO. 4
: TERMINAL NO.
OPTIONAL ARRANGEMENT
IGNITION
COIL NO. 6
A: B134
GND(L)-10
GND(L)-10
6. LHD ENGINE GROUND (3.0 L MODEL)
54
37
36
12
52
35
34
B21
E10
(LIGHT GRAY)
(BLACK)
E14
(GREEN)
(BLACK)
E48
(GREEN)
1 2
KNOCK
SENSOR 1
KNOCK
SENSOR 1
E31
E34
E32
E45
E33
E46
(BLACK)
(BLACK)
1 2 3 4 5 6
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
1 2 3 4
5 6 7 8
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
BL
BL
BL
BL
BL
BL
BL
BL
B
B
(GRAY)
B79
1
8
2 3
9 10
4 5
11 12
6 7
13 14
B21
A: B134 HR
1 2
8 9 10
18 19 20
28 29 30
BW
B122
1
2
3
D: B137 HR
BW
BW
BW
GE
E57
(BLACK)
BR
E48
BR
R
E14
ELECTRIC
THROTTLE
BR
E57
E10
CRANKSHAFT
POSITION
SENSOR
Or
E2
B: B135 HR
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
WI-39
(BLACK)
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
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
WI-03914
(GRAY)
C:
F3
(GRAY)
F19
(BLACK)
R51
R54
R56
(BLACK)
B
F6
F21
B
F23
HR
F17
F27
19
HR
(BLACK)
1 2
2 1
1 2
F58
F59
GB-1
GB-2
HR
HR
F35
B228
R50
1 2
3 4 5
6 7 8 9 10 11 12
1 2
3
4 5 6 7 8 9
10 11 12 13 14 15
4 5 6 7
1 2 3
8 9 10 11 12 13 14 15 16
F106
1 2 3
1 2
3
18
19
20 21
22
23
WI-40
24 25
26
27
10
8 9 11
12
30
28 29
31
1
2 4 5
3
13
14 16 17
15
F106
F7
R52
F23
1 2 3
1 2 3
4 5 6
B225
MIRROR HEATER RELAY

B
31
B225
SEAT HEATER RELAY

B
39
B225
POWER WINDOW RELAY

B
19
F27
MAIN FAN RELAY 2

(4-CYLINDER ENGINE
MODEL)
B
4
FWD SWITCH (4AT)
HEADLIGHT & FRONT

CLEARANCE LIGHT LH
F17
HR
HR
6
1
2
7
3
4
B90
7
B32
15
R50
B225
STARTER RELAY
(FOR KA MODEL)
TURN SIGNAL &

HAZARD MODULE
B228
OP CONNECTOR
B
7
F58
HEADLIGHT LEVELER LH
B
1
F19
FRONT TURN SIGNAL LIGHT LH

B
1
F21
FRONT FOG LIGHT LH

B
2
MAIN FAN MOTOR

3
F3
F7
F35
4
R55
2
R51
2
R54
GND(R)-01
R56
SPOT MAP LIGHT

B
1
R52
ROOM LIGHT
B
1
VANITY
MIRROR ILLUMI. LIGHT LH
VANITY
MIRROR ILLUMI. LIGHT RH
SUNROOF
CONTROL MODULE (SEDAN)
C:
MAIN FUSE BOX (M/B)

B C12
HEADLIGHT & FRONT

CLEARANCE LIGHT RH
F59
HEADLIGHT LEVELER RH
B
1
F6
FRONT FOG LIGHT RH

B
2
FRONT TURN
SIGNAL LIGHT RH
F106
PWM CONTROLLER
GND(R)-01
WIRING SYSTEM
Ground Circuit
7. RHD CHASSIS GROUND
GND(R)-02
B32
R55
1 2
3
4 5 6 7 8
1 2 3 4 5
6 7 8 9 10
(GRAY)
F27
B225
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
WI-03915
Ground Circuit
2
B8
B
FRONT WIPER MOTOR

(TURBO MODEL)
B70
23
BY
24
GND(R)-02
B318
VDC OFF SWITCH

BY
3
B366
LAN MODULE
BY 15
C: B281
B
BY
B
C
GND(R)-04
D
E
GND(R)-04
GND(R)-03
GND(R)-04
i1
BY
20
BY
B97
B: B280
BY
C9
BY B22
B231
STEERING
ANGLE SENSOR
BY
3
BY C8
B68
B81
BY
B184
BY
ROLL CONNECTOR
BY
8
DIAGNOSIS TERMINAL
BY
KEYLESS
ENTRY CONNECTOR
16
26
B372
15
B
B:
B
B54
B55
A:
BY B21
D: B152
ALARM
CONTROL MODULE
A14
B
BY A19
D8
FUSE &
RELAY BOX (F/B)
B301
TCM (5AT)
B A5
B116
AT SELECT LEVER
4
B
15
B
B358
ABS
CONTROL MODULE
AT INDICATOR LIGHT
B
2
6
B310
KA EK
1
B
B347
VDC
CONTROL MODULE
B350
B71
COMBINATION
SWITCH (WIPER)
VDC SHIELD
JOINT CONNECTOR
16
16
9
B
10
KEY LOCK SOLENOID

B
1
B371
B16
7
KA EK
B36
GND(R)-04
R1
BY
A
B
GND(R)-01
BRAKE FLUID LEVEL SWITCH

(TURBO MODEL)
COMBINATION
B
2
SWITCH (LIGHTING)
GND(R)-02
STARTER CUT CONNECTOR

B
1
WIRING SYSTEM
EK : FOR EK MODEL
KA : FOR KA MODEL
GB-6
(GRAY)
B16
GB-4
B347
B371
1
2
1
2
2 1
B358
B231
1 2
B318 HR
B350
HR
1
9
2
10
B70
B71
3 4 5 6
11 12 13 14 15
B:
B55
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
8
17
1
10
2
11
3
12
4 5 6
13 14 15
HR
(GRAY)
7
16
22
HR
1 2 3
4 5
1 2 3 4
EK :
B8
8
17
23
7
16
8
17
9
18
12
13
14
15
1
2 3
4 5 6 7 8
B116
KA :
3 4
1 2
5 6 7 8 9 10
1
9
B372
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
B366 HR
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
B71
D: B152
B97
B301
9
18
24
B68
1 2 3
4 5 6 7 8 9
10 11 12
13 14 15 16 17 18 19
20 21 22 23 24 25 26
C: B281 HR
B: B280 HR
B310
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
22 23
24 25 26
27 28
20 21
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
5
6
7
8
9
10
1 2 3 4
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
2
10
3 4 5 6
11 12 13 14 15
A:
B54
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
8
17
HR
7
16
22
8
17
23
9
18
24
i1
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
WI-03916
WI-41
B16
1 2
(GRAY)
1
2
B25
(BROWN)
HR
B29 (BLACK)
B362
3
4
A: B282
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B77
B177
HR
1 2 3 4 5
6 7 8 9 10
B10
1 2
2 1
3
1
4
2
B116
B12 HR
3 4
1 2
5 6 7 8 9 10
5
7 8
6
1 2 3 4
5 6 7 8
9 10 11 12
WI-42
GB-7
B86
B8
1 2
3 4
1 2 3
4 5
HR
B
BY
8
10
BY
3
B88
B20
i26
RADIO
11
GB-5
i97
i26
i99
1 2 3
4 5 6
7 8 9 10 11 12 13 14
i29
AUDIO BRACKET EARTH

B
i99

B
1
i97

BY
1
B362
FUEL PUMP RELAY

(TURBO AND
6-CYLINDER ENGINE MODEL)
B: B143
MAIN FUSE BOX (M/B)
EVAPORATION THERMO
SWITCH (MANUAL A/C)
B29
LO (AWD) SWITCH
B
2
B116
BY
2
B25
B12
11
B86
BLOWER FAN
RESISTOR (AUTO A/C)
B77
MODE ACTUATOR
(MANUAL A/C)
B
10
ND
INHIBITOR SWITCH
B
4
NEUTRAL POSITION SWITCH

(FOR 2.5L EK MODEL)
ND : FOR 2.5L EK MODEL
BY
GND(R)-02
BY
AT SELECT LEVER
BY
2
B8
2
B16
GND(R)-03
B177
WIPER DEICER
BRAKE FLUID LEVEL

SWITCH (NON-TURBO
MODEL)
B10
A/C PRESSURE SWITCH

B
3
FRONT WIPER MOTOR

(NON-TURBO MODEL)
A: B282
AUTO A/C ONTROL MODULE

BY A16
B298
BY
A/C MODE
GND(R)-03
WIRING SYSTEM
Ground Circuit
GB-3
GR
B88
1 2 3 4 5
HR
1 2 3 4 5 6
7 8 9 10 11 12
B: B143
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
WI-03917
R142 (BLACK)
R25
(BLACK)
1
R32
1
2
SD : SEDAN
R19
R189
(BLACK) R109
R191
GB-8
(BLACK) R188
1 2
1
2
3
R79
R122
i98
i102
1 2 3 4 5
6 7 8 9 10
3 4
1 2
5 6 7 8 9 10
i100
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
WI-43
BY
E
i102
18
R26
2
R190
R9
R16
R8
WG :
R26
SD :
R26
R58
1 2 3
R12
R22
R107
WG :
R28
SD :
R28
1 2
3 4
5 6
1 2 3 4
2 1
4 3
B97
R43
C: B281 HR
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
1 2 3 4 5
6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
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
1 2 3
4 5 6
1
R189
BY
REAR SEAT BELT

SWITCH RH
(KA MODEL)
R107
BY
FRONT SEAT BELT

SWITCH LH
R8
BY
FRONT SEAT BELT

SWITCH RH
REAR COMBINATION
LIGHT RH (SEDAN)
R110
AUDIO AMPLIFIER
(WITH MCINTOSH AUDIO)
R167
BY
11
BY
R43
20
3
R28
R22
REAR DOOR SWITCH LH

BY
3
R16
REAR DOOR SWITCH RH

BY
3
R58
BY
FUEL PUMP
B
6
REAR COMBINATION
LIGHT LH (SEDAN)
SEAT HEATER SWITCH

B
10
i98
BY
GROUND JOINT
CONNECTOR
i100
GROUND JOINT
CONNECTOR
1
B
B97
C11
C: B281
R191
REAR SEAT BELT SWITCHLH

(KA MODEL)
BY
1
R190
BY
REAR SEAT BELT SWITCH

CENTER (KA MODEL)
R1
11

(WAGON)
BY
WF
GND(R)-02
9
D
BY
GND(R)-02
B
GND(R)-02
R79
GND(R)-02
BY
TRAILER CONNECTOR
B
7
B
8
3
R26
3
R28
2
R25
5
R122
OF
1
R19
GND(R)-04
HIGH-MOUNTED
STOP LIGHT (SEDAN)
R142
CONDENSER (FUEL PUMP)
WF
FUEL PUMP
CONTROL MODULE
R109
POWER SEAT MOTOR RH

B
1
R188
POWER SEAT MOTOR LH

B
1
R32
REAR ACCESSORY
POWER SUPPLY SOCKET
B
1
CONDENSER
(REAR DEFOGGER)
R12
FRONT DOOR SWITCH RH

B
3
R9
FRONT DOOR SWITCH LH

B
3
REAR COMBINATION
LIGHT LH (WAGON)
REAR COMBINATION
LIGHT RH (WAGON)
GND(R)-04
Ground Circuit
WIRING SYSTEM
GND(R)-05
WG : WAGON
WF : WITH FUEL PUMP

CONTROL MODULE
OF : WITHOUT FUEL PUMP

CONTROL MODULE
GB-9
R110 HR
1 2 3 4
5 6 7 8
9 10 11 12 13 14 15 16 17 18
1 2 3 4 5 6
7 8 9 10 11 12
WI-03918
Ground Circuit
GND(R)-05
14
D7
POWER WINDOW
MAIN SWITCH
2
D82
DOOR KEY SWITCH
D72
3
B
FRONT DOOR LOCK

ACTUATOR RH
D44
LICENSE PLATE LIGHT
D39
HIGH-MOUNTED STOP LIGHT
R37
B
D33
REAR GATE
GROUND (WAGON)
28
BW
BW
AB6
27
B
B
AIRBAG
CONTROL MODULE
i99
2
D83
D5
R65
B
B
B
WG
REMOTE CONTROLLED
REARVIEW MIRROR RH
(WITHOUT MIRROR HEATER)
REAR DEFOGGER GROUND (SEDAN)
D91
1
B
BACK-UP
LIGHT LH
D87
1
B
BACK-UP
LIGHT RH
R24
B
SD
GND(R)-04
i76
GROUND
JOINT CONNECTOR
B
2
D5
10
REMOTE CONTROLLED
REARVIEW MIRROR
(WITH MIRROR HEATER)
D86
REAR FOG LIGHT

B
1
D43
D48
REAR WIPER MOTOR

B
3
D46
REAR DEFOGGER GROUND

B
R60
WD
D37
LUGGAGE ROOM LIGHT

B
1
REAR GATE LATCH SWITCH
B
1
R76
LICENSE PLATE LIGHT LH

B
2
R77
R186
LICENSE PLATE LIGHT RH

B
2
1
TRUNK LOCK
ACTUATOR
R66
2
B
GND(R)-05
HIGH-MOUNTED STOP
LIGHT (REAR SPOILER)
WIRING SYSTEM
SD : SEDAN
WG : WAGON
WM : WITH MIRROR HEATER
OM : WITHOUT MIRROR HEATER

WD : WITH DOUBLE LOCK
OD : WITHOUT DOUBLE LOCK
GAB-1
D46
(BLACK)
1
2
D39
D86
R76
D37
D44
D87
R77
R186
R66
D91
2 1
WM :
D5
4 3
2 1
10 9 8 7 6 5
GAB-2
GB-10
GB-11
R37
D82
1
2 3
1 2 3
GD
(BROWN)
D43
1 2
3 4
3 2 1
D72
R60
1 2 3 4 5 6
1 2
3
4 5 6 7 8
OM :
D5
3
2 1
8 7 6 5 4
1 2
i99
D7
1 2 3 4 5 6
7 8 9 10 11 12
1 2 3
4 5 6
7 8 9 10 11 12 13 14
OD :
D83
3 4
1 2
5 6 7 8 9
10 11 12 13 14 15
18 19
16 17
20 21 22 23 24 25
WD :
D83
3 4
1 2
5 6 7 8 9 10
11 12 13
14 15 16
17 18 19 20 21 22
23 24 25 26 27 28
AB6 (YELLOW)
4 5 6
1 2 3
7 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23 24 25 26 27 28
WI-03919
WI-44
Ground Circuit
WIRING SYSTEM
GB
13
SB
OrB B3
OrB B2
14
15
B53
PB
OrB
PB
20 OrB
19
GB
B
B
BW
TORQUE
CONVERTER
TURBINE
SPEED
SENSOR
B11
T4
BW
10
W
GOr
5
Y
Y
18
W
14 OrB
Y
VEHICLE
SPEED
SENSOR 2
GND(R)-06
PB A17
17
A8
PB
16
A16
JOINT
CONNECTOR
12
11
OrB A6
GOr A7
Y
SB
TCU (4AT)
A15
B: B55
A: B54
GND(R)-06
8. RHD AT TRANSMISSION GROUND (4AT MODEL)
AT CONTROL
HR
B11 (GRAY)
B53
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
1 2
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
A:
B54
HR
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
22 23 24
17 18 19 20 21
B:
B55
HR
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
WI-03920
WI-45
Ground Circuit
WIRING SYSTEM
B11
5
B12
T4
W
WB
T3
WB
GND(R)-07
YL B18
BW
WR B16
TCM (5AT)
YL
B: B55
BW A16
A: B54
WR
GND(R)-07
9. RHD AT TRANSMISSION GROUND (5AT MODEL)
AT1
TORQUE
CONVERTER
TURBINE
SPEED
SENSOR 1
VEHICLE
SPEED
SENSOR 1
(BROWN)
AT1
B12
1 2 3
1 2 3 4
5 6 7 8
B11
1 2
HR
(GRAY)
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
A:
B54
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
HR
7
16
22
8
17
23
9
18
24
B:
B55
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
HR
(GRAY)
7
16
22
8
17
23
9
18
24
WI-03921
WI-46
Ground Circuit
WIRING SYSTEM
GND(R)-08
GND(R)-08
10.RHD ENGINE GROUND (2.0 L NON-TURBO MODEL AND 2.5 L KA MODEL)

A: B134
B: B135 ECM (FOR 2.0L &
2.5L KA MODEL)
C: B136
C6
A2
D1
A7
BW
BW
BR
BW
BR
C5
BL
BL
BL
C2
C1
LR
LR
LR
B6
B5
R

SYSTEM [E/G(RHU)-05]
34
35
36
37
52
B21
BL
BL
BL
BL
IGNITION COIL &

IGNITOR ASSY
BR
E2
BR

SYSTEM [E/G(RHU)-06]
D: B137
CRANKSHAFT
POSITION
SENSOR
CAMSHAFT
POSITION
SENSOR
E10
(LIGHT GRAY)
E14
E15
(GRAY)
1 2
KNOCK
SENSOR
(DARK GRAY)
1 2 3 4
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
B: B135
BR
BR
FRONT OXYGEN
(A/F) SENSOR
E24
1
3
2
4
GE
(GRAY)
1 2 3
4 5 6
HR
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
D: B137 HR
(BLACK)
E78
1 2
A: B134 HR
BW
BW
1
E12
RL
ELECTRIC
THROTTLE
(BROWN)
E24
E14
E78
2
E15
E10
Or
E12
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
C: B136 HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
B21
(BLACK)
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
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
WI-03922
WI-47
Ground Circuit
WIRING SYSTEM
A: B134
B: B135
ECM
(FOR 2.5L EK MODEL)
D2
B1
B4
D7
BW
BW
BR
BW
BR
D1
BL
D3
BL
BL
B12
B
RL
RL
A6
A7

SYSTEM [E/G(RND)-06]
34
35
37
BY
BY
BY
BY
36
BW
E2
BW
IGNITION COIL &

IGNITOR ASSY
BL
47
52
B21
BW

SYSTEM [E/G(RND)-07]
D: B137
GND(R)-09
GND(R)-09
11.RHD ENGINE GROUND (3.0 L EK MODEL)
(LIGHT GRAY)
E14
E15
(GRAY)
1 2
(GRAY)
GE
(DARK GRAY)
1 2 3 4
FRONT OXYGEN
(A/F) SENSOR
E24
(GRAY)
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
1 2
3
8 9 10 11 12 13
20 21 22 23
28 29 30 31
BW
D: B137 HR
(BLACK)
E57
1 2 3
4 5 6
B: B135
GE
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
1 2 3 4 5 6
1 2
A: B134 HR
BL
KNOCK
SENSOR
E12
BL
BW
BR
BW
E24
E14
2
CRANKSHAFT
POSITION
SENSOR
E10
BR
RL
CAMSHAFT
POSITION
SENSOR
ELECTRIC
THROTTLE
E10
E15
E57
E12
HR
B21
4 5 6 7
14 15 16 17 18 19
24 25
26 27
32 33
34 35
(BLACK)
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
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
WI-03923
WI-48
Ground Circuit
WIRING SYSTEM
A: B134
: TERMINAL NO. OPTIONAL ARRANGEMENT
D2
A6
A7
LR
LR
D3
D1
BL
BL
B4
BW
BL
D7
B1
BP
BW
BP
BW
IGNITION
COIL NO. 4
2
E34
E33
BY
BY
E32
BY
BY
IGNITION
COIL NO. 3
IGNITION
COIL NO. 2
IGNITION
COIL NO. 1
2

SYSTEM [E/G(RTB)-07]

SYSTEM [E/G(RTB)-06]
BL
BL
B138
B12
8
B79
E31
D: B137
JOINT
CONNECTOR
CHECK
CONNECTOR
B: B135 ECM (TURBO MODEL)
GND(R)-10
GND(R)-10
12.RHD ENGINE GROUND (TURBO MODEL)
54
37
36
35
34
12
B21
E10
(DARK GRAY)
E31
E14
(BROWN)
E32
E62
(LIGHT GRAY)
E33
(BLACK)
E65
(LIGHT GRAY)
E34
(BLACK)
1 2
D: B137
HR
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
KNOCK
SENSOR
ELECTRIC
THROTTLE
(BLACK)
1 2 3 4 5 6
B
B
B
B
B
B
B138
1 2 3 4
5 6 7 8
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
B: B135 HR
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
WI-49
BY
GE-1
(GRAY)
B79
1
8
2 3
9 10
4 5
11 12
6 7
13 14
B21
A: B134 HR
1 2
8 9 10
18 19 20
28 29 30
B
GE-2
E57
1
2
3
E57
E14
2
EXHAUST
CAMSHAFT
POSITION
SENSOR RH
EXHAUST
CAMSHAFT
POSITION
ENSOR LH
RL
L
2
E62
E65
E10
CRANKSHAFT
POSITION
SENSOR
WR
E2
(BLACK)
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
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
WI-03924
Ground Circuit
WIRING SYSTEM
A: B134
ECM (3.0L MODEL)
B: B135
(LIGHT GRAY)
(BLACK)
E14
(GREEN)
(BLACK)
E48
(GREEN)
E31
E32
E45
(BLACK)
E33
E46
(BLACK)
(BLACK)
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
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
D3
A4
A5
RL
YB
YB
RL
YB
D1
BL
D2
A7
B12
B
B
BL
A6
R
R
BL
B4
R
BW
B1
BW
BR
D7
BR
37
54
36
12
52
35
34
BL
BL
BL
BL
BL
BL
BL
BL
E2
1 2 3 4
5 6 7 8
1 2 3 4 5 6
(GRAY)
B79
1
8
2 3
9 10
4 5
11 12
6 7
13 14
B21
A: B134 HR
1 2
8 9 10
18 19 20
28 29 30
B21
E46
B138
1
2
3
D: B137 HR
E34
BW
BW
BW
BW
IGNITION
COIL NO. 4
IGNITION
COIL NO. 5
BW
BW
BW
IGNITION
COIL NO. 3
BR
BR
BR
E45
GE
E57
E34
E33
IGNITION
COIL NO. 6
BL
B138
BL
KNOCK
SENSOR 1
BR
BR
R
KNOCK
SENSOR 1
E10
1 2
E48
6
ELECTRIC
THROTTLE
E14
2
E57
CRANKSHAFT
POSITION
SENSOR
Or
W
1
E10
IGNITION
COIL NO. 2
2
IGNITION
COIL NO. 1

SYSTEM [E/G(RH6)-0708]
E32
BW
8
B79
E31
D: B137
JOINT
CONNECTOR
CHECK
CONNECTOR
BW
GND(R)-11
GND(R)-11
13.RHD ENGINE GROUND (3.0 L MODEL)
B: B135 HR
1 2
3
8 9 10 11 12 13
20 21 22 23
28 29 30 31
WI-50
4 5 6 7
14 15 16 17 18 19
24 25
26 27
32 33
34 35
(BLACK)
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
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
WI-03925
Airbag System
WIRING SYSTEM
5. Airbag System
A: WIRING DIAGRAM
GY
GY
BrW
A3 BrW
GY
FB-41
F/B FUSE NO. 25
(IG)
FB-39
F/B FUSE NO. 12
(IG)
A4 BrW
A/B(L)-01

FB-36
F/B FUSE NO. 5
(IG)
FB-32
F/B FUSE NO. 4
(IG)
A/B(L)-01
1. LHD MODEL
REVERSE
CIRCUIT
AIRBAG
WARNING
LIGHT
COMBINATION
METER
i10
Lg A13
A:
Lg
RB
i1
14
GY
B36
Lg
CHECK
CONNECTOR
B79
DIAGNOSIS
CONNECTOR
RB
Lg
BY
B31
BY
GY
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(L)-02]
AB1 (YELLOW)
1
2
3 4 5 6
B82
1 2
3
4 5 6 7 8
AB6
B79
1
8
2 3
9 10
4 5
11 12
(GRAY)
6 7
13 14
A:
GY
6
Lg
3
RB
19
BY
Lg
AB1
B81
RB
DIAGNOSIS
TERMINAL
RB
B82
i10
1 2 3 4 5
11 12 13 14 15 16
6 7 8 9 10
17 18 19 20 21 22
i1
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
AB6 (YELLOW)
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
WI-03926
WI-51
Airbag System
FRONT SUB SENSOR RH
2
1
AB16
9
20
15
26
G
W
Br
L
G
W
Br
L
AB13
28
BW
27
B
YG
YW
YG
YW
16
17
YL
YB
AB2
2
1
4
3
AB9
2
1
YG
YW
YG
YW
YL
YB
14
13
8
7
YL
YB
YL
YB
AB7
Y
YB
AB10
YL
L
10
11
AB6
4
3
A/B(L)-02
FRONT SUB SENSOR LH
2
1
A/B(L)-02
WIRING SYSTEM
YL
L
Y
YB
ROLL
CONNECTOR
1 2
AB38 (BLACK)
1 2
AB13 (YELLOW)
AB2 (YELLOW)
AB16 (YELLOW)
AB9 (YELLOW)
1 2
1 2 3 4
BW
INFLATOR (DRIVER SIDE)
INFLATOR (PASSENGER SIDE)

AB37 (ORANGE)
2
1
AB38
2
1
AB37
GAB-1
GAB-2
AB6 (YELLOW)
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
WI-03927
WI-52
Airbag System
A/B(L)-03
12
11
RB
14
RW
RG
15
RL
10
5
YB
YG
13
16
7
W
RB
20
10
L
17
18
9
12
OC
YL
WC
YR
AB17
RG
A/B(L)-03
WIRING SYSTEM
AB19 (YELLOW)
AB31 (YELLOW)
AB21 (BLACK)
1 2
SIDE AIRBAG
SENSOR LH
AB23 (YELLOW)
INFLATOR
(SIDE LH)
OC : AB17 (YELLOW)
AB32 (YELLOW)
1 2 3 4 5 6
1 2
1 2 3 4
7 8 9 10 11 12
RB
1
1
AB20
PRETENSIONER LH
RG
RL
RB
RW
AB31
AB32
2
RG
YB
AB19
AB23
2
AB21
YG
YL
YR
OC : WITHOUT
CURTAIN AIRBAG
AB39
CURTAIN AIRBAG
SENSOR LH
INFLATOR
(CURTAIN) LH
WC : AB17 (YELLOW)
1 2
3 4
5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20
WI-03928
WI-53
Airbag System
A/B(L)-04
RB
RG
19
RW
2
YB
YG
12
18
RL
16
17
10
B
20
15
13
RB
11
12
OC
YL
WC
YR
AB18
RG
A/B(L)-04
WIRING SYSTEM
AB24 (YELLOW)
AB33 (YELLOW)
AB26 (BLACK)
1 2
SIDE AIRBAG
SENSOR RH
AB28 (YELLOW)
INFLATOR
(SIDE RH)
1 2 3 4 5 6
1 2
RB
1
AB40
CURTAIN AIRBAG
SENSOR RH
OC : AB18 (YELLOW)
AB34 (YELLOW)
1 2 3 4
7 8 9 10 11 12
AB33
AB25
PRETENSIONER RH
RG
RW
RL
RB
RG
AB34
AB24
2
YB
AB28
AB26
2
YG
YL
YR
OC : WITHOUT
CURTAIN AIRBAG
INFLATOR
(CURTAIN) RH
WC : AB18 (YELLOW)
1 2
3 4
5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20
WI-03929
WI-54
Airbag System
WIRING SYSTEM
GY
GY
6
BrW
A4 BrW
A3 BrW
GY
FB-41
F/B FUSE NO. 25
(IG)
FB-39
F/B FUSE NO. 12
(IG)
FB-36
F/B FUSE NO. 5
(IG)
FB-32
F/B FUSE NO. 4
(IG)
A/B(R)-01
A/B(R)-01
2. RHD MODEL
REVERSE
CIRCUIT
AIRBAG
WARNING
LIGHT
COMBINATION
METER
i10
Lg A13
A:
GY
Lg
RB
i1
14
B36
Lg
CHECK
CONNECTOR
B79
DIAGNOSIS
CONNECTOR
RB
Lg
BY
B31
BY
R
R
RB
Lg
19
BY
Lg
AB1
B81
RB
DIAGNOSIS
TERMINAL
RB
B82
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(R)-02]
AB1 (YELLOW)
1
2
3 4 5 6
B82
1 2
3
4 5 6 7 8
AB6
B79
1
8
2 3
9 10
4 5
11 12
(GRAY)
6 7
13 14
A:
i10
1 2 3 4 5
11 12 13 14 15 16
6 7 8 9 10
17 18 19 20 21 22
i1
3 4
1 2
5 6 7 8 9 10
11 12 13
14 15 16
17 18 19 20 21 22
23 24 25 26 27 28
AB6 (YELLOW)
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
WI-03930
WI-55
Airbag System
FRONT SUB SENSOR RH
2
1
AB16
9
20
15
26
G
W
Br
L
G
W
Br
L
AB13
28
BW
27
B
YG
YW
YG
YW
16
17
YL
YB
YG
YW
YG
YW
YL
YB
14
13
8
7
YL
YB
YL
YB
10
11
AB6
AB2
2
1
4
3
2
1
AB9
4
3
A/B(R)-02
FRONT SUB SENSOR LH
2
1
A/B(R)-02
WIRING SYSTEM
AB7
YL
L
Y
YB
AB10
YL
L
Y
YB
ROLL
CONNECTOR
AB37 (ORANGE)
1 2
AB38 (BLACK)
1 2
AB13 (YELLOW)
AB2 (YELLOW)
AB16 (YELLOW)
AB9 (YELLOW)
1 2
1 2 3 4
BW
INFLATOR (DRIVER SIDE)
INFLATOR (PASSENGER SIDE)
2
1
AB38
2
1
AB37
GAB-1
GAB-2
AB6 (YELLOW)
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
WI-03931
WI-56
Airbag System
A/B(R)-03
12
11
RB
14
RW
RG
15
RL
10
YB
YG
13
16
7
W
RB
20
10
L
17
18
9
12
6
2
YL
OC
YR
WC
AB17
RG
A/B(R)-03
WIRING SYSTEM
AB19 (YELLOW)
AB31 (YELLOW)
SIDE AIRBAG SENSOR LH
AB21 (BLACK)
1 2
AB23 (YELLOW)
INFLATOR
(SIDE LH)
1 2 3 4 5 6
1 2
RB
1
AB39
CURTAIN AIRBAG
SENSOR LH
OC : AB17 (YELLOW)
AB32 (YELLOW)
1 2 3 4
7 8 9 10 11 12
AB31
AB20
PRETENSIONER LH
RG
RW
RL
RB
AB32
AB19
1
RG
YB
AB23
AB21
1
YG
YL
YR
OC : WITHOUT
CURTAIN AIRBAG
INFLATOR
(CURTAIN) LH
WC : AB17 (YELLOW)
1 2
3 4
5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20
WI-03932
WI-57
Airbag System
A/B(R)-04
RB
19
RW
RG
YB
YG
18
12
RL
16
17
20
15
13
10
B
RB
11
12
OC
YL
WC
YR
AB18
RG
A/B(R)-04
WIRING SYSTEM
AB24 (YELLOW)
AB33 (YELLOW)
AB26 (BLACK)
1 2
SIDE AIRBAG
SENSOR RH
AB28 (YELLOW)
INFLATOR
(SIDE RH)
1 2 3 4 5 6
1 2
RB
1
AB40
CURTAIN AIRBAG
SENSOR RH
OC : AB18 (YELLOW)
AB34 (YELLOW)
1 2 3 4
7 8 9 10 11 12
AB33
AB25
PRETENSIONER RH
RG
RW
RL
RB
RG
AB34
AB24
1
YB
AB28
AB26
2
YG
YL
YR
OC : WITHOUT
CURTAIN AIRBAG
INFLATOR
(CURTAIN) RH
WC : AB18 (YELLOW)
1 2
3 4
5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20
WI-03933
WI-58
Air Conditioning System

WIRING SYSTEM
6. Air Conditioning System

A: WIRING DIAGRAM
M-A/C(L)-01
M-A/C(L)-01
1. MANUAL A/C LHD MODEL

GOr
FB-46
F/B FUSE NO. 22
(IG)
THROUGH
JOINT CONNECTOR
GOr
F109
GOr
M-A/C(L)-02
B360
LG
THROUGH
JOINT CONNECTOR
9
14
LOr B35
LOr
LOr
F108
B361
B: B135
MAGNET
CLUTCH
YB
GOr
YB
LOr
28 GOr
2
B
30
PRESSURE
SWITCH
A/C
RELAY
B10
1
Y
31
Y
A:
B38
F37
i3
F35
16
LG
A4
C:
B: B143
MAIN
FUSE BOX (M/B)
10
C3
F35
C7
C:
B13
C12
B: B143
LG
B20
F37
29
MAIN
FUSE BOX (M/B)
LG
A13
F27
C8
ECM
F24
A:
C: B136
i17
REF. TO GROUND
DISTRIBUTION SYSTEM
[GND(L)-02] [GND(L)-01]
F24
C:
B10
1 2
3
F35
(BLUE)
i17
A:
F108
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
1 2 3 4
5 6 7 8
9 10 11 12 13 14 15 16 17 18
F109
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4
10 11 12 13 14
B: B135
1 2
3
8 9 10 11 12 13
20 21 22 23
28 29 30 31
B360 (GRAY)
B361
1 2 3
4 5 6
7 8 9 10 11 12 13 14
1 2
3 4 5
6 7 8 9 10 11 12
1
4
2
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(L)-03]
A/C CONTROL PANEL
F37
B: B143
5 6 7 8 9
15 16 17 18 19 20
HR
4 5 6 7
14 15 16 17 18 19
24 25
26 27
32 33
34 35
1
2 4 5
3
B38
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
C: B136 HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
WI-59
F27
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
10
8 9 11
12
18
5 6
14 15 16
25 26 27
33 34 35
19
22
20 21
23
24 25
26
27
28 29
13
14 16 17
15
6
7
30
31
WI-03934

M-A/C(L)-02
M-A/C(L)-02
WIRING SYSTEM

FB-8
F/B FUSE NO. 27 (B)
F/B FUSE NO. 28 (B)
BY
GL
GOr
FB-45
F/B FUSE NO. 22
(IG)
EC : 2.0L EC, K4
MODEL
GL
1
RY
RY
LY
GY
LY
MODE
ACTUATOR
BLOWER
FAN
RELAY
B38
BR
VY
FRESH/RECIRC
ACTUATOR
BY
22
B225
B77
24
GOr
6
B86
GY
VY B11
GOr
7
EC
BODY
INTEGRATED UNIT
BLOWER
FAN
RESISTOR
21
ECM
M-A/C(L)-01
23 GOr
B: B135
LY
GY
BrY
BY
5
BR
5
4
3
2
1
10
RB
L
LB
LG
LW
B
i3
VY
2
3
i1
VY
i2
BLOWER
FAN
SWITCH
BY
12
5
1
2
3
6
PG
BL
RB
LOr
LB
LG
LW
i3
OFF
B87
B36
B37
B38
BLOWER
FAN
MOTOR
RB
L
LB
LG
LW
12 LgW
13 BL
3
1
B: B280
LgW
BL
YR B15
B91
i15
REF. TO GROUND
DISTRIBUTION
SYSTEM
[GND(L)-03]
VY
RB
LOr
LB
LG
LW
PG
BL
GOr
GOr
YR
GROUND
JOINT CONNECTOR
14
1
2
3
4
5
6
7
B367
B
i17
B87
B367
B86
1 2
1 2
1 2
3 4
B38
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
(GREEN)
i15
B91
1 2 3
4 5 6
1 2 3 4 5 6 7
i1
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
i99
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(L)-03]
A/C CONTROL PANEL
HEATER COCK SOLENOID

(FOR EC, K4 MODEL)
HR
B37
B77
1
2 3
4 5 6 7 8
1 2 3 4 5
6 7 8 9 10
HR
1 2 3
4 5
6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
23 24 25
26 27
28 29 30
21 22
B: B135
B
B
i100
i99
i17
i100
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
1 2 3 4 5 6
7 8 9 10 11 12
B: B280
7
12
B225
HR
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
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
WI-03935
WI-60

M-A/C(L)-03
M-A/C(L)-03
WIRING SYSTEM
AMBIENT SENSOR
B: B135 ECM
BL
BL
PW B20
BR
BR
F78
PW
13
4
REF. TO CLEARANCE LIGHT AND
ILLUMINATION LIGHT SYSTEM
[ILLUMI(L)-04]
C: B281
i84
3
B
B38
Sb A28
B88
Or
A:
EVAPORATION
THERMO SWITCH
11
C3
Or
C10 Sb
Or
Sb
B361
REF. TO REAR DEFOGGER

SYSTEM [R/DEF(L)-01]
11
10
THROUGH
JOINT
CONNECTOR
Or
14
F108
Or
i3
BW
RL
Or
15
GROUND
JOINT CONNECTOR
A/C CONTROL PANEL
12
i100
i99
13
i17
12
11
10
Sb
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(L)-03]
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(L)-03]
F78
1 2
(BLACK)
B88
i99
B361
1 2 3 4 5
i100
1 2 3
4 5 6
7 8 9 10 11 12 13 14
1 2 3 4 5 6
7 8 9 10 11 12
C: B281
HR
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
24 25 26
27 28
20 21
22 23
B: B135
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
HR
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
F108
B38
5 6 7 8
1 2 3 4
9 10 11 12 13 14 15 16 17 18
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
i17
A:
i84
HR
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
WI-03936
WI-61

WIRING SYSTEM
A-A/C(L)-01
A-A/C(L)-01
2. AUTO A/C LHD MODEL
FB-46
F/B FUSE NO. 22
(IG)
GOr
30
LOr
28 GOr
A/C
RELAY
HOLDER
A-A/C(L)-02
EC
LOr
F35
YB
4
9
F108
PRESSURE
SWITCH
3
B
MAGNET
CLUTCH
B10
2.0L & 2.5L KS MODEL
C:
F109
2.5L EC, K4 & 3.0L MODEL
B: B143
GOr
14
1
9
F37
YB C30 C8
THROUGH
JOINT
CONNECTOR
LOr
LG
A4
B13
A:
B361
THROUGH
JOINT
CONNECTOR
GOr
C7
C3
B360
MAIN
FUSE BOX
(M/B)
31
Y
LOr B33 B35
GOr
29
LG
F27
B: B135
C: B136
ECM
F24
BODY
INTEGRATED UNIT
MAIN
FUSE BOX (M/B)
C12
B20
A:
B: B280
B: B143
F35
F24
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(L)-01]
C:
B10
B367
3
1 2
1
4
2
1 2
3 4 5
6 7 8 9 10 11 12
A:
F108
5 6 7 8
1 2 3 4
9 10 11 12 13 14 15 16 17 18
B: B280
A10
A: B282
A: B282
B361
1 2 3
4 5 6
7 8 9 10 11 12 13 14
5 6 7 8 9
15 16 17 18 19 20
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
B: B135 HR
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
F27
1
2 4 5
3
F109
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
10
8 9 11
12
C: B136 HR
18
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
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(L)-03]
B360 (GRAY)
B: B143
F37
1 2 3 4
10 11 12 13 14
HR
HEATER COCK
SOLENOID
(EC, K4 MODEL)
(BLUE)
F35
B367
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(L)-02]
A9 GOr
YR
GOr
C:
B
F37
YR B15
A13
EC : EC, K4 MODEL
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
WI-62
5 6
14 15 16
25 26 27
33 34 35
19
22
20 21
23
24 25
26
27
28 29
13
14 16 17
15
6
7
30
31
WI-03937

A-A/C(L)-02
A-A/C(L)-02
WIRING SYSTEM
GL
YR
FB-8
F/B FUSE NO. 27 (B)
F/B FUSE NO. 28 (B)
GOr
21
GL
A
23 GOr
7
BLOWER
FAN
RELAY
B225
22
: WITH IMMOBILIZER :D16

WITHOUT IMMOBILIZER :D17
BR
*1
24
1
BL
B91
VY
3
LgW
FRESH/RECIRC
ACTUATOR
BR
A-A/C(L)-01
FB-29
F/B FUSE NO. 31
(ACC)
LR

MB-29
M/B FUSE NO. 8
(B)
BLOWER
FAN
MOTOR
*1
BY
B87
D13 VY
BY
3
1
B
B86
A: B282
B: B283
B86
B91
1 2
1 2
3 4
1 2 3 4 5 6 7
A: B282
B: B283
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B: B135 HR
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
LY
B3 GW
B2
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(L)-03]
(GREEN)
B87
B13 VY
PW
B6
B20 BL
B10 LgW
YR
A2
A1
LR
BLOWER
FAN
RESISTOR
LY
3.0L MODEL
ECM
GW
D: B137
PW
2.5L EC, K4 MODEL
B: B135
2.0L & 2.5L KS MODEL
D17 B20
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
D: B137 HR
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
B225
1
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
WI-03938
WI-63

A-A/C(L)-03
FB-28
F/B FUSE NO. 31
(ACC)
FB-45
F/B FUSE NO. 22
(IG)
AMBIENT SENSOR
BL
BL
YR
2
BR
GOr
1
YR
GOr
F78
BR
A-A/C(L)-03
WIRING SYSTEM
13
14
F108
THROUGH
JOINT
CONNECTOR
i88
(BLACK)
1 2
11
Sb
C10 Sb
C3
Or
5
BY
WB
BODY
INTEGRATED UNIT
B: B280
V
B11
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(L)-03]
B1
BY
TWISTED WIRE
BY
i97
B25
C: B281
B26
W
1
10
WB
WR
B38
B16 WB
B15 WR

[ILLUMI(L)-04]
GROUND
JOINT
CONNECTOR
i3
B: B283
F78
Or
B361
BY
7
W
8
BW
WB
4
V
10
A/C CONTROL PANEL
i88
i97
B361
F108
1 2 3 4
5 6 7 8
1 2 3 4 5 6
7 8 9 10 11 12
1 2 3
4 5 6
7 8 9 10 11 12 13 14
5 6 7 8
1 2 3 4
9 10 11 12 13 14 15 16 17 18
B38
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
B: B283
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
C: B281
HR
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
24 25 26
27 28
20 21
22 23
B: B280 HR
4 5
6 7
1 2 3
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22
23 24 25
26 27
28 29 30
WI-03939
WI-64
A-A/C(L)-04
BY A16
Sb A15
Sb
BY A14
A3
WR
WR
B7
RB
LW B17
RB
B8
A4
BL
BL
LW
B18
Br
PG
Br
BrW A13
WG A5
B: B283
Sb
WG
A8
YB
WL
YB
WL
A6
A: B282
PG
A-A/C(L)-04
WIRING SYSTEM
SUNLOAD
SENSOR
B88
i51
1
2
i55
IN VEHICLE
TEMPERATURE
SENSOR
B77 HR
1 2 3 4 5
B77
B235 (GREEN)
1 2 3 4 5 6 7
1 2
B235
MODE ACTUATOR
AIR MIX ACTUATOR
BY
B88
EVAPORATION
THERMO SWITCH
WL
Sb
Sb
WL
BrW
i55
Sb
Sb
12
11
OrG
OrG
i51
i3
YB
WR
YB
WR
B38
A: B282
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(L)-03]
B38
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
B: B283
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
WI-03940
WI-65

WIRING SYSTEM
M-A/C(R)-01
M-A/C(R)-01
3. MANUAL A/C RHD MODEL

GOr
FB-46
F/B FUSE NO. 22
(IG)
THROUGH
JOINT CONNECTOR
GOr
F109
GOr
M-A/C(R)-02
B360
LG
THROUGH
JOINT CONNECTOR
9
14
LOr B35
LOr
LOr
F108
B361
B: B135
MAGNET
CLUTCH
C: B136
C8
YB
GOr
YB
4
ECM
LOr
30
28 GOr
F24
PRESSURE
SWITCH
A/C
RELAY
B10
3
B
1
Y
31
Y
B: B143
A:
MAIN
FUSE BOX (M/B)
B38
10
C3
F35
C7
C:
B13
C12
B
F37
LG
B20
B
A:
29
MAIN
FUSE BOX (M/B)
LG
A13
F27
F37
i3
Y
F35
B
A4
C:
16
LG
B: B143
i17
REF. TO GROUND
DISTRIBUTION SYSTEM
[GND(R)-03] [GND(R)-01]
F24
C:
B10
1 2
3
F35
(BLUE)
1 2 3
4 5 6
7 8 9 10 11 12 13 14
A:
F108
i17
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
1 2 3 4
5 6 7 8
9 10 11 12 13 14 15 16 17 18
F109
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
B360 (GRAY)
B361
1 2
3 4 5
6 7 8 9 10 11 12
1
4
2
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(R)-03]
A/C CONTROL PANEL
1 2 3 4
10 11 12 13 14
B: B135
B: B143
F37
5 6 7 8 9
15 16 17 18 19 20
HR
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
1
2 4 5
3
B38
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
C: B136 HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
WI-66
F27
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
5 6
14 15 16
25 26 27
33 34 35
10
8 9 11
12
18
19
20 21
22
23
24 25
26
27
28 29
13
14 16 17
15
6
7
30
31
WI-03941
M-A/C(R)-02
M-A/C(R)-02
WIRING SYSTEM

FB-8
F/B FUSE NO. 27 (B)
F/B FUSE NO. 28 (B)
BY
GL
GOr
FB-45
F/B FUSE NO. 22
(IG)
EK : FOR EK MODEL
GL
1
BY
BY
2
LY
GY
LY
BY
22
1
BrY
GY
3
LY
BY
BR
5
4
3
2
1
10
RB
L
LB
LG
LW
B
i3
VY
12
5
1
2
3
6
2
3
i1
i2
VY
RB
LP
LB
LG
LW
LgW
BL
i3
14
VY
RB
LP
LB
LG
LW
LgW
BL
1
2
3
4
5
6
7
GOr
GOr
YR
B
i17
B87
B367
B86
1 2
1 2
1 2
3 4
B38
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
(GREEN)
i15
B91
1 2 3
4 5 6
1 2 3 4 5 6 7
i1
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
HR
B37
B77
1
2 3
4 5 6 7 8
1 2 3 4 5
6 7 8 9 10
1
i99
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(R)-03]
A/C CONTROL PANEL
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
B: B135
12
i100
i99
i17
i100
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
1 2 3 4 5 6
7 8 9 10 11 12
B: B280 HR
GROUND
JOINT CONNECTOR
HEATER COCK
SOLENOID
i15
BLOWER
FAN
SWITCH
REF. TO GROUND
DISTRIBUTION
SYSTEM
[GND(R)-03]
B367
B36
B37
B38
OFF
B87
BY
RB
L
LB
LG
LW
12 LgW
13 BL
BLOWER
FAN
MOTOR
3
1
LgW
BL
B77
BR
B38
24
VY
MODE
ACTUATOR
B91
YR B15
GY
VY B11
B225
FRESH/RECIRC
ACTUATOR
B: B280
B86
BLOWER
FAN
RELAY
GOr
GOr
EK
BODY
INTEGRATED UNIT
BLOWER
FAN
RESISTOR
22
ECM
M-A/C(R)-01
24 GOr
B: B135
B225
HR
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
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
WI-03942
WI-67

M-A/C(R)-03
M-A/C(R)-03
WIRING SYSTEM
AMBIENT SENSOR
B: B135 ECM
B20
BL
BL
BR
BR
F78
13
4
[ILLUMI(R)-04]
C: B281
i84
3
B
B88
Or
A:
EVAPORATION
THERMO SWITCH
B38
11
C3
Or
C10 Sb
Or
Sb
B361
REF. TO REAR DEFOGGER

SYSTEM [R/DEF(R)-01]
11
10
THROUGH
JOINT
CONNECTOR
Or
14
F108
Or
Sb A28
i3
BW
RL
Or
15
GROUND
JOINT CONNECTOR
A/C CONTROL PANEL
12
i100
i99
13
i17
12
11
10
Sb
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(R)-03]
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(R)-03]
F78
1 2
(BLACK)
B88
i99
B361
1 2 3 4 5
i100
1 2 3
4 5 6
7 8 9 10 11 12 13 14
1 2 3 4 5 6
7 8 9 10 11 12
C: B281 HR
B: B135 HR
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
24 25 26
27 28
20 21
22 23
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
F108
B38
5 6 7 8
1 2 3 4
9 10 11 12 13 14 15 16 17 18
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
i17
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
A:
i84
HR
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
WI-03943
WI-68

WIRING SYSTEM
A-A/C(R)-01
A-A/C(R)-01
4. AUTO A/C RHD MODEL
FB-46
F/B FUSE NO. 22
(IG)
GOr
30
LOr
A/C
RELAY
A
EK
LOr
YB
2.5L EK & TURBO & 3.0L MODEL
F109
F35
LOr
B13
LG
GOr
A4
B: B143
C:
GOr
THROUGH
JOINT
CONNECTOR
9
F37
YB C30 C8
14
1
THROUGH
JOINT
CONNECTOR
9
A:
B361
31
Y
C7
C3
B360
MAIN
FUSE BOX
(M/B)
A-A/C(R)-02
LOr B33 B35
GOr
29
LG
F27
F108
PRESSURE
SWITCH
3
B
MAGNET
CLUTCH
B10
B: B135
2.0L & 2.5L KA MODEL
28 GOr
C: B136
ECM
F24
MAIN
FUSE BOX (M/B)
C12
B20
A:
F37
EK : EK MODEL
YR B15
A13
BODY INTEGRATED
UNIT
B: B280
B: B143
F24
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(R)-01]
C:
B10
B367
3
1 2
1
4
2
1 2
3 4 5
6 7 8 9 10 11 12
A:
F108
5 6 7 8
1 2 3 4
9 10 11 12 13 14 15 16 17 18
B: B280
A10
A: B282
A: B282
B361
1 2 3
4 5 6
7 8 9 10 11 12 13 14
5 6 7 8 9
15 16 17 18 19 20
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
B: B135 HR
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
F27
1
2 4 5
3
F109
1 2 3 4 5
6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24
10
8 9 11
12
C: B136 HR
18
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
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(R)-03]
B360 (GRAY)
B: B143
F37
1 2 3 4
10 11 12 13 14
HR
HEATER COCK
SOLENOID
(BLUE)
F35
B367
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(R)-03]
A9 GOr
GOr
YR
F35
C:
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
WI-69
5 6
14 15 16
25 26 27
33 34 35
19
22
20 21
23
24 25
26
27
28 29
13
14 16 17
15
6
7
30
31
WI-03944

A-A/C(R)-02
A-A/C(R)-02
WIRING SYSTEM
GL
YR
FB-8
F/B FUSE NO. 27 (B)
F/B FUSE NO. 28 (B)
GOr
22
GL
A
24 GOr
21
BR
BL
23
3
LgW
B91
VY
B225
FRESH/RECIRC
ACTUATOR
BR
BLOWER
FAN
RELAY
A-A/C(R)-01
FB-29
F/B FUSE NO. 31
(ACC)
LR

MB-29
M/B FUSE NO. 8
(B)
BLOWER
FAN
MOTOR
B87
VY
BY
D13
2.0L & 2.5L KA MODEL
1
B
B86
A: B282
B: B283
(GREEN)
B87
B86
B91
1 2
1 2
3 4
1 2 3 4 5 6 7
B: B283
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
LY
B3 GW
B2
B13 VY
B6
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(R)-03]
A: B282
B: B135 HR
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
B20 BL
YR
A2
B10 LgW
LR
A1
4
LY
BLOWER
FAN
RESISTOR
GW
ECM
3.0L MODEL
2.5L EK & TURBO MODEL
D: B137
P
BY
D17 D17 B20
B: B135
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
D: B137 HR
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
B225
1
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
WI-03945
WI-70

A-A/C(R)-03
FB-28
F/B FUSE NO. 31
(ACC)
FB-45
F/B FUSE NO. 22
(IG)
AMBIENT SENSOR
BL
BL
YR
2
BR
GOr
1
YR
GOr
F78
BR
A-A/C(R)-03
WIRING SYSTEM
13
14
F108
THROUGH
JOINT
CONNECTOR
i88
(BLACK)
1 2
11
Sb
C10 Sb
C3
Or
5
BY
WB
BODY
INTEGRATED UNIT
B: B280
V
B11
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(R)-03]
B1
BY
TWISTED WIRE
BY
i97
B25
C: B281
B26
W
1
10
WB
WR
B38
B16 WB
B15 WR

[ILLUMI(R)-04]
GROUND
JOINT
CONNECTOR
i3
B: B283
F78
Or
B361
BY
7
W
8
BW
WB
4
V
10
A/C CONTROL PANEL
i88
i97
B361
F108
1 2 3 4
5 6 7 8
1 2 3 4 5 6
7 8 9 10 11 12
1 2 3
4 5 6
7 8 9 10 11 12 13 14
5 6 7 8
1 2 3 4
9 10 11 12 13 14 15 16 17 18
B38
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
C: B281 HR
B: B280 HR
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
24 25 26
27 28
20 21
22 23
4 5
6 7
1 2 3
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22
23 24 25
26 27
28 29 30
B: B283
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
WI-03946
WI-71
A-A/C(R)-04
BY A16
Sb A15
Sb
BY A14
A3
WR
WR
B7
RB
LW B17
RB
B8
A4
BL
BL
LW
B18
Br
PG
Br
BrW A13
WG A5
B: B283
Sb
WG
A8
A6
YB
WR
YB
WR
B5
GL
LB B14
B4
GB
A: B282
PG
A-A/C(R)-04
WIRING SYSTEM
B88
i51
1
2
i55
1 2
SUNLOAD
SENSOR
IN VEHICLE
TEMPERATURE
SENSOR
HR
B364
B77
1 2
3 4
1 2 3 4 5
B77
B235 (GREEN)
1 2 3 4 5 6 7
B235
AIR MIX ACTUATOR
BY
B88
EVAPORATION
THERMO SWITCH
WR
Sb
Sb
WR
BrW
i55
Sb
Sb
12
11
OrG
OrG
RAM MONITOR
i51
B364
i3
YB
WR
YB
WR
LB
GL
GB
B38
MODE ACTUATOR
A: B282
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(R)-03]
B38
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
B: B283
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
WI-03947
WI-72
Anti-lock Brake System

WIRING SYSTEM
7. Anti-lock Brake System

A: WIRING DIAGRAM
FB-3
F/B FUSE NO. 8
(B)
FB-36
F/B FUSE NO. 5
(IG)
MB-27
M/B FUSE NO. 13
(B)
FB-32
F/B FUSE NO. 4
(IG)
GY
WL
BrW
GY
A4 BrW
i10
GY
VR
12
BL
B79
LgB A5
BrR F5
F: B159
FUSE &
RELAY BOX (F/B)
REVERSE
CIRCUIT
LgR A7
REVERSE
CIRCUIT
DATA LINK
CONNECTOR
W
VR
10
BL
12
BL
13
B40
REF. TO ENGINE
ELECTRICAL SYSTEM
[E/G(LHU)-04]
[E/G(LND)-04]
[E/G(LH6)-04]
WC : B65
F9 BrW
BrW 2 3
A:
ABS WARNING
LIGHT
OC : B64
WC
OC
COMBINATION
METER
PARKING BRAKE/
BRAKE FLUID LEVEL
WARNING LIGHT
STOP
LIGHT
SWITCH
CHECK
CONNECTOR
LgR 20
1 2
WC
OC
ABS(L)-01
FB-44
F/B FUSE NO. 33
(IG)
A3 BrW
MB-2
M/B FUSE NO. 1
(B)
RY

MB-1
SBF-2
(B)
WR
i3
B38
LgB
ABS(L)-01
1. LHD MODEL
WC : WITH CRUISE
CONTROL
OC : WITHOUT CRUISE
CONTROL
DIAGNOSIS CONNECTOR
8
RY
B301
7
25
VR
RY
22 LgB
LgR
BrR
20
GY
18
RY
14
13
WR
B82
VALVE RELAY
MOTOR RELAY
A
B
ABS(L)-02
ABS(L)-02
DIAGNOSIS TERMINAL
BY
BY
B81
OC :
B64
(BLACK)
WC :
B65
(BLACK)
B38
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
A:
6 7 8 9 10
17 18 19 20 21 22
RR OUTLET
BY
F: B159 (BROWN)
1
5
2
6
3
8
4
9
B79
1
8
i10
1 2 3 4 5
11 12 13 14 15 16
RR INLET
RL OUTLET
RL INLET
FR OUTLET
FL OUTLET
FR INLET
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(L)-02]
B82
1 2
3
4 5 6 7 8
1 2
3 4
1 2
FL INLET
SOLENOID
VALVE
ABS CONTROL MODULE
2 3
9 10
4 5
11 12
(GRAY)
B40
6 7
13 14
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
B301
12
13
14
15
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
WI-03948
WI-73
ABS(L)-01
ABS(L)-01
ABS(L)-02
ABS(L)-02
WIRING SYSTEM
15
12
11
26
REF. TO CAN
COMMUNICATION
SYSTEM
[CAN(L)-02]
GB
23
24
21
10
L
G
B
W
R
3
4
Lg
2
LgB 17
L
G
Lg
5
14 LgB
6
15
B98
GA
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(L)-03]
B228
5
1
2
3
B292
B
W
R
L
P
1
2
1
2
R72
1
2
R73
B6
GB
REF. TO ENGINE
ELECTRICAL SYSTEM
[E/G(LHU)-02]
[E/G(LND)-02]
[E/G(LH6)-02]
L
P
Lg
BY
Lg
BY
B
W
B15
1
2
B301
R2
GOr
GB
TWISTED WIRE
TWISTED WIRE
B
W
GOr
GB
5
6
16
1
ABS CONTROL MODULE
OP CONNECTOR
ABS G SENSOR
FRONT ABS WHEEL
SPEED SENSOR LH
B6
HR
B15 HR
R72
B292
1 2 3
FRONT ABS WHEEL

SPEED SENSOR RH
HR
REAR ABS WHEEL

SPEED SENSOR LH
REAR ABS WHEEL

SPEED SENSOR RH
B228
B98
1 2
3
4 5 6 7 8 9
10 11 12 13 14 15
4 5 6 7
1 2 3
8 9 10 11 12 13 14 15 16
B301
12
13
14
1 2 3 4 5 6 7 8 9 10 11
15
16 17 18 19 20 21 22 23 24 25 26
R73
1 2
WI-03949
WI-74

WIRING SYSTEM
ABS(R)-01
FB-36
F/B FUSE NO. 5
(IG)
MB-27
M/B FUSE NO. 13
(B)
FB-32
F/B FUSE NO. 4
(IG)
GY
WL
BrW
GY
WC : B65
REVERSE
CIRCUIT
LgB A5
BrR F5
F: B159
VR
12
BL
DATA LINK
CONNECTOR
W
1
FUSE &
RELAY BOX (F/B)
GY
B79
LgR A7
REVERSE
CIRCUIT
F9 BrW
BrW 2 3
WC
OC
CHECK
CONNECTOR
i10
i1
LgB
B36
LgR
VR
10
BL
12
BL
13
B40
REF. TO ENGINE
ELECTRICAL SYSTEM
[E/G(RHU)-04]
[E/G(RND)-04]
[E/G(RTB)-04]
[E/G(RH6)-04]
OC : B64
A:
ABS WARNING
LIGHT
PARKING BRAKE/
BRAKE FLUID LEVEL
WARNING LIGHT
STOP
LIGHT
SWITCH
COMBINATION
METER
1 2
WC
OC
A4 BrW
FB-3
F/B FUSE NO. 8
(B)
A3 BrW
MB-1
SBF-2
(B)
FB-44
F/B FUSE NO. 33
(IG)
RY

MB-2
M/B FUSE NO. 1
(B)
WR
ABS(R)-01
2. RHD MODEL
WC : WITH CRUISE
CONTROL
OC : WITHOUT CRUISE
CONTROL
DIAGNOSIS CONNECTOR
8
RY
MOTOR RELAY
B301
7
25
VR
RY
22 LgB
LgR
BrR
20
GY
18
14
13
RY
WR
B82
A
B
ABS(R)-02
ABS(R)-02
VALVE RELAY
DIAGNOSIS TERMINAL
BY
BY
OC :
B64
(BLACK)
WC :
1
3
1 2
A:
B65
(BLACK)
6 7 8 9 10
17 18 19 20 21 22
1
5
2
6
3
8
B301
12
13
14
15
BY
RR OUTLET
RR INLET
RL OUTLET
RL INLET
FR OUTLET
FR INLET
FL OUTLET
F: B159 (BROWN)
B82
2
4
B81
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(R)-02]
1 2
3
4 5 6 7 8
i10
1 2 3 4 5
11 12 13 14 15 16
FL INLET
SOLENOID
VALVE
ABS CONTROL MODULE
4
9
B79
1
8
2 3
9 10
4 5
11 12
(GRAY)
B40
6 7
13 14
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
i1
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
3 4
1 2
5 6 7 8 9 10
11 12 13
14 15 16
17 18 19 20 21 22
23 24 25 26 27 28
WI-03950
WI-75
ABS(R)-01
ABS(R)-01
ABS(R)-02
ABS(R)-02
WIRING SYSTEM
15
12
11
26
REF. TO CAN
COMMUNICATION
SYSTEM
[CAN(R)-02]
GB
23
24
21
10
L
G
R
W
B
3
4
Lg
2
LgB 17
L
G
Lg
7
18 LgB
8
19
B97
B292
GA
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(R)-02]
B228
5
1
2
3
1
2
1
2
1
2
R
W
B
L
P
R72
R73
B6
GB
REF. TO ENGINE
ELECTRICAL SYSTEM
[E/G(RHU)-02]
[E/G(RND)-02]
[E/G(RTB)-02]
[E/G(RH6)-02]
L
P
Lg
BY
Lg
BY
B
W
B15
1
2
B301
R1
GOr
GB
TWISTED WIRE
TWISTED WIRE
B
W
GOr
GB
5
6
16
1
ABS CONTROL MODULE
OP CONNECTOR
ABS G SENSOR
FRONT ABS WHEEL
SPEED SENSOR LH
B6
HR
B15 HR
R72
B292
1 2 3
FRONT ABS WHEEL

SPEED SENSOR RH
HR
REAR ABS WHEEL

SPEED SENSOR LH
REAR ABS WHEEL

SPEED SENSOR RH
B228
B97
1 2
3
4 5 6 7 8 9
10 11 12 13 14 15
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
B301
12
13
14
1 2 3 4 5 6 7 8 9 10 11
15
16 17 18 19 20 21 22 23 24 25 26
R73
1 2
WI-03951
WI-76

WIRING SYSTEM
WI-77
AT Control System
WIRING SYSTEM
8. AT Control System
A: WIRING DIAGRAM
1. LHD 4AT MODEL
SBF-7
IGNITION SWITCH
BATTERY
SBF-1
SBF-9
CHECK CONNECTOR
DATA LINK CONNECTOR
OFF ACC ON ST
+B
F/B FUSE NO. 31
F/B FUSE NO. 12
IG1
F/B FUSE NO. 5
F/B FUSE NO. 4
M/B FUSE NO. 13
M/B FUSE NO. 12
ACC
IG 2
RELAY
IG2
ST
B12
B16
B21
B31
B27
JOINT CONNECTOR (AT)
B28
INHIBITOR SWITCH
COMBINATION METER
B29
D
A5
A14
AWD INDICATOR
LIGHT
A22
A4
ECM:
SPORT
PILOT LIGHT
ND
: FOR 2.5L EC, K4 MODEL
HU
: FOR 2.0L & 2.5L KS MODEL
ND
A19
ND
A13
ND
A10
HU
A19
HU
A13
HU
A10
JOINT CONNECTOR C
ACCELERATOR PEDAL
POSITION SENSOR
VDC : WITH VDC

ABS : WITHOUT VDC
JOINT CONNECTOR C
HU
DRIVER
ECM:
AT OIL TEMP.
WARNING LIGHT
ND
TCM
DIMMER & STABILIZING

POWER CIRCUIT
ACCELERATOR PEDAL
POSITION SENSOR

POWER CIRCUIT
B18
CAN JOINT CONNECTOR (STR)
VDC
P
ABS
STEERING
ANGLE SENSOR
ECM
VDC
VDC
N
ABS
CAN TRANSCEIVER &

RECEIVER
LCD (SPORT SHIFT)
VDC
MICRO COMPUTER
I/F
TWISTED WIRE
VDC
CONTROL
MODULE
VDC
VDC
ABS
ABS
ABS
CONTROL
MODULE
CAN JOINT
CONNECTOR
A3
A12
CAN JOINT CONNECTOR (TCM)
CAN JOINT
CONNECTOR (INT)
AT SELECT
LEVER
GROUND JOINT
CONNECTOR
WI-03952
WI-78
AT Control System
WIRING SYSTEM
1
B17
ABS
A2
ABS
A11
ABS
FWD SWITCH
AT G SENOR
AT CONTROL
ATF TEMPERATURE SENSOR
ABS
A21
A9
LINE PRESSURE LINEAR SOLENOID
B19
B20
LOW CLUTCH DUTY SOLENOID
B9
HIGH CLUTCH DUTY SOLENOID
B8
LOW & REVERSE DUTY SOLENOID
B7
2-4 BRAKE DUTY SOLENOID
B6
LOCK-UP DUTY SOLENOID
B5
AWD DUTY SOLENOID
TCM
B4
A23
VEHICLE SPEED SENSOR 1
A24
A6
A15
A7
TORQUE CONVERTER TURBINE SPEED SENSOR
A16
A8
A17
B2
ABS : WITHOUT VDC
B3
HU
HU : FOR 2.0L & 2.5L KS MODEL
2
WI-03953
WI-79
AT Control System
4AT(L)-01

FB-36
F/B FUSE NO. 5
(IG)
LCD
(SPORT SHIFT)
MICRO COMPUTER
AWD
INDICATOR
LIGHT
I/F

POWER CIRCUIT
SPORT PILOT
LIGHT

POWER CIRCUIT
AT OIL TEMP.
WARNING LIGHT
A4 BrW
A3 BrW
BrW
COMBINATION
METER
A:
i10
DRIVER
BY A11
BY
BY A12
A22
V
7
P
1
A21
CAN TRANSCEIVER &

RECEIVER
GROUND JOINT
CONNECTOR
CAN JOINT
CONNECTOR
1
BY
i97
i77
TWISTED WIRE
A
B
4AT(L)-02
4AT(L)-02
BY
4AT(L)-01
WIRING SYSTEM
REF. TO GROUND DISTRIBUTION SYSTEM [GND(L)-03]
i77
i97
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6
7 8 9 10 11 12
A:
i10
1 2 3 4 5
11 12 13 14 15 16
6 7 8 9 10
17 18 19 20 21 22
WI-03954
WI-80
AT Control System
A
B
A:
i84
V
A26
GY
B55
TCM
VR B12
FB-32
F/B FUSE NO. 4
(IG)
B:
MB-27
M/B FUSE NO. 13
(B)
4AT(L)-02
A27
4AT(L)-01
TWISTED WIRE
4AT(L)-01
C: B281
OrB C26
VW C15
Sb C25
OrB
VW
Sb
DOWN
AT SELECT
LEVER
REF. TO ENGINE
ELECTRICAL SYSTEM
[E/G(LHU)-04]
[E/G(LND)-04]
10
BY
BY
BL
VR
GY
BL
BL
VR
BY
B116
BY
UP
SPORT MODE &

MANUAL MODE
SWITCH
3 4
1 2
5 6 7 8 9 10
B:
B55
HR
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
1
8
2 3
9 10
A:
12
B79
CHECK
CONNECTOR
(GRAY)
B40
6 7
13 14
1 2 3 4 5 6 7 8
4 5
11 12
i84
13
DATA LINK
CONNECTOR
B79
B116
12
B40
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(L)-0203]
10
4AT(L)-02
WIRING SYSTEM
9 10 11 12 13 14 15 16
C: B281
HR
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
27 28
20 21
22 23
24 25 26
HR
3 4
5 6
7 8
1 2
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
WI-03955
WI-81
AT Control System
4AT(L)-03
Lg
30
B30
L
L
7
B20
R
R
5
29
L
B310
VDC CONTROL MODULE
VDC
13
R
BODY
INTEGRATED
UNIT
11
B: B280
VDC
CONTROL
MODULE
B310
ABS
CONTROL
MODULE
26
B301
4AT(L)-03
WIRING SYSTEM
VDC
ABS
ABS
TWISTED WIRE
CAN JOINT
CONNECTOR (INT)
1
B352
CAN JOINT
CONNECTOR (STR)
L
Lg
1
B231
L
7
1 2 3 4
B352
B355
L
D26 C14
L
A12
B234
TCM
D18 C13
R
A3
ND
B231
BY
B234
HU
B54
VDC
B355
A:
VDC
ABS
VDC
CAN JOINT
CONNECTOR
(TCM)
STEERING
ANGLE
SENSOR
C: B136
A:
HU : FOR 2.0L &

2.5L KS MODEL
ND : FOR 2.5L EC, K4
MODEL
VDC : WITH VDC
ABS : WITHOUT VDC
D: B137
B54 HR
ECM
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(L)-02]
B301
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21
22 23 24
12
13
14
15
BY
ABS
VDC
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
B: B280
HR
1 2 3
4 5
6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22
23 24 25
26 27
28 29 30
1 2 3 4
5 6 7 8
D: B137 HR
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
C: B136 HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B310
5 6
14 15 16
25 26 27
33 34 35
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
WI-03956
WI-82
AT Control System
FB-38
F/B FUSE NO. 12
(IG)
GR
4AT(L)-04
MB-26
M/B FUSE NO. 12
(B)
YR

FB-29
F/B FUSE NO. 31
(ACC)
YR
4AT(L)-04
WIRING SYSTEM

ND : FOR 2.5L EC, K4 MODEL
C
ACCELERATOR
PEDAL POSITION
SENSOR
B: B135
C: B136
2
Or
Or
1
Or D30
Or
5
2
R
B27
C28
A23
P
B138
13
GR
GR
LY
15
YR
LY C16
LY
GR
2
YR
4
5
JOINT
CONNECTOR C
B138
B53
14
B315
JOINT
CONNECTOR
C
JOINT
CONNECTOR
(AT)
YR
B315
D18
ECM HU
ECM ND
YR
D: B137
A: B134
A:
B54
B315
B138
B53
1 2 3 4 5 6
1 2 3 4
5 6 7 8
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
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
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
HU
R
HU
P
A13
A19
HU
G
A10
4AT(L)-06
TCM
A:
B54 HR
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21
22 23 24
B: B135 HR
A: B134 HR
1 2
8 9 10
18 19 20
28 29 30
ND
ND
P
B55
A13
B:
A19
A10 LY
B31 GR
B21 GR
B29 YR
B28 YR
B27 YR
B16 YR
ND
D: B137 HR
4AT(L)-06
ACCELERATOR
PEDAL POSITION
SENSOR
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
B:
B55 HR
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
C: B136 HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
WI-03957
WI-83
AT Control System
4AT(L)-05
A2
W
ABS
ABS
A4
A11
TCM
ABS
B55
BG B17
B:
B18
B54
LG
BG A22
RG A14
REF. TO BACK-UP LIGHT

SYSTEM [BACK/L(L)-01]
B: B280
BODY
INTEGRATED
UNIT
B6
BG

WG A5
A:
B361
13
4AT(L)-05
WIRING SYSTEM
BG
LG
BG
RG
WG
GL
BrY
*1
*2
11
THROUGH
JOINT
CONNECTOR
F108
10
11
12
B12
W
3
18
3
P
INHIBITOR
SWITCH
R
N
AT
SELECT
LEVER
SHIFT LOCK
SOLENOID
T7
4AT(L)-06
BG
YG
10
E
R
BW
2
Br
RW
1
BY
12
BW
7
T3
AIR
CONDITIONING
RELAY HOLDER
FWD
SWITCH
B116
4
19
B
B
F27
T3
4
HU : WL
B12
ABS : WITHOUT VDC
LY
HU : WB
ND : GL
B359
*2
ND : B
ND : FOR 2.5L EC, K4 MODEL
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(L)-03]
B359 HR
1 2 3
A:
B54
HR
B116
B12
3 4
1 2
5 6 7 8 9 10
1 2 3 4
5 6 7 8
9 10 11 12
HR
3 4 5 6 7
1 2
8 9 10 11 12 13 14 15 16
17 18 19 20 21
22 23 24
B: B280
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(L)-02]
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(L)-01]
AT G SENOR
T7
B361
F108
1 2 3 4 5 6
7 8 9 10 11 12
1 2 3
4 5 6
7 8 9 10 11 12 13 14
5 6 7 8
1 2 3 4
9 10 11 12 13 14 15 16 17 18
F27
1
2 4 5
3
HR
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
B:
B55
10
8 9 11
12
HR
18
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
19
22
20 21
23
24 25
26
27
28 29
13
14 16 17
15
6
7
30
31
WI-03958
WI-84
B:
B55
AT1
AT2
AT3
B11
1 2 3
1 2
3 4
1 2 3
4 5 6
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
HR
(GRAY)
1 2
WI-85
B53
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
Br
Gr
YG
17
7
8
P
Or
P
Or
HU
SB
YG
RY
WL
YL
BrY
A:
20
19
12
SB
BW
Br
Gr
YG
BY
BW
RW
LR
LY
Or
11
AT2
G
SB
BW
AWD DUTY SOLENOID
BY
15
11
A7
Lg
B9
A16
A8
A17
B3
B2
P
P
Or
Or
6
16
19
18
TCU
LgB 20
B54
4AT(L)-06
A15
B4
YG
B5
RY
B6
WL
12
B7
YL
BrY B8
BW
RW B19
A9
LR B20
LY
Or A21
A6
Or A23
Sb A24
B55
L
G
Or
Sb
5
Lg
10 LgB
14
18
17
B:
Or
Y
W
Y
W
B54
Or
GR
A:
AT1
TORQUE CONVERTER TURBINE

SPEED SENSOR
4AT(L)-04
13
LB
RB
4AT(L)-04
LB
RB
4AT(L)-05
4AT(L)-06
AT Control System
WIRING SYSTEM
JOINT
CONNECTOR
(AT)
10
B53
B11
T4
HU : FOR 2.0L & 2.5L

KS MODEL
AT3
AT CONTROL
HR
3 4 5 6 7
1 2
8 9 10 11 12 13 14 15 16
17 18 19 20 21
22 23 24
HR
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
WI-03959
AT Control System
WIRING SYSTEM
2. LHD 5AT MODEL

SBF-7
BATTERY
CHECK CONNECTOR
IGNITION SWITCH
SBF-9
SBF-1
DATA LINK CONNECTOR
OFF ACC ON ST
+B
IG 2
RELAY
ACC
IG1
F/B FUSE NO. 31
F/B FUSE NO. 12
F/B FUSE NO. 5
F/B FUSE NO. 18
F/B FUSE NO. 4
M/B FUSE NO. 13
M/B FUSE NO. 12
IG2
ST
A20
B2
B1
B10
A1
P-VIGN RELAY
COMBINATION METER
A7
A8
A10
AWD INDICATOR
LIGHT
BACK-UP LIGHT RELAY

POWER CIRCUIT
BACK-UP LIGHT
B11
B15
SPORT
PILOT LIGHT
VDC : WITH VDC
ABS : WITHOUT VDC
CAN JOINT
CONNECTOR (STR)
TCM
AT OIL TEMP.
WARNING LIGHT
DRIVER
VDC
ABS
STEERING
ANGLE SENSOR
B19
ECM
VDC
ABS
VDC
CONTROL
MODULE
VDC
VDC
ABS
ABS
ABS
CONTROL
MODULE
VDC
CAN JOINT
CONNECTOR
(INT)

POWER CIRCUIT
VDC
CAN JOINT
CONNECTOR
A4
CAN JOINT
CONNECTOR (TCM)
CAN TRANSCEIVER &

RECEIVER
LCD (SPORT SHIFT)
MICRO COMPUTER
I/F
TWISTED WIRE
A3
AT SELECT
LEVER
ROLL
CONNECTOR
GROUND
JOINT
CONNECTOR
WI-03960
WI-86
AT Control System
WIRING SYSTEM
B5
ABS
B6
ABS
AT G SENOR (WITHOUT VDC)
ABS
ABS : WITHOUT VDC
A13
B24
B23
A23
A9
A18
A24
A22
A17
A15
B7
A11
TCM
A2
CONTROL VALVE ASSY
A6
A21
A12
B8
B17
B12
B14
B3
B22
B4
B20
B13
A16
B18
B16

TORQUE CONVERTER TURBINE SPEED SENSOR 1
A5
A14
A19
B21
WI-03961
WI-87
AT Control System
5AT(L)-01

FB-36
F/B FUSE NO. 5
(IG)
LCD
(SPORT SHIFT)
MICRO COMPUTER
AWD
INDICATOR
LIGHT
I/F
DIMMER &
STABILIZING
POWER CIRCUIT
SPORT PILOT
LIGHT
DIMMER &
STABILIZING POWER CIRCUIT
AT OIL TEMP.
WARNING LIGHT
A4 BrW
A3 BrW
BrW
COMBINATION
METER
A:
i10
DRIVER
BY A11
BY
BY A12
A22
V
7
P
1
A21
CAN TRANSCEIVER &

RECEIVER
CAN
JOINT CONNECTOR
GROUND
JOINT CONNECTOR
1
BY
i97
i77
TWISTED WIRE
A
B
5AT(L)-02
5AT(L)-02
BY
5AT(L)-01
WIRING SYSTEM
REF. TO GROUND DISTRIBUTION SYSTEM [GND(L)-03]
i77
i97
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6
7 8 9 10 11 12
A:
i10
1 2 3 4 5
11 12 13 14 15 16
6 7 8 9 10
17 18 19 20 21 22
WI-03962
WI-88
AT Control System
5AT(L)-02
A
B
A:
i84
A27
A26
FB-32
F/B FUSE NO. 4
(IG)
B54
TCM
VR A20
MB-27
M/B FUSE NO. 13
(B)
GY
A:
TWISTED WIRE
5AT(L)-01
5AT(L)-01
C: B281
OrB C26
VW C15
Sb C25
OrB
VW
Sb
DOWN
AT SELECT
LEVER
10
BY
BY
B116
BY
UP
SPORT MODE &

MANUAL
MODE SWITCH
REF. TO ENGINE
ELECTRICAL SYSTEM
[E/G(LH6)-04]
BL
VR
GY
BL
BL
VR
BY
B116
3 4
1 2
5 6 7 8 9 10
C: B281
HR
4 5 6 7
1 2 3
8 9 10 11 12 13 14 15 16 17 18 19
27 28
20 21
22 23
24 25 26
B79
1
8
2 3
9 10
DATA LINK
CONNECTOR
CHECK
CONNECTOR
(GRAY)
B40
6 7
13 14
1 2 3 4 5 6 7 8
4 5
11 12
A:
i84
B79
12
13
12
B40
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(L)-03]
10
5AT(L)-02
WIRING SYSTEM
9 10 11 12 13 14 15 16
A:
1 2 3 4
10 11 12 13
19 20 21
B54 HR
5 6
14 15
7
16
22
8
17
23
9
18
24
HR
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
WI-03963
WI-89
AT Control System
B20
B30
30
29
13
R
VDC CONTROL MODULE
11
L
B310
BODY
INTEGRATED
UNIT
VDC
26
VDC CONTROL
MODULE
5AT(L)-03
B: B280
B310
ABS
CONTROL
MODULE
Lg
B301
5AT(L)-03
WIRING SYSTEM
VDC : WITH VDC

ABS
L
7
ABS
VDC
ABS : WITHOUT VDC
TWISTED WIRE
CAN JOINT
CONNECTOR (INT)
B352
CAN JOINT
CONNECTOR (STR)
L
Lg
1
B231
CAN
JOINT
CONNECTOR
(TCM)
VDC
B355
VDC
ABS
VDC
BY
B234
A:
B54
B231
B234
1 2 3 4
B352
B355
R
D18
TCM
D26
L
A3
A4
BY
STEERING
ANGLE
SENSOR
ABS
VDC
D: B137
A:
1 2 3 4
10 11 12 13
19 20 21
B54 HR
5 6
14 15
7
16
22
ECM
B301
8
17
23
9
18
24
12
13
14
15
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(L)-02]
B: B280
HR
1 2 3
4 5
6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22
23 24 25
26 27
28 29 30
1 2 3 4
5 6 7 8
D: B137
HR
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
B310
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
WI-03964
WI-90
AT Control System
5AT(L)-04
5AT-(L)-04
WIRING SYSTEM
FB-38
F/B FUSE NO. 12
(IG)
YR
GR
FB-35
F/B FUSE NO. 18
(IG)
GL
GL
4
GR
3
GR
1
GL
FB-29
F/B FUSE NO. 31
(ACC)
YR

MB-26
M/B FUSE NO. 12
(B)
BACK-UP
LIGHT
RELAY
P-VIGN
RELAY
B356
B357
1 2
3
4
A:
B54
HR
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
9
18
24
B54
B:
B55
TCM
B:
B55
HR
(GRAY)
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
B11 BrR
3
BrY
REF. TO BACK-UP
LIGHT SYSTEM
[BACK/L(L)-01]
4
GL
GL
GL
A7
A8
B356
BrR
2
BL
A10 BL
GR
B1
YR
B2
A:
B10 GR
YR
A1
B357
9
18
24
WI-03965
WI-91
AT Control System
5AT(L)-05
B5
P
ABS
B6
W
ABS
BY A19
BY B21
A5
A14
TCM
B55
B:
B15
B54
GL B19
A:
5AT(L)-05
WIRING SYSTEM
ABS : WITHOUT VDC

B: B280
BODY
INTEGRATED
UNIT
B6
5AT(L)-06
AT
SELECT
LEVER
SHIFT LOCK
SOLENOID
LY
BY
D9
GL
B116
D: B137 ECM
B359 HR
1 2 3
B116
3 4
1 2
5 6 7 8 9 10
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(L)-02]
A:
B54
HR
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
9
18
24
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(L)-02]
B:
B55
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
HR
(GRAY)
7
16
22
8
17
23
B359
AT G SENSOR
B: B280 HR
9
18
24
4 5
6 7
1 2 3
8 9 10 11 12 13 14 15 16 17 18 19 20
23 24 25
26 27
28 29 30
21 22
D: B137 HR
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
WI-03966
WI-92
B:
B55
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
AT1
B12
1 2 3
1 2 3 4
5 6 7 8
(BROWN)
T6
T5
4 3
2 1
12 11 10 9 8 7 6 5
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16
HR
(GRAY)
WI-93
B11
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
1 2
BW
GOr
Or
G
WR
BOr
YR
R
B
BW
GOr
Or
G
WR
BOr
YR
R
B
Br
B4
B3
B14
B13
B20
B22
B23
A22
A23
A24
A11
A15
A17
A18
A9
B13
B17
B7
B8
A21
A12
A6
A2
B12
TCM
HR
(GRAY)
A:
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
5AT(L)-06
GW
RG
GR
RY
LgW
RB
RW
RL
G
8 GW
16 RG
20 GR
17 RY
6 LgW
13 RB
15 RW
18 RL
19
G
B12
LY
B
WL
BY
W
BL
WB
WG
BL
ABS
LY
B
WL
BY
W
BL
WB
WG
BL
BW A16
R
RG
RW
W
WG
LG
YL B18
WR B16
B55
12
3
1
4
10
9
11
5
2
BW
R
RG
RW
W
WG
LG
YL
WR
B:
11
10
6
9
2
1
12
8
7
3
RG
RY
BR
BY
GB
GW
RB
RW
P
RG
RY
BR
BY
GB
GW
RB
RW
P
4
3
2
1
8
6
B54
1
11
14
12
9
10
8
16
13
WB
WB
B
R
G
Y
L
Br
WB
T3
B
R
G
Y
L
A:
15
6
5
4
3
2
TORQUE CONVERTER
TURBINE SPEED
SENSOR 1
SAT(L)-05
AT1
5AT(L)-06
AT Control System
WIRING SYSTEM
B11
T4
T5
T6
ABS : WITHOUT VDC

CONTROL VALVE ASSY
AT CONTROL
B54 HR
9
18
24
9
18
24
WI-03967
AT Control System
WIRING SYSTEM
3. RHD 4AT MODEL (2.0 L NON-TURBO MODEL AND 2.5 L KA MODEL)

SBF-7
CHECK CONNECTOR
IGNITION SWITCH
BATTERY
SBF-1
SBF-9
DATA LINK CONNECTOR
OFF ACC ON ST
+B
IG 2
RELAY
ACC
F/B FUSE NO. 31
F/B FUSE NO. 12
F/B FUSE NO. 5
F/B FUSE NO. 4
M/B FUSE NO. 13
M/B FUSE NO. 12
IG1
IG2
ST
B12
B16
B21
B31
B27
COMBINATION METER
INHIBITOR SWITCH
P
B28
B29
A5
AWD INDICATOR
LIGHT
A14
A4
SPORT
PILOT LIGHT
B18
VDC CONTROL MODULE
TCM
CAN JOINT
CONNECTOR (STR)
STEERING
ANGLE
SENSOR
VDC
ACCELERATOR
PEDAL POSITION
SENSOR
ABS
ECM
VDC
ABS
CONTROL
MODULE

POWER CIRCUIT
AT OIL TEMP.
WARNING LIGHT
DRIVER

POWER CIRCUIT
A22
A19
A13
A10
CAN TRANSCEIVER &

RECEIVER
LCD (SPORT SHIFT)
MICRO COMPUTER
I/F
ABS
TWISTED WIRE
CAN JOINT
CONNECTOR
CAN JOINT
CONNECTOR
(INT)
A3
A12
JOINT
CONNECTOR
AT SELECT
LEVER
2
WI-03968
WI-94
AT Control System
WIRING SYSTEM
1
FWD SWITCH
B17
A2
A11
AT G SENOR
AT CONTROL
A21
A9
B19
B20
B9
B8
B7
B6
TCM
B5
AWD DUTY SOLENOID
B4
A23
A24
A6
A15
A7
A16
A8
A17
B2
B3
2
WI-03969
WI-95
AT Control System
P
MICRO COMPUTER
AWD
INDICATOR
LIGHT
LCD
(SPORT SHIFT)
4AT(RHU)-01

POWER CIRCUIT
SPORT PILOT
LIGHT

POWER CIRCUIT
I/F
AT OIL TEMP.
WARNING LIGHT
FB-36
F/B FUSE NO. 5
(IG)
A4 BrW
A3 BrW
BrW
4AT(RHU)-01
WIRING SYSTEM
COMBINATION
METER
A:
i10
DRIVER
DOWN
Sb
9
UP
BY A11
A22
V
BY A12
A21
BY
V
8
V
P
1
2
P
Sb C25
W
SPORT MODE
AND MANUAL
MODE SWITCH
BY
i97
CAN
JOINT
CONNECTOR
i77
AT
SELECT
LEVER
10
BY
BY
B116
3 4
1 2
5 6 7 8 9 10
C: B281 HR
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
27 28
20 21
22 23
24 25 26
BY
8
BY
B116
BY
OrB
C15
OrB C26
GROUND
JOINT CONNECTOR
C: B281
i84
TWISTED WIRE
A:
A26
A27
CAN TRANSCEIVER &

RECEIVER
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(R)-0203]
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(R)-03]
i77
i97
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6
7 8 9 10 11 12
A:
i84
A:
i10
1 2 3 4 5
11 12 13 14 15 16
6 7 8 9 10
17 18 19 20 21 22
HR
3 4
5 6
7 8
1 2
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
WI-03970
WI-96
AT Control System
30
Lg
STEERING
ANGLE SENSOR
Lg
BY
B231
B234
CAN JOINT
CONNECTOR
(STR)
VDC
ABS
VDC : WITH VDC

ABS : WITHOUT VDC
VDC
BY
L
11
ABS
10
L
L
26
R
R
8
20
18
R
R
A3
A12
19
4AT(RHU)-02
29
L
L
3
13
R
R
1
B20
B30
L
L
3
C14
L
R
R
1
C13
R
TWISTED WIRE
B352
B53
VDC CONTROL
MODULE
BODY INTEGRATED
UNIT
CAN JOINT
CONNECTOR
(INT)
JOINT
CONNECTOR
B310
B: B280
C: B136 ECM
4AT(RHU)-02
WIRING SYSTEM
B301
A: B54
ABS
CONTROL
MODULE
TCM
B231
A: B54 HR
1 2 3 4
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21
22 23 24
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(R)-02]
B: B280 HR
B301
12
13
14
15
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
4 5
6 7
1 2 3
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22
23 24 25
26 27
28 29 30
B234
C: B136
HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B310
5 6
14 15 16
25 26 27
33 34 35
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
B53
B352
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
1 2 3 4
5 6 7 8
WI-03971
WI-97
AT Control System
4AT(RHU)-03
FB-29
F/B FUSE NO. 31
(ACC)
FB-38
F/B FUSE NO. 12
(IG)
MB-27
M/B FUSE NO. 13
(B)
FB-32
F/B FUSE NO. 4
(IG)
YR
GR
GY

MB-26
M/B FUSE NO. 12
(B)
YR
4AT(RHU)-03
WIRING SYSTEM
A
ACCELERATOR
PEDAL POSITION
SENSOR
4AT(RHU)-05
B: B135
CHECK
CONNECTOR
GY 7
C: B136 ECM
B27
D18
C17
C16
LY
YG
LY
Or
B315
Or
YG C18
D: B137
12
BL
B79
DATA LINK
CONNECTOR
JOINT
CONNECTOR C
VR
*
B138
VR
10
BL
12
BL
13
REF. TO ENGINE
ELECTRICAL SYSTEM
[E/G(RHU)-04]
Or
B40
: TERMINAL NO.
OPTIONAL
ARRANGEMENT
JOINT
CONNECTOR
B
B122
A:
B315
B122
1 2 3 4 5 6
B138
1 2 3 4
5 6 7 8
B79
1
8
2 3
9 10
4 5
11 12
B54
B:
B55
B40
6 7
13 14
1 2 3 4 5 6 7 8
B: B135 HR
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
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
B12 VR
G
A10
4AT(RHU)-05
TCM
(GRAY)
D: B137 HR
A13
A19
B31 GR
B21 GR
B16 YR
B29 YR
B28 YR
B27 YR
A:
9 10 11 12 13 14 15 16
B54 HR
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21
22 23 24
B:
B55 HR
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
C: B136 HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
WI-03972
WI-98
AT Control System
4AT(RHU)-04
A2
A4
LY
TCM
A11
B55
B:
B18
B54
LG
BG A22
RG A14
WG A5
A:
BG B17
4AT(RHU)-04
WIRING SYSTEM
B361
13
B6
11
THROUGH
JOINT
CONNECTOR
BG
REF. TO STARTER
SYSTEM [ST(GER)-01]

SYSTEM [BACK/L(R)-01]
BODY
INTEGRATED
UNIT
BG
B: B280
F108
AT
SELECT
LEVER
SHIFT LOCK
SOLENOID
AIR
CONDITIONING
RELAY
HOLDER
FWD
SWITCH
B116
F27
B
B
INHIBITOR
SWITCH
P
R
19
YG
Br
8
10
Y
9
BW
2
BY
RW
1
BW
T3
12
BG
10
11
12
B12
4AT(RHU)-05
18
LG
BG
RG
WG
GL
BrY
WB
WR
T7
LY
YW
B359
T3
B12
REF. TO GROUND
DISTRIBUTIONSYSTEM
SOHC: [GND(R)-03]
DOHC: [GND(R)-01]
B359 HR
1 2 3
A:
B54
HR
B116
B12
3 4
1 2
5 6 7 8 9 10
1 2 3 4
5 6 7 8
9 10 11 12
HR
3 4 5 6 7
1 2
8 9 10 11 12 13 14 15 16
17 18 19 20 21
22 23 24
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(R)-02]
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(R)-01]
AT G SENOR
T7
B361
F108
1 2 3 4 5 6
7 8 9 10 11 12
1 2 3
4 5 6
7 8 9 10 11 12 13 14
5 6 7 8
1 2 3 4
9 10 11 12 13 14 15 16 17 18
B: B280 HR
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
F27
1
2 4 5
3
B:
B55
10
8 9 11
12
HR
18
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
19
22
20 21
23
24 25
26
27
28 29
13
14 16 17
15
6
7
30
31
WI-03973
WI-99
B:
B55
AT1
AT2
AT3
1 2 3
1 2
3 4
1 2 3
4 5 6
HR
B11 (GRAY)
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
1 2
WI-100
B53
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
Gr
Y
Br
Gr
Y
Br
OrB
20 OrB
3
6
13
SB
PB
YG
RY
WL
YL
GB
PB
19
12
BrY
BW
RW
12
A:
BW
YG
YG
LR
11
AT2
Y
SB
BW
AWD DUTY SOLENOID
BY
BY
YW
Br
A9
YW
B54
PB A17
OrB B3
OrB B2
17
14
15
4AT(RHU)-05
PB
16
A8
A16
7
A15
B4
YG
B5
RY
B6
WL
B7
BrY B8
YL
B9
BW
RW B19
LR B20
A21
Br
TCM
15
11
GOr A7
B55
AT1
B:
Or
Or
5 GOr
10 GB
OrB A6
Or A23
Sb A24
B54
Y
W
14 OrB
Y
18
Or
Sb
A:

SPEED SENSOR
Y
W
17
GR
4AT(RHU)-03
13
LB
RB
4AT(RHU)-04
LB
RB
4AT(RHU)-03
4AT(RHU)-05
WIRING SYSTEM
AT Control System
JOINT
CONNECTOR
(AT)
B53
B11
T4
AT3
AT CONTROL
HR
3 4 5 6 7
1 2
8 9 10 11 12 13 14 15 16
17 18 19 20 21
22 23 24
HR
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
WI-03974
AT Control System
WIRING SYSTEM
WI-101
AT Control System
WIRING SYSTEM
4. RHD 4AT MODEL (2.5 L EK MODEL)

SBF-7
IGNITION SWITCH
BATTERY
SBF-1
SBF-9
CHECK CONNECTOR
DATA LINK CONNECTOR
OFF ACC ON ST
+B
IG2
F/B FUSE NO. 31
F/B FUSE NO. 12
IG1
F/B FUSE NO. 5
F/B FUSE NO. 4
M/B FUSE NO. 13
M/B FUSE NO. 12
ACC
IG 2
RELAY
ST
B12
B16
B21
B31
B27
COMBINATION METER
B28
INHIBITOR SWITCH
P
B29
A5
AWD INDICATOR
LIGHT
A14
A4
SPORT PILOT
LIGHT
B18
VDC CONTROL MODULE
ACCELERATOR
PEDAL POSITION
SENSOR
P
GROUND
JOINT
CONNECTOR
A10
VDC
TCM
CAN JOINT
CONNECTOR (STR)
STEERING
ANGLE
SENSOR
ABS
ABS
CONTROL
MODULE
VDC

POWER CIRCUIT
AT OIL TEMP.
WARNING LIGHT
DRIVER

POWER CIRCUIT
A22
CAN TRANSCEIVER &

RECEIVER
MICRO COMPUTER
I/F
A19
A13
ABS
LCD (SPORT SHIFT)
ECM
TWISTED WIRE
CAN JOINT
CONNECTOR
CAN JOINT
CONNECTOR
(INT)
A3
A12
JOINT
CONNECTOR
AT SELECT
LEVER
WI-03975
WI-102
AT Control System
WIRING SYSTEM
FWD SWITCH
B17
A2
A11
AT G SENOR
AT CONTROL
A21
A9
B19
B20
B9
B8
B7
B6
B5
AWD DUTY SOLENOID
TCM
B4
A23
A24
A6
A15
A7
A16
A8
A17
B2
B3
WI-04300
WI-103
AT Control System
LCD
(SPORT SHIFT)
MICRO COMPUTER
AWD
INDICATOR
LIGHT
4AT(RND)-01

POWER CIRCUIT
SPORT PILOT
LIGHT

POWER CIRCUIT
I/F
AT OIL TEMP.
WARNING
LIGHT
FB-36
F/B FUSE NO. 5
(IG)
A4 BrW
A3 BrW
BrW
4AT(RND)-01
WIRING SYSTEM
COMBINATION
METER
A:
i10
DRIVER
BY A11
A22
V
V
BY
BY
UP
DOWN
8
V
Sb C25
Sb
9
C15
W
W
5
i97
CAN
JOINT
CONNECTOR
i77
AT
SELECT
LEVER
10
BY
BY
B116
3 4
1 2
5 6 7 8 9 10
C: B281 HR
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
27 28
20 21
22 23
24 25 26
BY
8
BY
B116
BY
OrB C26
OrB
7
SPORT MODE
AND MANUAL
MODE SWITCH
C: B281
i84
TWISTED WIRE
A:
BY A12
A21
P
GROUND
JOINT CONNECTOR
A26
A27
CAN TRANSCEIVER &

RECEIVER
REF. TO GROUND
DISTRIBUTION
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(R)-03]
i77
i97
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6
7 8 9 10 11 12
A:
i84
A:
i10
1 2 3 4 5
11 12 13 14 15 16
6 7 8 9 10
17 18 19 20 21 22
HR
3 4
5 6
7 8
1 2
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
WI-03976
WI-104
AT Control System
29
30
Lg
L
3
13
R
R
1
B20
B30
L
L
3
Lg
BY
5
R
4
L
STEERING
ANGLE SENSOR
B231
VDC
ABS
VDC : WITH VDC
VDC
ABS : WITHOUT VDC
BY
ABS
B234
CAN JOINT
CONNECTOR
(STR)
10
L
L
11
18
R
R
A3
A12
19
R
R
8
20
B53
26
D26
L
R
R
1
D18
R
TWISTED WIRE
B352
JOINT
CONNECTOR
VDC CONTROL
MODULE
BODY INTEGRATED
UNIT
CAN JOINT
CONNECTOR
(INT)
4AT(RND)-02
B310
B: B280
D: B137 ECM
4AT(RND)-02
WIRING SYSTEM
B301
A:
B54
ABS
CONTROL
MODULE
TCM
B231
A: B54 HR
1 2 3 4
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21
22 23 24
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(R)-02]
B: B280 HR
B301
12
13
14
15
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
4 5
6 7
1 2 3
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22
23 24 25
26 27
28 29 30
B234
D: B137
HR
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
B310
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
B53
B352
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
1 2 3 4
5 6 7 8
WI-03977
WI-105
AT Control System
4AT(RND)-03
4AT(RND)-03
WIRING SYSTEM
FB-29
F/B FUSE NO. 31
(ACC)
FB-38
F/B FUSE NO. 12
(IG)
MB-27
M/B FUSE NO. 13
(B)
FB-32
F/B FUSE NO. 4
(IG)
YR
YR
GR
GY

MB-26
M/B FUSE NO. 12
(B)
ACCELERATOR
PEDAL POSITION
SENSOR
4AT(RND)-05
A: B134
ECM
CHECK
CONNECTOR
C16
C28
A23
YG
LY
B315
LY
YG C35
C: B136
VR
12
BL
B79
JOINT
CONNECTOR C
GY
DATA LINK
CONNECTOR
W
1
*
B138
VR
10
BL
12
BL
13
: TERMINAL NO.
OPTIONAL
ARRANGEMENT
LY
JOINT
CONNECTOR
B
REF. TO ENGINE
ELECTRICAL SYSTEM
[E/G(RND)-04]
*
*
LY
B40
A:
B315
B122
1 2 3 4 5 6
B138
1 2 3 4
5 6 7 8
A: B134 HR
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B79
1
8
2 3
9 10
4 5
11 12
B54
B:
B55
P
A13
B12 VR
R
A19
A10 LY
B31 GR
B21 GR
B16 YR
B29 YR
B28 YR
B27 YR
LY
B122
TCM
(GRAY)
B40
6 7
13 14
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
A:
B54 HR
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16
17 18 19 20 21
22 23 24
B:
B55 HR
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
C: B136 HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
WI-03978
WI-106
AT Control System
4AT(RND)-04
A2
A4
LY
TCM
A11
B55
B18
B:
B54
LG
BG A22
RG A14
WG A5
A:
BG B17
4AT(RND)-04
WIRING SYSTEM
B361
13
B6
11
THROUGH
JOINT
CONNECTOR
BG
REF. TO STARTER
SYSTEM [ST(GER)-01]

SYSTEM [BACK/L(R)-01]
BODY
INTEGRATED
UNIT
BG
B: B280
F108
BG
10
11
12
B12
AT
SELECT
LEVER
SHIFT LOCK
SOLENOID
AIR
CONDITIONING
RELAY
HOLDER
FWD
SWITCH
B116
F27
B
B
INHIBITOR
SWITCH
P
R
19
YG
10
Br
8
BW
2
BY
RW
1
BW
T3
12
4AT(RND)-05
18
LG
BG
RG
WG
GL
BrY
WB
WR
T7
LY
YW
B359
T3
B12
B359 HR
3 4
1 2
5 6 7 8 9 10
1 2 3
A:
B116
B54
HR
3 4 5 6 7
1 2
8 9 10 11 12 13 14 15 16
17 18 19 20 21
22 23 24
REF. TO GROUND
DISTRIBUTION SYSTEM
SOHC: [GND(R)-03]
DOHC: [GND(R)-01]
B12
HR
1 2 3 4
5 6 7 8
9 10 11 12
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(R)-02]
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(R)-01]
AT G SENOR
T7
B361
F108
1 2 3 4 5 6
7 8 9 10 11 12
1 2 3
4 5 6
7 8 9 10 11 12 13 14
5 6 7 8
1 2 3 4
9 10 11 12 13 14 15 16 17 18
B: B280 HR
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
F27
1
2 4 5
3
B:
B55
10
8 9 11
12
HR
18
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
19
22
20 21
23
24 25
26
27
28 29
13
14 16 17
15
6
7
30
31
WI-03979
WI-107
B:
AT1
AT2
AT3
B11
1 2 3
1 2
3 4
1 2 3
4 5 6
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
HR
(GRAY)
1 2
WI-108
AT2
B53
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
YG
Gr
Y
Br
YG
Gr
Y
Br
6
4
OrB
20 OrB
PB
YG
RY
WL
YL
BrY
SB
PB
19
12
12
13
A:
BW
BY
BY
BW
RW
LR
SB
GB
YW
Br
BW
AWD DUTY SOLENOID
15
11
5 GOr
10 GB
B9
A16
PB
PB A17
OrB B3
OrB B2
16
17
14
15
TCM
11
B54
4AT(RND)-05
A8
A15
B4
YG
B5
RY
B6
WL
B7
YL
BrY B8
BW
RW B19
A9
YW
LR B20
A21
Br
GOr A7
OrB A6
Or A23
Sb A24
B55
Or
Sb
14 OrB
Y
18
17
GR
B:
Or
Or
Y
W
9
13
B54
Y
W
LB
A:
AT1

SPEED SENSOR
RB
LB
4AT(RND)-03
RB
4AT(RND)-04
4AT(RND)-05
WIRING SYSTEM
AT Control System
JOINT
CONNECTOR
(AT)
B53
B11
T4
AT3
AT CONTROL
HR
3 4 5 6 7
1 2
8 9 10 11 12 13 14 15 16
17 18 19 20 21
22 23 24
B55 HR
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
WI-03980
AT Control System
WIRING SYSTEM
WI-109
AT Control System
WIRING SYSTEM
5. RHD 5AT MODEL

SBF-7
BATTERY
IGNITION SWITCH
SBF-9
SBF-1
CHECK CONNECTOR
DATA LINK CONNECTOR
OFF ACC ON ST
+B
IG 2
RELAY
ACC
IG1
F/B FUSE NO. 31
F/B FUSE NO. 12
F/B FUSE NO. 5
F/B FUSE NO. 18
F/B FUSE NO. 4
M/B FUSE NO. 13
M/B FUSE NO. 12
IG2
ST
A20
B2
B1
B10
A1
P-VIGN RELAY
COMBINATION METER
A7
A8
A10
AWD INDICATOR
LIGHT
BACK-UP LIGHT RELAY
B11
CAN JOINT
CONNECTOR
(STR)
STEERING
ANGLE
SENSOR
TCM
VDC CONTROL MODULE
AT OIL TEMP.
WARNING LIGHT
ECM
B19
VDC
R
N
ABS
ABS
CONTROL
MODULE
VDC

POWER CIRCUIT
B15
SPORT PILOT
LIGHT
DRIVER

POWER CIRCUIT
BACK-UP LIGHT
CAN JOINT
CONNECTOR
(TCU)
A3
A4
ABS
CAN TRANSCEIVER &

RECEIVER
LCD (SPORT SHIFT)
MICRO COMPUTER
I/F
CAN JOINT
CONNECTOR
CAN JOINT
CONNECTOR
(INT)

TB
TB
AT SELECT
LEVER
STEERING
SWITCH
TB
TB :TURBO MODEL
WI-03981
WI-110
AT Control System
WIRING SYSTEM
B5
ABS
B6
ABS
AT G SENOR (WITHOUT VDC)
VDC : WITH VDC

ABS : WITHOUT VDC
B22
B24
A9
A18
A17
A15
A11
A24
A23
A22
B23
B12
A2
A6
CONTROL VALVE ASSY
A21
B8
B7
B17
ABS
TCM
A12
A13
A16
B20
B13
B14
B3
B4
B18
B16

TORQUE CONVERTER TURBINE SPEED SENSOR 1
A5
A14
A19
B21
WI-03982
WI-111
AT Control System
MICRO COMPUTER
SPORT PILOT
LIGHT
LCD
(SPORT SHIFT)
TB : TURBO MODEL
5AT(R)-01

POWER CIRCUIT
AWD
INDICATOR
LIGHT

POWER CIRCUIT
I/F
AT OIL TEMP.
WARNING LIGHT
FB-36
F/B FUSE NO. 5
(IG)
A4 BrW
A3 BrW
BrW
5AT(R)-01
WIRING SYSTEM
COMBINATION
METER
A:
i10
DRIVER
BY A11
A22
V
BY A12
A21
P
BY
8
V
Sb C25
OrB C26
C15
C: B281
i84
TWISTED WIRE
A:
GROUND
JOINT CONNECTOR
A26
A27
CAN TRANSCEIVER &

RECEIVER
BY
i97
CAN
JOINT
CONNECTOR
i77
B116
Sb
GR
Sb
BY
BW
10
BY
BY
TB
REF. TO GROUND
DISTRIBUTION
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(R)-03]
ST4
B68
BY
STEERING SWITCH
BY
AT
SELECT
LEVER
DOWN
UP
SPORT MODE
AND MANUAL
MODE SWITCH
TB
BY
ROLL
CONNECTOR
TB
B68
B116
ST4
i97
i77
1
2 3
4 5 6 7 8
3 4
1 2
5 6 7 8 9 10
1 2 3 4 5
6 7 8 9 10
1 2 3 4 5 6
7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 11 12
A:
i10
1 2 3 4 5
11 12 13 14 15 16
6 7 8 9 10
17 18 19 20 21 22
C: B281 HR
A:
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
27 28
20 21
22 23
24 25 26
i84
HR
3 4
5 6
7 8
1 2
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
WI-03983
WI-112
AT Control System
B310
B: B280
29
30
Lg
L
3
13
R
R
1
B20
B30
L
L
3
STEERING
ANGLE SENSOR
Lg
BY
B231
4
L
B234
CAN JOINT
CONNECTOR
(STR)
VDC
VDC : WITH VDC
ABS
VDC
ABS : WITHOUT VDC
BY
ABS
11
4
L
L
L
3
R
R
1
2
R
R
A4
A3
26
D26
R
R
1
D18
B352
CAN JOINT
CONNECTOR
(INT)
B355
CAN JOINT
CONNECTOR
(TCM)
VDC CONTROL
MODULE
BODY INTEGRATED
UNIT
TWISTED WIRE
D: B137 ECM
5AT(R)-02
5AT(R)-02
WIRING SYSTEM
B301
A:
B54
B231
ABS
CONTROL
MODULE
TCM
A: B54
1 2 3 4
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
HR
7
16
22
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(R)-02]
B: B280 HR
B301
8
17
23
9
18
24
12
13
14
15
4 5
6 7
1 2 3
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22
23 24 25
26 27
28 29 30
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
B234
D: B137 HR
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
B310
B352
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
B355
1 2 3 4
5 6 7 8
WI-03984
WI-113
AT Control System
5AT(R)-03
5AT(R)-03
WIRING SYSTEM
FB-29
F/B FUSE NO. 31
(ACC)
FB-38
F/B FUSE NO. 12
(IG)
FB-35
F/B FUSE NO. 18
(IG)
MB-27
M/B FUSE NO. 13
(B)
FB-32
F/B FUSE NO. 4
(IG)
YR
YR
GR
GL
GY

MB-26
M/B FUSE NO. 12
(B)
CHECK
CONNECTOR
GY
VR
12
BL
GL
DATA LINK
CONNECTOR
GL
1
GR
GR
B79
BACK-UP
LIGHT
RELAY
P-VIGN
RELAY
B357
B356
VR
10
BL
12
BL
13
(GRAY)
B40
6 7
13 14
1 2 3 4 5 6 7 8
1
8
2 3
9 10
4 5
11 12
REF. TO ENGINE
ELECTRICAL SYSTEM
[E/G(RTB)-04]
[E/G(RH6)-04]
BrY
A20 VR
REF. TO BACK-UP
LIGHT SYSTEM
[BACK/L(R)-01]
TCM
B357
1 2
3
4
B11 BrR
GL
GL
B55
A8
B:
A7
B54
GL
BL
B79
A10 BL
GR
B1
YR
B2
B356
B10 GR
YR
A1
A:
BrR
B40
9 10 11 12 13 14 15 16
A:
B54
HR
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
7
16
22
8
17
23
9
18
24
B:
B55
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
HR
(GRAY)
7
16
22
8
17
23
9
18
24
WI-03985
WI-114
AT Control System
5AT(R)-04
B23
A22
A23
A24
A11
A15
A17
A18
A9
GW
RG
GR
RY
R
RB
RW
RL
G
GW
RG
GR
RY
R
RB
RW
RL
G
8
16
20
17
6
13
15
18
19
B11
T4
BW
GOr
Or
G
WR
BOr
YR
R
B
7
12
3
1
4
10
9
11
5
2
7
5
4
3
2
1
8
6
3
1
2
W
W
B
R
G
Y
L
Br
BY
BW
Y
B
WL
BY
W
BL
WB
WG
BL
B12
T3
BW
Y
B
WL
BY
W
BL
WB
WG
BL
WR
YL
R
RG
RW
W
WG
YB
LY
P
Y
GL
ABS
B359
D9
A16
A13
B17
B7
B8
A21
A12
A6
A2
B12
TCM
ABS
ABS
B16
B18
B4
B3
B14
B13
B20
B22
B55
WR
YL
R
RG
RW
W
WG
YB
B:
B6
B5
B54
LY
P
GL B19
B15
R
BY A19
BY B21
B
B
A5
A14
A:
WB
RG
RY
BR
BY
GB
GW
RB
RW
P
5AT(R)-04
WIRING SYSTEM
D: B137
ECM
AT G SENOR
(WITHOUT VDC)
AT
SELECT
LEVER
SHIFT
LOCK
SOLENOID
WB
3
1
B
R
G
Y
L
WB
RG
RY
BR
BY
GB
GW
RB
RW
P
BW
GOr
Or
G
WR
BOr
YR
R
B
Br
AT1
B116
TORQUE CONVERTER
TURBINE SPEED
SENSOR 1
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(R)-02]
11
10
6
9
2
1
12
8
7
3
T6
B6
6
5
4
3
2
15
1
11
14
12
9
10
8
16
13
T5
ABS : WITHOUT
VDC
CONTROL VALVE ASSY

B: B280
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(R)-02]
AT CONTROL
B12
B116
T6
T5
1 2 3 4
5 6 7 8
3 4
1 2
5 6 7 8 9 10
4 3
2 1
12 11 10 9 8 7 6 5
1 2 3
4 5 6
7 8 9 10 11 12 13 14 15 16
AT1
B359 HR
BODY
INTEGRATED
UNIT
1 2 3
B:
B55
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
HR
(GRAY)
7
16
22
8
17
23
9
18
24
B: B280 HR
D: B137 HR
1 2 3
4 5
6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
23 24 25
26 27
28 29 30
21 22
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
B11
1 2
HR
(GRAY)
3 4
6 7
8
9 10
11 12
13
14 15
16
17 18
19 20
5
A:
B54
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
HR
7
16
22
8
17
23
9
18
24
WI-03986
WI-115
Audio System
WIRING SYSTEM
9. Audio System
A: WIRING DIAGRAM
LR
D2
BW
7
11
YB
YB
6
1
2
D29
1
2
D23
FRONT DOOR
TWEETER RH
FRONT DOOR
SPEAKER RH
FRONT DOOR
SPEAKER LH
FRONT DOOR
TWEETER LH
REAR DOOR
SPEAKER RH
REAR DOOR
SPEAKER LH
RW
LY
YB
D28
1
2
D93
YB
5
6
RW
LY
D22
RW
LY
WB
RY
WB
RY
RW
LY
5
6
R13
2
1
G
BrW
14
13
5
LW
LY
R10
D12
R167
2
1
G
BrW
R98
1
2
D97
RB
WR
12
4
RW
LY
RW
LY
LW
LY
D83
i29
i102
i53
25
24
WB
RY
D84
AUDIO
BRACKET
EARTH
i76
TWISTED WIRE
G
25
BrW 24
i101
RADIO
17
18
9
3
G
BrW
WB
RY
G
BrW
8
2
WB
RY
i26
RB
WR
LR
6
i83
16
15
YR
i82
10
LR
BR
WR
LR
BR
WR
YR
FB-10
M/B FUSE NO. 8
(B)
JOINT CONNECTOR
(ILLUMINATION &
BACK-UP LIGHT)
AUDIO(L)-01
REF. TO CLEARANCE
LIGHT AND ILLUMINATION
LIGHT SYSTEM
[ILLUMI(L)-04]

FB-25
F/B FUSE NO. 24
(ACC)
AUDIO(L)-01
1. LHD MODEL
R97
ANTENNA
AMPLIFIER
GR
HR
D2
D23
(BLACK)
D93
R10
i82
i26
D12
D29
(BLACK)
D97
R13
i83
1 2 3
4 5 6
7 8 9 10 11 12 13 14
1
2
1
2 3
4 5 6 7 8
1 2 3 4 5 6
7 8 9 10 11 12
1
2
i53
i102
1 2 3 4
5 6 7 8
9 10 11 12 13 14 15 16 17 18
1
2
D83
D84
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
WI-03988
WI-116
Audio System
WIRING SYSTEM
LR
YR
FB-10
M/B FUSE NO. 8
(B)
JOINT CONNECTOR
(ILLUMINATION & BACK-UP LIGHT)
4
2
1
2
1
1
2
1
2
1
2
D29
FRONT DOOR
SPEAKER RH
FRONT DOOR
SPEAKER LH
FRONT DOOR
TWEETER LH
REAR DOOR
SPEAKER RH
REAR DOOR
SPEAKER LH
(BLACK) D23
D12
D29
(BLACK)
D93
1
2
1
2
1
2
i53
D83
i102
D84
1 2 3 4
5 6 7 8
9 10 11 12 13 14 15 16 17 18
D97
R10
R13
1
2 3
4 5 6 7 8
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
BW
7
11
YB
YB
5
i82
i83
1 2 3 4 5 6
7 8 9 10 11 12
YB
D28
RW
LY
D23
D93
YB
5
6
D22
RW
LY
RW
LY
5
6
R13
RW
LY
WB
RY
WB
RY
G
BrW
D2
R167
FRONT DOOR
TWEETER RH
D2
V
RB
WR
RB
WR
R10
D12
14
13
5
12
4
RW
LY
17
18
LW
LY
LW
LY
TWISTED WIRE
G
BrW
R98
1
2
D97
i29
i102
i53
D83
WB
RY
D84
AUDIO
BRACKET
EARTH
i76
25
24
G
28
BrW 27
i101
RADIO
RW
LY
9
3
G
BrW
WB
RY
G
BrW
8
2
WB
RY
i26
14
13
LR
6
i83
BR
WR
YR
i82
10
LR
BR
WR
LR
AUDIO(LWS)-01
REF. TO CLEARANCE
LIGHT & ILLUMINATION
LIGHT SYSTEM
[ILLUMI(L)-04]

FB-25
F/B FUSE NO. 24
(ACC)
AUDIO(LWS)-01
2. LHD MODEL WITH SATELLITE SWITCH
R97
ANTENNA
AMPLIFIER
GR
i26
HR
1 2 3
4 5 6
7 8 9 10 11 12 13 14
WI-04308
WI-117
Audio System
AUDIO(LWS)-02
15
BY
Br
Br
25
Y
Y
24
BW
BW
26
W
OrW
13
WL
WL
VW
B366 LAN MODULE
FB-18
F/B FUSE NO. 7
(B)
23
AUDIO(LWS)-02
WIRING SYSTEM
SATELLITE SWITCH
POWER
7
VW
VOL +
22
20
Br
i1
Y
BW
21
W
19
B36
VOL
MODE
IE BUS
JOINT CONNECTOR
SEEK
Y
WN
WN
Br
WN
Br
ON
WN
SEEK
OrW
BW
REF. TO CLEARANCE LIGHT &

[ILLUMI(L)-01]
ON
B68
i95
REF.TO NAVIGATION
SYSTEM [NAVI(L)-02]
WN : WITH NAVIGATION SYSTEM
Br
BW
Br
19
20
18
R
11
WL
10
GOr
7
17
BrW
3
12
RY
BY
ON : WITHOUT
NAVIGATION SYSTEM
i86
i95
B68
1 2 3 4 5 6
2 3
1
4 5 6 7 8
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(L)-02]
RADIO
B366 HR
i86
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
4 5 6 7 8 9
1 2 3
10 11 12
13 14 15 16 17 18 19
20 21 22 23 24 25 26
i1
3 4
1 2
5 6 7 8 9 10
11 12 13
14 15 16
17 18 19 20 21 22
23 24 25 26 27 28
WI-04309
WI-118
Audio System
WIRING SYSTEM
LR
V
17
18
R98
BW
7
YB
YB
5
R167
YB
D84
11
14
13
5
12
4
RW
LY
i102
i53
LW
LY
G
25
BrW 24
RW
LY
G
BrW
G
BrW
WB
RY
WB
RY
D83
i101
i29
R13
R97
2
1
2
1
1
2
1
2
1
2
D23
FRONT DOOR
TWEETER RH
FRONT DOOR
SPEAKER RH
FRONT DOOR
SPEAKER LH
FRONT DOOR
TWEETER LH
REAR DOOR
SPEAKER RH
REAR DOOR
SPEAKER LH
RW
LY
D29
D97
D22
YB
RW
LY
D28
1
2
D12
5
6
5
6
R10
RW
LY
RW
LY
D2
D93
G
BrW
G
BrW
WB
RY
WB
RY
BR
WR
LW
LY
TWISTED WIRE
WB
RY
WD OD
28 25
27 24
i76
AUDIO
BRACKET
EARTH
RADIO
9
3
8
2
i26
RB
WR
LR
6
i83
RB
WR
YR
10
LR
i82
14
13
LR
BR
WR
YR

JOINT CONNECTOR
(ILLUMINATION &
BACK-UP LIGHT)
AUDIO(R)-01
FB-10
M/B FUSE NO. 8
(B)
REF. TO CLEARANCE
LIGHT SYSTEM
[ILLUMI(R)-04]

FB-25
F/B FUSE NO. 24
(ACC)
AUDIO(R)-01
3. RHD MODEL
ANTENNA
AMPLIFIER
GR
HR
D2
D23
(BLACK)
D93
R10
i82
i26
D12
D29
(BLACK)
D97
R13
i83
1 2 3
4 5 6
7 8 9 10 11 12 13 14
1
2
1
2 3
4 5 6 7 8
1
2
1
2
OD :
D83
1 2 3 4 5 6
7 8 9 10 11 12
WD :
D83
D84
i102
i53
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
1 2 3 4
5 6 7 8
9 10 11 12 13 14 15 16 17 18
3 4
1 2
5 6 7 8 9
10 11 12 13 14 15
16 17
18 19
20 21 22 23 24 25
WI-119
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
WI-03989
Audio System
WIRING SYSTEM
FB-10
M/B FUSE NO. 8
(B)
LR
YR

JOINT CONNECTOR
4
R98
LW
LY
2
1
2
1
1
2
1
2
1
2
D23
FRONT DOOR
SPEAKER RH
FRONT DOOR
SPEAKER LH
FRONT DOOR
TWEETER LH
REAR DOOR
SPEAKER RH
REAR DOOR
SPEAKER LH
D12
(BLACK) D23
D29 (BLACK)
1
2
1
2
D93
D97
1
2
i102
i53
4 5 6 7
1 2 3
8 9 10 11 12 13 14 15 16
1 2 3 4
5 6 7 8
9 10 11 12 13 14 15 16 17 18
R10
R13
1
2 3
4 5 6 7 8
OD :
D83
BW
7
11
i82
i83
1 2 3 4 5 6
7 8 9 10 11 12
WD :
B
B
YB
RW
LY
RW
LY
D22
FRONT DOOR
TWEETER RH
D2
YB
YB
5
YB
5
6
D28
RW
LY
RW
LY
5
6
R10
D29
D97
R167
1
2
D12
G
BrW
G
BrW
D2
D93
14
RB
WR
RB
WR
R13
WB
RY
WB
RY
13
5
12
4
RW
LY
RW
LY
D84
i29
i102
i53
17
18
G
25
BrW 24
i101
TWISTED WIRE
WB
RY
D83
AUDIO
BRACKET
EARTH
LW
LY
9
3
G
BrW
G
BrW
8
2
WB
RY
WB
RY
WD OD
28 25
27 24
i76
V
RADIO
i26
14
13
LR
6
i83
BR
WR
YR
i82
10
LR
BR
WR
LR
AUDIO(RWS)-01
REF. TO CLEARANCE
LIGHT SYSTEM
[ILLUMI(R)-04]

FB-25
F/B FUSE NO. 24
(ACC)
AUDIO(RWS)-01
4. RHD MODEL WITH SATELLITE SWITCH
R97
ANTENNA
AMPLIFIER
GR
i26
HR
1 2 3
4 5 6
7 8 9 10 11 12 13 14
D83
D84
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
WI-120
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
WI-04310
Audio System
AUDIO(RWS)-02
15
BY
Br
Br
25
Y
Y
24
BW
BW
26
W
OrW
13
WL
WL
VW
B366 LAN MODULE
FB-18
F/B FUSE NO. 7
(B)
23
AUDIO(RWS)-02
WIRING SYSTEM
SATELLITE SWITCH
POWER
7
VW
VOL +
22
20
Br
i1
Y
BW
21
W
19
B36
VOL
MODE
IE BUS JOINT
CONNECTOR
SEEK
Y
WN
WN
Br
WN
Br
ON
WN
SEEK
OrW
BW

[ILLUMI(R)-01]
ON
B68
i95
REF.TO NAVIGATION
SYSTEM [NAVI(R)-02]
i95
B68
1 2 3 4 5 6
2 3
1
4 5 6 7 8
Br
BW
Br
18
L
12
20
R
11
WL
10
19
GOr
7
BrW
3
i86
17
RY
BY
RADIO
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(R)-02]
B366 HR
i86
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
ON : WITHOUT
NAVIGATION SYSTEM
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
i1
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
WI-04311
WI-121
Audio System
WIRING SYSTEM
AUDIO(RM)-01
AUDIO(RM)-01
5. RHD MODEL WITH MCINTOSH
MB-3
M/B FUSE NO. 5
(B)
RB
YR
FB-10
M/B FUSE NO. 8
(B)
LR

FB-25
F/B FUSE NO. 24
(ACC)
JOINT CONNECTOR
LR
6
RB
B98
RB
R2
RB
YR
10
LR
i83
RB
i82
LR
DIN CORD
RADIO
14
11
YB
10
2
RADIO AMPLIFIER
AUDIO
BRACKET EARTH
W
V
1
V
R110
BW
i26
i29
15
16
R98
YB
23
24
i76
6
5
TWISTED WIRE
R167
W
V
D83
i102
YB
REF. TO CLEARANCE
LIGHT AND ILLUMINATION
LIGHT SYSTEM
[ILLUMI(R)-04]
W
V
i53
W
V
7
4
8
3
D94
D93
W
V
W
V
W
V
R97
W
V
YB
W
V
W
V
W
V
9
2
10
1
JOINT
CONNECTOR
D92
1
2
1
2
2
1
D2
1
2
D4
FRONT
TWEETER
(INNER) RH
FRONT
TWEETER
(GUSSET) RH
FRONT
SQUAWKER
RH
FRONT
SPEAKER
RH
GR
ANTENNA
AMPLIFIER
D2
D4
(BLACK)
D92
1
2
(GREEN)
D93
B98
D94
1
2
1
2 3
4 5 6 7 8
1 2 3 4 5 6 7 8 9 10
1 2
HR
i82
i26
i83
1 2 3
4 5 6
7 8 9 10 11 12 13 14
i53
i102
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
1 2 3 4 5 6
7 8 9 10 11 12
D83
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
R110 HR
1 2 3 4
5 6 7 8
9 10 11 12 13 14 15 16 17 18
WI-03990
WI-122
Audio System
AUDIO(RM)-02
AUDIO(RM)-02
WIRING SYSTEM
SUB WOOFER
W
15
18
8
B
W
Or
16
6
W
P
W
Lg
17
7
RADIO AMPLIFIER
11
3
R110
TWISTED WIRE
R117
11
12
R167
R10
23
24
D22
W
P
6
5
W
Lg
D28
W
Lg
D84
5
6
R13
5
6
i101
W
Or
W
Lg
W
P
i102
D97
D12
1
2
W
Lg
W
Lg
W
P
W
P
D29
1
2
1
2
2
1
1
2
1
2
D23
1
2
D12
FRONT
TWEETER
(INNER) LH
FRONT
TWEETER
(GUSSET) LH
FRONT
SQUAWKER
LH
FRONT
SPEAKER
LH
REAR
DOOR
SPEAKER RH
REAR
DOOR
SPEAKER LH
D23
(BLACK)
D29
(BLACK)
1 2
1
2
R110
D96
D14
D96
D14
D98
7
4
8
3
W
P
W
P
W
P
W
P
W
P
W
P
9
2
10
1
JOINT
CONNECTOR
(BLACK)
D84
HR
1 2 3 4
5 6 7 8
9 10 11 12 13 14 15 16 17 18
D97
1
2
R117
1
2
(GREEN)
R10
D98
R13
1 2 3 4 5 6 7 8 9 10
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(R)-04]
i102
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
1
2 3
4 5 6 7 8
3 4
1 2
5 6 7 8 9
10 11 12 13 14 15
16 17
18 19
20 21 22 23 24 25
WI-03991
WI-123
CAN Communication System

WIRING SYSTEM
10.CAN Communication System

A: WIRING DIAGRAM
CAN(L)-01
COMBINATION
METER
TV MONITOR
A6
P
12
A:
i90
CAN JOINT
CONNECTOR
BODY INTEGRATED
UNIT
C9
C8
i77
BY
BY
C: B281
BY
B: B280
BY B22
i84
BY A21
A:
C2
B7
LR
WL
TWISTED WIRE
A26
i10
A27
LR
A:
A14
A21
FB-18
F/B FUSE NO. 7
(B)
WL
MB-29
M/B FUSE NO. 8
(B)
A22
CAN(L)-01
1. LHD MODEL
i97
BY
BY
BY
GROUND
JOINT
CONNECTOR
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(L)-03]
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(L)-02]
A:
i77
i97
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6
7 8 9 10 11 12
A:
i90
1 2 3 4 5
11 12 13 14 15 16
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
C: B281 HR
B: B280 HR
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
22 23
24 25 26
27 28
20 21
1 2 3
4 5
6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22
23 24 25
26 27
28 29 30
i10
A:
i84
6 7 8 9 10
17 18 19 20 21 22
HR
3 4
5 6
7 8
1 2
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
WI-03992
WI-124
A:
B54
B310
TCM
13
29
A3
ABS
BY
A3 A12
VDC
A4
VDC
VDC
TWISTED WIRE
VDC
5AT
ABS
4AT
D26 C14
D18 C13
R
Lg
Br
FOR 2.0L &

2.5L KS MODEL
FOR 2.5L EC, K4 &
3.0L MODEL
VDC
CONTROL
MODULE
STEERING
ANGLE SENSOR
CAN(L)-02
D: B137 ECM
C: B136
30
B231
Lg
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(L)-02]
VDC
BODY
INTEGRATED
UNIT
B20
CAN JOINT
CONNECTOR
(INT)
CAN JOINT
CONNECTOR
(TCM)
B352
B355
ABS
ABS
B30
B: B280
VDC
L
4
B234
R
2
CAN JOINT
CONNECTOR
(STR)
CAN(L)-02
WIRING SYSTEM
11
26
B301
VDC : WITH VDC
ABS : WITHOUT VDC
ABS
CONTROL
MODULE
B231
1 2 3 4
4AT A:
B54 HR
3 4 5 6 7
1 2
8 9 10 11 12 13 14 15 16
17 18 19 20 21
22 23 24
5AT A:
1 2 3 4
10 11 12 13
19 20 21
B54 HR
5 6
14 15
7
16
22
B301
8
17
23
9
18
24
12
13
14
B234
B352
1 2 3 4 5 6 7 8 9 10 11
15
16 17 18 19 20 21 22 23 24 25 26
B355
1 2 3 4
5 6 7 8
B: B280 HR
D: B137 HR
4 5
6 7
1 2 3
8 9 10 11 12 13 14 15 16 17 18 19 20
23 24 25
26 27
28 29 30
21 22
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
C: B136 HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B310
5 6
14 15 16
25 26 27
33 34 35
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
WI-03993
WI-125

WIRING SYSTEM
COMBINATION
METER
TV MONITOR
CAN(R)-01
CAN(R)-01
2. RHD MODEL
TV MONITOR
2
P
i103
TWISTED WIRE
A6
A14
i90
V
7
P
1
11
A26
ON
CAN JOINT
CONNECTOR
BODY INTEGRATED
UNIT
8
V
C9
BY
C8
BY
i77
BY
BY B22
C: B281
A:
ON
A27
WL
C2
LR
B7
B: B280
i84
BY A21
A:
WN
i10
WN
A21
A22
A:
TWISTED WIRE
LR
WL
FB-18
F/B FUSE NO. 7
(B)
MB-29
M/B FUSE NO. 8
(B)
i97
ON : WITHOUT NAVIGATION SYSTEM
BY
BY
BY
GROUND
JOINT
CONNECTOR
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(R)-03]
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(R)-02]
A:
i103
i77
i97
1 2
3 4
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6
7 8 9 10 11 12
C: B281 HR
B: B280 HR
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
27 28
20 21
22 23
24 25 26
1 2 3
4 5
6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22
23 24 25
26 27
28 29 30
A:
i90
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
A:
i10
1 2 3 4 5
11 12 13 14 15 16
i84
6 7 8 9 10
17 18 19 20 21 22
HR
3 4
5 6
7 8
1 2
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
WI-03994
WI-126
CAN(R)-02
CAN(R)-02
WIRING SYSTEM
B310
29
13
30
Lg
A3
A3 A12
R
3
*6
L
*5
R
B20
CAN JOINT
CONNECTOR
(STR)
B30
B355 : 5AT
*3
: 4AT
B53
VDC
CONTROL
MODULE
*1
*2
B: B280
TCM
A4
5AT
*4
JOINT
CONNECTOR
4AT
OTHER MODELS
D26 C14
FOR 2.0L & 2.5L KA MODEL
B54
A:
D: B137 ECM
D18 C13
C: B136
STEERING
ANGLE SENSOR
Lg
BY
VDC
CAN JOINT
CONNECTOR
(INT)
: 4AT:19
5AT:5
B352
: 4AT:9
5AT:7
BY
ABS
5
L
: 4AT:8
5AT:1
L
ABS
: 4AT:20
5AT:3
: 4AT:10
5AT:4
TWISTED WIRE
: 4AT:18
5AT:2
VDC
R
2
26
B301
11
*1
*2
*3
*4
*5
*6
B231
TWISTED WIRE
B234
VDC : WITH VDC

ABS : WITHOUT
VDC
4AT : 4AT
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(R)-02]
ABS
CONTROL
MODULE
5AT : 5AT
B234
B231
B352
1 2 3 4
B355 : 5AT
4AT A:
B54 HR
5AT A:
3 4 5 6 7
1 2
8 9 10 11 12 13 14 15 16
17 18 19 20 21
22 23 24
1 2 3 4
10 11 12 13
19 20 21
B54 HR
5 6
14 15
7
16
22
B301
8
17
23
9
18
24
12
13
14
1 2 3 4 5 6 7 8 9 10 11
15
16 17 18 19 20 21 22 23 24 25 26
1 2 3 4
5 6 7 8
B53
: 4AT
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
B: B280 HR
D: B137 HR
4 5
6 7
1 2 3
8 9 10 11 12 13 14 15 16 17 18 19 20
23 24 25
26 27
28 29 30
21 22
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
C: B136 HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B310
5 6
14 15 16
25 26 27
33 34 35
10
5
6
7
8
9
1 2 3 4
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
WI-03995
WI-127
Charging System
WIRING SYSTEM
11.Charging System
CHG-01
CHG-01
A: WIRING DIAGRAM
A4 BrW
*1
CHARGE
WARNING LIGHT
A3 BrW
BrW
FB-36
F/B FUSE NO. 5
(IG)
: LHD : WB
RHD : BW
COMBINATION
METER
A:
BW A6
i10
WB
REF. TO POWER SUPPLY CIRCUIT

[P-SUP(L)-02]
[P-SUP(R)-02]
BW
RHD
LHD
i3
6
18
i1
WB
LHD
*1
*1
B11
B: B143
BW A7
F37
BR
BW
WR
A:
REF. TO ENGINE ELECTRICAL SYSTEM

[E/G(LHU)-01]
[E/G(LND)-01]
[E/G(LH6)-01]
[E/G(RHU)-01]
[E/G(RND)-01]
[E/G(RTB)-01]
[E/G(RH6)-01]
F26
2
13 OP CONNECTOR
B228
MAIN
FUSE BOX
(M/B)
B36
RHD
BW
B38
GENERATOR
F26
B228
1 2 3
1 2
3
4 5 6 7 8 9
10 11 12 13 14 15
B38
B: B143
A:
F37
1 2 3 4
10 11 12 13 14
5 6 7 8 9
15 16 17 18 19 20
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
A:
i10
1 2 3 4 5
11 12 13 14 15 16
6 7 8 9 10
17 18 19 20 21 22
i1
3 4
1 2
5 6 7 8 9 10
11 12 13
14 15 16
17 18 19 20 21 22
23 24 25 26 27 28
WI-03996
WI-128
Clock System
WIRING SYSTEM
12.Clock System
FB-25
F/B FUSE NO. 24
(ACC)
FB-12
F/B FUSE NO. 16
(TAIL & ILLUMINATION RELAY)
COMBINATION METER
LR
*1
FB-33
F/B FUSE NO. 11
(IG)
YR
CLK-01

FB-10
M/B FUSE NO. 8
(B)
Y
i83
A:
i83
JOINT
CONNECTOR
(ILLUMINATION &
BACK-UP LIGHT)
MICRO
COMPUTER
DRIVER
A18
CLK-01
A: WIRING DIAGRAM
i10
JOINT
CONNECTOR
(ILLUMINATION &
BACK-UP LIGHT)
i82
LR
i82
A:
A30
i84
*1
YR
: LHD : GB
RHD : OrG
BRIGHT-LED
FIXED
VOLTAGE
CIRCUIT
CLOCK
VFD
BY
i59
DISP
IG ACC UART ILL

MICRO COMPUTER
BRIGHT
[]
SET
DISPLAY-LED
[+]
i97
GROUND
JOINT
CONNECTOR
BY
BY
*1
10
LR
REF. TO GROUND
DISTRIBUTION SYSTEM
[GND(L)-03][GND(R)-03]
HR
i82
1 2 3 4 5
6 7 8 9 10
i83
i59
i97
A:
i10
1 2 3 4 5
11 12 13 14 15 16
6 7 8 9 10
17 18 19 20 21 22
A:
i84
HR
3 4
5 6
7 8
1 2
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
1 2 3 4 5 6
7 8 9 10 11 12
WI-03997
WI-129

WIRING SYSTEM
13.Combination Meter System

METER-01
METER-01
A: WIRING DIAGRAM
B:
i11
CONNECT
B6
B14
B5
B13
B4
B3
B8
B2
B7
B1
A:
i10
CONNECT
A22
A10
A21
A9
A6
A5
A12
A2
A11
A1
WI-03684
WI-130
WI-131
B4
A14
A9
AIRBAG WARNING LIGHT
TURN SIGNAL PILOT LIGHT RH
TURN SIGNAL PILOT LIGHT LH
HI-BEAM PILOT LIGHT
LO (AWD) INDICATOR LIGHT
MALFUNCTION INDICATOR LIGHT
OIL PRESSURE
WARNING LIGHT
ABS WARNING LIGHT
CHARGE WARNING LIGHT
PARKING BRAKE/
BRAKE FLUID
LEVEL WARNING LIGHT
A13
B1
A10
B3
A4
A3
METER-02
AIRBAG CONTROL
MODULE
TURN SIGNAL &

HAZARD MODULE
HEADLIGHT RELAY
IGNITION SWITCH (IG)
BATTERY
DIMMER SWITCH
LO (AWD) SWITCH
SEAT BELT SWITCH
A16
A15
A5
A6
A8
A7
REVERSE
CIRCUIT
ECM
VDC
OIL PRESSURE SWITCH
ABS
ABS
REVERSE
CIRCUIT
ABS CONTROL MODULE
VDC CONTROL MODULE
GENERATOR
BRAKE FLUID LEVEL SWITCH
PARKING BRAKE SWITCH
ABS CONTROL MODULE
VDC CONTROL MODULE
METER-02

WIRING SYSTEM
DIMMER &
STABILIZING
POWER CIRCUIT
A
METER-03
REVERSE
CIRCUIT
VDC
ABS : WITHOUT VDC

VDC : WITH VDC
WI-03998
WI-132
ABS : WITHOUT VDC

VDC : WITH VDC
ON : WITHOUT NAVIGATION SYSTEM
A19
H
F
C
E
A12
A11
I/F
VDC CONTROL MODULE
ABS
LCD (ODO/TRIP METER)

ENGINE
COOLANT
TACHOMETER
TEMPERATURE
GAUGE
ABS CONTROL MODULE
I/F
A20
DRIVER
LCD (SPORT SHIFT)
BACK LIGHT
ECM
CAN
TRANSCEIVER &
RECEIVER
TRIP RESET SWITCH
EEPROM
TAIL & ILLUMINATION

PILOT LIGHT
I/F
A22
I/F
I/F
B12
B2
A2
A1
METER-03
A21
DRIVER
A18
SECURITY/IMMOBILIZER PILOT LIGHT
POWER
CIRCUIT
DIAGNOSIS CONNECTOR
ON
A17
METER-02
CLOCK
METER-03
WIRING SYSTEM
B
METER-04
C
METER-04
SPEEDOMETER
FUEL GAUGE
MICRO COMPUTER
DRIVER
VDC
WI-03999
WI-133
DIMMER &
STABILIZING
POWER CIRCUIT
ODO/TRIP
LCD BACK LIGHT
LOW-FUEL WARNING LIGHT
VEHICLE OUTLINE
REAR GATE
REAR DOOR RH
REAR DOOR LH
FRONT DOOR RH
FRONT DOOR LH
DIMMER &
STABILIZING
POWER CIRCUIT
DIMMER &
STABILIZING
POWER CIRCUIT
S/S BACK LIGHT
BUZZER (SPORT SHIFT)
VDC OFF PILOT LIGHT
VDC WARNING LIGHT
REAR FOG PILOT LIGHT
FRONT FOG PILOT LIGHT
DIMMER &
STABILIZING
POWER CIRCUIT
AWD INDICATOR LIGHT
DIMMER &
STABILIZING
POWER CIRCUIT
SPORT PILOT LIGHT
CRUISE PILOT LIGHT
METER-03
CRUISE SET PILOT LIGHT
AT OIL TEMP. WARNING LIGHT
METER-03
METER-04
METER-04

WIRING SYSTEM
DRIVER
WI-04000
Cruise Control System

WIRING SYSTEM
14.Cruise Control System

A: WIRING DIAGRAM
C/C4(L)-01
C/C4(L)-01
1. LHD 2.0 L MODEL AND 2.5 L KS MODEL
FB-32
F/B FUSE NO. 4
(IG)
FB-38
F/B FUSE NO. 12
(IG)
WL
GY
GR

FB-3
F/B FUSE NO. 8
(B)
*1
: AT : WR
MT : GL
MT
GY
GY
4
STOP
LIGHT &
BRAKE
SWITCH
Br
YL
Gr
MAIN SW
CANCEL
SET/COAST
B107
RES/ACC
BL
RY
CLUTCH
SWITCH
(M/T)
B65
BrW
CRUISE CONTROL SWITCH
WL
2
ROLL
CONNECTOR
ST1
ST3
F9 BrW
B68
C/C4(L)-03
C/C4(L)-03
C/C4(L)-03

GL
BL
F: B159
B25
T2
T2
B25
MT
BrR F5
FUSE &
RELAY BOX
(F/B)
B: B135
B25
(BROWN)
B107 (BLUE)
ST3
B65
1 2 3
1 2
3 4
C: B136
(BLACK)
D: B137
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
24 25
26 27
20 21 22 23
32 33
28 29 30 31
34 35
*1
F: B159 (BROWN)
1
5
2
6
1 2
B: B135 HR
B12
ECM
B68
1
2 3
4 5 6 7 8
C21 YL
D14
B13 GR
D22 RY
D12
D13 BrR
MT
AT
3
8
4
9
D: B137
HR
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
C: B136 HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
WI-04001
WI-134
C/C4(L)-02
C/C4(L)-02
WIRING SYSTEM

FB-36
F/B FUSE NO. 5
(IG)
WR
WR
6
WL
WR
MB-24
SBF-8
(B)
A4 BrW
A3 BrW
BrW
MB-23
SBF-8
(B)

POWER CIRCUIT
MAIN
RELAY
i10
YL
A:
COMBINATION
METER
Lg
CRUISE
PILOT LIGHT
CRUISE SET
PILOT LIGHT
B47
I/F
WL
7
B362
B362
1 2
8
LR
RL
BY
REF. TO CAN COMMUNICATION

LINE SYSTEM [CAN(L)-01]
3
4
C: B136
D: B137
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
YL
YL
RL
LR
LR
D9
D7
D6
ECM
A:
i97
1 2 3 4 5 6
7 8 9 10 11 12
5
7 8
6
B: B135 HR
C4
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(L)-03]
B47
2
4
6
ELECTRIC
THROTTLE RELAY
BY
i97
B: B135
1
3
5
YL
BY A12
A22
BY A11
BY
C3
L
C14
GROUND
JOINT CONNECTOR
B14 Lg
R
C13

A21
CAN TRANSCEIVER &

RECEIVER
DRIVER
MICRO COMPUTER
1 2 3 4 5
11 12 13 14 15 16
i10
6 7 8 9 10
17 18 19 20 21 22
D: B137 HR
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
C: B136 HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
31 32
28 29 30
5 6
14 15 16
25 26 27
33 34 35
WI-04002
WI-135
C/C4(L)-03
C5
C6
BL
D2
GY
BL
D3
GY
YG C18
D5
D4
WB
RB C30
D: B137 ECM
C: B136
LY C17
Lg D23
LgB D24
WB B23
B: B135
WB
C/C4(L)-03
WIRING SYSTEM
JOINT CONNECTOR B
BL
BL
*
*
YG
*2
JOINT
CONNECTOR A
12
B12
*1
*2
YG
*1
:TERMINAL NO.
OPTIONAL
ARRANGEMENT
AMONG NO.1,2,5 AND 6
*2
:TERMINAL NO.
OPTIONAL
ARRANGEMENT
BL
YG
GY
WB
LY
: TERMINAL NO.
OPTIONAL
ARRANGEMENT
36
19
38
WL
YL
LW
WL
YL
LW
39
Or
E2
E1
T7
B21
Or
BL
B20
20
INHIBITOR
SWITCH (AT)
15
P
R
Lg
16 LgB
12
BY
SB
B83
T3
B122
RB
WB
C/C4(L)-01
A
B
*1
C/C4(L)-01
BW
C/C4(L)-01
E78
1 2 3
4 5 6
(BLACK)
E78
BW
B12
BW
WR
11
T3
ELECTRIC THROTTLE
GE
B83
B122
1 2 3 4
5 6 7 8
B12 HR
T7
1 2 3 4 5 6
7 8 9 10 11 12
1 2 3 4
5 6 7 8
9 10 11 12
C: B136 HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B21
5 6
14 15 16
25 26 27
33 34 35
B20
(BLACK)
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
D: B137 HR
B: B135 HR
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
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
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
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
WI-04003
WI-136

WIRING SYSTEM
C/C6(L)-01
C/C6(L)-01
2. LHD 2.5 L EC, K4 MODEL AND 3.0 L MODEL
FB-38
F/B FUSE NO. 12
(IG)
GY
GR
B55
B:
TCM
H6
GL B19
FB-32
F/B FUSE NO. 4
(IG)
WL

FB-3
F/B FUSE NO. 8
(B)
H4
GY
GY
4
STOP
LIGHT &
BRAKE
SWITCH
Br
YL
Gr
MAIN SW
CANCEL
SET/COAST
B107
RES/ACC
2
1
Y
BL
RY
CLUTCH
SWITCH
(M/T)
B65
BrW
WL
2
ROLL
CONNECTOR
ST3
ST1
H6 : 6-CYLINDER ENGINE MODEL
B65
1 2 3
1 2
3 4
A: B134 HR
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
(BLACK)
W
C: B136
D: B137
F: B159 (BROWN)
B68
1
2 3
4 5 6 7 8
C7
D9
GL
D14 GR
C10 RY
C9
C8 BrR
1 2
ST3
C11 YL
H6
H4 : 4-CYLINDER ENGINE MODEL
F: B159
A: B134
B107 (BLUE)
C/C6(L)-03
FUSE &
RELAY
BOX (F/B)
H4
BrR F5
F9 BrW
B68
1
5
2
6
3
8
4
9
ECM
B:
B55
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
HR
(GRAY)
7
16
22
8
17
23
D: B137 HR
9
18
24
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
C: B136 HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
WI-04004
WI-137
C/C6(L)-02
C/C6(L)-02
WIRING SYSTEM

FB-36
F/B FUSE NO. 5
(IG)
WR
WR
6
WL
WR
MB-24
SBF-8
(B)
A4 BrW
A3 BrW
BrW
MB-23
SBF-8
(B)

POWER CIRCUIT
MAIN
RELAY
i10
YL
A:
COMBINATION
METER
Lg
CRUISE
PILOT LIGHT
CRUISE SET
PILOT LIGHT
B47
I/F
YL
WL
7
BY A12
A22
BY A11
A21
P
CAN TRANSCEIVER &

RECEIVER
DRIVER
MICRO COMPUTER
ELECTRIC
THROTTLE RELAY
B362
1
3
5
2
4
6
1 2
3
4
LR
D6
RL
6
B: B135
i97
1 2 3 4 5 6
7 8 9 10 11 12
D: B137
A:
YL
LR
YL
ECM
i10
1 2 3 4 5
11 12 13 14 15 16
B6
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(L)-03]
B47
B35 RL
3
BY
BY
i97
B5
L
D26
GROUND
JOINT CONNECTOR
D16 Lg
R
D18


BY
B362
6 7 8 9 10
17 18 19 20 21 22
5
7 8
6
D: B137 HR
B: B135 HR
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
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
WI-04005
WI-138
BL
MT
SB
C/C6(L)-03
D1
D2
*
YG
BL
YG
GY
WB
LY
36
19
38
*
*2
39
*4
20
15
16
B12
H4
H4
H6
H6
H4 : 4-CYLINDER
ENGINE MODEL
H6 : 6-CYLINDER
ENGINE MODEL
*
*6
E57
*
*2
YW
*4
*3
*5
MT
1 2
E2
T3
1 :TERMINAL NO.
OPTIONAL
ARRANGEMENT
(BROWN)
B21
E1
:TERMINAL NO.
OPTIONAL
ARRANGEMENT
B25
B20
AT
YL
2
B25
*3
*5
: 4-CYLINDER
ENGINE MODEL : BR
6-CYLINDER
ENGINE MODEL : B
YG
T2
H6
11
: 4-CYLINDER
ENGINE MODEL : BW
6-CYLINDER
ENGINE MODEL : BL
*1
T7
*6
H4
N
D
: 4-CYLINDER
ENGINE MODEL : W
6-CYLINDER
ENGINE MODEL : Or
B83
B138
LY
12
INHIBITOR
SWITCH
(AT)
P
NEUTRAL
POSITION
SWITCH
(MT)
: 4-CYLINDER
ENGINE MODEL : P
6-CYLINDER
ENGINE MODEL : LR
T2
JOINT
CONNECTOR A
YW
B25
JOINT
CONNECTOR
C
BW
: 4-CYLINDER
ENGINE MODEL : LB
6-CYLINDER
ENGINE MODEL : Y
YG
LY
*1
T3
*3
BL
B12
12
: 4-CYLINDER
ENGINE MODEL : LW
6-CYLINDER
ENGINE MODEL : W
B122
BY
: 4-CYLINDER
ENGINE MODEL : G
6-CYLINDER
ENGINE MODEL : GOr
*
*
H4
AT
H6
*1
BL
JOINT CONNECTOR B
*7
*7
C/C6(L)-01
BL
D5
YG C35
D4
GY
YL C18
YG C29
D9
GL
H4
WB
D: B137 ECM
C: B136
LY C16
C/C6(L)-03
WIRING SYSTEM
ELECTRIC THROTTLE
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(L)-03]
E57
(BLACK)
1 2 3 4 5 6
5 6
14 15 16
25 26 27
33 34 35
B12
B138
B122
1 2 3 4
5 6 7 8
C: B136 HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B83
GE
HR
1 2 3 4
5 6 7 8
9 10 11 12
D: B137 HR
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
T7
1 2 3 4 5 6
7 8 9 10 11 12
B21
B20
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
(BLACK)
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
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
WI-04006
WI-139

WIRING SYSTEM
FB-32
F/B FUSE NO. 4
(IG)
FB-38
F/B FUSE NO. 12
(IG)
WL
GY
GR

FB-3
F/B FUSE NO. 8
(B)
*1
: AT : WR
MT : GL
C/C(R20)-01
C/C(R20)-01
3. RHD 2.0 L NON-TURBO MODEL AND 2.5 L KA MODEL
MT
GY
GY
4
STOP
LIGHT &
BRAKE
SWITCH
Br
YL
Gr
MAIN SW
CANCEL
SET/COAST
B107
RES/ACC
1
Y
BL
RY
CLUTCH
SWITCH
(M/T)
B65
BrW
WL
2
ROLL
CONNECTOR
ST3
ST1
F9 BrW
B68
C/C(R20)-03
C/C(R20)-03
C/C(R20)-03

GL
BL
F: B159
B25
T2
T2
B25
MT
BrR F5
FUSE &
RELAY BOX
(F/B)
B: B135
B25
(BROWN)
B107 (BLUE)
ST3
1 2 3
B65
1
3
(BLACK)
2
4
C: B136
*1
B12
C21 YL
D14
B13 GR
D22 RY
D12
D13 BrR
MT
AT
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
32 33
28 29 30 31
34 35
F: B159 (BROWN)
B68
1
2 3
4 5 6 7 8
1 2
B: B135 HR
ECM
D: B137
1
5
2
6
3
8
4
9
D: B137
HR
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
C: B136 HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
WI-04007
WI-140

C/C(R20)-02
C/C(R20)-02
WIRING SYSTEM

FB-36
F/B FUSE NO. 5
(IG)
WR
6
WR
WR
WR
MB-24
SBF-8
(B)
A4 BrW
A3 BrW
BrW
MB-23
SBF-8
(B)

POWER CIRCUIT
MAIN
RELAY
i10
YL
A:
COMBINATION
METER
Lg
CRUISE SET
PILOT LIGHT
CRUISE
PILOT LIGHT
B47
I/F
B362
1 2
WR
7
B362
B47
2
4
6
ELECTRIC
THROTTLE RELAY
BY
3
4
i97
1 2 3 4 5 6
7 8 9 10 11 12
C: B136
D: B137
A:
1 2 3 4 5
11 12 13 14 15 16
YL
YL
RL
LR
LR
C3
C4
D9
D7
D6
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(R)-04]
LR
RL
BY
i97
B: B135
1
3
5
YL
BY A12
A22
BY A11
A21
P
BY
B14 Lg
L
C14
GROUND
JOINT CONNECTOR

LINE SYSTEM [CAN(R)-01]
R
C13

CAN TRANSCEIVER &

RECEIVER
DRIVER
MICRO COMPUTER
ECM
i10
6 7 8 9 10
17 18 19 20 21 22
5
7 8
6
D: B137 HR
B: B135 HR
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
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
C: B136 HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
WI-04008
WI-141

C/C(R20)-03
C5
C6
BL
BL
D3
GY
RB C30
D2
GY
YG C18
D5
D4
D: B137 ECM
WB
Lg D23
LY C17
C: B136
AT
LgB D24
WB B23
B: B135
WB
C/C(R20)-03
WIRING SYSTEM
JOINT CONNECTOR A
C/C(R20)-01
C/C(R20)-01
A
B
BL
MT
BL
*
*
BL
SB
*12
*
WB
YG
B83
B12
12
JOINT
CONNECTOR B
T3
RB
BL
YG
GY
WB
LY
Lg
36
19
38
BL
BY
BL
BY
E2
LW
E1
T7
B21
LW
B20
39
INHIBITOR
SWITCH (AT)
20
15
16 LgB
12
BY
YG
*12
*
B122
BW
E78
4
B12
:TERMINAL NO.
OPTIONAL
ARRANGEMENT
*2
T3
:TERMINAL NO.
OPTIONAL
ARRANGEMENT
*1
11
: TERMINAL NO.
OPTIONAL
ARRANGEMENT
WR
ELECTRIC THROTTLE
C/C(R20)-01
E78
1 2 3
4 5 6
C
B83
GE
B122
1 2 3 4
5 6 7 8
B12 HR
1 2 3 4 5 6
7 8 9 10 11 12
1 2 3 4
5 6 7 8
9 10 11 12
C: B136 HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B21
5 6
14 15 16
25 26 27
33 34 35
D: B137
B20
T7
(BLACK)
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
HR
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
B: B135
HR
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
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
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
WI-04009
WI-142

WIRING SYSTEM
C/C(RTB&25)-01
FB-38
F/B FUSE NO. 12
(IG)
GR
TCM
B55
B:
TB
GL B19
FB-32
F/B FUSE NO. 4
(IG)
GY

FB-3
F/B FUSE NO. 8
(B)
WL
C/C(RTB&25)-01
4. RHD 2.5 L EK AND TURBO MODEL
MT
GY
GY
4
STOP
LIGHT &
BRAKE
SWITCH
Br
YL
Gr
MAIN SW
CANCEL
SET/COAST
B107
RES/ACC
BL
RY
CLUTCH
SWITCH
(M/T)
B65
BrW
WL
2
TB
ROLL
CONNECTOR
ST3
ST1
F9 BrW
B68
TB : TURBO MODEL
F: B159
B107 (BLUE)
1 2
1 2 3
A: B134
1 2
8 9 10
18 19 20
28 29 30
ST3
HR
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B65
1
3
2
4
(BLACK)
W
C7
C11 YL
TB
C: B136
D: B137
F: B159 (BROWN)
B68
1
2 3
4 5 6 7 8
GL
C10 RY
A: B134
D9
MT
GY
A1
D14 GR
TB
Y
C9
MT : 2.5L MT MODEL
C8 BrR
BrR F5
FUSE &
RELAY BOX
(F/B)
C/C(RTB&25)-03
1
5
2
6
3
8
4
9
ECM
B:
B55
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
HR
(GRAY)
7
16
22
8
17
23
D: B137
9
18
24
HR
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
C: B136 HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
WI-04010
WI-143
C/C(RTB&25)-02
C/C(RTB&25)-02
WIRING SYSTEM

FB-36
F/B FUSE NO. 5
(IG)
WR
6
WR
WR
WR
MB-24
SBF-8
(B)
A4 BrW
A3 BrW
BrW
MB-23
SBF-8
(B)
MAIN
RELAY

POWER CIRCUIT
i10
YL
A:
COMBINATION
METER
Lg
CRUISE
PILOT LIGHT
CRUISE SET
PILOT LIGHT
B47
I/F
YL
WR
7
BY A12
A22
BY A11
A21
P
CAN TRANSCEIVER &

RECEIVER
DRIVER
MICRO COMPUTER
ELECTRIC
THROTTLE RELAY
B362
1
3
5
2
4
6
1 2
3
4
LR
D6
RL
6
B: B135
i97
1 2 3 4 5 6
7 8 9 10 11 12
D: B137
A:
1 2 3 4 5
11 12 13 14 15 16
YL
LR
YL
B6
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(R)-04]
B47
B35 RL
3
BY
BY
i97
B5
L
D26
GROUND
JOINT CONNECTOR
D16 Lg
R
D18


BY
B362
ECM
i10
6 7 8 9 10
17 18 19 20 21 22
5
7 8
6
D: B137 HR
B: B135 HR
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
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
WI-04011
WI-144
C/C(RTB&25)-01
BL
*
*
SB
MT
C/C(RTB&25)-03
*
*
BL
YG
GY
WB
LY
Or
36
19
38
39
16
15
20
E2
*4
*5
*6
*7
*4
*5
*6
*7
*3
E1
B25
: TURBO MODEL
: BL
FOR 2.5L EK MODEL : P
B21
B20
*3
T7
D
7
: TURBO MODEL
: LW
FOR 2.5L EK MODEL : LB
INHIBITOR
SWITCH
(AT)
N
2
*3
YG
12
P
: TERMINAL NO.
OPTIONAL
ARRANGEMENT
BW
: TURBO MODEL
:3
FOR 2.5L EK MODEL : 2
B83
B122
T2
*2
JOINT
CONNECTOR A
LY
BY
*2
T3
T2
BL
YG
LY
*1
AT
JOINT
CONNECTOR B
12
L
B25
: TURBO MODEL
:7
FOR 2.5L EK MODEL : 1
B138
B12
D2
D1
JOINT CONNECTOR C
NEUTRAL
POSITION
SWITCH
(MT)
BL
BL
D5
GY
YG C35
D4
WB
C18
LY C16
D: B137 ECM
25
GL
D9
Or C29
C: B136
C/C(RTB&25)-03
WIRING SYSTEM
B12
25
1 2
(BROWN)
E57
(BLACK)
1 2 3 4 5 6
B83
B12
B122
HR
1 2 3 4
5 6 7 8
9 10 11 12
1 2 3 4
5 6 7 8
B21
5 6
14 15 16
25 26 27
33 34 35
GE-2
B138
C: B136 HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
*8
ELECTRIC THROTTLE
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(R)-03]
: 2.5L MODEL
B25
: TURBO MODEL
:B
FOR 2.5L EK MODEL : BW
*8
E57
3
: TURBO MODEL
: BY
FOR 2.5L EK MODEL : LW
*7
MT
: TURBO MODEL
:R
FOR 2.5L EK MODEL : G
*6
: TURBO MODEL
:W
FOR 2.5L EK MODEL : YW
*5
AT
11
T3
T7
1 2 3 4 5 6
7 8 9 10 11 12
D: B137 HR
B20
1
5
9
13
2
6
10
14
3
7
11
15
GE-1
4
8
12
16
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
(BLACK)
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
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
WI-04012
WI-145

WIRING SYSTEM
C/C(RH6)-01
C/C(RH6)-01
5. RHD 3.0 L MODEL
FB-38
F/B FUSE NO. 12
(IG)
GY
GR
B:
B55
TCM
GL B19
FB-32
F/B FUSE NO. 4
(IG)
WL

FB-3
F/B FUSE NO. 8
(B)
WL
GY
ROLL
CONNECTOR
W
Br
YL
Gr

MAIN SW
CANCEL
STOP
LIGHT &
BRAKE
SWITCH
SET/COAST
RES/ACC
B65
BrW
BL
ST3
ST1
F9 BrW
B68
C/C(RH6)-03
W
C7
C: B136
ST3
1 2 3
B65
1
3
(BLACK)
2
4
D: B137
F: B159 (BROWN)
B68
1
2 3
4 5 6 7 8
C11 YL
GL
D9
C9
D14 GR
F: B159
C8 BrR
BrR F5
FUSE &
RELAY BOX
(F/B)
1
5
2
6
3
8
4
9
ECM
B:
B55
1 2 3 4
10 11 12 13
19 20 21
5 6
14 15
HR
(GRAY)
7
16
22
8
17
23
D: B137 HR
9
18
24
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
C: B136 HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
WI-04013
WI-146

C/C(RH6)-02
C/C(RH6)-02
WIRING SYSTEM

FB-36
F/B FUSE NO. 5
(IG)
WR
6
WR
WR
WR
MB-24
SBF-8
(B)
A4 BrW
A3 BrW
BrW
MB-23
SBF-8
(B)

POWER CIRCUIT
MAIN RELAY
i10
YL
A:
COMBINATION
METER
Lg
CRUISE
PILOT LIGHT
CRUISE SET
PILOT LIGHT
B47
I/F
YL
WR
7
BY A12
BY A11
A22
ELECTRIC
THROTTLE
RELAY
B362
B362
1
3
5
2
4
6
1 2
3
4
LR
D6
RL
6
B: B135
i97
1 2 3 4 5 6
7 8 9 10 11 12
D: B137
A:
1 2 3 4 5
11 12 13 14 15 16
YL
LR
YL
B6
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(R)-04]
B47
B35 RL
3
1
BY
BY
REF. TO CAN COMMUNICATION LINE

SYSTEM [CAN(R)-01]
i97
B5
L
D26
GROUND JOINT
CONNECTOR
D16 Lg
R
D18
REF. TO CAN COMMUNICATION LINE

SYSTEM [CAN(R)-02]
BY
A21
P
CAN TRANSCEIVER &

RECEIVER
DRIVER
MICRO COMPUTER
ECM
i10
6 7 8 9 10
17 18 19 20 21 22
5
7 8
6
D: B137 HR
B: B135 HR
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
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
WI-04014
WI-147

C/C(RH6)-03
D1
D2
BL
BL
YG C35
D4
D5
GY
D: B137 ECM
LY C16
C18
Or C29
C: B136
WB
C/C(RH6)-03
WIRING SYSTEM
JOINT CONNECTOR C
C/C(RH6)-01
BL
SB
*
*
BL
YG
LY
B138
JOINT
CONNECTOR
A
B122
: TERMINAL NO.
OPTIONAL
ARRANGEMENT
YG
B83
BL
YG
GY
WB
LY
36
19
BL
B
BL
E57
4
W
W
38
YW
GOr
LR
LR
E2
YW
Or
Or
E1
GOr
39
B21
20
15
16
B20
Or
LY
JOINT
CONNECTOR
B
ELECTRIC THROTTLE
GE-2
E57
(BLACK)
1 2 3 4 5 6
B83
B122
B138
1 2 3 4
5 6 7 8
D: B137 HR
B20
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
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
GE-1
C: B136 HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B21
5 6
14 15 16
25 26 27
33 34 35
(BLACK)
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
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
WI-04015
WI-148
Coolant Temperature System

WIRING SYSTEM
15.Coolant Temperature System
LW
LW
19
*1
YG
YG
BrW
*1
YG
B83
C35 C18 YG
C14 C22 BrW
YG
C35
C/TEMP-01
RW
BY
BY
19
YG
YG
*1
*1
B83
*2
*3
L
R
: FOR 2.0L & 2.5L KS, KA MODEL
D26 C14
D18 C13
D: B137 ECM
: FOR 2.5L EC, K4, EK MODEL & TURBO & 3.0L MODEL
i84
REF. TO GROUND
DISTRIBUTION SYSTEM
[GND(L)-03] [GND(R)-03]
R
L
B: B280
JOINT
CONNECTOR A
TWISTED WIRE
BY
BODY
INTEGRATED UNIT
B21
YG
BrW
C14
YG
C35
C: B136
i97
*1
*2
*3
RW
Gr
W
W
Gr
8
BrW
B83
*1
BrW
C14
BY
3
1
B21
BY
i77
*2
*3
GROUND
JOINT
CONNECTOR
E2
JOINT
CONNECTOR A
YG
BY A12
BY A11
A21
A22
P
V
P
V
1
7
CAN
JOINT
CONNECTOR
2
8
19
JOINT
CONNECTOR A
P
V
A27
A26
YG
YG
i10
CAN TRANSCEIVER &

RECEIVER
B20
B30
GY
8
BrW
A:
*1
MICRO COMPUTER
B21
COMBINATION
METER
E8
E2
E2
ENGINE
COOLANT
TEMPERATURE
GAUGE
I/F
A:
E8
E8
GY
A4 BrW
BrW
FB-36
F/B FUSE NO. 5
(IG)
ENGINE COOLANT
ENGINE COOLANT
ENGINE COOLANT
TEMPERATURE
TEMPERATURE SENSOR
TEMPERATURE
SENSOR (3.0L MODEL)
(TURBO MODEL)
SENSOR (SOHC MODEL)
A3 BrW
C/TEMP-01
A: WIRING DIAGRAM
E8
1 2
(BLACK)
B83
i77
i97
1 2 3 4
5 6 7 8
1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6
7 8 9 10 11 12
D: B137 HR
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
A:
i84
A:
HR
3 4
5 6
7 8
1 2
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25
26 27 28 29
30 31 32 33
34 35
B: B280 HR
i10
1 2 3 4 5
11 12 13 14 15 16
1 2 3
4 5
6 7
8 9 10 11 12 13 14 15 16 17 18 19 20
21 22
23 24 25
26 27
28 29 30
6 7 8 9 10
17 18 19 20 21 22
C: B136 HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B21
5 6
14 15 16
25 26 27
33 34 35
(BLACK)
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
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
WI-04016
WI-149
Engine Electrical System

WIRING SYSTEM
16.Engine Electrical System

A: WIRING DIAGRAM
1. LHD 2.0 L MODEL AND 2.5 L KS MODEL
IGNITION SWITCH
SBF-7
OFF ACC ON ST
BATTERY
SBF-1
INHIBITOR
SWITCH
STARTER MOTOR
1
2
3
4
5
SBF-9
+B
N
ACC
R
IG1
P
IG2
AT
AT
STARTER RELAY
MT
B23
AT
F/B FUSE NO. 21
F/B FUSE NO. 12
ST
F/B FUSE NO. 5
F/B FUSE NO. 4
F/B FUSE NO. 7
M/B FUSE NO. 13
B12
B13
FUEL PUMP
RELAY
MAIN
RELAY
*1
FUEL
PUMP
CONDENSER
ELECTRIC
THROTTLE
RELAY
FUEL
PUMP
*1
WITH IMMOBILIZER
: B17
WITHOUT IMMOBILIZER : A18
D6
D7
D9
B14
C3
C4
A3
A4
A12
A13
EGR VALVE
PURGE CONTROL SOLENOID VALVE
A8
FUEL INJECTOR NO. 1
A17
FUEL INJECTOR NO. 2
A27
FUEL INJECTOR NO. 3
A34
FUEL INJECTOR NO. 4
A33
D12
D13
D22
B2
B3
C33
C35
STOP LIGHT & BRAKE SWITCH (CRUISE CONTROL)

CLUTCH SWITCH (MT-CRUISE CONTROL)
FRONT OXYGEN (A/F) SENSOR
ECM
M/B FUSE NO. 11
SBF-8
SBF-6
IG 2
RELAY
C34
A1
C19
REAR OXYGEN SENSOR

SUB FAN RELAY
MAIN FAN RELAY 1
AIR CONDITIONING PRESSURE SWITCH
A/C RELAY
BODY INTEGRATED UNIT (CAN COMMUNICATION LINE)
BODY INTEGRATED UNIT (IMMOBILIZER)
A10
A9
C8
B20
B35
C13
C14
B25
B33
C21
D14
6
7
8
WI-04017
WI-150

WIRING SYSTEM
CHECK CONNECTOR
DATA LINK CONNECTOR
1
2
3
4
5
COMBINATION METER
MALFUNCTION
INDICATOR LIGHT
OIL PRESSURE
WARNING LIGHT

(CAN COMMUNICATION
LINE)
B32
A23
A24
B15
B27
I/F
B24
ABS CONTROL MODULE
NEUTRAL POSITION
SWITCH (MT)
B12
MT
MT
B29
MT
MT
I/F
I/F
POWER CIRCUIT
MICRO COMPUTER
C7
CAN TRANSCEIVER &

RECEIVER
IGNITION COIL &

IGNITOR ASSY
TACHOMETER
SPEEDOMETER
TEST MODE TEST MODE

CONNECTOR SUB CONNECTOR
ENGINE
COOLANT
TEMPERATURE
GAUGE
JOINT CONNECTOR B
D29
D30
D19
AT
AT
MT
ACCELERATOR
PEDAL POSITION
SENSOR
D25
D31
ECM
C18
C30
OIL PRESSURE
SWITCH
GROUND
JOINT CONNECTOR
JOINT
CONNECTOR A
C22
ENGINE COOLANT TEMPERATURE SENSOR
C28
INTAKE AIR TEMPERATURE SENSOR
C20
MANIFOLD ABSOLUTE PRESSURE SENSOR
D23
D24
D4
D5
D2
D3
C17
ELECTRIC THROTTLE
C23
C12
KNOCK SENSOR
3
C24
CRANKSHAFT POSITION SENSOR
2
C25
CAMSHAFT POSITION SENSOR

JOINT
CONNECTOR C
C32
TCM
D18
C1
C2
B5
B6
C5
C6
A7
A2
D1
B16
B8
6
7
8
AT
POWER
STEERING
OIL
PRESSURE
SWITCH
: C26
IMMOBILIZER
*2 : WITH
WITHOUT IMMOBILIZER : C27
MAIN
FUSE BOX (M/B)
IMMOBILIZER
: C27
*3 : WITH
GENERATOR
ENGINE GROUND
WI-04018
WI-151

E/G(LHU)-01
E/G(LHU)-01
WIRING SYSTEM
MB-25
M/B FUSE NO. 11
(B)
ALT-1
GENERATOR
GR
WG
BR

FB-38
F/B FUSE NO. 12
(IG)
*1
16
REF. TO CRUISE CONTROL

SYSTEM [C/C4(L)-01]
RB
REF. TO AIR CONDITIONING SYSTEM

[A-A/C(L)-0102]
[M-A/C(L)-010203]
FUEL
PUMP
CONDENSER
FUEL
PUMP
R58
R142
A: B134 B: B135 C: B136 D: B137
R142 (BLACK)
1
2
B362
R58
1 2
3 4
5 6
B: B135 HR
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
1 2
B97
1 2 3
4 5 6 7
8 9 10 11 12 13 14 15 16
3
4
5
7 8
6
W
D14
D22 RY
Y
D12
D13 BrR
C21 YL
B35 LOr
YB
C8
B20 PW
B16 BR
B33 BR
B25 WL
WR
A9
A10 LR
Lg
*1
B13 GR
REF. TO IMMOBILIZER
SYSTEM [IMB(L)-01]
RB
R1
B97
REF. TO RADIATOR FAN

SYSTEM [R/F(H4)-01]
RB
1
RB
RB
: WITH IMMOBILIZER
: B17
WITHOUT IMMOBILIZER : A18
4
Lg
B362
WG
2
FUEL
PUMP
RELAY
E/G(LHU)-09
GR
3
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(L)-04]
ECM
D: B137
HR
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
A: B134 HR
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
C: B136 HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
WI-04019
WI-152

E/G(LHU)-02
E/G(LHU)-02
WIRING SYSTEM
i102
WL
R167
WL
WL
11
A2
WL
TACHOMETER
POWER CIRCUIT
COMBINATION
METER
BY A12
BY A11
A22
GB A19
i10
CAN TRANSCEIVER &

RECEIVER
I/F
A:
A21
I/F
RW A20
MICRO COMPUTER
OrW A16
GOr A15
OIL PRESSURE
WARNING LIGHT
MALFUNCTION
INDICATOR LIGHT
I/F
ENGINE
COOLANT
TEMPERATURE
GAUGE
SPEEDOMETER
A3 BrW
A4 BrW
WL
A1
FB-17
F/B FUSE NO. 7
(B)
BrW

FB-36
F/B FUSE NO. 5
(IG)
BY
GB
18
19
B38
GB
E11
B: B135
B27
C13
C14
B15 OrW
23
B301
C: B136 ECM
i97
i102
B38
5 6 7 8
1 2 3 4
9 10 11 12 13 14 15 16 17 18
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
B: B135 HR
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
24 25
26 27
20 21 22 23
32 33
28 29 30 31
34 35
A:
1
BY
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(L)-03]
i10
1 2 3 4 5
11 12 13 14 15 16
C: B136 HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
i97
ABS
CONTROL
MODULE
OIL PRESSURE SWITCH
1 2 3 4 5 6
7 8 9 10 11 12
GROUND
JOINT CONNECTOR
BY
E2

SYSTEM [CAN(L)-01]
REF. TO CAN
COMMUNICATION
SYSTEM
[CAN(L)-02]
B21
BrB
BrB
31 GOr
OrW
GOr 17
i3
B301
6 7 8 9 10
17 18 19 20 21 22
12
13
14
1 2 3 4 5 6 7 8 9 10 11
15
16 17 18 19 20 21 22 23 24 25 26
B21 (BLACK)
5 6
14 15 16
25 26 27
33 34 35
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
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
WI-04020
WI-153

E/G(LHU)-03
E/G(LHU)-03
WIRING SYSTEM
WY
WR
MB-22
SBF-6
(B)
WR
WR
WY
STARTER
RELAY
WB
WB
MB-23
SBF-8
(B)
WL
WL
15
MB-24
SBF-8
(B)
MT : WB
AT : WL
*2
13
ST-2
IG SW
(ST)
WL

ST-1
F/B FUSE NO. 21
(ST)
BY
12
T3
B47
T7
YL
B12
12
WB
WB
YL
BW
11
WL
AT
MT
WL
LG
P
AT
MAIN
RELAY
14
*2
INHIBITOR
SWITCH (AT)
16
B
B225
E/G(LHU)-05
E/G(LHU)-07
STARTER MOTOR
MT
ELECTRIC
THROTTLE
RELAY
BATTERY
AT
LR
WB
6
RL
B362
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(L)-02]
B47
1
3
5
YL
YL
C3
C4
RL
D9
B14 LG
LR
LR
D6
B: B135 C: B136 D: B137 ECM
(BROWN)
2
4
6
D7
B12 WL
B23 WB
AT
B14
B362
1 2
3
4
5
7 8
6
B12
HR
1 2 3 4
5 6 7 8
9 10 11 12
D: B137 HR
T7
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
1 2 3 4 5 6
7 8 9 10 11 12
B225
B: B135 HR
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
24 25
26 27
20 21 22 23
32 33
28 29 30 31
34 35
C: B136
HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
WI-154
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
WI-04021
B368 (GREEN)
1
2
B76
B24
(GREEN)
B79
TEST MODE
CONNECTOR
(GRAY)
B40
1
2
2 3
9 10
4 5
11 12
6 7
13 14
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
E/G(LHU)-09
E/G(LHU)-09
E/G(LHU)-09
BL
B368
B369
1
B76
B369 (GREEN)
1
8
P
1
13
12
10
DATA LINK CONNECTOR
C: B136 ECM
C7
W
VR B32
BL
BL
VR
GW
LgR
5
LgR
(GREEN)
B75
B40
GW
BL
8
12
10
VR
GY
GY
P
4
B79
CHECK CONNECTOR
B75
B: B135
MB-27
M/B FUSE NO. 13
(B)
E/G(LHU)-04

FB-32
F/B FUSE NO. 4
(IG)
E/G(LHU)-04
WIRING SYSTEM
TEST MODE
SUB CONNECTOR
B: B135 HR
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
C: B136 HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
WI-04022
WI-155
A10
A19
YG
LY
Or
B315
Y
E2
B54
A:
Lg
T5
GB
50
B21
B19
WB
TCM
E/G(LHU)-05
ACCELERATOR PEDAL
POSITION SENSOR
WB
E/G(LHU)-03
E/G(LHU)-05
WIRING SYSTEM
FRONT
OXYGEN (A/F)
SENSOR
REAR
OXYGEN
SENSOR
YL
E24
E/G(LHU)-06
E/G(LHU)-06
AT
Or
AT
Or
JOINT
CONNECTOR C
MT
51
WB
B21
W
3
YG
B19
W
E/G(LHU)-08
E2
T5
WB
B138
E/G(LHU)-08
E/G(LHU)-08
T5
1 2
3 4
E24
2
4
(GRAY)
1
3
A: B134 HR
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
B315 (BLACK)
1 2 3 4 5 6
1 2 3 4
5 6 7 8
B: B135
HR
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
24 25
26 27
20 21 22 23
32 33
28 29 30 31
34 35
B: B135
C: B136
A:
B54
D: B137
D: B137
HR
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
C: B136 HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
ECM
HR
3 4 5 6 7
1 2
8 9 10 11 12 13 14 15 16
17 18 19 20 21
22 23 24
D18
D19 SB
Y
D29
D30 Or
R
D31
B
C35
B138
D25 GB
A: B134
C34 SB
WB
WB
B2
C33
B3
WB
A1
C19
AT
5 6
14 15 16
25 26 27
33 34 35
B21
(BLACK)
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
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
WI-04023
WI-156

E/G(LHU)-06
C32
B
D3
GY
D5
D2
GY
D4
WB
LY C17
WB
D: B137 ECM
LgB D24
C23
SB C12
*4
C24
*3
Y
Or C25
C: B136
Lg D23
E/G(LHU)-06
WIRING SYSTEM
SB
SB
E/G(LHU)-05
B138
GY
38
LY
WB
39
Lg
20
E10
(LIGHT GRAY)
E14
E15
(GRAY)
1 2
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B21
5 6
14 15 16
25 26 27
33 34 35
E/G(LHU)-08
E/G(LHU)-09
E/G(LHU)-09
LW
YL
WL
2
1 2 3 4
5 6 7 8
HR
D: B137
B20
1 2
C: B136
E/G(LHU)-08
ELECTRIC THROTTLE
B138
1 2 3
4 5 6
E78
KNOCK
SENSOR
(BLACK)
E78
Or
RL
2
(BROWN)
E14
CRANKSHAFT
POSITION SENSOR
CAMSHAFT
POSITION SENSOR
E10
E/G(LHU)-08
YL
WL
Or
RL
L
L
E15
E2
E1
G
: WITH IMMOBILIZER
: C26
: WITH IMMOBILIZER
: C27
B21
B20
15
16 LgB
W
13
Or
*3
*4
E/G(LHU)-05
JOINT
CONNECTOR C
7
3
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
HR
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
(BLACK)
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
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
WI-04024
WI-157
C
YL
E/G(LHU)-03
E/G(LHU)-07
E/G(LHU)-07
WIRING SYSTEM
B21
48
E20 : 2.0L EC, K4 MODEL
LB
2
LB
2
LB
1
BrY
GOr
BR
Or
BrY
GOr
BR
Or
2
YR
YR
6
YB
E20
4
BrG
E20
3
E20
1
RY
GY
E20
E17
E6
E16
E5
E4
FUEL
INJECTOR
NO. 4
FUEL
INJECTOR
NO. 3
E18
FUEL
INJECTOR
NO. 2
FUEL
INJECTOR
NO. 1
PURGE
CONTROL
SOLENOID
VALVE
EGR VALVE
LB
LB
1
LB
5
E20
LB
2
E20
LB
E2
45
44
43
42
41
PB
A34 PB
PG
PL
A27 PL
A33 PG
P
P
B21
A17
RG
RG
A8
30
29
Y
Y
A4
YR
YR
A3
A13 BOr
26
BL
BOr 25
A12 BL
E2
A: B134 ECM
E4
1 2
(BLUE)
E5
(LIGHT GRAY)
E18
E6
(LIGHT GRAY)
E16
(LIGHT GRAY)
1 2 3
4 5 6
E17
(LIGHT GRAY)
A: B134 HR
(DARK GRAY)
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
B21 (BLACK)
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
42
1 2
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
WI-04025
WI-158
SB
YG
YG
YG
BrW
YG
E/G(LHU)-08
JOINT
CONNECTOR A
B83
RB C30
YG C18
RB
YG
B21
E2
RW
YW
LW
19
LY
LW
LY
(BLACK)
E20
1 2
1 2
(BLACK)
B83
1 2 3 4
5 6 7 8
1 2 3
B21
5 6
14 15 16
25 26 27
33 34 35
LW
RW
(GRAY)
C: B136 HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
MANIFOLD
ABSOLUTE
PRESSURE SENSOR
INTAKE
AIR TEMPERATURE
SENSOR
E21
E8
E21
E20
1
POWER STEERING
OIL PRESSURE SWITCH
WB
E19
E8
SB
M
N
LOr
E/G(LHU)-06
E/G(LHU)-06
WB
LOr
YL
PB
E/G(LHU)-05
E/G(LHU)-05
LW
E/G(LHU)-06
K
L
G
J
YL C28
B8
PB
E/G(LHU)-05
C: B136 ECM
YW C20
B: B135
BrW C22
E/G(LHU)-08
WIRING SYSTEM
ENGINE COOLANT
TEMPERATURE
SENSOR
B: B135
HR
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
24 25
26 27
20 21 22 23
32 33
28 29 30 31
34 35
(BLACK)
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
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
WI-04026
WI-159

E/G(LHU)-09
D1
A7
BW
BR
BR
C6
A2
BW
BW
C5
BL
C2
BL
BL
C1
LR
B6
LR
B5
LR
T2
NEUTRAL POSITION
SWITCH (MT)
T2
B25
1
MT
BL
F
E
BL
BL
BL
*
*
*
JOINT
CONNECTOR B
B122
BL
E/G(LHU)-04
GL
E/G(LHU)-04
MT
B25
MT
GL B12
D: B137 ECM
C: B136
BL B29
B: B135
RY A23
A: B134
YG A24
E/G(LHU)-09
WIRING SYSTEM
RY
GR
E/G(LHU)-01
D
A
YG
E/G(LHU)-04
34
35
36
37
52
BL
BL
BL
BL
BR
BR
2.0L
BW
2.5L
: TERMINAL NO.
OPTIONAL ARRANGEMENT
BW
O
P
E12
BR
E2
BR
BrG
BrG
15
GB
13
RG
E/G(LHU)-06
GB
E/G(LHU)-06
RG
49
B21
GE
IGNITION COIL & IGNITOR ASSY
B25
(BROWN)
E12
(DARK GRAY)
1 2 3 4
1 2
A: B134 HR
B122
D: B137 HR
1 2 3 4
5 6 7 8
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
1 2
8 9 10
18 19 20
28 29 30
B21
B: B135 HR
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
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
(BLACK)
C: B136 HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
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
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
WI-04027
WI-160

WIRING SYSTEM
WI-161

WIRING SYSTEM
2. LHD 2.5 L EC, K4 MODEL

IGNITION SWITCH
SBF-7
OFF ACC ON ST
BATTERY
INHIBITOR
SWITCH
+B
ACC
IG1
IG2
SBF-9
IG 2
RELAY
SBF-8
1
2
3
4
5
F/B FUSE NO. 21
F/B FUSE NO. 12
F/B FUSE NO. 5
F/B FUSE NO. 4
F/B FUSE NO. 7
M/B FUSE NO. 13
ST
M/B FUSE NO. 11
SBF-6
SBF-1
STARTER MOTOR
STARTER RELAY
D9
B32
D8
*1
OXYGEN
(A/F)
SENSOR
RELAY
FUEL
PUMP
RELAY
MAIN
RELAY
*2
FUEL
PUMP
CONDENSER
ELECTRIC
THROTTLE
RELAY
FUEL
PUMP
RELAY
HOLDER

STOP LIGHT & BRAKE SWITCH
(CRUISE CONTROL)
CLUTCH SWITCH (MT-CRUISE CONTROL)
C7
C11
C8
C9
C10
D19
D27
D6
B35
4
B5
B6
A8
A9
A10
A11
EGR VALVE
C6
FUEL INJECTOR NO. 2
C5
FUEL INJECTOR NO. 3
C4
FUEL INJECTOR NO. 4
C3
C13
C31
C23
MASS AIR FLOW SENSOR
C32
A2
A3
A26
A33
FRONT OXYGEN (A/F) SENSOR
A25
B2
D24
REAR OXYGEN SENSOR

SUB FAN RELAY
MAIN FAN RELAY 1
A/C RELAY
BLOWER FAN RELAY
IMMOBILIZER
: B27
*2 WITH
WITHOUT IMMOBILIZER : B26
IMMOBILIZER
: D17
*3 WITH
WITHOUT IMMOBILIZER : D16
: D16
4 WITH IMMOBILIZER
A14
FUEL INJECTOR NO. 1
IMMOBILIZER
: D14
*1 WITH
ECM
D31
A31
B34
C30
3
B33
D13
D18
D26
TGV LH
A28
A29
TGV RH
A18
A19
6
7
8
WI-04028
WI-162

WIRING SYSTEM
CHECK CONNECTOR
DATA LINK CONNECTOR
1
2
3
4
5
COMBINATION METER
MALFUNCTION
INDICATOR LIGHT
OIL PRESSURE
WARNING LIGHT
B19
D20

(CAN COMMUNICATION)
D29
B17
B18
A17
A23
I/F
*5
TEST MODE
CONNECTOR
D22
I/F
ABS
POWER CIRCUIT
TACHOMETER
SPEEDOMETER
VDC
ABS CONTROL MODULE
I/F
MICRO COMPUTER
CAN TRANSCEIVER &

RECEIVER
IGNITION COIL &

IGNITOR ASSY
TEST MODE
SUB CONNECTOR
VDC CONTROL MODULE

ENGINE
COOLANT
TEMPERATURE
GAUGE
MT
JOINT CONNECTOR B
C17
C15
C28
C34
ACCELERATOR
PEDAL
POSITION
SENSOR
C35
OIL PRESSURE
SWITCH
GROUND JOINT
CONNECTOR
JOINT
CONNECTOR A
C14
ECM
C26
TGV OPENING SENSOR LH
C27
TGV OPENING SENSOR RH
C22
MANIFOLD ABSOLUTE PRESSURE SENSOR
C18
C29
D4
D5
ELECTRIC THROTTLE
C25
C33
B10
B22
KNOCK SENSOR
B11
B23
B31
C16
CAMSHAFT POSITION SENSOR

JOINT
CONNECTOR C
D7
B1
B4
D1
D2
D3
B12
A6
A7
A22
D10
6
7
8
TCM
VDC : WITH VDC

ABS : WITHOUT VDC
IMMOBILIZER
: D15
*5 : WITH
POWER
STEERING
OIL
PRESSURE
SWITCH
MAIN FUSE
BOX (M/B)
GENERATOR
ENGINE GROUND
WI-04029
WI-163

E/G(LND)-01
E/G(LND)-01
WIRING SYSTEM
1
RB
B362
Lg
WITH IMMOBILIZER
: D14
*1
*2
*3
FUEL
PUMP
RELAY
WITH IMMOBILIZER
: B27
WITHOUT IMMOBILIZER : B26
: D17
WITH IMMOBILIZER
RB
16
RB
R1

SYSTEM [C/C6(L)-01]
FUEL
PUMP
CONDENSER
FUEL
PUMP
R58
A: B134 B: B135 C: B136 D: B137
R142 (BLACK)
R58
1 2
3 4
5 6
1
2
B: B135 HR
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
B362
1 2
3
4
GL
D9
C11 YL
Y
C9
ECM
C10 RY
C8 BrR
C7
D13 VY
PW
*3
B33 LOr
C30 YB
A22 BR
D27 BR
D19 WL
B34 WR
Lg
*2
A31 LR
GR
*1
R142
REF. TO AIR CONDITIONING

SYSTEM [A-A/C(L)-0102]
REF. TO IMMOBILIZER
SYSTEM [IMB(L)-01]

SYSTEM [R/F(H4)-01]
RB
B97
RB
BR
WG
2
WG
GR
ALT-1
GENERATOR
MB-25
M/B FUSE NO. 11
(B)
GR

FB-38
F/B FUSE NO. 12
(IG)
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(L)-04]
B97
D: B137 HR
1 2 3 4
5 6 7
8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 23
24 25
26 27
28 29
30 31
5
7 8
6
A: B134
1 2
8 9 10
18 19 20
28 29 30
HR
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
C: B136 HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
WI-04030
WI-164

E/G(LND)-02
E/G(LND)-02
WIRING SYSTEM
FB-17
F/B FUSE NO. 7
(B)
BrW
WL

FB-36
F/B FUSE NO. 5
(IG)
VDC : WITH VDC

WL
11
WL
WL
WL
A2
i102
A1
A3 BrW
A4 BrW
ABS : WITHOUT VDC

R167
TACHOMETER
POWER CIRCUIT
COMBINATION
METER
BY A12
BY A11
A22
V
GB A19
i10
CAN TRANSCEIVER &

RECEIVER
A21
I/F
A:
I/F
RW A20
MICRO COMPUTER
OrW A16
GOr A15
OIL PRESSURE
WARNING LIGHT
MALFUNCTION
INDICATOR LIGHT
I/F
ENGINE
COOLANT
TEMPERATURE
GAUGE
SPEEDOMETER
i102
B38
1 2 3 4 5 6
7 8 9 10 11 12
5 6 7 8
1 2 3 4
9 10 11 12 13 14 15 16 17 18
1 2 3 4
5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20
A: B134 HR
D: B137 HR
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
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
A:
BY
3
1
BY
36
L
D26
OIL PRESSURE SWITCH
BY
GB
GB
R
D18
D: B137 ECM
B310
23
P
A23
A17 OrW
B301
i97
i97
VDC
E11
A: B134
GROUND
JOINT CONNECTOR
ABS
E2
B38
REF. TO CAN
COMMUNICATION
SYSTEM
[CAN(L)-01]
REF. TO CAN
COMMUNICATION
SYSTEM
[CAN(L)-02]
GB
18
19
8
OrW
B21
BrB
BrB
31 GOr
GOr 17
i3
ABS
CONTROL
MODULE
VDC
CONTROL
MODULE
REF. TO GROUND
DISTRIBUTION
SYSTEM [GND(L)-03]
i10
1 2 3 4 5
11 12 13 14 15 16
6 7 8 9 10
17 18 19 20 21 22
B301
12
13
14
15
B21 (BLACK)
B310
10
5
6
7
8
9
1 2 3 4
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
1 2 3 4 5 6 7 8 9 10 11
16 17 18 19 20 21 22 23 24 25 26
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
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
WI-04031
WI-165

E/G(LND)-03
E/G(LND)-03
WIRING SYSTEM
MB-23
SBF-8
(B)
MB-22
SBF-6
(B)
WY
5
WY
WY
6
WR
5
WR
WR
6
WR
WL
WR
MB-24
SBF-8
(B)
WB
13
WB
WL
15
ST-2
IG SW
(ST)
WL

ST-1
F/B FUSE NO. 21
(ST)
OXYGEN (A/F)
SENSOR
RELAY
MAIN
RELAY
STARTER
RELAY
B47
16
14
WB
LG
YL
WB
LG
YB
RB
B327
BL
B225
A
B
C
D
STARTER MOTOR
WL
YL
BATTERY
WB
*4
ELECTRIC
THROTTLE
RELAY
B14
E/G(LND)-05
E/G(LND)-05
E/G(LND)-09
E/G(LND)-05
: WITH IMMOBILIZER : D16

: WITHOUT
IMMOBILIZER
: D17
B: B135
B47 (BROWN)
B362
B327 (BROWN)
1 2
1
3
5
2
4
6
3
4
5
7 8
6
YL
YL
LG
B5
B6
*4
RL
B35 RL
LR
LR
D6
B32 BL
D8
WL
B362
D: B137 ECM
D: B137 HR
B: B135 HR
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
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
B225
1
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
WI-04032
WI-166
*5
D: B137 ECM
B75
(GREEN)
B368 (GREEN)
1
2
B76
B79
TEST MODE
CONNECTOR
(GRAY)
B40
6 7
13 14
1 2 3 4 5 6 7 8
B369 (GREEN)
1
2
1
8
2 3
9 10
4 5
11 12
9 10 11 12 13 14 15 16
: WITH IMMOBILIZER
: D15
: WITHOUT IMMOBILIZER : D14
L
B368
1
B76
1
13
12
10
DATA LINK CONNECTOR
(GREEN)
BL
BL
VR
GW
LgR
5
CHECK CONNECTOR
B75
B40
4
LgR
9
GW
BL
8
10
VR
12
GY
*5
B79
E/G(LND)-04
D29
V
B19
W
VR D20
MB-27
M/B FUSE NO. 13
(B)
GY
B: B135
FB-32
F/B FUSE NO. 4
(IG)
E/G(LND)-09
E/G(LND)-09
E/G(LND)-09
BL
B369
1
E/G(LND)-04
WIRING SYSTEM
TEST MODE
SUB CONNECTOR
D: B137 HR
B: B135 HR
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
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
WI-04033
WI-167
B19
E/G(LND)-07
ACCELERATOR PEDAL
POSITION SENSOR
50
B21
T5
E2
WL
MASS
AIR FLOW
SENSOR
YG
LY
B315
L
4
YL
YG
3
LR
BG
FRONT
OXYGEN
(A/F)
SENSOR
REAR
OXYGEN
SENSOR
B3
2
E/G(LND)-05
YB
RB
E/G(LND)-03
E/G(LND)-03
D
B
A
GB
E/G(LND)-03
YL
E/G(LND)-05
WIRING SYSTEM
1
3
G
L
YL
E24
E/G(LND)-06
E/G(LND)-08
E/G(LND)-09
E/G(LND)-08
E/G(LND)-09
4
3
51
C34
C17
R
C28
C15 GB
C13 YL
C32 SB
W
B
A26
A33
C23 LR
WB
A3
C31 BG
WB
A2
D31 SB
W
B
WB
B21
A25 SB
3
W
D24
4
YG
WB
B19
WB
E/G(LND)-08
E2
T5
B2
A: B134 B: B135 C: B136 D: B137 ECM
B19 HR
1 2
3 4
B3
HR
(BLACK)
1 2 3 4 5
B315 (BLACK)
1 2 3 4 5 6
C: B136 HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
B21
5 6
14 15 16
25 26 27
33 34 35
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
1 2 3
4 5 6
A: B134 HR
D: B137 HR
(GRAY)
E24
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
B: B135 HR
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
(BLACK)
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
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
WI-04034
WI-168
E/G(LND)-05
E/G(LND)-06
B31
LY C16
LY
D5
SB
SB
LY
LY
LY
D4
C25
W
GY
B22
B
WB
B10
W
D: B137 ECM
C: B136
YG C29
B23
B
SB C33
B11
W
B: B135
YL C18
E/G(LND)-06
WIRING SYSTEM
7
3
5
2
6
JOINT
CONNECTOR
C
B138
TCM
LY A10
GY
38
LY
WB
39
YL
20
15
E/G(LND)-08
E/G(LND)-08
BR
BR
BW
LW
3
E57
4
E/G(LND)-09
G
G
P
P
YW
LB
LB
RL
RL
B
B
E14
YW
16
13
5
G
L
L
W
E10
E2
E1
E15
B54
B21
B20
BW
YG
A:
GE
CAMSHAFT
CRANKSHAFT
POSITION SENSOR POSITION SENSOR
E10
(LIGHT GRAY)
E14
E15
(GRAY)
1 2
(BROWN)
E57
KNOCK
SENSOR
(BLACK)
1 2 3 4 5 6
B138
1 2 3 4
5 6 7 8
1 2
B: B135
HR
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
C: B136 HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
ELECTRIC THROTTLE
A:
B20
1
5
9
13
2
6
10
14
3
7
11
15
4
8
12
16
3 4 5 6 7
1 2
8 9 10 11 12 13 14 15 16
17 18 19 20 21
22 23 24
B21
5 6
14 15 16
25 26 27
33 34 35
B54 HR
D: B137 HR
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
(BLACK)
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
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
WI-04035
WI-169
H
YL
E/G(LND)-05
E/G(LND)-07
E/G(LND)-07
WIRING SYSTEM
48
B21
LB
2
LB
2
LB
BrG
YB
YR
BrY
GOr
BR
Or
BrG
YB
YR
BrY
GOr
BR
Or
1
RY
GY
RY
E17
GY
E6
E16
E5
E4
FUEL
INJECTOR
NO. 4
FUEL
INJECTOR
NO. 3
FUEL
INJECTOR
NO. 2
E18
FUEL
INJECTOR
NO. 1
PURGE
CONTROL
SOLENOID
VALVE
EGR VALVE
LB
2
LB
LB
5
LB
2
LB
E2
(BLUE)
1 2
(DARK GRAY)
E5
E16
(DARK GRAY)
E18
(DARK GRAY)
E6
E17
(DARK GRAY)
1 2 3
4 5 6
45
44
PG
PB
PB
C4
PG
PL
PL
C5
C3
P
P
C6
B21
A: B134
E4
43
42
41
RG
A14 RG
30
29
Y
Y
A8
YR
YR
A9
A11 BOr
26
BL
BOr 25
A10 BL
E2
C: B136 ECM
A: B134 HR
(DARK GRAY)
1 2
B21 (BLACK)
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
C: B136 HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
5 6
14 15 16
25 26 27
33 34 35
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
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
WI-04036
WI-170

E/G(LND)-08
YG
LgY C27
YG C35
BrW C14
D: B137 ECM
C: B136
RB C26
A18
V
Lg A19
A29
P
Sb A28
PB D10
A: B134
YW C22
E/G(LND)-08
WIRING SYSTEM
E/G(LND)-05
E/G(LND)-05
E/G(LND)-05
I
K
M
*
*
*
*
YG
YG
YG
YG
BrW
YG
E2
RW
YW
LW
7
LY
LW
LY
GW
19
10 LgY
RB
11
Sb
Lg
21
PW
32
WB
PW
Sb
Br
Br
33
BL
BL
22
PB
9
LOr
WB
1 2
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
(BLACK)
E54
(BLACK)
1 2 3 4
5 6 7 8
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
(BLACK)
1 2 3
B21
RW
LW
E50
E55
LW
GW
LW
D: B137 HR
E21
5 6
14 15 16
25 26 27
33 34 35
MANIFOLD
ENGINE COOLANT
ABSOLUTE
TEMPERATURE
PRESSURE SENSOR
SENSOR
B83
(BLACK)
1 2
TGV OPENING
SENSOR RH
E8
E21
E54
(BLACK)
E51
C: B136 HR
TGV OPENING
SENSOR LH
TGV RH
POWER STEERING
OIL PRESSURE SWITCH
(BLACK)
E50
TGV LH
Sb
E55
E51
E19
E8
B21
P
Q
LOr
E/G(LND)-06
B83
: TERMINAL NO.
OPTIONAL
ARRANGEMENT
E/G(LND)-06
JOINT
CONNECTOR
A
A: B134 HR
1 2
8 9 10
18 19 20
28 29 30
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
33 34
31 32
(BLACK)
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
42
35
43
48
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
WI-04037
WI-171

E/G(LND)-09
B4
BR
BR
D7
BW
BW
D2
B1
D1
BW
D3
BL
BL
B12
B
RL
RL
A6
BY D22
MT
A7
D: B137 ECM
C: B136
B: B135
RY B18
A: B134
GY B17
E/G(LND)-09
WIRING SYSTEM
E/G(LND)-04
G
F
O
N
BL
*
*
BY
MT
E/G(LND)-04
E/G(LND)-06
E/G(LND)-05
BL
BL
SB
SB
RELAY HOLDER
15A
1
LB
LB
B225
B122
: TERMINAL NO.
OPTIONAL
ARRANGEMENT
R
WB
JOINT
CONNECTOR
B
GY
RY
E/G(LND)-03
*
*
*
*
BL
E/G(LND)-04
35
34
36
BY
BY
BY
BY
E2
BW
37
47
52
BW
BrG
BrG
BL
GB
15
RG
GB
BW
BW
BL
BL
E/G(LND)-05
RG
49
13
B21
E12
GE
IGNITION COIL & IGNITOR ASSY
E12
(DARK GRAY)
1 2 3 4
B122
D: B137 HR
1 2 3 4
5 6 7 8
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
A: B134
1 2
8 9 10
18 19 20
28 29 30
HR
B21
3 4 5 6 7
11 12 13 14 15 16 17
21 22 23 24 25 26 27
31 32
33 34
B: B135 HR
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
C: B136
35
43
48
HR
1 2 3 4
7 8 9 10 11 12 13
17 18 19 20 21 22 23 24
28 29 30
31 32
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
42
B225
1
5 6
14 15 16
25 26 27
33 34 35
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
WI-172
(BLACK)
36
49
37
44
50
38
45
51
39
52
40
46
53
41
47
54
WI-04038

WIRING SYSTEM
WI-173

WIRING SYSTEM
3. LHD 3.0 L MODEL

SBF-7
STARTER MOTOR
IGNITION SWITCH
OFF ACC ON ST
SBF-1
SBF-9
IG1
F/B FUSE NO. 21
F/B FUSE NO. 12
ACC
F/B FUSE NO. 5
F/B FUSE NO. 4
F/B FUSE NO. 7
M/B FUSE NO. 13
M/B FUSE NO. 11
SBF-8
IG 2
RELAY
SBF-6
1
2
3
4
5
+B
IG2
STARTER RELAY
ST
B32
D8
B19
D14
MAIN
RELAY 1
GENERATOR
MAIN
RELAY 2
RELAY
HOLDER
MAIN FUSE BOX (M/B)

FUEL PUMP
RELAY
A22
D9
TCM
D27
D28
FUEL PUMP
CONTROL MODULE
ELECTRIC
THROTTLE
RELAY
POWER STEERING
OIL PRESSURE SWITCH
STOP LIGHT & BRAKE SWITCH (CRUISE CONTROL)

FUEL PUMP
PWM CONTROLLER
RADIATOR FAN RELAY
A/C RELAY
A/C LOCK SENSOR
MASS AIR FLOW SENSOR

CAMSHAFT POSITION SENSOR LH
D10
C8
C9
C7
C11
A31
B30
D17
C30
B33
B23
D19
D27
D18
D26
D6
B35
D16
B5
B6
C13
C31
C23
C32
B8
CAMSHAFT POSITION SENSOR RH
B9
EGR VALVE
A10
A11
A9
A8
A14
FUEL INJECTOR NO. 1
C6
FUEL INJECTOR NO. 2
C5
FUEL INJECTOR NO. 3
C4
FUEL INJECTOR NO. 4
C3
FUEL INJECTOR NO. 5
C2
FUEL INJECTOR NO. 6
C1
A1
B7
A27
A34
A25
A26
A33
A2
A3
B3
D25
D31
D24
FRONT OXYGEN (A/F) SENSOR LH
FRONT OXYGEN (A/F) SENSOR RH
REAR OXYGEN SENSOR LH
REAR OXYGEN SENSOR RH
ECM
BATTERY
B2
6
7
8
9
WI-04039
WI-174

WIRING SYSTEM
CHECK CONNECTOR
DATA LINK CONNECTOR

COMBINATION METER
1
2
3
4
5
OIL PRESSURE
WARNING LIGHT
I/F
I/F
I/F
POWER CIRCUIT
MICRO COMPUTER
BODY INTEGRATED
UNIT (CAN
COMMUNICATION
LINE)
TACHOMETER
SPEEDOMETER
JOINT CONNECTOR B
ACCELERATOR
PEDAL POSITION
SENSOR
ENGINE GROUND
OIL
PRESSURE
SWITCH
C27
ENGINE
COOLANT
TEMPERATURE
GAUGE
VDC CONTROL MODULE
TEST MODE
SUB
CONNECTOR
ABS CONTROL MODULE
VDC
ABS
TEST MODE
CONNECTOR
C17
C28
C15
C34
CAN TRANSCEIVER &

RECEIVER
IGNITION COIL NO. 6
IGNITION COIL NO. 5
IGNITION COIL NO. 4
IGNITION COIL NO. 3
D20
D29
B18
B17
B16
B15
B14
B13
A17
A23
D15
IGNITION COIL NO. 2
IGNITION COIL NO. 1
MALFUNCTION
INDICATOR LIGHT
GROUND
JOINT
CONNECTOR
OIL TEMPERATURE SWITCH
C18
C29
ECM
D4
D5
ELECTRIC THROTTLE
C16
C22
INTAKE MANIFOLD PRESSURE SENSOR
C14
JOINT CONNECTOR A
C35
A19
A29
A18
A28
B25
B24
A21
A20
B10
B22
B31
C25
INTAKE OIL FLOW CONTROL SOLENOID VALVE LH

INTAKE OIL FLOW CONTROL SOLENOID VALVE RH
OIL SWITCHING SOLENOID VALVE LH
OIL SWITCHING SOLENOID VALVE RH
KNOCK SENSOR 1
C24
KNOCK SENSOR 1
C33
B29
VVL DIAGNOSIS OIL PRESSURE SWITCH LH
B21
D3
D7
B1
B4
D1
D2
B12
A4
A5
A6
A7
VVL DIAGNOSIS OIL PRESSURE SWITCH RH
VDC : WITH VDC

ABS : WITHOUT VDC
6
7
8
9
ENGINE GROUND
WI-175
WI-04040
6
Lg
LgR
E/G(LH6)-01
B23
W
YB C30
LOr B33
PW D17
WR B30
LR A31
BR D27
WL D19
C7
W
YL C11
C9
Y
BrR C8
D9
R1
LgR
Lg
8
B97
RB
RB
10
REF. TO AIR CONDITIONING

SYSTEM [A-A/C(L)-0102]
1
RB
16
RB
D: B137 ECM
C: B136

SYSTEM [R/F(H6)-01]
B362
B: B135
REF. TO IMMOBILIZER
SYSTEM [IMB(L)-01]
FUEL
PUMP
RELAY
GL
REF. TO AT CONTROL
SYSTEM [5AT(L)-05]
Lg B27
LgR D28
Lg
15 LgR
BR A22
GR D14
BR
WG
2
WG
GR
ALT-1
GENERATOR
GR
A: B134
MB-25
M/B FUSE NO. 11
(B)

SYSTEM [C/C6(L)-01]

FB-38
F/B FUSE NO. 12
(IG)
E/G(LH6)-01
WIRING SYSTEM
5
B
7
GY
GR
GY
GR
R122 FUEL PUMP CONTROL MODULE
REF. TO GROUND
DISTRIBUTION

2004 Service Manual Subaru

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2004 Service Manual Subaru

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2004 Model Year

PDF Service Manual

GENERAL INFORMATION SECTION (Pub.No.G2320GE1)

2004 LEGACY SERVICE MANUAL

QUICK REFERENCE INDEX

This service manual has been prepared

HOW TO USE THIS MANUALS

PERIODIC MAINTENANCE SERVICES

All information, illustration and specifications contained in this manual are

HOW TO USE THIS MANUALS

How to Use This Manuals

1. How to Use This Manuals

How to Use This Manuals

:Should be lubricated with grease.

.... :Tightening torque

How to Use This Manuals

15.Main Shaft Assembly for Single-Range

1) Remove the manual transmission assembly

How to Use This Manuals

How to Use This Manuals

Air Assist Injection

Main Fuse & Relay Box

2.0 L DOHC turbo

1,165 (45.9), 1,100 (43.3)1

2.0 L DOHC turbo

1,190 (46.9), 1,145 (45.1)1

2.0 L DOHC turbo

Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine

cm3 (cu in)

Idle speed at Park or Neutral

2.0 L DOHC turbo

Type and manufacturer

Auxiliary transmission gear

Auxiliary transmission gear

5MT: 5-forward speeds with synchromesh and 1-reverse

Macpherson strut type suspension

Except for 2.0 L DOHC turbo

205/55 R16 89V

215/45 R17 87W

215/60 R16 95V

215/55 R17 94V

205/55 R16 89V

2 (US gal, Imp gal)

2.0 L DOHC turbo

2 (US qt, Imp qt)

4.5 (4.8, 4.0)

2 (US qt, Imp qt)

5.0 (5.3, 4.4)

4.0 (4.2, 3.5)

0.8 (0.8, 0.7)

Transmission gear oil

2 (US qt, Imp qt)

2 (US qt, Imp qt)

8.4 (8.9, 7.4)

2 (US gal, Imp gal)

9.8 (10.4, 8.6)

7.3 (7.7, 6.4)

2 (US qt, Imp qt)

4.5 (4.8, 4.0)

7.2 (7.6, 6.3)

2 (US qt, Imp qt)

4.0 (4.2, 3.5)